1. Manuals
  2. Brands
  3. Allied Systems Manuals
  4. Winches
  5. H5C Series
  6. Service manual

Allied Systems H5C Series Service Manual

Hide thumbs Also See for H5C Series:
Table of Contents

Advertisement

Quick Links

Download this manual
Service Manual
H5C
Hydraulic Winch
Applicable to winches with serial numbers H5C***1226*** and later.
A Product of
Please check the Allied Systems website
regularly for updates to this manual.
www.alliedsystems.com
Sherwood, OR USA
P/N 599028W
Printed in U.S.A.
12/16/2020

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the H5C Series and is the answer not in the manual?

Questions and answers

Related Manuals for Allied Systems H5C Series

Summary of Contents for Allied Systems H5C Series

  • Page 1 Service Manual Hydraulic Winch Applicable to winches with serial numbers H5C***1226*** and later. A Product of Please check the Allied Systems website regularly for updates to this manual. www.alliedsystems.com Sherwood, OR USA P/N 599028W Printed in U.S.A. 12/16/2020...
  • 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 NOTE: All possible safety hazards cannot be foreseen so as to be included in this The following pages contain general safety warnings manual. Therefore, you must always which supplement specific warnings and cautions be alert to potential hazards that could appearing elsewhere in this manual.
  • Page 4 • Inspect the winch before each use: • Do not use winch as a hoist. Tractor and skidder mounted winches are designed for towing. » Make sure that the controls and instruments operate correctly. » Report the need for repairs immediately. »...
  • Page 5 Safety Summary • Make sure that any hand signals used by ground • Your winch may have temperature shut-off system personnel are clearly defi ned and understood by for protection of tractor and winch. Manual override everyone involved. of high temperature shut-off will cause damage to tractor and winch.
  • 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 Service ..............3-1 General ..............3-1 General ..............1-1 Maintenance .............3-1 Introduction ...............1-1 Maintenance Points ..........3-1 Description ...............1-1 Maintenance Schedule ........3-1 Unit Identifi cation ..........1-2 Checks Before Operation ........3-2 Serial Number Codes .........1-3 Checks During Operation ........3-2 Nameplate ............1-3 FREESPOOL Drag Adjustment ......3-2 Specifi...
  • Page 8 Notes...

  • Page 9: General

    Section 1 General Introduction Description This service manual is for the H5C hydraulic winch. The The H5C Winch is a Power Forward (LINE-IN) and Power following information is included in this manual: Reverse (LINE-OUT) winch. The winch is powered by an internal hydraulic motor connected to the tractor hydraulic Section 1.

  • Page 10: Unit Identifi Cation

    General Unit Identifi cation Allied Winch S/N Nameplate Data For Tractor Mountings 1235 K371 Winch Model Vehicle Code See Figure 1-2 Sequence Number Hydraulic Operation Type T = Standard Internal Options Tractor Direction Valve, Single or 2-Speed D = External Pump, PFR, FS, Overwind, 2-Speed (Rescue) G = External Pump, PFR, FS, Overwind, 2-Speed (Rescue), DRAG-BRAKE (HI-P)

  • Page 11: Serial Number Codes

    Section 1 Serial Number Codes ALLIED SYSTEMS COMPANY The serial number codes are described on page 1-2 of 21433 SW OREGON STREET this manual. The nameplate with the serial number code SHERWOOD, OREGON 97140 USA WWW.ALLIEDSYSTEMS.COM is found on the top left hand side of the winch case. The...

  • Page 12: Specifi Cations

    General Specifi cations Drum Wire Rope Capacities (Drum: 9 Inch Diameter) Length Length WIRE ROPE DIAMETER (2/3 Drum Capacity*) (Full Drum Capacity**) 16 mm (5/8 in) 85 m (279 ft.) 129 m (423 ft.) 19 mm (3/4 in) 60 m (197 ft.) 91 m (298 ft.) 22 mm (7/8 in) 43 m (142 ft.)

  • Page 13: Maintenance Decal

    Section 1 Maintenance Decal Torque Specifi cations Hydraulic Winch Maintenance TORQUE VALUES Hardware Size Recommended Winch Service Intervals ft-lbs. kg-m Hours or Months Filter Winch Brake & Major 3/8-UNC Grade 8 33 - 35 45 - 47 4.6 - 4.8 Gear Oil Clutch Overhaul...

  • Page 14: Gear Train

    General Gear Train (See Fig. 1-8) Freespool Fork The tractor pump or designated winch pump drives the hydraulic motor with hydraulic oil supply. The amount of pressure in the motor is dependent on the size of the load. The motor shaft rotates to give LINE-IN or LINE-OUT. Return oil is directed back to the tractor reservoir in open loop systems and back to the pump in hydrostatic closed Drum...

  • Page 15: Freespool Operation

    Section 1 INTERMEDIATE FREESPOOL Operation (See Fig. 1-10 & 1-11) GEAR The FREESPOOL arrangement allows mechanical dis- DENTAL COLLAR engagement of the drum gear from the remainder of the DRUM PINION GEAR gear train. When FREESPOOL is selected, a hydraulically- INTERMEDIATE actuated sleeve disengages the dental clutch from the SHAFT...

  • Page 16: Operation And Control

    General Operation & Control (See Fig 1-12, 1-13) The switch panel may contain three rocker switches that control FREESPOOL, HI-SPEED and DRAG-BRAKE. The tractor must be running to supply hydraulic power to The H5C winch is designed to operate with a pilot oper- operate these functions.
  • Page 17 Section 1 Figure 1-12 Winch Controls (Installation on Komatsu D51-24 shown. Your controls may vary.) Figure 1-13 Winch Controls (Installation on CAT D6K2 shown. Your controls may vary.) 1 - 9...
  • Page 18 General Note: - ID Towards Minimum pack height of Piston (#10) service items #20 and #21 is 1.397”. Brake Mounting Plate 15. Capscrew Brake Housing 16. Snap Ring Capscrew 17. Belleville Spring Sleeve 18. Snap Ring, External Snap Ring 19. Pressure Plate O-Ring 20.
  • Page 19 Section 1 Seal Plate Snap Ring 14. Screw Seal 15. Timing Plate Steel Plate 16. Stator Seal Plate O-Ring 17. Rotor Bearing Snap Ring 18. Rotor Vane Ball Bearing 19. Rotor Vane Spring, Outer Shaft 20. Rotor Vane Spring, Inner Bolt 21.
  • Page 20 General Counterbalance Valve Relief Valve Port A Port B Port A1 Port B Relief Valve Figure 1-16 Counterbalance Relief Manifold Counterbalance Relief Manifold (See Fig. 1-16) The counterbalance relief (CBR) manifold houses the counterbalance valve allows oil to free fl ow in the LINE- counterbalance valve and the high pressure relief valves.

  • Page 21: Brake

    Section 1 Control Manifold on Installations without DRAG- BRAKE (See Fig. 1-17) pressure rises to the brake release pressure setting, the brake valve sends pilot pressure to release the brake. The control manifold contains the brake valve, two solenoid valves and a shuttle valve to direct pilot pressure to release The solenoids receive electrical signals from switches on the BRAKE and control hydraulic motor displacement.

  • Page 22: Freespool

    General FRONT Typical In-Cab Controls (Your Installation may vary) Freespool Shifter Fork Manifold PRESS-A Control Brake Manifold Freespool Parking Brake Brake Brake Motor 2-Speed Port A Hydraulic Motor Motor Port B High Pressure Low Pressure Back Pressure Drain Pressure Pilot Pressure Figure 1-19 Sequence of Operation - BRAKE-ON, K371 and L39 1 - 14...
  • Page 23 Section 1 Sequence of Operation - BRAKE-ON, K371 and L39 With control lever centered, the tractor ripper valve blocks Pilot pressure is present at the control manifold. All control fl ow to the winch. lines are open to tank. The spring-applied holding brake locks the motor shaft from rotating.

  • Page 24: Freespool

    General FRONT Typical In-Cab Controls (Your Installation may vary) Freespool Shifter Fork Manifold PRESS-A Control Brake Manifold Energized during High Speed Freespool Parking Brake Brake Brake Motor 2-Speed Port A Hydraulic Motor Motor Port B High Pressure Low Pressure Back Pressure Drain Pressure Pilot Pressure Figure 1-20 Sequence of Operation - LINE-IN, K371 and L39...
  • Page 25 Section 1 Sequence of Operation - LINE-IN, K371 and L39 If the operator selects HI-SPEED mode by the rocker Pulling the control lever toward the operator commands switch on the control panel, an electric solenoid valve on the tractor ripper valve to send oil fl owing to the winch, the control manifold sends pilot pressure to the C port through the counterbalance relief manifold and to the motor “A”...

  • Page 26: Freespool

    General FRONT Typical In-Cab Controls (Your Installation may vary) Freespool Shifter Fork Manifold PRESS-A Control Brake Manifold Energized during High Speed Freespool Parking Brake Brake Brake Motor 2-Speed Port A Hydraulic Motor Motor Port B High Pressure Low Pressure Back Pressure Drain Pressure Pilot Pressure Figure 1-21 Sequence of Operation - LINE-OUT, K371 and L39...
  • Page 27 Section 1 Sequence of Operation - LINE-OUT, K371 and L39 If the operator selects HI-SPEED mode by the rocker LINE-OUT operation is similar to LINE-IN except moving switch on the control panel, an electric solenoid valve on the control lever away from the operator reverses fl ow the control manifold sends pilot pressure to the C port at the tractor ripper valve and directs fl...
  • Page 28 General FRONT Typical In-Cab Controls (Your Installation may vary) Freespool Shifter Fork Manifold PRESS-A Control Brake Manifold Freespool Parking Brake Brake Brake Motor 2-Speed Port A Hydraulic Motor Motor Port B High Pressure Low Pressure Back Pressure Drain Pressure Pilot Pressure Figure 1-22 Sequence of Operation - FREESPOOL, K371 and L39 1 - 20...
  • Page 29 Section 1 Sequence of Operation - FREESPOOL, K371 and L39 The dental collar may not fully re-engage until the motor The operator moves the slide lock and depresses the is powered in LINE-IN or LINE-OUT. FREESPOOL switch. By depressing the FREESPOOL switch, pilot oil pressure is diverted to the FREESPOOL piston.
  • Page 30 General FRONT Typical In-Cab Controls (Your Installation may vary) Freespool Shifter Fork TP-B TP-A Manifold PRESS-A Control Brake Manifold Freespool Parking Brake Brake Brake Motor 2-Speed Port A Hydraulic Motor Motor Port B High Pressure Low Pressure Back Pressure Drain Pressure Pilot Pressure Figure 1-23 Sequence of Operation - BRAKE-ON, C805, R371, R42 1 - 22...
  • Page 31 Section 1 Sequence of Operation - BRAKE-ON, C805, R371, R42 With control lever centered, the tractor ripper valve blocks Pilot pressure is present at the control manifold. All control fl ow to the winch. lines are open to tank. The spring-applied holding brake locks the motor shaft from rotating.
  • Page 32 General FRONT Typical In-Cab Controls (Your Installation may vary) Freespool Shifter Fork TP-B TP-A Manifold PRESS-A Control Brake Manifold Energized during High Speed Freespool Parking Brake Brake Brake Motor 2-Speed Port A Hydraulic Motor Motor Port B High Pressure Low Pressure Back Pressure Drain Pressure Pilot Pressure...
  • Page 33 Section 1 Sequence of Operation - LINE-IN, C805, R371, R42 If the operator selects HI-SPEED mode by the rocker Pulling the control lever toward the operator commands switch on the control panel, an electric solenoid valve on the tractor ripper valve to send oil fl owing to the winch, the control manifold sends pilot pressure to the C port through the counterbalance relief manifold and to the motor “A”...
  • Page 34 General FRONT Typical In-Cab Controls (Your Installation may vary) Freespool Shifter Fork TP-B TP-A Manifold PRESS-A Control Brake Manifold Energized during High Speed Freespool Parking Brake Brake Brake Motor 2-Speed Port A Hydraulic Motor Motor Port B High Pressure Low Pressure Back Pressure Drain Pressure Pilot Pressure...
  • Page 35 Section 1 Sequence of Operation - LINE-OUT, C805, R371, R42 If the operator selects HI-SPEED mode by the rocker LINE-OUT operation is similar to LINE-IN except moving switch on the control panel, an electric solenoid valve on the control lever away from the operator reverses fl ow the control manifold sends pilot pressure to the C port at the tractor ripper valve and directs fl...
  • Page 36 General FRONT Typical In-Cab Controls (Your Installation may vary) Freespool Shifter Fork TP-B TP-A Manifold PRESS-A Control Brake Manifold Freespool Parking Brake Brake Brake Motor 2-Speed Port A Hydraulic Motor Motor Port B High Pressure Low Pressure Back Pressure Drain Pressure Pilot Pressure Figure 1-26 Sequence of Operation - FREESPOOL, C805, R371, R42 1 - 28...
  • Page 37 Section 1 Sequence of Operation - FREESPOOL, C805, R371, R42 The dental collar may not fully re-engage until the motor The operator moves the slide lock and depresses the is powered in LINE-IN or LINE-OUT. FREESPOOL switch. By depressing the FREESPOOL switch, pilot oil pressure is diverted to the FREESPOOL piston.
  • Page 38 General Freespool Shifter Drag Fork Brake Housing TP-B TP-A Manifold Brake Control Manifold Parking Brake 2-Speed High Pressure Hydraulic Low Pressure Motor Back Pressure Drain Pressure Pilot Pressure Figure 1-27 Sequence of Operation - BRAKE-ON, Y46F 1 - 30...
  • Page 39 Section 1 Sequence of Operation - BRAKE-ON, Y46F With control lever centered, the tractor ripper valve blocks Pilot pressure is present at the control manifold. All control fl ow to the winch. lines are open to tank. The spring-applied holding brake locks the motor shaft from rotating.
  • Page 40 General Freespool Shifter Drag Fork Brake Housing TP-B TP-A Manifold Brake Control Engergized Manifold During HI-SPEED Parking Brake 2-Speed High Pressure Hydraulic Low Pressure Motor Back Pressure Drain Pressure Pilot Pressure Figure 1-28 Sequence of Operation - LINE-IN, Y46F 1 - 32...
  • Page 41 Section 1 Sequence of Operation - LINE-IN, Y46F If the operator selects HI-SPEED mode, an electric Activating LINE-IN commands the tractor ripper valve to solenoid valve on the control manifold sends pilot pressure send oil fl owing to the winch, through the counterbalance to the C port on the motor.
  • Page 42 General Freespool Shifter Drag Fork Brake Housing TP-B TP-A Manifold Brake Control Engergized Manifold During HI-SPEED Parking Brake 2-Speed High Pressure Hydraulic Low Pressure Motor Back Pressure Drain Pressure Pilot Pressure Figure 1-29 Sequence of Operation - LINE-OUT, Y46F 1 - 34...
  • Page 43 Section 1 Sequence of Operation - LINE-OUT, Y46F If the operator selects HI-SPEED mode, an electric LINE-OUT operation is similar to LINE-IN except LINE- solenoid valve on the control manifold sends pilot pressure OUT reverses fl ow at the tractor ripper valve and directs to the C port on the motor.
  • Page 44 General Freespool Shifter Drag Fork Brake Housing TP-B TP-A Manifold Brake Control Manifold Parking Brake 2-Speed High Pressure Hydraulic Low Pressure Motor Back Pressure Drain Pressure Pilot Pressure Figure 1-30 Sequence of Operation - FREESPOOL, Y46F 1 - 36...
  • Page 45 Section 1 Sequence of Operation - FREESPOOL, Y46F The dental collar may not fully re-engage until the motor When FREESPOOL is activated, pilot oil pressure is di- is powered in LINE-IN or LINE-OUT. verted to the FREESPOOL piston. Pilot control pressure moves the FREESPOOL shifter fork, allowing the dental clutch to disengage the drum pinion gear from the inter- mediate gear.
  • Page 46 General Freespool Shifter Drag Fork Brake Housing TP-B TP-A Manifold Brake Control Manifold Parking Brake 2-Speed High Pressure Hydraulic Low Pressure Motor Back Pressure Drain Pressure Pilot Pressure Figure 1-31 Sequence of Operation - DRAG-BRAKE, Y46F 1 - 38...
  • Page 47 Section 1 Sequence of Operation - DRAG-BRAKE, Y46F Pilot control pressure engages the drag brake. This sup- When DRAG-BRAKE is activated, pilot oil pressure is plies some amount of resistance to rotation of the drum, diverted to the FREESPOOL piston, the parking brake, but doesn’t lock it, allowing the vehicle to drive away from the drag brake, and the HI-SPEED port on the motor.
  • Page 48 General Notes 1 - 40...
  • Page 49 Section 1 H5CT-C805 2-SPEED (CAT D6K2, T4F) Figure 1-32 H5C Hydraulic/Electrical Schematic, Caterpillar D6K2 T4f (C805) 1 - 41...
  • Page 50 Section 1 H5CT-K371 2-SPEED (KOM D51-24) Figure 1-33 H5C Hydraulic/Electrical Schematic, Komatsu D51-24 (K371) 1 - 42...
  • Page 51 Section 1 H5CT-L39 2-SPEED (LIEBHERR PR716) Figure 1-34 H5C Hydraulic/Electrical Schematic, Liebherr PR716 (L39) 1 - 43...
  • Page 52 Section 1 H5CT-R42 2-SPEED (CNH 1650M) H5CT-R371 2-SPEED (CNH 1150M) Figure 1-35 H5C Hydraulic/Electrical Schematic, Case 1650M (R42) & 1150M (R371) 1 - 44...
  • Page 53 Section 1 H5CT-Y46 2-SPEED (TIGERCAT 920) WITH DRAG-BRAKE Figure 1-36 H5C Hydraulic/Electrical Schematic, Tigercat 920 (Y46F) 1 - 45...

  • Page 54: General

    Section 2 Troubleshooting General Mechanical/Hydraulic Troubleshooting Winch problems fall into one of three categories: control For proper hydraulic troubleshooting, the winch oil oper- system, hydraulic system or mechanical system. Follow ating temperature should not exceed 180°F (82°C). Oil the troubleshooting steps below to isolate the problem reservoir temperature is monitored at the dozer.
  • Page 55 Troubleshooting PROBLEM POSSIBLE CAUSE CORRECTION ACTION Winch Operates But Exhibits The Following Problems Winch operates in LINE- Brake shuttle stuck. Check for debris. IN only. Counterbalance valve pilot Check for plugged control manifold passage or missing signal blocked or connected manifold plug.
  • Page 56 Section 2 PROBLEM POSSIBLE CAUSE CORRECTION ACTION Winch Operates But Exhibits The Following Problems 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 specifi cations. Winch coated with dirt.
  • Page 57 Troubleshooting PROBLEM POSSIBLE CAUSE CORRECTION ACTION Winch Operates But Exhibits The Following Problems No HI-SPEED mode HI-SPEED switch Replace switch. malfunction. Wire harness. Check connections and continuity or wire damage - repair or replace harness. Solenoid malfunction. Check solenoid coil resistance and replace if measurement is not between 46-51 Ohms.
  • Page 58 Section 2 PROBLEM POSSIBLE CAUSE CORRECTION ACTION Winch Operates But Exhibits The Following Problems Line speed is abnormally 1. Poor pressure signal. Visually inspect to check for wear on control lever as- slow for LINE-IN, LINE- 2. Leak in the pilot controller sembly.
  • Page 59 Troubleshooting Notes 2 - 6...

  • Page 60: Service

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

  • Page 61: Maintenance Schedule

    Service Checks Before Operation Hydraulic System Pressure Checks Check that the wire rope and hook are not worn or The hydraulic oil and fi lter(s) should be maintained as damaged beyond serviceable condition. Check that the indicated in the dozer Service Manual. If any problems periodic inspection and maintenance have been done are found, they should be corrected before operating the at the recommended operating hours.
  • Page 62 Section 3 Brake Test Port Freespool Test Port Motor A Test Port Motor B Test Port Figure 3-3 Hydraulic Pressure Test Ports (Units without optional DRAG-BRAKE) Motor B Test Port Motor A Test Port Figure 3-4 Hydraulic Pressure Test Ports (Units with optional DRAG-BRAKE) 3 - 3...

  • Page 63: Pilot Supply Pressure Check

    Service Pilot Supply Pressure Check All installations Instructions 1000 PSI Gauge 1. Shut engine off but turn dozer key switch back on to at Dozer Pilot provide electrical power to the winch. Test Port 2. Move dozer work equipment lever to unlock position to enable winch.

  • Page 64: Motor Supply Pressure Check

    Section 3 Motor Supply Pressure Check All installations without optional DRAG-BRAKE If the motor supply pressure is not as specifi ed in Table 3-3, check for: 1. If pressure is too high, check dozer hydraulic system. 2. If it is too low, proceed with troubleshooting to identify other possible problems, including a possibly damaged motor or pump.

  • Page 65: Brake Pressure Check

    Service Brake Pressure Check All installations without optional DRAG-BRAKE Instructions 1. With the engine shut off, connect a 1000 psi pressure gauge to the TP-BRAKE pressure test port on the control manifold. 2. Start dozer and set to high-free idle 3.

  • Page 66: Brake Valve Pressure Check & Adjustment

    Section 3 Brake Valve Pressure Check and Adjustment All installations without optional DRAG-BRAKE 5. Check pressure as indicated in Table 3-4. The brake valve sets the overlap between the hydraulic motor drive and brake release. 6. A low setting on the brake release valve will release the brake before the motor begins driving.

  • Page 67: Freespool Pressure Check

    Service FREESPOOL Pressure Check All installations with optional DRAG-BRAKE Instructions 1. With the engine shut off, connect a 1000 psi pressure gauge to the FREESPOOL pressure test port. 2. Start dozer and set to high-free idle 3. Measure pressure with the FREESPOOL switch activated.

  • Page 68: Line-In Pressure Check

    Section 3 LINE-IN Pressure Check All installations without optional DRAG-BRAKE Instructions 1. With the engine shut off, connect pressure gauge in line on the RI hose at the control manifold. 2. Start dozer and set to high-free idle. 3. Measure pressure with the control lever in the LINE- IN position.

  • Page 69: Line-Out Pressure Check

    Service LINE-OUT Pressure Check All installations without optional DRAG-BRAKE Instructions 1. With the engine shut off, connect pressure gauge in line on the RO hose at the control manifold. 2. Start dozer and set to high-free idle. 3. Measure pressure with the control lever in the LINE- OUT position.

  • Page 70: Motor Supply Pressure Check

    Section 3 Motor Supply Pressure Check All installations with optional DRAG-BRAKE If the motor supply pressure is not as specifi ed in Table 3-7, check for: 1. If pressure is too high, check dozer hydraulic system. 2. If it is too low, proceed with troubleshooting to identify other possible problems, including a possibly damaged motor or pump.

  • Page 71: Brake Pressure Check

    Service Brake Pressure Check All installations with optional DRAG-BRAKE Instructions 1. With the engine shut off, connect a 1000 psi pressure gauge in line with the BR port on the control manifold. 2. Start dozer and set to high-free idle 3.

  • Page 72: Brake Valve Pressure Check & Adjustment

    Section 3 Brake Valve Pressure Check and Adjustment All installations with optional DRAG-BRAKE 5. Check pressure as indicated in Table 3-8. The brake Brake Valve valve sets the overlap between the hydraulic motor drive and brake release. 6. A low setting on the brake release valve will release 1000 PSI Gauge the brake before the motor begins driving.

  • Page 73: Freespool Pressure Check

    Service FREESPOOL Pressure Check All installations with optional DRAG-BRAKE Instructions 1. With the engine shut off, use tees and fi ttings as available to connect a 1000 psi pressure gauge to the FR port. 2. Start dozer and set to high-free idle 3.

  • Page 74: Line-In Pressure Check

    Section 3 LINE-IN Pressure Check LINE-IN Pressure Check All installations without optional DRAG-BRAKE All installations with optional DRAG-BRAKE Instructions 1. With the engine shut off, connect pressure gauge in line on the RI hose at the control manifold. 2. Start dozer and set to high-free idle. 3.

  • Page 75: Line-Out Pressure Check

    Service LINE-OUT Pressure Check All installations with optional DRAG-BRAKE Instructions 1. With the engine shut off, connect pressure gauge in line on the RO hose at the control manifold. 2. Start dozer and set to high-free idle. 3. Measure pressure with the control lever in the LINE- OUT position.

  • Page 76: Drag-Brake Pressure Check

    Section 3 DRAG-BRAKE Pressure Check All installations with optional DRAG-BRAKE Instructions 1. With the engine shut off, connect pressure gauge in line on the DV hose at the control manifold. 2. Start dozer and set to high-free idle 3. Measure pressure with the DRAG-BRAKE switch activated.
  • Page 77 Notes Service 3 - 18...

  • Page 78: Repairs

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

  • Page 79: Drum And Drum Shaft

    Repairs - Drum and Drum Shaft Disassembly Shims Keeper, Ferrule Flangescrew Retainer Washer Capscrew Flangescrew Washer Capscrew 10. Oil Seal 11. Retainer 12. Oil Seal 13. Drum Gear 14. Spacer 15. Roller Bearing Cone 16. Roller Bearing Cup 17. Drum Shaft 18.
  • Page 80 Section 4 O-Ring 11. Roller Bearing Cone Spring, Freespool 12. Roller Bearing Cup O-Ring 13. Nut Capscrew 14. Screw Freespool Shaft 15. Intermediate Gear Freespool Adjust Piston 16. Freespool Shifter Fork O-Ring 17. Freespool Adjust Housing Bearing Cone 18. Flangescrew Roller Bearing Cup 21.

  • Page 81: Motor Removal

    Repairs - Motor Removal Motor Removal Control Manifold Winches without optional DRAG-BRAKE 1. Drain oil from gear compartment or remove breather and install pipe plug. Manifold Note: Tag or label all hydraulic hose ends and tubes to aid during reinstallation. Also note the location of any hose clamps.

  • Page 82: Winches With Optional Drag-Brake

    Section 4 Motor Removal Winches with optional DRAG-BRAKE 1. Drain oil from gear compartment or remove breather 7. Remove the control manifold. and install pipe plug. Note: Tag or label all hydraulic hose ends and tubes to aid during reinstallation. Also note the location of any hose clamps.

  • Page 83: Motor Disassembly

    5/8-11 bolts. ranty. If the motor malfunctions before its warranty period expires, please contact Allied Systems Com- pany fi rst before attempting to repair it. Remove snap ring. Remove front housing. NOTE: Two 5/16” ball checks and one main body O-ring may be dislodged and fall free.
  • Page 84 Section 4 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 85 Repairs - Motor Disassembly 15. Vanes: Normal wear results in slight fl attening of 12. Remove the spool assembly. vane tips which does not impair motor performance. Replace vane if radius is reduced by 50%. Clearance between the rotor vane and rotor vane slot varies with the vane selection.
  • Page 86 Section 4 Intentionally Blank 4 - 9...

  • Page 87: Brake Removal

    Repairs - Brake Removal Brake Removal If you need to service the brake piston, you need to remove 5. Remove the left hand frame side cover. the hydraulic motor to get access to the entire brake as- Note: Be aware that the freespool shaft, idler shaft sembly by using the following procedure.
  • Page 88 Section 4 7. Remove freespool shaft, the gear and the bearing 9. Disconnect the freespool hydraulic hose, remove the from the motor shaft. shift fork assembly and the intermediate gear. Shift Fork Spring Freespool Shaft Gear Motor Shaft (Ref) Snap Ring Bearing Dental Clutch Intermediate Gear...
  • Page 89 Repairs - Brake Removal 11. Temporarily install two longer capscrews removed 13. The oil seals are contained in the brake mounting from the brake mounting plate, to hold the brake plate. Inspect the seals for damage and note the housing to the winch frame. These capscrews need direction they are installed.
  • Page 90 Section 4 This holds the brake piston back and relieves the tension 16. Inspect the friction disc for wear and the separator on the brake disc. plates for wear and fl atness. Note: Care should be taken to keep the friction disc free from oil contamination.

  • Page 91: Brake Disassembly

    Repairs - Brake Disassembly Brake Disassembly Remove brake piston and brake discs. Remove the motor from the motor mounting plate. Re- fer to Hydraulic Motor Removal procedures described earlier. Then loosen the two 1/2” capscrews (one at the The brake is a dry multi-disc design. Do not 12 o’clock, and on at the 6 o’clock position).

  • Page 92: Drag Brake Disassembly

    Section 4 Drag Brake Disassembly If you need to service the drag brake (winches with op- tional DRAG-BRAKE): 1. The drag brake may be serviced with the winch still 7. Remove the drag brake piston, and all O-Rings. Dis- card all O-Rings. installed on the dozer if necessary.

  • Page 93: Winch Assembly

    Repairs - Winch Assembly Winch Assembly been removed. Used bearings often appear satisfactory, All components should be inspected for wear or damage but may fail when placed under a load. When in doubt, as they are removed. Refer to Figure 4-4, Visual Inspec- it is recommended to install a new bearing.
  • Page 94 Section 4 Figure 4-4 Visual Inspection (continued) ITEM INSPECTION REQUIREMENTS CORRECTIVE ACTION Winch Motor Inspect motor shaft seal for wear or dam- Note: A leaky motor shaft seal will contaminate the age. brake with oil and the brake will likely require service. Replace seal.

  • Page 95: Drag Brake Assembly

    Repairs - Brake Assembly Drag Brake Assembly 5. Manually align the internal teeth on the friction discs. 6. Install the internal snap ring to retain the friction and 1. Clean all parts thoroughly. All O-rings, the oil seal, separator plates. and the gasket should be replaced.

  • Page 96: Brake Assembly

    Section 4 Brake Assembly Install brake springs. Make sure that they are stacked together like dinner plates with the outer rim towards Clean all parts thoroughly. you. Install brake discs starting with a separator disc, and Install mounting plate. Hand tighten all four cap- then alternate with a friction disc.

  • Page 97: Brake Installation

    Repairs - Brake Installation Brake Installation 3. Install the brake disc starting with separator plate, then a friction, and continue alternating. You should 1. Remove, clean, and then re-install the round magnet end with a separator plate. There should be a total of that is positioned on the bottom of the winch case (8) separator plates and (7) friction discs.
  • Page 98 Section 4 5. With the piston fully retracted, install the pressure 7. Install the roller bearing in to the mounting plate to plate and the internal snap ring into the groove in help guide the seals over the shaft, to prevent dam- the brake housing.
  • Page 99 Repairs - Brake Installation 12. Install the intermediate gear, the dental clutch, and 14. Install the pinion shaft. the freespool shift fork with the spring. Spring Shift Fork Dental Pinion Shaft Clutch Intermediate Gear 13. Install the freespool shaft and the capscrew. Recon- 15.
  • Page 100 Section 4 16. Position the bearings on the end of the motor and 18. Install the freespool bearing (cone and cup). Inspect the idler shafts. o-ring on freespool adjustment piston, and replace if damaged. Then, install freespool adjustment hous- ing using adhesive/sealant. Torque capscrews to 80 Idler Shaft LBS FT.

  • Page 101: 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 102 Section 4 Press shaft and bearing assembly into front housing Place rotor/stator cartridge onto rear housing. by pressing on the outer race of bearing. NOTE: Make sure assembly marks from step 3 in the Motor Assembly section are lined up. Place seal in seal plate.
  • Page 103 Repairs - Motor Assembly 11. Install 5/8-11 bolts. Torque bolts to 50 ft. lbs. 13. Reassemble the spool assembly. Ensure spool, spring and plug are oriented as shown for high- performance winches. 12. Rotate shaft in both directions to assure that the shaft turns smoothly.
  • Page 104 Section 4 Intentionally Blank 4 - 27...

  • Page 105: Motor Installation Winches Without Optional Drag-Brake

    Repairs - Motor Installation Motor Installation 5. Install right-hand side cover and reposition winch to the upright position. Refi ll gear compartment with the Winches without optional DRAG-BRAKE proper oil, or remove installed pipe plug and reinstall 1. Using suitable lifting device position new motor in breather.

  • Page 106: Winches With Optional Drag-Brake

    Section 4 Motor Installation 3. Reinstall CBR manifold in its original position and hand tighten fasteners only. Winches with optional DRAG-BRAKE 4. Reinstall all tube assemblies, hose assemblies, and 1. Using suitable lifting device position new motor in wiring harnesses. winch frame, in the same orientation as original motor.

  • Page 107: Winch Installation

    Repairs - Winch Installation Winch Installation Align the studs with the mounting holes to prevent thread damage. Thoroughly clean the mounting surfaces on the Loosely install the two top nuts or capscrews before winch and the tractor. Clean the mounting holes and the winch is fully seated against the tractor.
  • Page 109 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 599028W 12/16/2020 Printed in U.S.A.

This manual is also suitable for:

H5ct-c805H5ct-k371H5ct-l39H5ct-r42H5ct-r371H5ct-y46

Table of Contents