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Allied Systems Allied H6G Series Service Manual

Hydraulic towing winch
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CUSTOMER
EDITION
P/N 599026W
Printed in USA
12/13/2011

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Summary of Contents for Allied Systems Allied H6G Series

  • Page 1 Please check the Allied Systems website regularly for updates to this manual. www.alliedsystems.com CUSTOMER EDITION P/N 599026W Printed in USA 12/13/2011...
  • 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 Safety Summary • Make sure ground personnel are in plain view of the • Your winch may have temperature shut-off system operator, and at a distance of at least 1½ times the for protection of tractor and winch. Manual override working length of the wire rope.
  • Page 6 When ordering replacement parts, give the unit serial number, part number, name of part and quantity required. For any further information on parts, service or ordering, consult your local winch dealer, or contact Allied Systems Company: Allied Systems Company 21433 SW Oregon Street...

  • Page 7: Table Of Contents

    Contents Contents Safety Summary ..............i Maintenance Schedule ..........3-1 Checks Before Operation ........... 3-2 General ................1-1 Checks During Operation ........... 3-2 Introduction ................ 1-1 FREESPOOL Drag Adjustment ......... 3-2 Description ................ 1-1 Hydraulic System Pressure Checks ........3-2 Unit Identifi cation ............1-2 Preparation ..............
  • 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 Vehicle Code H6G was previously known as WH6G. See Figure 1-2 The "W" designation has been dropped for simplicity. Sequence Number Hydraulic Operation Type Internal Options H = High Performance: Winch Direction Valve, Variable or 2 Speed.

  • 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

    General Specifi cations Drum Line Capacities (Drum: 10 Inch Dia) Hydraulic Specifi cations Wire Rope Diameter Capacity Motor ......Dual displacement vane-type 19mm (3/4 in) 121 m (399 ft) 22mm (7/8 in.) 87 m (287 ft) Brake ....... Dry multi-disc spring applied 25mm (1.0 in.) 68 m (223 ft) Note: Loosely or unevenly spooled line will change...

  • 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) The tractor pump drives the hydraulic motor with hydraulic oil supply. Pressure in the hydraulic motor is load induced DRUM GEAR through the winch gear train. Supply oil provides the power for the LINE-IN and LINE-OUT functions. The supply oil is pumped through the circuit by the rotation of the motor INTERMEDIATE GEAR shaft.
  • Page 15 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 train. When FREESPOOL is selected, a hydraulically- GEAR actuated sleeve disengages the dental clutch from the intermediate shaft.

  • Page 16: Operation And Control

    General FROM S/N 1094 AND UP, THIS DECAL, BRAKE-OFF, WAS REMOVED Figure 1-11 Winch Controls Operation & Control (See Fig. 1-11) The switch panel may contain three rocker switches to The H6G winch is designed to operate on a load sense, pilot control FREESPOOL, BRAKE-OFF and HI-SPEED.

  • Page 17: Hydraulic System

    Section 1 Hydraulic System Planetary Reducer (See Fig. 1-12) 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. between the brake and the gear side of the winch. Oil in this housing is common to the gear side of the winch and Output Shaft 11.

  • 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 Plate Seal 15. Two-Speed Plate Shaft Seal 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: Direction Control Manifold

    General Direction Control Manifold (High-Performance Winch exceeds the pilot setting of the valve. The BRAKE-OFF, HI- Only) SPEED, and FREESPOOL valves are 2-way electric over hydraulic valves that communicate pressure responses to The direction control manifold controls the direction of hy- respective functions when activated.

  • Page 21: Sequence Of Operation, Rescue Winch

    Section 1 Figure 1-15 Sequence of Operation - BRAKE-ON Sequence of Operation, Rescue Winch - BRAKE-ON control manifold and the control lever. There is no pressure The direction control valve spool is spring centered to on the control lines, which are open to the tractor reservoir. neutral.

  • Page 22: Line-In

    General Figure 1-16 Hydraulic System - LINE-IN Sequence of Operation, Rescue Winch - LINE-IN control spool and to the tractor reservoir. Simultaneously, The operator pulls back the control lever, which sends pilot control pressure at the brake valve is connected to pilot control pressure to the direction control valve and the brake release valve.

  • Page 23: Line-Out

    Section 1 Figure 1-17 Hydraulic System - LINE-OUT Sequence of Operation, Rescue Winch - LINE-OUT The operator pushes the control lever forward, which brake is fully released. Low pressure case drain oil fl ows sends pilot control pressure to the direction control valve from the hydraulic motor back to the tractor reservoir.
  • Page 24 General Figure 1-18 Sequence of Operation - FREESPOOL S e q u e n c e o f O p e r a t i o n , R e s c u e W i n c h - FREESPOOL drum pinion gear from the intermediate gear.
  • Page 25 Section 1 Intentionally Blank 1 - 17...
  • Page 26 General Figure 1-19 Sequence of Operation - BRAKE-ON 1 - 18...

  • Page 27: Sequence Of Operation, High-Performance Winch

    Section 1 Sequence of Operation, High-Performance Winch - BRAKE-ON control manifold and the control lever. There is no pressure The direction control valve spool is spring centered to on the control lines which are open to the tractor reservoir. neutral. In this position, the motor work ports are open to Similarly, there is no pressure in the load sense line as it the tractor reservoir, and pump standby supply pressure is vented back to the tractor reservoir through an orifi...
  • Page 28 General Figure 1-20 Hydraulic System - LINE-IN 1 - 20...
  • Page 29 Section 1 Sequence of Operation, High-Performance Winch - LINE-IN The operator pulls back the control lever, which sends spool and to the tractor reservoir. Simultaneously, pilot pilot control pressure to the direction control valve and control pressure at the brake valve is connected to the the brake release valve.
  • Page 30 General Figure 1-21 Hydraulic System - HI-SPEED LINE-IN 1 - 22...

  • Page 31: Hi-Speed Line-In

    Section 1 Sequence of Operation, High-Performance Winch - HI- SPEED LINE-IN The operator pulls back the control lever, which sends When the operator depresses the HI-SPEED switch, the pilot control pressure to the direction control valve and HI-SPEED solenoid valve in the logic manifold opens, and the brake release valve.
  • Page 32 General Figure 1-22 Hydraulic System - LINE-OUT 1 - 24...

  • Page 33: Line-Out

    Section 1 Sequence of Operation, High-Performance Winch - LINE-OUT The operator pushes the control lever forward, which brake is fully released. Low pressure case drain oil fl ows sends pilot control pressure to the direction control valve from the hydraulic motor back to the tractor reservoir. This and the brake release valve.
  • Page 34 General Figure 1-23 Hydraulic System - HI-SPEED LINE-OUT 1 - 26...

  • Page 35: Hi-Speed Line-Out

    Section 1 Sequence of Operation, High-Performance Winch - HI- SPEED LINE-OUT When the winch is operated in LINE-OUT, and a load The operator pushes the control lever forward, which pulls line from the winch, pressure builds on the A port sends pilot control pressure to the direction control valve and the brake release valve.
  • Page 36 General Figure 1-24 Hydraulic System - BRAKE-OFF 1 - 28...

  • Page 37: Brake-Off

    Section 1 Sequence of Operation, High-Performance Winch - BRAKE-OFF The operator depresses the BRAKE-OFF switch. Pilot The operator drives away from the load, and the entire control pressure communicates in the logic control mani- gear train rotates as wire rope spools off the drum. The fold to release the brake, open the BRAKE-OFF valve, hydraulic motor effectively operates as a pump and circu- and shift the hydraulic motor to HI-SPEED displacement.
  • Page 38 General Figure 1-25 Hydraulic System - FREESPOOL 1 - 30...

  • Page 39: Freespool

    Section 1 Sequence of Operation, High-Performance Winch - FREESPOOL shift the hydraulic motor to HI-SPEED displacement. Pilot The operator depresses the FREESPOOL switch. Elec- control oil fl ow also saturates the inlet B port of the motor. tronic circuitry also enables the BRAKE-OFF switch, and Pilot control pressure communicates to the FREESPOOL all modes of BRAKE-OFF are active during FREESPOOL shifter fork, allowing the dental clutch to disengage the...
  • Page 40 General Notes 1 - 32...
  • Page 41 Section 1 H6GH*B Figure 1-26 H6GH*B Schematic, High-Performance Winch 1 - 33...
  • Page 42 General H6GH*E Figure 1-27 H6GH*E Schematic, High-Performance Winch 1 - 34...
  • Page 43 Section 1 H6GH*J Figure 1-28 H6GH*J Schematic, High-Performance Winch 1 - 35...
  • Page 44 General H6GT*E Figure 1-29 H6GT*E Schematic, Rescue Winch 1 - 36...

  • Page 45: Troubleshooting

    Section 2 Troubleshooting General Inspect the winch gear train for problems. Winch problems generally fall into one of three categories: 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 Make sure the joystick control assembly (including operating temperature should not exceed pilot controller unit) is functioning properly, with a full...

  • Page 46: 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 47 Section 2 1.14 Operate lever in both directions. Is pressure at RI & RO greater than Verify that pilot pressure to direc- the standby pilot pressure of 275±15 psi? tion spool PA & PB will cause the pump to load sense & cause pilot pressure to increase.
  • Page 48 Troubleshooting PROBLEM POSSIBLE CAUSE CORRECTION Winch gets very hot Low oil level. Add oil; refer to tractor oil specifi cations. Improper oil viscosity. Use correct oil grade; refer to tractor oil speci- fi cations. Winch coated with dirt. Clean winch. Clogged fi...
  • Page 49 Section 2 PROBLEM POSSIBLE CAUSE CORRECTION Winch will not generate suffi - Leak in motor speed spool relief car- Check that the pressures at motor test Ports cient line pull or does not LINE tridge (HI-SPEED only). A & B are suffi cient for operating the winch in -IN or LINE-OUT LINE-IN/OUT with the brake line plugged.
  • Page 50 Troubleshooting PROBLEM POSSIBLE CAUSE CORRECTION HI-SPEED function will not 2-speed spool in motor stuck. Clean and/or repair 2-speed spool. operate. 2-speed pressure switch malfunction- Repair or replace 2-speed pressure switch. ing (normally closed.) 2-speed relay malfunctioning. Repair or replace relay. 2-speed solenoid is not energized.
  • Page 51 Section 2 Notes 2 - 7...
  • Page 52 Troubleshooting Notes 2 - 8...

  • Page 53: Service

    ® Section 3 Service General Maintenance This section provides the instructions for performing main- The Maintenance Schedule is a program that includes tenance and making checks and adjustments. Standard periodic inspection and lubrication. Use the operating shop tools are used in doing the work described in this time on the hour meter of the tractor to determine the section.

  • Page 54: Maintenance Schedule

    Service ® Checks Before Operation a hammer to make sure the bearing is slid- ing. Check resistance to rotation after each adjustment. Check that the cable and hook are not worn or damaged. Check that the periodic inspection and maintenance have been done at the recommended operating hours.

  • Page 55: Standby Pilot Supply Pressure Check

    ® Section 3 Logic Case LINE-OUT Manifold (RO) LINE-IN (RI) HI-SPEED (HS) HI-SPEED (HS) Motor B Brake (BR) Motor A FREESPOOL (FS) Figure 3-4 Hydraulic Pressure Test Ports: S/N H6G-1020 and below Standby Pilot Supply Pressure Check Maximum Pilot Supply Pressure Check With the engine shut off, connect a 1000 psi gauge to the With the same gauge installed from the Standby Pilot tractor pilot test port.

  • Page 56: Counterbalance Valve Pressure Check

    Service ® Counterbalance Valve Pressure Check pressure and OUT to increase pressure. Adjust pres- sures as shown in Figure 3-6. With the engine shut off, connect one 5000 psi pressure gauge to Motor Port B. Start the engine and place han- Motor Supply Pressure Check dlever in LINE-OUT to build pressure against the coun- terbalance valve.

  • Page 57: Brake Pressure Check

    ® Section 3 Measure the pressure at Motor Port A for LINE-IN Loosen Brake Valve locknut. Turn adjusting capscrew or Port B for LINE-OUT. OUT to decrease pressure and IN to increase pres- sure. Adjust pressures as shown in Figure 3-6. Loosen Load Sense Valve locknut.

  • Page 58: Brake-Off Pressure Check

    Service ® If the HI-SPEED pressure is not as specified in Figure is resistance on the winch such as a high FREESPOOL 3-6, check for: drag setting. Pressure should be as specified in Figure 3-6. Improper pilot supply pressure. If the line in pressure is not as specified in Figure 3-6, check for: Malfunctioning solenoid valve.

  • Page 59: Pilot Supply Reducing Valve

    ® Section 3 Pilot supply reducing valve reaches 148-155 psi, adjust valve in until the increase oc- curs at 148-155 psi. Similarly, if the spike does not occur until the pressure at RI is more than148-155 psi, adjust See tractor Service Manual. valve out until it occurs at 148-155 psi.
  • Page 60 Service Notes ® 3 - 8...

  • Page 61: Repairs

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

  • Page 62: Intermediate & Freespoool Shaft Removal

    Repairs - Intermediate & FREESPOOL Shaft Removal Capscrew FREESPOOL Piston O-ring Cover Intermediate Shaft Drum Pinion Gear Dental Clutch Washer Setscrew 10. Nut 11. Bearing Cup 12. Bearing Cone 11,12 13. FREESPOOL Shaft 14. Spring 15. FREESPOOL Piston 16. FREESPOOL Shifter Fork 17.
  • Page 63 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 by rotating counter clockwise and cover and take the cover off. remove the fork.
  • Page 64 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 65 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 66: 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 reassem- bly. Remove retainer ring by removing retainer cap- Remove both drum shaft locknut and the retainer screws.
  • Page 67 Section 4 Remove roller bearing. Carefully remove the drum from winch frame. Ensure that the adapter does not fall. Note: Part of frame shown removed for Roller Bearing clarity Attach a sling around the drum and hoist until there Remove adapter. is no slack, then drive the shaft out the right hand side.
  • Page 68 Repairs - Drum Shaft & Drum Removal 10. Remove and discard adapter seal. 12. Remove and discard shaft seal from drum. (Seal lip should be pointed in.) Adapter Seal Remove and Discard Remove and Discard 13. Using a suitable lifting device, the drum gear can now be removed.
  • Page 69 Section 4 Hydraulic System Disassembly, Rescue Winch Disconnecting the hoses is necessary in order to remove sure to clearly mark the hose ends of any hoses removed with their corresponding ports. the motor shaft assembly. For easier re-installation, be 1,2,3 Detail at Counterbalance Detail at Freespool Valve Manifold...

  • Page 70: Hydraulic System Disassembly, Rescue Winch

    Repairs - Hydraulic System Disassembly, Rescue Winch Capscrew Washer Fitting, Tee Coupler, Male Fitting, El Fitting, El Tube Assembly Capscrew 10. Washer 11. Cross Port Relief Manifold 12. Relief Valve 14. Control Manifold 15. Fitting 16. Fitting 17. Fitting, Tee 18.
  • Page 71 Section 4 Drain oil from winch and remove covers as shown. Remove tube assembly at Port A on the motor. Remove three remaining hoses. Remove the two freespool hoses. Remove the control manifold. Remove the two hoses at the Cross Port Relief Manifold.
  • Page 72 Repairs - Hydraulic System Disassembly, Rescue Winch Remove the cross port relief manifold. Remove the counterbalance valve manifold. 4 - 12...

  • Page 73: Hydraulic System Disassembly, High-Performance Winch

    Section 4 Hydraulic System Disassembly, High-Perfor- mance Winch Disconnecting the hoses is necessary in order to remove sure to clearly mark the hose ends of any hoses removed with their corresponding ports. the motor shaft assembly. For easier re-installation, be Detail at Brake-Off Manifold Detail at...
  • Page 74 Repairs - Hydraulic System Disassembly, Hi-PRFM Winch Connect to Freespool Shifter Fork Detail at Logic Manifold 20. Washer 39. 3-Port Manifold 21. Hose Assembly, Logic Manifold RI Port to Tractor 40. Manifold RI Port 41. Fitting, El 22. Hose Assembly, Directional Manifold Case to Motor 42.
  • Page 75 Section 4 Drain oil from winch. Remove cover plates as shown. Remove the fi ve hoses and wire harness that exit through the frame. Remove the freespool hoses. Remove both hoses at the directional manifold. 4 - 15...
  • Page 76 Repairs - Hydraulic System Disassembly, Hi-PRFM Winch 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 77 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 brake-off manifold assembly from frame.

  • Page 78: 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. FREESPOOL Shaft Removal section).
  • Page 79 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 - 19...
  • Page 80 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 - 20...
  • Page 81 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 82: 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 83 Section 4 12. Remove the spool asssembly. 4 - 23...

  • Page 84: Brake Disassembly

    Repairs - Brake Disassembly Brake Disassembly expires, please contact Allied Systems Company fi rst NOTE: Disassembling the brake while it’s still under its before attempting to repair it. warranty period immediately invalidates the warranty. If the brake malfunctions before its warranty period...
  • Page 85 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). tion. NOTE: Tap female end of spline shaft assembly (item 6) and 1.

  • Page 86: 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 87 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 88: 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 89 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. No- ticeable wear may be apparent along the corner of one side of the vane slot.

  • Page 90: 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 91 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 92: Brake Assembly

    Repairs - Brake Assembly Brake Assembly expires, please contact Allied Systems Company fi rst NOTE: Disassembling the brake while it’s still under its before attempting to repair it. warranty period immediately invalidates the warranty. If the brake malfunctions before its warranty period...
  • Page 93 Section 4 NOTE: Lubricate all rubber components with clean 10. Install springs (item 15) according to pattern and hydraulic fl uid before reassembly. color recorded during disassembly. Clean all parts thoroughly before assembling. 11. Affi x case gaskets (item 11) to pressure plate (item 22) and plate (item 14).

  • Page 94: 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 95 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 over ball Install snap ring. checks and O-ring, then wipe off excess grease.
  • Page 96 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 for high-per- shaft again in both directions to assure that the shaft formance winches.
  • Page 97 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 and The motor and brake can be installed independently of Intermediate Shaft and Gear (see Intermediate Shaft other components (other than various hoses and fi...

  • Page 98: 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 99 Section 4 Reinstall the brake. Install the hydraulic motor. NOTE: For High-Performance winches, Port A and Port B BRAKE-OFF hoses must be installed Install the brackets. before placing motor in winch frame. 4 - 39...

  • Page 100: Hydraulic System Assembly, Rescue Winch

    Repairs - Hydraulic System Assembly, Rescue Winch Hydraulic System Assembly, Rescue Winch 1,2,3 Detail at Counterbalance Detail at Freespool Valve Manifold Shifter Fork 10,35 Detail at Motor Detail at Cross Port and Brake Relief Manifold Figure 4-12 Hydraulic System Components, Rescue Winch_1 4 - 40...
  • Page 101 Section 4 Capscrew Washer Fitting, Tee Coupler, Male Fitting, El Fitting, El Tube Assembly Capscrew 10. Washer 11. Cross Port Relief Manifold 12. Relief Valve 14. Control Manifold 15. Fitting 16. Fitting 17. Fitting, Tee 18. Fitting, El 19. Fitting, Tee 20.
  • Page 102 Repairs - Hydraulic System Assembly, Rescue Winch Install the counterbalance valve manifold. Install the control manifold. Connect the hoses between the control manifold and Install the cross port relief manifold. counterbalance valve manifold. Install tube assembly at Port A on the motor. 4 - 42...
  • Page 103 Section 4 Install the hoses at the cross port relief manifold. Install the two freespool hoses. Figure 4-13 Hydraulic System, Rescue Winch 4 - 43...

  • Page 104: Hydraulic System Assembly, High-Performance Winch

    Repairs - Hydraulic System Assembly, Hi-PRFM Winch Hydraulic System Assembly, High-Perfor- mance Winch Detail at Brake-Off Manifold Detail at Directional Manifold Directional Manifold Counterbalance Valve Cartridge Flangescrew Fitting, El Fitting Fitting Hose Assembly, Motor Port B to Directional Manifold Port B Hose Assembly, Motor Port A to Directional Manifold Port A 10.
  • Page 105 Section 4 Connect to Freespool Shifter Fork Detail at Logic Manifold 19. Hose Assembly, Brake to Logic Manifold BR Port 39. 3-Port Manifold 20. Washer 40. Manifold 21. Hose Assembly, Logic Manifold RI Port to Tractor 41. Fitting, El RI Port 42.
  • Page 106 Repairs - Hydraulic System Assembly, Hi-PRFM Winch Install the brake-off 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 - 46...
  • Page 107 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 108 Repairs - Hydraulic System Assembly, Hi-PRFM Winch 10. Connect the freespool hoses. Figure 4-15 Hydraulic System, High-Performance Winch 4 - 48...
  • Page 109 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 110: 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 Lubriplate or lip seal.
  • Page 111 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 112 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 113 Section 4 13. Install retainer plate using the eight special cap- 16. Secure retainer with capscrews and lockwashers. screws. Tighten capscrews to 90 ft-lbs (12 kg-m). Tighten capscrews to 75 ft-lbs (10 kg-m). 17. Coat shaft nut threads with anti-seize. Install both shaft nuts and torque to 400 ft-lbs (55 kg-m).

  • Page 114: Intermediate & Freespool Shaft Installation

    Repairs - Intermediate & FREESPOOL Shaft Installation Capscrew Freespool Piston O-ring Cover Intermediate Shaft Drum Pinion Gear Dental Clutch Washer Setscrew 10. Nut 11. Bearing Cup 12. Bearing Cone 11,12 13. Freespool Shaft 14. Spring 15. Freespool Piston 16. Freespool Shifter Fork 17.
  • Page 115 Section 4 Intermediate Shaft Installation,FREESPOOL These fi gures show the winch removed from the tractor Place dental clutch on pinion gear. Ensure chamfered with the clutch shaft and brake shaft removed. ramp faces pinion. Install inner bearing assembly if previously removed. Use a liberal amount of lubriplate or other light lube grease to hold the inner bearing cone in place.
  • Page 116 Repairs - Intermediate & FREESPOOL Shaft Installation Install the outer bearing cup and cone. Make sure that Coat the winch frame and retainer with silicone or the cup is fi rmly seated against the bearing cone. other suitable sealing compound. Install shim pack (if necessary) and cover.
  • Page 117 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 118: 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 119 Section 4 Notes 4 - 59...
  • Page 120 Repairs Notes 4 - 60...
  • Page 122 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 12/13/2011 Printed in USA...

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