Allied Systems Allied H6G Series Service Manual Download

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Safety Precautions

Read, understand and observe the precautions on the following pages

to prevent injury to personnel and damage to equipment.

Winch serial number _________________________

Date put into service _________________________

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.

Summary of Contents for Allied H6G Series

Page 1: ...CUSTOMER EDITION P N 599026W Printed in USA 12 13 2011 Please check the Allied Systems website regularly for updates to this manual www alliedsystems com...

Page 2: ...___________________ Date put into service _________________________ NOTE This publication may be translated to different languages for sole purpose of easy reference in non English speaking locations...

Page 3: ...seen so as to be included in this manual Therefore you must always be alert to poten tial hazards that could endanger personnel and or damage the equipment Safety Regulations Each country has its own...

Page 4: ...e or load Do not use the winch as an anchor for a double or two part line Do not pull the hook through the throat or over the drum which will cause damage When the winch is not in use make sure the co...

Page 5: ...e the ground and tractor are stable enough to pull the intended load Do not attempt to pull loads in excess of the rated capacity of the winch Keep yourself informed of any applicable codes regulation...

Page 6: ...ormation on parts service or ordering consult your local winch dealer or contact Allied Systems Company Allied Systems Company 21433 SW Oregon Street Sherwood OR 97140 USA Phone 503 625 2560 Fax 503 6...

Page 7: ...2 Hydraulic System Pressure Checks 3 2 Preparation 3 2 Pressure Gauges 3 2 Standby Pilot Supply Pressure Check 3 3 Maximum Pilot Supply Pressure Check 3 3 Counterbalance Valve Pressure Check 3 4 Motor...

Page 8: ...vi Notes...

Page 9: ...ted through a holding brake a planetary speed reducer and two gear reductions to the drum Hydraulic oil is supplied by the tractor mounted auxiliary pump cir cuit and utilizes oil filtration and cooli...

Page 10: ...4 88 1 H High Performance Winch Direction Valve Variable or 2 Speed T Rescue Tractor Direction Valve Single Speed See Figure 1 2 B External Pump PFR FS BRAKE OFF Cluch E External Pump PFR FS Early Un...

Page 11: ...h as it is equipped is shown on the nameplate Each winch is shipped from the factory with a nameplate as shown in Figure 1 3 If the nameplate is missing or the cable does not match the information on...

Page 12: ...G TEMPERATURE RANGE TYPICAL AMBIENT TEMPERATURE RANGE ISO SAE F C F C VG 22 10W 5 to 140 20 to 60 5 to 40 20 to 4 VG 32 15W 10 to 160 12 to 71 10 to 55 12 to 13 VG 46 20 20 to 180 7 to 82 20 to 70 7 t...

Page 13: ...rum Shaft Assembly Drum Adapter to Drum Capscrews 5 8 UNF Gr 8 Bearing Retainer Capscrews 1 2 UNF Gr 8 155 90 210 122 22 12 Motor Shaft Gear Retainer Capscrews 3 8 UNC Gr 8 3 Port Manifold to Motor Ca...

Page 14: ...ghly twice the speed A planetary gear assembly gives a 1 6 gear reduction between the hydraulic motor and the planetary output gear Motor shaft direction of rotation is the same as the planetary outpu...

Page 15: ...the dental clutch from the intermediate shaft The drum is now disconnected from the brake and the winch cannot support a load FREESPOOL should not be used if there is a load on the wire rope An uncon...

Page 16: ...speed increases proportionally as the lever is moved farther The switch panel may contain three rocker switches to control FREESPOOL BRAKE OFF and HI SPEED Not every winch is equipped with all three...

Page 17: ...ar side of the winch and Figure 1 12 Planetary Reducer 10 11 13 14 12 15 16 18 17 19 6 7 8 9 4 3 5 1 1 Output Shaft 3 Bearing Cone 4 Bearing Cup 5 Plug 6 Hub 7 Bearing Cup 8 Bearing Cone 9 Thrust Wash...

Page 18: ...earing 4 Oil Seal 5 Cover Plate 6 Spline Shaft Assembly 7 Socket Head Shoulder Bolts 8 Primary Disc 9 Rotor Disc 10 Stator Disc 11 Case Gasket 12 Capscrew 13 Dowel Pin 14 Spring Plate 15 Springs 16 Pi...

Page 19: ...not signaled by the winch to the spool Output speed is proportional to input flow from the pump and inversely proportional to the motor displacement 1 Seal Plate Snap Ring 2 Plate Seal 3 Shaft Seal 4...

Page 20: ...ifted to LINE IN or LINE OUT The two other shuttle valves allow com munication between BRAKE OFF HI SPEED and FREE SPOOL functions The brake valve provides pressure to the brake when the LINE IN or LI...

Page 21: ...e motor work ports are open to the tractor reservoir and pump standby supply pressure is blocked Pilot control pressure is available at the logic control manifold and the control lever There is no pre...

Page 22: ...o the tractor pump load sense controller and the pump displacement is increased or decreased depending on the load induced pressure Oil flows through the motor back through the direction control spool...

Page 23: ...flows through the motor back through the direction control spool and to the trac tor reservoir Simultaneously pilot control pressure at the brake valve is connected to the brake release port and the...

Page 24: ...OOL The operator depresses the FREESPOOL switch Pilot control pressure communicates to the FREESPOOL shifter fork allowing the dental clutch to disengage the drum pinion gear from the intermediate gea...

Page 25: ...Section 1 1 17 Intentionally Blank...

Page 26: ...General 1 18 Figure 1 19 Sequence of Operation BRAKE ON...

Page 27: ...s are open to the tractor reservoir and pump standby supply pressure is blocked Pilot control pressure is available at the logic control manifold and the control lever There is no pressure on the cont...

Page 28: ...General 1 20 Figure 1 20 Hydraulic System LINE IN...

Page 29: ...actor pump load sense controller and the pump displacement is increased or decreased depending on the load induced pressure Oil flows through the motor back through the direction control spool and to...

Page 30: ...General 1 22 Figure 1 21 Hydraulic System HI SPEED LINE IN...

Page 31: ...voir When pressure on the inlet A port of the motor exceeds 3500 psi the load sense relief valve opens The load sense pressure signal decreases and the tractor pump strokes back reducing displacement...

Page 32: ...General 1 24 Figure 1 22 Hydraulic System LINE OUT...

Page 33: ...otor back through the direction control spool and to the trac tor reservoir Simultaneously pilot control pressure at the brake valve is connected to the brake release port and the brake is fully relea...

Page 34: ...General 1 26 Figure 1 23 Hydraulic System HI SPEED LINE OUT...

Page 35: ...B side of the hydraulic motor drops below the pilot setting of the counterbalance valve the counterbalance valve closes and acts as a relief valve on the A port of the hydraulic motor The valve reliev...

Page 36: ...General 1 28 Figure 1 24 Hydraulic System BRAKE OFF...

Page 37: ...also saturates the inlet B port of the motor The operator drives away from the load and the entire gear train rotates as wire rope spools off the drum The hydraulic motor effectively operates as a pu...

Page 38: ...General 1 30 Figure 1 25 Hydraulic System FREESPOOL...

Page 39: ...BRAKE OFF to relieve load on the gear train Pilot con trol pressure communicates in the logic control manifold to release the brake open the BRAKE OFF valve and shift the hydraulic motor to HI SPEED...

Page 40: ...General 1 32 Notes...

Page 41: ...Section 1 1 33 Figure 1 26 H6GH B Schematic High Performance Winch H6GH B...

Page 42: ...General 1 34 Figure 1 27 H6GH E Schematic High Performance Winch H6GH E...

Page 43: ...Section 1 1 35 H6GH J Figure 1 28 H6GH J Schematic High Performance Winch...

Page 44: ...General 1 36 H6GT E Figure 1 29 H6GT E Schematic Rescue Winch...

Page 45: ...ndicator 3 Check winch hydraulic pressures Start with control pressures see Figure 2 1 then check main system pressures 4 Inspect the winch gear train for problems For best operation and life the winc...

Page 46: ...ace or pilot check port right side of dozer No Proceed to step 1 12 Yes Proceed to step 1 7 1 7 Is the pilot standby pressure at least 275 15 psi while the dozer is running at slow idle No Proceed to...

Page 47: ...faults in the drive beyond the motor shaft Yes Operate the winch 2 Winch is sluggish or erratic 2 1 Is the lever assembly in good condition Is there air in pilot lines No Repair or replace the lever...

Page 48: ...induction Motor damaged Some noise is normal However excessive clattering could indicate damage Inspect pump and motor thoroughly Gear or bearing damage Visually inspect repair as needed Drum continue...

Page 49: ...shaft for wear or dam age repair or replace as necessary Motor damaged Repair or replace motor refer to Section 4 BRAKE OFF function will not operate or is difficult to engage BRAKE OFF solenoid is no...

Page 50: ...ly Replace worn parts or entire assembly as necessary Winch does not respond to lever movement 1 Leak in the pilot controller unit on lever control assembly 2 Control valve seized or blocked Check for...

Page 51: ...Section 2 2 7 Notes...

Page 52: ...Troubleshooting 2 8 Notes...

Page 53: ...er 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 as necessary through fill plug item 5 Do not operate t...

Page 54: ...no cable since the drum will rotate during the tests Tractor engine must be shut OFF before dis connecting drum cable Be careful when you remove the cable from the drum The end of the cable can move...

Page 55: ...l 3 Leaking pressure hoses or fittings Maximum Pilot Supply Pressure Check With the same gauge installed from the Standby Pilot Pressure Check bottom tractor blade cylinders and measure Relief Pilot S...

Page 56: ...alance valve adjusting capscrew IN to decrease pressure and OUT to increase pressure Adjust pres sures as shown in Figure 3 6 Motor Supply Pressure Check With the engine shut off connect one 5000 psi...

Page 57: ...se pressure and IN to increase pres sure Adjust pressures as shown in Figure 3 6 FREESPOOL Pressure Check With the engine shut off connect 1000 psi pressure gauges in line on the FS hose at the logic...

Page 58: ...essure will be greater than the standby pilot pressure due to mechanical drag and if there is resistance on the winch such as a high FREESPOOL drag setting Pressure should be as specified in Figure 3...

Page 59: ...lube load sense 1000 psi 6895 kPa gauge FREESPOOL See Table B Check plumbing for leakage Check DV lube orifice Check respective solenoid valves HI SPEED High Perfor mance Winch only HS HI SPEED 1000...

Page 60: ...Service 3 8 Notes...

Page 61: ...inch Removal 1 Drain the oil from the winch 2 Remove the arch or fairlead from the winch If these accessories are left on the winch the winch will not remain level when lifted from the tractor 3 Remov...

Page 62: ...nion Gear 7 Dental Clutch 8 Washer 9 Setscrew 10 Nut 11 Bearing Cup 12 Bearing Cone 13 FREESPOOL Shaft 14 Spring 15 FREESPOOL Piston 16 FREESPOOL Shifter Fork 17 O Ring 18 O Ring 19 Intermediate Gear...

Page 63: ...1 Remove the capscrews securing the shifter shaft cover and take the cover off 2 Disconnect the hose assembly 3 Withdraw the shaft by rotating counter clockwise and remove the fork 4 Remove the inter...

Page 64: ...the location of compo nents 9 Remove bearing cup and cone and the intermediate shaft while ensuring that the intermediate gear does not fall 10 Remove intermediate gear NOTE Remove drum shaft retainer...

Page 65: ...nded attachments whenever possible To remove the drum gear it will be necessary to first remove the intermediate shaft see Intermediate FREESPOOL Shaft Removal section 1 2 3 4 4 5 6 7 8 8 9 10 11 12 1...

Page 66: ...Remove both drum shaft locknut and the retainer capscrews 3 Remove bearing retainer and shim pack NOTE Tag shim pack for reference during reassem bly 4 Remove retainer ring by removing retainer cap s...

Page 67: ...Support or sling the drum gear so that it does not fall during shaft removal 7 Remove two remaining drum capscrews 8 Carefully remove the drum from winch frame Ensure that the adapter does not fall 9...

Page 68: ...hand end of the drum Adapter Seal Remove and Discard Roller Bearing Assembly Drum Seal Spacer Spacer O Ring NOTE Refer to Figure 4 2 on page 4 5 for location of components 12 Remove and discard shaft...

Page 69: ...t Freespool Shifter Fork 36 29 23 22 24 17 18 32 1 2 3 21 8 34 15 27 28 Detail at Counterbalance Valve Manifold 6 7 30 5 5 6 25 8 24 26 33 31 34 19 Detail at Motor and Brake 11 13 13 12 12 20 20 33 32...

Page 70: ...8 Fitting 29 Hose Assembly FS port on Control Manifold to FS port on Bulkhead 30 Hose Assembly Brake port on Control Manifold to Brake 31 Hose Assembly Drain Port on Control Manifold to Motor Drain 32...

Page 71: ...winch and remove covers as shown 3 Remove the two hoses at the Cross Port Relief Manifold 4 Remove tube assembly at Port A on the motor 5 Remove three remaining hoses 6 Remove the control manifold 2...

Page 72: ...Repairs 4 12 7 Remove the cross port relief manifold 8 Remove the counterbalance valve manifold Hydraulic System Disassembly Rescue Winch...

Page 73: ...60 1 Directional Manifold 2 Counterbalance Valve Cartridge 3 Flangescrew 5 Fitting El 6 Fitting 7 Fitting 8 Hose Assembly Motor Port B to Directional Manifold Port B 9 Hose Assembly Motor Port A to Di...

Page 74: ...Port to Tee Fit ting item 52 33 Hose Assembly Tee Fitting item 52 to Tractor Case 34 Fitting Tee 35 O Ring 36 Pressure Switch 37 HoseAssembly DirectionalManifoldTPCPorttoPres sure Switch 38 Brake Off...

Page 75: ...n 4 4 15 1 Drain oil from winch Remove cover plates as shown 3 Remove the five hoses and wire harness that exit through the frame 4 Remove both hoses at the directional manifold 2 Remove the freespool...

Page 76: ...directional manifold to the logic manifold 6 Remove the two hoses connecting the logic manifold to the motor and brake 7 Remove the three hoses off the DV port on the logic manifold 8 Remove the logic...

Page 77: ...nifold bracket from the motor 12 Remove the brake off manifold assembly from frame 9 Remove the hoses between the high pressure A and B ports on the motor and the direction manifold assembly NOTE Port...

Page 78: ...d Gear first see Intermediate FREESPOOL Shaft Removal section Inspect all parts for damage and wear as specified in Figure 4 8 20 17 16 14 9 21 6 5 4 12 10 11 3 29 8 32 26 30 2 15 1 15 23 34 24 22 15...

Page 79: ...Section 4 4 19 2 Remove the support brackets 3 Remove the brake 4 Remove cover plate 5 Remove manifold support bracket from frame 6 Remove planetary reducer assembly 1 Remove the hydraulic motor...

Page 80: ...Repairs 4 20 7 Remove and discard O rings 8 Remove reducer mounting gear retainer spacer and seal ring from reducer 9 Remove and discard O rings from seal ring Motor Shaft Removal Disassembly...

Page 81: ...ring If re leased accidentally it can become an airborne hazard 2 Pry out shaft seal plate with two screwdrivers Remove seal plate O ring from groove in bearing bore 3 Mark one side of the motor for p...

Page 82: ...Place cartridge on any object which will hold it off the table Remove screws and timing plate 9 Remove O ring and springs with a small screwdriver Remove dowels pins 10 Replace plate on rotor stator...

Page 83: ...Section 4 4 23 12 Remove the spool asssembly...

Page 84: ...tempting to repair it 1 Retaining Ring 2 Retaining Ring 3 Bearing 4 Oil Seal 5 Cover Plate 6 Spline Shaft Assembly 7 Socket Head Shoulder Bolts 8 Primary Disc 9 Rotor Disc 10 Stator Disc 11 Case Gaske...

Page 85: ...osition Do not remove shoulder bolts without pres surizing brake to approximately 300 psi or damage may result 7 Remove primary disc item 8 rotor discs item 9 and stator discs item 10 NOTE 1 Primary d...

Page 86: ...please contact Allied Systems Company first before attempting to repair it 10 11 13 14 12 15 16 18 17 19 6 7 8 9 4 3 5 1 1 Output Shaft 3 Bearing Cone 4 Bearing Cup 5 Plug 6 Hub 7 Bearing Cup 8 Beari...

Page 87: ...rom remaining assembly NOTE It may be necessary to strike ring gear with a rubber mallet to loose from hub 5 Remove retaining ring item 10 from groove in out put shaft item 1 Lift thrust washer item 9...

Page 88: ...k age into the brake housing Replace damaged seals Inspect the brake motor shaft for wear or damage Replace a damaged shaft Check that the separator plates are flat free of large blue areas caused by...

Page 89: ...es FREESPOOL Shifter Check oil level in winch is not over full This is an indication that the FREESPOOL hose or piston seals are leaking Tighten or replace FREESPOOL shifter hose Replace piston seals...

Page 90: ...please contact Allied Systems Company first before attempting to repair it Figure 4 9 Planetary Reducer Assembly Planetary Reducer Assembly 10 11 13 14 12 15 16 18 17 19 6 7 8 9 4 3 5 1 1 Output Shaf...

Page 91: ...stalled 5 Clean mating surfaces and apply a bead of silicone sealant to the face of the hub that mates with the ring gear item 11 See instructions on sealant pack age 6 Assemble ring gear item 11 to h...

Page 92: ...g to repair it 1 Retaining Ring 2 Retaining Ring 3 Bearing 4 Oil Seal 5 Cover Plate 6 Spline Shaft Assembly 7 Socket Head Shoulder Bolts 8 Primary Disc 9 Rotor Disc 10 Stator Disc 11 Case Gasket 12 Ca...

Page 93: ...threaded holes in piston are in alignment with through holes in spring plate item 14 when installed 10 Install springs item 15 according to pattern and color recorded during disassembly 11 Affix case...

Page 94: ...ch stator vane points to the rotor and the radiused edge of each rotor vane points to the stator 3 Place cartridge on any object which will hold it off the table Install screws and timing plate 2 Repl...

Page 95: ...n are lined up 7 Install dowel pins and ballchecks into rear housing Install main body O ring 9 Install main body O ring and ball checks into front housing Place a small amount of grease over ball che...

Page 96: ...t the shaft turns smoothly Torque motor to 190 ft lbs Rotate shaft again in both directions to assure that the shaft turns smoothly 13 Reassemble the spool assembly Ensure spool spring and plug are or...

Page 97: ...efore the Freespool Shifter Fork and Intermediate Shaft and Gear see Intermediate Shaft Installation section Figure 4 11 Motor Shaft Components 20 17 16 14 9 21 6 5 4 12 10 11 3 29 8 32 26 30 2 15 1 1...

Page 98: ...cer mounting gear retainer spacer and seal ring in the reducer 3 Install new O rings on reducer mounting 4 Install planetary reducer assembly 5 Install manifold support bracket in frame 1 Install new...

Page 99: ...n 4 4 39 7 Reinstall the brake 8 Install the brackets 9 Install the hydraulic motor NOTE For High Performance winches Port A and Port B BRAKE OFF hoses must be installed before placing motor in winch...

Page 100: ...22 24 17 18 32 1 2 3 21 8 34 15 27 28 Detail at Counterbalance Valve Manifold 6 7 30 5 5 6 25 8 24 26 33 31 34 19 Detail at Motor and Brake 11 13 13 12 12 20 20 33 32 10 35 Detail at Cross Port Relief...

Page 101: ...g Tee 27 Fitting El 28 Fitting 29 Hose Assembly FS port on Control Manifold to FS port on Bulkhead 30 Hose Assembly Brake port on Control Manifold to Brake 31 Hose Assembly Drain Port on Control Manif...

Page 102: ...anifold 2 Install the cross port relief manifold 3 Install the control manifold 4 Connect the hoses between the control manifold and counterbalance valve manifold 5 Install tube assembly at Port A on...

Page 103: ...Section 4 4 43 6 Install the hoses at the cross port relief manifold 7 Install the two freespool hoses Figure 4 13 Hydraulic System Rescue Winch...

Page 104: ...sembly Motor Port B to Directional Manifold Port B 9 Hose Assembly Motor Port A to Directional Manifold Port A 10 Fitting 11 Fitting 12 Hose Assembly Logic Manifold FS Port to Free spool Bulkhead 13 H...

Page 105: ...Fitting item 52 32 Hose Assembly Logic Manifold PD Port to Tee Fit ting item 52 33 Hose Assembly Tee Fitting item 52 to Tractor Case 34 Fitting Tee 35 O Ring 36 Pressure Switch 37 HoseAssembly Directi...

Page 106: ...all the directional manifold bracket 3 Install the directional manifold assembly 4 Install the hoses between the high pressure A and B ports on the motor and the directional manifold assembly 5 Instal...

Page 107: ...ct the hoses from the logic manifold to the motor and the brake 8 Install the hoses connecting the directional manifold to the logic manifold 9 Connect the hoses that exit through the frame and the wi...

Page 108: ...Repairs 4 48 10 Connect the freespool hoses Figure 4 15 Hydraulic System High Performance Winch Hydraulic System Assembly Hi PRFM Winch...

Page 109: ...ation of the intermediate shaft and motor shaft assembly 1 2 3 4 4 5 6 7 8 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 Drum 2 Drum Shaft 3 Bearing Retainer 4 Locknut 5 Adapter 6 Capscrew 7 Thimble 8...

Page 110: ...ip seal 3 Install drum seal Double Lip Seal NOTE To prevent drum adapter from falling out insert eyebolt on marked hole then slip metal bar through eyebolt Drum Seal Roller Bearing Assembly Drum Drum...

Page 111: ...move the seal ring 6 Lubricate right hand drum bore Coat right hand seal ring and groove with O ring lube Install new seal ring Drum Spacer O Ring Seal Ring 8 Align adapter and drum holes then install...

Page 112: ...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 Do not...

Page 113: ...im pack to provide a net fit with 0 005 inch 0 1288 mm tolerance 15 Coat winch frame and bearing retainer with silicone Install drum shaft O ring Install finalized shim pack determined in step 15 If i...

Page 114: ...n Gear 7 Dental Clutch 8 Washer 9 Setscrew 10 Nut 11 Bearing Cup 12 Bearing Cone 13 Freespool Shaft 14 Spring 15 Freespool Piston 16 Freespool Shifter Fork 17 O Ring 18 O Ring 19 Intermediate Gear 20...

Page 115: ...bearing assembly if previously removed Use a liberal amount of lubriplate or other light lube grease to hold the inner bearing cone in place 3 Place dental clutch on pinion gear Ensure chamfered ramp...

Page 116: ...frame and retainer with silicone or other suitable sealing compound Install shim pack if necessary and cover 9 Tighten the six capscrews to 75 ft lbs 10 kg m 10 Position the FREESPOOL shifter fork on...

Page 117: ...ent and disengage ment of intermediate shaft gear Nominal adjust ment should be recessed so two frame threads are exposed in frame Shifter Shaft Cover Gasket 13 Secure the shifter shaft cover and the...

Page 118: ...kg 3 500 lbs before lifting the winch 4 Align the studs with the mounting holes to prevent thread damage 5 Loosely install the two top nuts or capscrews before the winch is fully seated against the tr...

Page 119: ...Section 4 4 59 Notes...

Page 120: ...Repairs 4 60 Notes...

Page 121: ......

Page 122: ...599026W 12 13 2011 Printed in USA To find 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...

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