1. Manuals
  2. Brands
  3. Allied Manuals
  4. Winches
  5. H6G
  6. Service manual

Allied H6G Service Manual

Hydraulic towing winch for 850jr tractor
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Please check the Allied Systems website
regularly for updates to this manual.
www.alliedsystems.com
CUSTOMER
EDITION
P/N 599026W-H6GH1JE47
Printed in USA
10/28/2011

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the H6G and is the answer not in the manual?

Questions and answers

Related Manuals for Allied H6G

Summary of Contents for Allied H6G

  • Page 1 Please check the Allied Systems website regularly for updates to this manual. www.alliedsystems.com CUSTOMER EDITION P/N 599026W-H6GH1JE47 Printed in USA 10/28/2011...
  • Page 2 NOTE: This publication may be translated to different languages for sole purpose of easy reference in non-English speaking locations. Should there be differences in interpretations to the text, please refer to the English language edition published by Allied Systems Company as the controlling document.

  • Page 3: Safety Summary

    Safety Summary Safety Summary General Safety Notices Safety Regulations Each country has its own safety legislation. It is in the The following pages contain general safety warnings operator’s own interest to be conversant with these regu- which supplement specifi c warnings and cautions appear- lations and to comply with them in full.
  • Page 4 » If the wire rope and ferrule must be removed from the drum, make sure the end of the wire rope and ferrule are controlled when the ferrule is released. The end of the wire rope can sud- denly move from the drum like a compressed spring when the ferrule is released, and cause an injury.
  • Page 5 Oil List. See pages 1-4 and 1-5. • Replace any parts only with genuine Allied • Do not weld on any part of the winch. Contact Allied Winch parts. Refer to Parts Manual 599027W- Systems if weld repairs are needed. H6GH1JE47.
  • Page 6 Notes...

  • Page 7: Table Of Contents

    Contents Contents Safety Summary Maintenance Schedule ..........3-1 ............i Checks Before Operation ........... 3-2 Checks During Operation ........... 3-2 General ................. 1-1 FREESPOOL Drag Adjustment ......... 3-2 Introduction ................ 1-1 Hydraulic System Pressure Checks ........3-2 Description ................ 1-1 Preparation ..............3-2 Unit Identifi...
  • Page 8 Notes...

  • Page 9: General

    Section 1 General Introduction Description This service manual is for the H6G winch. The following The H6G Winch is a Power Forward (LINE-IN) and Power information is included in this manual: Reverse (LINE-OUT) winch. The winch is powered by an internal hydraulic motor connected to the tractor hy- Section 1.

  • Page 10: Unit Identifi Cation

    General Unit Identifi cation Allied Winch S/N Nameplate Data For Tractor Mountings 1501 Winch Model John Deere 850JR Tractor H6G was previously known as WH6G. The "W" designation has been dropped for simplicity. Hydraulic Operation Type Sequence Number H = High Performance...

  • Page 11: Serial Number Codes

    Section 1 Serial Number Codes The serial number codes are described on page 1-2 of this manual. The nameplate with the serial number code is found on the top left hand side of the winch case. The serial number code is also stamped on the left hand side of the winch frame.

  • Page 12: Specifi Cations

    Drum Wire Rope Capacities (Drum: 10 Inch Dia) Oil Capacity Wire Rope Diameter H6G Capacity The oil capacity for the H6G winch is 8.5 quarts (8 29 mm (1 1/8 in.) 51 m (167 ft) liters). Note: Loosely or unevenly spooled line will change Hydraulic Specifi...

  • Page 13: Torque Specifi Cations

    Section 1 Torque Specifi cations TORQUE VALUES ITEM ft-lbs. kg-m Housing Covers (1/2 UNC Gr. 8) Drum Shaft Assembly Drum Adapter to Drum Capscrews (5/8 UNF Gr. 8) Bearing Retainer Capscrews (1/2 UNF Gr. 8) Motor Shaft Gear Retainer Capscrews (3/8 UNC Gr. 8) 3-Port Manifold to Motor Capscrews (7/16 UNC Gr.

  • Page 14: Gear Train

    General Gear Train (See Fig. 1-7 & 1-8) The tractor pump drives the hydraulic motor with hydraulic Durm Gear oil supply. Pressure in the hydraulic motor is load induced through the winch gear train. The motor shaft rotates to give LINE-IN or LINE-OUT with supply oil and return oil Intermediate Gear is directed back to the tractor reservoir.

  • Page 15: Freespool Operation

    Section 1 FREESPOOL Operation (See Fig. 1-9 & 1-10) The FREESPOOL arrangement allows mechanical dis- engagement of the drum gear from the remainder of the INTERMEDIATE GEAR gear train. When FREESPOOL is selected, a hydraulically- actuated sleeve disengages the dental clutch from the DENTAL CLUTCH intermediate shaft.

  • Page 16: Operation And Control

    Operation & Control (See Fig. 1-11) The switch panel contains two rocker switches to control The H6G winch is designed to operate on a load sense, pilot FREESPOOL and HI-SPEED. The tractor must be running operated hydraulic system. When the tractor is running, the to supply hydraulic power to operate these functions.

  • Page 17: Hydraulic System

    Section 1 Hydraulic System Planetary Reducer (See Fig. 1-12) this housing is common to the gear side of the winch and output shaft rotation is the same as input shaft rotation The planetary speed reducer is the fi rst gear reduction at 1/6th the speed.

  • Page 18: Brake

    General Retaining Ring Retaining Ring Bearing Oil Seal Cover Plate Spline Shaft Assembly Socket Head Shoulder Bolts Primary Disc Rotor Disc 10. Stator Disc 11. Case Gasket 12. Capscrew 13. Dowel Pin 14. Spring Plate 15. Springs 16. Piston 17. Back-Up Ring 18.

  • Page 19: Motor

    Section 1 Seal Plate Snap Ring 14. Screw Seal Plate 15. Two-Speed Plate Seal Shaft 16. Stator Steel Plate 17. Rotor Seal Plate O-Ring 18. Rotor Vane Bearing Snap Ring 19. Rotor Vane Spring, Outer Ball Bearing 20. Rotor Vane Spring, Inner Shaft 21.

  • Page 20: Directional Control Manifold

    General Directional Control Manifold HI-SPEED Limit Switch The directional control manifold controls the direction The HI-SPEED limit mechanism is comprised of a pres- of hydraulic fl ow to the winch motor. When the operator sure switch and electric relay. When the HI-SPEED func- moves the control lever into the LINE-IN or LINE-OUT tion is activated, the solenoid valve in the logic control position, a pressure response is signaled to one side of...

  • Page 21: Brake-On

    Section 1 Figure 1-15 Sequence of Operation - BRAKE-ON Sequence of Operation, BRAKE-ON control manifold and the control lever. There is no pressure The directional control valve spool is spring centered to on the control lines which are open to the tractor reservoir. neutral.
  • Page 22 General Figure 1-16 Hydraulic System - LINE-IN 1 - 14...
  • Page 23 Section 1 Sequence of Operation, LINE-IN The operator pulls back the control lever which sends control spool and to the tractor reservoir. Simultaneously, pilot control pressure to the directional control valve and pilot control pressure at the brake valve is connected to the brake release valve.
  • Page 24 General Figure 1-17 Hydraulic System - HI-SPEED LINE-IN 1 - 16...
  • Page 25 Section 1 Sequence of Operation, HI-SPEED LINE-IN When the operator depresses the HI-SPEED switch the The operator pulls back the control lever which sends HI-SPEED solenoid valve in the logic manifold opens and pilot control pressure to the directional control valve and pilot control pressure is communicated to the HI-SPEED the brake release valve.
  • Page 26 General Figure 1-18 Hydraulic System - LINE-OUT 1 - 18...
  • Page 27 Section 1 Sequence of Operation, LINE-OUT The operator pushes the control lever forward, which fully released. Low pressure case drain oil fl ows from the sends pilot control pressure to the directional control hydraulic motor back to the tractor reservoir. This condition valve and the brake release valve.
  • Page 28 General Figure 1-19 Hydraulic System - HI-SPEED LINE-OUT 1 - 20...
  • Page 29 Section 1 Sequence of Operation, HI-SPEED LINE-OUT When the winch is operated in LINE-OUT and a load pulls The operator pushes the control lever forward, which line from the winch pressure builds on the A port of the sends pilot control pressure to the directional control motor up to the load sense relief setting.
  • Page 30 General Figure 1-20 Hydraulic System - FREESPOOL 1 - 22...
  • Page 31 Section 1 Sequence of Operation, FREESPOOL The operator depresses the FREESPOOL switch. Elec- Pilot control pressure communicates to the FREESPOOL tronic circuitry also releases the brake and activates a shifter fork, allowing the dental clutch to disengage the bypass for the hydraulic motor. This allows the operator to drum pinion gear from the intermediate gear.
  • Page 32 General Notes 1 - 24...
  • Page 33 Section 1 Figure 1-22 H6G Schematic 1 - 25...
  • Page 34 General Intentionally Blank 1 - 26...

  • Page 35: General

    Section 2 Troubleshooting General Winch problems generally fall into one of three categories: Inspect the winch gear train for problems. controls, hydraulic system, or mechanical system. Follow the troubleshooting steps below to isolate the probable location of the malfunction. For best operation and life, the winch oil op- Make sure the control lever assembly (including pi- erating temperature should not exceed 180°F lot controller unit) is functioning properly, with a full...

  • Page 36: Step-By-Step Pump & Controller Troubleshooting

    Troubleshooting Step-by-Step Pump and Controller Troubleshooting Winch does not operate with the tractor running. 1.1 Is there oil in the reservoir? Fill tractor reservoir. Proceed to step 1.2. 1.2 Is the winch in FREESPOOL? Proceed to step 1.3. Shift winch out of FREESPOOL Function.
  • Page 37 Section 2 1.14 Operate control lever in both directions. Is pressure at RI & RO greater Verify that pilot pressure to direc- than the standby pilot pressure of 275±15 psi? tional spool PA & PB will cause the pump to load sense & cause pilot pressure to increase.
  • Page 38 Troubleshooting PROBLEM POSSIBLE CAUSE CORRECTION Winch gets very hot Low oil level. Add oil (MIL-PRF-2105E); refer to tractor oil specifi cations. Improper oil viscosity. Use correct oil grade (MIL-PRF-2105E); refer to tractor oil specifi cations. Winch coated with dirt. Clean winch. Clogged fi...
  • Page 39 Section 2 PROBLEM POSSIBLE CAUSE CORRECTION Winch will not generate suf- Leak in motor speed spool relief car- Check that the pressures at motor test ports ficient line pull or does not tridge (HI-SPEED only). A & B are suffi cient for operating the winch in LINE-IN or LINE-OUT LINE-IN/OUT with the brake line plugged.
  • Page 40 Troubleshooting PROBLEM POSSIBLE CAUSE CORRECTION Control lever does not auto- 1. Plunger seal sticking in control Remove and inspect pilot controller unit on matically return to BRAKE-ON lever. control lever assembly. Replace worn parts or position. 2. Spring in pilot controller unit entire assembly as necessary.
  • Page 41 Section 2 Notes 2 - 7...
  • Page 42 Troubleshooting Notes 2 - 8...

  • Page 43: Service

    Access Cover for Motor and Winch Hydraulics Fill Plug Plug to Check Oil Level Breather Plug to Drain Oil Figure 3-1 H6G Winch Maintenance Points INTERVAL PROCEDURE OR QUANTITY SPECIFICATION 50 hours or weekly Check oil level at plug (item 2). Add oil ( See Oil Selection in Section 1.

  • Page 44: Checks Before Operation

    Service Checks Before Operation Check that the wire rope and hook are not worn or dam- Tractor engine must be shut OFF before dis- aged. Check that the periodic inspection and maintenance connecting drum wire rope. Be careful when have been done at the recommended operating hours. you remove the wire rope from the drum.

  • Page 45: Maximum Pilot Supply Pressure Check

    Section 3 Leaking pressure hoses or fi ttings Load Sense Valve Adjustment: Maximum Pilot Supply Pressure Check Leave the brake pressure supply disconnected. With the same gauge installed from the Standby Pilot Start the engine and operate the winch in LINE-IN Pressure Check, bottom tractor blade cylinders and or LINE-OUT.

  • Page 46: Freespool Pressure Check

    Service the motor against the brake before the brake releases. Leaking pressure hoses or fi ttings Note: Some brake valves are not adjustable. Restriction in pressure hose or manifold port FREESPOOL Pressure Check Loose DV lube orifi ce in B motor port block fi tting. With the engine shut off, connect 1000 psi pressure gauges in line on the FS hose at the logic control manifold, BR pressure test port, in line on the HS hose, and in line...

  • Page 47: High Speed Pressure Check

    Section 3 HI-SPEED Pressure Check If the LINE-IN pressure is not as specifi ed in Figure 3-5, check for: With the engine shut off, connect a 1000 psi pres- sure gauge in line on the HS hose at the logic control Improper pilot supply pressure.
  • Page 48 Service Figure 3-5 Hydraulic System Pressure Tests TEST ITEM CHECK PORT TEST EQUIPMENT CONTROL PRESSURE CORRECTIVE AC- REQUIRED POSITION TION Pilot Supply Tractor Pilot 1000 psi (6895 kPa) Tractor blade 650 psi (4482 Adjust tractor pilot Test Port gauge over relief kPa) reducing valve.
  • Page 49 Section 3 Notes 3 - 7...
  • Page 50 Service Notes 3 - 8...
  • Page 51 Access Cover for Motor and Winch Hydraulics Fill Plug Plug to Check Oil Level Breather Plug to Drain Oil Figure 3-1 H6G Winch Maintenance Points INTERVAL PROCEDURE OR QUANTITY SPECIFICATION 50 hours or weekly Check oil level at plug (item 2). Add oil ( See Oil Selection in Section 1.
  • Page 52 Service Checks Before Operation Check that the wire rope and hook are not worn or dam- Tractor engine must be shut OFF before dis- aged. Check that the periodic inspection and maintenance connecting drum wire rope. Be careful when have been done at the recommended operating hours. you remove the wire rope from the drum.
  • Page 53 Section 3 Leaking pressure hoses or fi ttings Load Sense Valve Adjustment: Maximum Pilot Supply Pressure Check Leave the brake pressure supply disconnected. With the same gauge installed from the Standby Pilot Start the engine and operate the winch in LINE-IN Pressure Check, bottom tractor blade cylinders and or LINE-OUT.
  • Page 54 Service the motor against the brake before the brake releases. Leaking pressure hoses or fi ttings Note: Some brake valves are not adjustable. Restriction in pressure hose or manifold port FREESPOOL Pressure Check Loose DV lube orifi ce in B motor port block fi tting. With the engine shut off, connect 1000 psi pressure gauges in line on the FS hose at the logic control manifold, BR pressure test port, in line on the HS hose, and in line...
  • Page 55 Section 3 HI-SPEED Pressure Check If the LINE-IN pressure is not as specifi ed in Figure 3-5, check for: With the engine shut off, connect a 1000 psi pres- sure gauge in line on the HS hose at the logic control Improper pilot supply pressure.
  • Page 56 Service Figure 3-5 Hydraulic System Pressure Tests TEST ITEM CHECK PORT TEST EQUIPMENT CONTROL PRESSURE CORRECTIVE AC- REQUIRED POSITION TION Pilot Supply Tractor Pilot 1000 psi (6895 kPa) Tractor blade 650 psi (4482 Adjust tractor pilot Test Port gauge over relief kPa) reducing valve.
  • Page 57 Section 3 Notes 3 - 7...
  • Page 58 Service Notes 3 - 8...

  • Page 59: Repairs

    Section 4 Repairs General This section includes the removal and disassembly of all major assemblies, inspection of components, and reas- sembly and installation. The wear points detailed in Figure Be careful when you remove the wire rope 4-8 should be inspected at the time of disassembly so that from the drum.

  • Page 60: Intermediate & Freespoool Shaft Removal

    Repairs - Intermediate & FREESPOOL Shaft Removal Capscrew FREESPOOL Piston O-ring Cover 11, 12 Intermediate Shaft Drum Pinion Gear Dental Clutch Washer Setscrew 10. Nut 11. Bearing Cup 12. Bearing Cone 13. FREESPOOL Shaft 14. Spring 15. FREESPOOL Piston 16. FREESPOOL Shifter Fork 17.
  • Page 61 Section 4 Intermediate and FREESPOOL Shaft Re- moval The intermediate and FREESPOOL shafts can be re- moved with the winch mounted on the tractor. Remove the capscrews securing the shifter shaft Withdraw the shaft and remove the fork. cover and take the cover off. Freespool Fork Gasket...
  • Page 62 Repairs - Intermediate & FREESPOOL Shaft Removal Tag shims for reference during reassembly (not Remove bearing cup and cone and the intermediate shown). shaft, while ensuring that the intermediate gear does not fall. Screw a 3/4-16 UNF slide hammer into the end of the intermediate shaft and partially pull it out.
  • Page 63 Section 4 Drum Shaft & Drum Removal Figure 4-2 shows the location of drum and drum shaft possible. To remove the drum gear it will be necessary to components. Do not attempt to remove heavy components fi rst remove the intermediate shaft (see Intermediate & such as the drum or drum gear by hand.

  • Page 64: Drum Shaft & Drum Removal

    Repairs - Drum Shaft & Drum Removal Loosen the drum capscrews, then remove capscrews Remove bearing retainer and shim pack. with thimbles, leaving two located 180° apart. Bearing Retainer Shim Pack NOTE: Tag shim pack for reference during reassembly. Remove both drum shaft locknut and the retainer Remove retainer ring by removing retainer cap- capscrews.
  • Page 65 Section 4 Remove roller bearing. Carefully remove the drum from winch frame. Ensure NOTE: Bearing cones, cups and spacer are matched that the adapter does not fall. set. Note: Part of frame shown removed for clarity Attach a sling around the drum and hoist until there Remove adapter.
  • Page 66 Remove and Discard 13. Using a suitable lifting device, the drum gear can now be removed. NOTE: This seal must be replaced with a new Allied Systems Company-approved seal during reassembly. 11. Remove double tapered roller bearing assembly and drum seal spacer from the left-hand end of the drum.
  • Page 67 Section 4 Hydraulic System Disassembly sure to clearly mark the hose ends of any hoses removed Disconnecting the hoses is necessary in order to remove with their corresponding ports. the motor shaft assembly. For easier re-installation, be 67, 66, 65 67, 66, 64 Detail at Bypass Manifold...

  • Page 68: Hydraulic System Disassembly

    Repairs - Hydraulic System Disassembly Connect to Freespool Shifter Fork Detail at Logic Manifold 38. Bypass Manifold 39. 3-Port Manifold 40. Manifold 41. Fitting 42. Fitting (Orifi ce) 19. Hose Assembly, Brake to Logic Manifold BR Port 43. Check Valve 20.
  • Page 69 Section 4 Drain oil (MIL-PRF-2105E) from winch. Remove cover Remove the fi ve hoses and wire harness that exit plates as shown. through the frame. Remove the FREESPOOL hoses. Remove both hoses at the directional manifold. 4 - 11...
  • Page 70 Repairs - Hydraulic System Disassembly Remove the four hoses connecting the directional Remove the three hoses off the DV port on the logic manifold to the logic manifold. manifold. Remove the two hoses connecting the logic manifold Remove the logic manifold. to the motor and brake.
  • Page 71 Section 4 Remove the hoses between the high-pressure A 11. Remove the directional manifold bracket from the and B ports on the motor and the direction manifold motor. assembly. 10. Remove the directional manifold assembly. 12. Remove the bypass manifold assembly from frame.

  • Page 72: Motor Shaft Removal & Disassembly

    Repairs - Motor Shaft Removal & Disassembly Motor Shaft Removal and Disassembly Removal and disassembly of the motor shaft assembly can housing requires removing the FREESPOOL Shifter Fork and Intermediate Shaft and Gear fi rst (see Intermediate be accomplished while the winch is mounted on the tractor. &...
  • Page 73 Section 4 Remove the hydraulic motor. Remove cover plate. Remove manifold support bracket from frame. Remove the support brackets. Remove the brake. Remove planetary reducer assembly. 4 - 15...
  • Page 74 Repairs - Motor Shaft Removal & Disassembly Remove and discard O-rings. Remove and discard O-rings from seal ring. Remove reducer mounting, gear retainer, spacer and seal ring from reducer. 4 - 16...
  • Page 75 If the motor malfunctions before its warranty upside down. Secure the motor prior to loosening the period expires, please contact Allied Systems Com- 5/8-11 bolts. pany fi rst before attempting to repair it.

  • Page 76: Motor Disassembly

    Repairs - Motor Disassembly Remove snap ring from shaft. Press shaft out of bear- Remove O-ring and springs with a small screwdriver. ing. Remove dowels pins. Lift up rotor/stator cartridge and remove from the rear 10. Replace plate on rotor/stator cartridge. Turn rotor/ housing.
  • Page 77 Section 4 12. Remove the spool assembly. 4 - 19...

  • Page 78: Brake Disassembly

    - Brake Disassembly Brake Disassembly NOTE: Disassembling the brake while it’s still under its expires, please contact Allied Systems Company fi rst warranty period immediately invalidates the warranty. before attempting to repair it. If the brake malfunctions before its warranty period...
  • Page 79 Section 4 Remove the four socket head capscrews (item 23). A Remove primary disc (item 8), rotor discs (item 9) suitable holding fi xture is useful to keep brake in posi- and stator discs (item 10). NOTE: Primary disc is tion.

  • Page 80: Planetary Reducer Disassembly

    - Planetary Reducer Disassembly Planetary Reducer Disassembly NOTE: Disassembling the reducer while it’s still un- ranty period expires, please contact Allied Systems der its warranty period immediately invalidates the Company fi rst before attempting to repair it. warranty. If the reducer malfunctions before its war- Output Shaft 11.
  • Page 81 Section 4 Remove capscrews (item 18) and washers (item 17) Remove retaining ring (item 10) from groove in out- from cover (item 15). Thrust washer (item 14) usually put shaft (item 1). Lift thrust washer (item 9) from remains with cover (item 15). assembly.

  • Page 82: Winch Assembly

    Repairs - Winch Assembly Winch Assembly but may fail when placed under a load. When in doubt, All components should be inspected for wear or damage it is recommended to install a new bearing. Any com- as they are removed. Refer to Figure 4-8, Visual Inspec- ponent that indicates excessive wear or damage should tion.
  • Page 83 Section 4 Figure 4-8 Visual Inspection (continued) ITEM INSPECTION REQUIREMENTS CORRECTIVE ACTION Winch Motor (Cont.) Inspect stator for wear or damage. Normal wear results in polishing of cam form which does not impair motor performance. Notice- able wear may be apparent along the corner of one side of the vane slot.

  • Page 84: Planetary Reducer Assembly

    - Planetary Reducer Assembly Planetary Reducer Assembly NOTE: Disassembling the reducer while it’s still un- ranty period expires, please contact Allied Systems der its warranty period immediately invalidates the Company fi rst before attempting to repair it. warranty. If the reducer malfunctions before its war- Output Shaft 11.
  • Page 85 Section 4 Press bearing cups (items 4 & 7) into each side of Place carrier assembly (item 12) into ring gear while hub (item 6). It is recommended that bearing cups aligning gear teeth. Carrier splines mesh with splines and cones (items 3 & 8) be replaced in sets. on output shaft (item 1).

  • Page 86: Brake Assembly

    - Brake Assembly Brake Assembly NOTE: Disassembling the brake while it’s still under its expires, please contact Allied Systems Company fi rst warranty period immediately invalidates the warranty. before attempting to repair it. If the brake malfunctions before its warranty period...
  • Page 87 Section 4 NOTE: Lubricate all rubber components from repair 10. Install springs (item 15) according to pattern and kit with clean hydraulic fl uid (MIL-PRF-2105E) before color recorded during disassembly. reassembly. 11. Affi x case gaskets (item 11) to pressure plate (item Clean all parts thoroughly before assembling.

  • Page 88: Motor Assembly

    NOTE: Disassembling the motor while it’s still under its warranty period immediately invalidates the war- ranty. If the motor malfunctions before its warranty period expires, please contact Allied Systems Com- pany fi rst before attempting to repair it. Install the rotor and stator vanes. Install the rotor.
  • Page 89 Section 4 Place seal in seal plate. Place O-ring into groove in Install main body O-ring and ball checks into front the front housing, then press seal plate into housing. housing. Place a small amount of grease (MIL-G- Install snap ring. 10924F) over ball checks and O-ring, then wipe off excess grease (MIL-G-10924F).
  • Page 90 Repairs - Motor Assembly 12. Rotate shaft in both directions to assure that the shaft 13. Reassemble the spool assembly. Ensure spool, turns smoothly. Torque motor to 190 ft. lbs. Rotate spring and plug are oriented as shown. shaft again in both directions to assure that the shaft turns smoothly.
  • Page 91 Section 4 Motor Shaft Assembly and Installation Assembly and installation of the motor shaft assembly can but taking out the planetary reducer and reducer housing be accomplished while the winch is mounted on the tractor. must be installed before the FREESPOOL Shifter Fork The motor and brake can be installed independently of and Intermediate Shaft and Gear (see Intermediate Shaft other components (other than various hoses and fi...

  • Page 92: Motor Shaft Assembly & Installation

    Repairs - Motor Shaft Assembly & Installation Install new O-rings on seal ring. Install planetary reducer assembly. Install the reducer mounting, gear retainer, spacer Install manifold support bracket in frame. and seal ring in the reducer. Install new O-rings on reducer mounting. Reinstall cover plate.
  • Page 93 Section 4 Reinstall the brake. Install the hydraulic motor. NOTE: Port A and Port B bypass hoses must be in- stalled before placing motor in winch frame. Install the brackets. 4 - 35...

  • Page 94: Hydraulic System Assembly

    Repairs - Hydraulic System Assembly Hydraulic System Assembly 67, 66, 65 67, 66, 64 Detail at Bypass Manifold Detail at Directional Manifold Directional Manifold Counterbalance Valve Cartridge Flangescrew Fitting Fitting Fitting Hose Assembly, Motor Port B to Directional Manifold Port B Hose Assembly, Motor Port A to Directional Manifold Port A 10.
  • Page 95 Section 4 Connect to Freespool Shifter Fork Detail at Logic Manifold 38. Bypass Manifold 39. 3-Port Manifold 40. Manifold 41. Fitting 42. Fitting (Orifi ce) 19. Hose Assembly, Brake to Logic Manifold BR Port 43. Check Valve 20. Washer 44. Hose Assembly, Bypass Valve #3 to Bypass Motor 21.
  • Page 96 Repairs - Hydraulic System Assembly Install the bypass manifold assembly. Install the hoses between the high-pressure A and B ports on the motor and the directional manifold assembly. Install the directional manifold bracket. Install the logic manifold. Install the directional manifold assembly. 4 - 38...
  • Page 97 Section 4 Install the hoses to the DV port on the logic mani- Install the hoses connecting the directional manifold fold. to the logic manifold. Connect the hoses from the logic manifold to the motor Connect the hoses that exit through the frame and and the brake.
  • Page 98 Repairs - Hydraulic System Assembly 10. Connect the freespool hoses. Figure 4-13 Hydraulic System 4 - 40...
  • Page 99 Section 4 Drum and Drum Shaft Installation If the drum gear was removed, it must be installed prior to installation of the intermediate shaft and motor shaft assembly. 20,21,22 Drum Drum Gear 16. O-Ring Drum Shaft 10. Capscrew 17. Oil Seal Bearing Retainer 11.

  • Page 100: Drum & Drum Shaft Installation

    Repairs - Drum & Drum Shaft Installation Coat seal bore with sealant. Install double-lip seal Install drum seal. with smooth side toward the drum in the right hand side of the frame. Double-Lip Seal Drum Seal NOTE: Smooth side of seal must face outboard. Install drum adapter by pushing it through the double- Lubricate the left-hand drum bore with grease...
  • Page 101 Section 4 Replace drum spacer O-ring and install spacer in Move the drum into position while being careful not drum bore. to move the seal ring. Drum Spacer O-Ring Lubricate right-hand drum bore. Coat right-hand seal Align adapter and drum holes, then install the thim- ring and groove with O-ring lube.
  • Page 102 Repairs - Drum & Drum Shaft Installation Install drum gear. 11. Make sure that double-tapered roller bearing, seal and spacer are properly seated in the left-hand side of the drum. Then install the shaft until it bottoms solidly against the left hand tapered roller bearing. Tighten left hand nut.
  • Page 103 Section 4 13. Install retainer plate using the eight special cap- 15. Coat winch frame and bearing retainer with silicone. screws. Tighten capscrews to 90 ft-lbs (12 kg-m). Install drum shaft O-ring. Install fi nalized shim pack (determined in step 15). If intermediate shaft as- sembly not installed, install before retainer.

  • Page 104: Intermediate & Freespool Shaft Installation

    Repairs - Intermediate & FREESPOOL Shaft Installation Capscrew Freespool Piston O-ring 11, 12 Cover Intermediate Shaft Drum Pinion Gear Dental Clutch Washer Setscrew 10. Nut 11. Bearing Cup 12. Bearing Cone 13. Freespool Shaft 14. Spring 15. Freespool Piston 16. Freespool Shifter Fork 17.
  • Page 105 Section 4 Intermediate & FREESPOOL Shaft Installa- tion Place dental clutch on pinion gear. Ensure chamfered ramp faces pinion. These fi gures show the winch removed from the tractor with the clutch shaft and brake shaft removed. Install inner bearing assembly if previously removed. Use a liberal amount of grease (MIL-G-10924F) to hold the inner bearing cone in place.
  • Page 106 Repairs - Intermediate & FREESPOOL Shaft Installation Install the outer bearing cup and cone. Make sure Coat the winch frame and retainer with silicone or that the cup is fi rmly seated against the bearing cone. other suitable sealing compound. Install shim pack (if necessary) and cover.
  • Page 107 Section 4 11. Install hose assembly. 13. Secure the shifter shaft cover and the gasket with capscrews. Hose Assembly Gasket Shifter Shaft Cover 12. Apply adhesive-sealant to threads of FREESPOOL 14. Install cover. Tighten capscrews on shifter shaft to shaft. Adjust for proper engagement and disengage- 75 ft-lbs (10 kg-m).

  • Page 108: Winch Installation

    Repairs - Winch Installation Winch Installation Align the studs with the mounting holes to prevent Thoroughly clean the mounting surfaces on the thread damage. winch and the tractor. Clean the mounting holes and hardware of dirt, grit and oil. Loosely install the two top nuts or capscrews before the winch is fully seated against the tractor.
  • Page 109 Section 4 Notes 4 - 51...
  • Page 110 Repairs Notes 4 - 52...
  • Page 112 To fi nd a dealer in your area, Call: (503) 625-2560, Fax: (503) 625-7269 , or Email: marketing@alliedsystems.com, or Visit our website: http://www.alliedsystems.com 599026W-H6GH1JE47 10/28/2011 Printed in USA...

Table of Contents