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General

1 - 22

Figure 1-21  Sequence of Operation - BRAKE-ON, Option Code D 

To Tractor 
Ripper
Valve

Tractor 
Control
Lever

Electric
Operated

Pilot
Supply
From
Tractor

Control Lever
Center Position

To Tractor 
Drain

M5

Brake

Planetary
Reducer

Brake-Off
Clutch

A

B

X1

Counterbalance
Relief Manifold

Control
Manifold

Note: Electrical control wiring 
between the Brake-Off and 
Hi-Speed control switches and 
control manifold are not shown 
for clarity.

High Pressure

Low Pressure

Pilot Pressure

Drain Pressure

ECM

d

Motor

Summary of Contents for H12E

Page 1: ...P N 599049W Printed in U S A 4 7 2020 Hydraulic Winch Please check the Allied Systems website regularly for updates to this manual www alliedsystems com A Product of Sherwood OR USA Service Manual H12E ...

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 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: ...at may improve equipment reliability and or personnel performance NOTE All possible safety hazards cannot be foreseen so as to be included in this manual Therefore you must always be alert to potential hazards that could endanger personnel and or damage the equipment Safety Regulations Each country has its own safety legislation It is in the operator s own interest to be conversant with these regu...

Page 4: ... tension Do not permit riders on the vehicle 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 control lever is in BRAKE ON position and the winch brake is applied Do not use winch as a hoist Tractor and skidder mounted winches are designed for towing Al...

Page 5: ...ad Do not attempt to pull loads in excess of the rated capacity of the winch Keep yourself informed of any applicable codes regulations and standards for the job Your winch may have temperature shut off system for protection of tractor and winch Manual override of high temperature shut off will cause damage to tractor and winch This winch is neither intended designed nor rated for any application ...

Page 6: ...formation 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 503 625 5132 E Mail parts alliedsystems com Also see our website www alliedsystems com where the most current copy of this manual is always available ...

Page 7: ...ce 3 1 General 3 1 Maintenance 3 1 Maintenance Points 3 1 Maintenance Schedule 3 1 Hydraulic System Pressure Tests Ports 3 2 Checks Before Operation 3 3 Checks During Operation 3 3 Hydraulic System Pressure Checks 3 3 Preparation 3 3 Pilot Supply Pressure Check 3 4 Motor Supply Pressure Check 3 5 Brake Pressure Check 3 6 BRAKE OFF Pressure Check 3 7 Brake Valve Pressure Check Adjustment 3 8 LINE I...

Page 8: ...vi Notes ...

Page 9: ...transmitted through a holding brake a planetary speed reducer and two gear reductions to the drum Hydraulic oil is supplied by the tractor mounted pump The tractor provides hydraulic power filtration and cooling Operation of the winch is controlled by a control lever and a BRAKE OFF switch located at the tractor s control station The H12E winch BRAKE OFF function permits the wire rope to be pulled...

Page 10: ...Winch T Standard Tractor Controls Pump Vehicle Code See Figure 1 2 Internal Options B External Pump PFR BRAKE OFF Clutch D External Pump PFR BRAKE OFF Clutch and Hi Speed Control 1 In Addition to the serial number plate the serial number is stamped on the top left hand side of the frame See Figure 1 1 on page 1 1 2 Circled numbers in Figure 1 2 indicate possible gear ratio Notes C O D E C Caterpil...

Page 11: ...Figure 1 3 If the nameplate is missing or the wire rope does not match the information on the nameplate do not operate the winch until its capacity is known and a new nameplate is installed Each winch must be operated within its rated capacity as shown on the nameplate Figure 1 3 Nameplate ALLIED SYSTEMS COMPANY 21433 SW OREGON STREET SHERWOOD OREGON 97140 USA WWW ALLIEDSYSTEMS COM MODEL SERIAL NO...

Page 12: ... center 3 Ferrule Junior 2 3 8 Long X 2 1 4 Diameter Figure 1 4 Drum Wire Rope Capacities Hydraulic Specifications Motor Bent axis variable displacement Brake Dry multi disc spring applied Oil Specifications The hydraulic winch motor and control system operate off of the tractor implement hydraulic system The winch gear case is filled with hydraulic transmission oil and is separate from the tracto...

Page 13: ... 6 8 8 16 Cover Plate 55 60 74 6 81 4 24 94 27 2 Brake Off Clutch Assembly Clutch Plate 35 40 48 54 15 8 18 1 Clutch Housing to Planetary Reducer 33 44 14 9 Keeper 80 108 11 Drum Adapter to Drum Bearing Retainer Plate 180 244 25 Motor to Brake Brake Manifold Bracket 280 379 38 Bearing Cover Clutch Housing Planetary Reducer to Frame Cover Top Clamp Gasket Frame to Top Guard Top Guard to Tractor Mou...

Page 14: ...hydraulic leakage to the motor A planetary gear assembly provides a 18 8 1 gear reduction between the hydraulic motor and the planetary output gear The planetary output gear rotates at the same direction as the hydraulic motor An intermediate gear shaft assembly gives further gear reduction to increase torque at the winch drum Figure 1 8 Rotation Torque Transfer Figure 1 7 Gear Train DRUM GEAR INT...

Page 15: ...s hydraulic pressure to release the brake off clutch BRAKE OFF is used when there is a load attached to the winch wire rope and the operator wants to move the tractor away from the load with wire rope spooling off the drum in a controlled manner In BRAKE OFF hydraulic pressure is applied to release the brake off clutch As wire rope is pulled from the winch the turning drum back drives the winch ge...

Page 16: ... Components CONTROL MANIFOLD CBR MANIFOLD COUNTERBALANCE RELIEF BRAKE OFF CLUTCH BRAKE HYDRAULIC MOTOR PLANETARY REDUCER HYDRAULIC MOTOR BRAKE BRAKE OFF CLUTCH CONTROL MANIFOLD CBR MANIFOLD COUNTERBALANCE RELIEF PLANETARY REDUCER GEAR SPIDER CLUTCH ...

Page 17: ...nimum displacement depending on pressure If the PCOR pressure is set incorrectly the winch may not be able to shift to maximum displacement causing a stall in the motor If the PCOR is set higher than the system pressure of the machine hydraulics the PCOR will never be allowed to shift causing the winch to be stuck in high speed See Section 3 for testing procedures to evaluate if the PCOR is set co...

Page 18: ...plates have teeth that engage the splines inside the brake housing and are held stationary Teeth in the friction discs engage the splines on the motor shaft and rotate with the shaft 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 Capscrew 13 Dowel Pin 14 Spring Pl...

Page 19: ...n the brake and the gear side of the winch Oil in this housing is common to the gear side of the winch Output shaft rotation is the same as input shaft rotation at a reduced speed 1 Sun Gear 2 Primary Carrier Assembly 3 Secondary Carrier Assembly 4 Ring Gear 5 Cover 6 Thrust Washer 7 Fitting 8 Fitting 9 Fitting 10 Label 4 3 2 1 8 5 9 7 6 10 ...

Page 20: ...he motor in the event supply pressure drops below a set point in LINE OUT mode The counterbalance valve allows oil to free flow in the LINE IN mode through a check valve The high pressure relief valves act as an overload relief when supply pressure exceeds the setting of the valve Figure 1 15 Counterbalance Relief Manifold Port A1 Port B Relief Valve Port A Port B Relief Valve Counterbalance Valve...

Page 21: ...LINE IN or LINE OUT to the brake valve When control pressure rises to the brake release pressure setting the brake valve sends pilot pressure to release the brake One solenoid valve is used to send pilot pressure to release the BRAKE OFF CLUTCH The solenoid receives an electrical signal from a switch on the operator console The second solenoid is used on Option Code D winches to command high speed...

Page 22: ...re Drain Pressure To Tractor Ripper Valve Tractor Control Lever Pilot Operated Pilot Supply From Tractor Control Lever Center Position To Tractor Drain Motor Brake Planetary Reducer Brake Off Clutch Note Electrical Control Wiring between the Brake Off control switch and control manifold is not shown for clarity A B X1 Counterbalance Relief Manifold Control Manifold ...

Page 23: ... Option Code B With control lever centered the tractor ripper valve blocks flow to the winch Pilot pressure is present at the control manifold All control lines are open to tank The spring applied holding brake locks the motor shaft from rotating ...

Page 24: ... Valve Tractor Control Lever Pilot Operated Pilot Supply From Tractor Control Lever LINE IN Position To Tractor Drain Motor Brake Planetary Reducer Brake Off Clutch A B X1 RI X1 BR RI Counterbalance Relief Manifold Control Manifold Note Electrical Control Wiring between the Brake Off control switch and control manifold is not shown for clarity ...

Page 25: ...om the control lever applies pressure to the RI port through the shuttle valve to the brake valve At the set pressure the brake valve directs pilot flow to release the brake Pilot pressure at motor X1 port is proportional to control lever position When the pressure at X1 reaches a preset level the motor servo reduces motor displacement to increase line speed If working pressure increases to PCOR s...

Page 26: ... Tractor Ripper Valve Tractor Control Lever Pilot Operated Pilot Supply From Tractor Control Lever LINE OUT Position To Tractor Drain Motor Brake Planetary Reducer Brake Off Clutch A B X1 Controlled by Counterbalance Valve Control Manifold X1 RO RO Note Electrical Control Wiring between the Brake Off control switch and control manifold is not shown for clarity ...

Page 27: ...through the counterbalance relief manifold to the B port and returns through A port Brake release and motor speed control X1 operate the same as in LINE IN mode In LINE OUT operation oil flowing from motor port A to the counterbalance relief manifold is controlled by the counterbalance valve The counterbalance valve maintains sufficient pressure in the motor outlet A line to prevent uncontrolled l...

Page 28: ... Ripper Valve Tractor Control Lever Pilot Operated Pilot Supply From Tractor Control Lever Center Position To Tractor Drain Motor Brake Planetary Reducer Brake Off Clutch A B X1 Counterbalance Relief Manifold Control Manifold Note Electrical Control Wiring between the Brake Off control switch and control manifold is not shown for clarity ...

Page 29: ... activated by a switch located on the operator console An electric signal shifts the BRAKE OFF solenoid valve directing pilot pressure to release the spring applied BRAKE OFF clutch BRAKE OFF should not be used to lower a suspended load or a load that can slide down a slope ...

Page 30: ... Tractor Control Lever Center Position To Tractor Drain M5 Brake Planetary Reducer Brake Off Clutch A B X1 Counterbalance Relief Manifold Control Manifold Note Electrical control wiring between the Brake Off and Hi Speed control switches and control manifold are not shown for clarity High Pressure Low Pressure Pilot Pressure Drain Pressure ECM d Motor ...

Page 31: ... centered the tractor ripper valve blocks flow so hot oil is flowing to the winch counterbalance relief manifold Pilot pressure is present at the counterbalance relief manifold All control lines are open to tank The spring applied holding brake locks the motor shaft from rotating ...

Page 32: ...ifold d High Pressure Low Pressure Pilot Pressure Drain Pressure To Tractor Ripper Valve Pilot Supply From Tractor To Tractor Drain Brake Planetary Reducer Brake Off Clutch A B X1 Counterbalance Relief Manifold ECM M5 Motor Note Electrical control wiring between the Brake Off and Hi Speed control switches and control manifold are not shown for clarity ...

Page 33: ...tractor ripper valve to send oil flowing to the winch through the counterbalance relief manifold and to the motor A port Motor pressure from motor port M5 is directed to the control manifold RO port through the shuttle valve to the brake valve At the set pressure the brake valve directs pilot flow to release the brake ...

Page 34: ...gh Pressure Low Pressure Pilot Pressure Drain Pressure To Tractor Ripper Valve Pilot Supply From Tractor To Tractor Drain Brake Planetary Reducer Brake Off Clutch A B X1 Counterbalance Relief Manifold BR HI SPEED switch activated ECM M5 Motor Note Electrical control wiring between the Brake Off and Hi Speed control switches and control manifold are not shown for clarity ...

Page 35: ...witch on the control panel an electric solenoid valve on the control manifold sends pilot pressure to the X1 port on the motor Pressure commands the servo to reduce motor displacement to increase line speed If working pressure increases to PCOR setting the motor servo begins to increase displacement to increase line pull ...

Page 36: ... Position Control Manifold High Pressure Back Pressure Pilot Pressure Drain Pressure To Tractor Ripper Valve Pilot Supply From Tractor To Tractor Drain Brake Planetary Reducer Brake Off Clutch A B X1 Counterbalance Relief Manifold BR ECM M5 Motor Note Electrical control wiring between the Brake Off and Hi Speed control switches and control manifold are not shown for clarity ...

Page 37: ...ns through A port Brake release operates the same as LINE IN mode In LINE OUT operation oil flowing from motor port A to the counterbalance relief manifold is controlled by the counterbalance valve The counterbalance valve maintains sufficient pressure in the motor outlet A line to prevent uncontrolled lowering of a load If HI SPEED is selected by the operator pilot pressure is sent to the X1 moto...

Page 38: ... Pressure Low Pressure Pilot Pressure Drain Pressure To Tractor Ripper Valve Pilot Supply From Tractor To Tractor Drain Brake Planetary Reducer Brake Off Clutch A B X1 Counterbalance Relief Manifold BO BRAKE OFF switch activated ECM M5 Motor Note Electrical control wiring between the Brake Off and Hi Speed control switches and control manifold are not shown for clarity ...

Page 39: ... activated by a switch located on the operator console An electric signal shifts the BRAKE OFF solenoid valve directing pilot pressure to release the spring applied BRAKE OFF clutch BRAKE OFF should not be used to lower a suspended load or a load that can slide down a slope ...

Page 40: ...6 Sequence of Operation BRAKE ON Komatsu D155AX 6 7 K64 RI X1 PP PD BO RO FS BRAKE A B ACCUM B TS A B X1 L1 Pilot Supply Pilot Drain Pilot Pressure Drain Pressure Brake On Counterbalance Relief Manifold Control Manifold FRONT ...

Page 41: ...KE ON K64 With control lever centered the tractor ripper valve blocks flow to the winch Pilot pressure is present at the control manifold All control lines are open to tank The spring applied holding brake locks the motor shaft from rotating ...

Page 42: ...7 K64 RI X1 PP PD BO RO FS BRAKE A B ACCUM B TS A B X1 L1 Pilot Supply Pilot Drain Low Pressure High Pressure Pilot Pressure Drain Pressure From Dozer Ripper Valve To Dozer Ripper Valve Line In Energized During Hi Speed Counterbalance Relief Manifold Control Manifold FRONT ...

Page 43: ...on the control manifold The brake valve directs pilot flow to release the brake If the operator selects HI SPEED mode by the rocker switch on the control panel an electric solenoid valve on the control manifold sends pilot pressure to the X1 port on the motor Pressure commands the servo to reduce motor displacement to increase line speed If working pressure increases to PCOR setting the motor serv...

Page 44: ...I X1 PP PD BO RO FS BRAKE A B ACCUM B TS A B X1 L1 Pilot Supply Pilot Drain Low Pressure High Pressure Pilot Pressure Drain Pressure To Dozer Ripper Valve From Dozer Ripper Valve Line Out Energized During Hi Speed Back Pressure Counterbalance Relief Manifold Control Manifold FRONT ...

Page 45: ...o the RO port on the control manifold and returns through A port Brake release operates the same as LINE IN mode In LINE OUT operation oil flowing from motor port A to the counterbalance relief manifold is controlled by the counterbalance valve The counterbalance valve maintains sufficient pressure in the motor outlet A line to prevent uncontrolled lowering of a load If HI SPEED is selected by the...

Page 46: ... Sequence of Operation BRAKE OFF Komatsu D155AX 6 7 K64 RI X1 PP PD BO RO FS BRAKE A B ACCUM B TS A B X1 L1 Pilot Supply Pilot Drain Pilot Pressure Drain Pressure Brake Off Counterbalance Relief Manifold Control Manifold FRONT ...

Page 47: ... activated by a switch located on the operator console An electric signal shifts the BRAKE OFF solenoid valve directing pilot pressure to release the spring applied BRAKE OFF clutch BRAKE OFF should not be used to lower a suspended load or a load that can slide down a slope ...

Page 48: ...General 1 40 Notes ...

Page 49: ...Section 1 1 41 Figure 1 30 H12E Hydraulic Electrical Schematic Option Code B Komatsu D275AX 5 K65 ...

Page 50: ...Section 1 1 42 Figure 1 31 H12E Hydraulic Electrical Schematic Option Code D Komatsu D155AX 6 7 K64 Last Used on SN 1044 ...

Page 51: ...Section 1 1 43 Figure 1 32 H12E Hydraulic Electrical Schematic Option Code D Komatsu D155AX 7 8 K64 First Used on SN 1045 ...

Page 52: ...Section 1 1 44 Figure 1 33 H12E Hydraulic Electrical Schematic Option Code B Komatsu D85 15 K50 ...

Page 53: ...Section 1 1 45 Figure 1 34 H12E Hydraulic Electrical Schematic Option Code B Liebherr PR754 L54 ...

Page 54: ...Section 1 1 46 Figure 1 35 H12E Hydraulic Electrical Schematic Option Code B CAT D8T C74 ...

Page 55: ...Section 1 1 47 Figure 1 36 H12E Hydraulic Electrical Schematic Option Code D CAT D8T C74 ...

Page 56: ...Section 1 1 48 Figure 1 37 H12E Hydraulic Electrical Schematic Option Code B John Deere JD 1050K E75 ...

Page 57: ...Section 1 1 49 Figure 1 38 H12E Hydraulic Electrical Schematic Option Code D John Deere JD 1050K E75 ...

Page 58: ...Section 1 1 50 Figure 1 39 H12E Hydraulic Electrical Schematic Option Code D Shantui SD32DQ U64 ...

Page 59: ...Section 1 1 51 Figure 1 40 H12E Hydraulic Electrical Schematic Option Code D CAT D8R C59 ...

Page 60: ...ing supplied to winch Tractor work equipment lever is in locked position Unlock tractor work equipment lever Improper winch hose routing Verify hose connections are in accordance with hydraulic schematic and installation instructions for specific application Low oil Check for proper oil level No pilot pressure PS Tractor work equipment lever is locked Unlock tractor work equipment lever Improper w...

Page 61: ...te sufficient line pull Tractor implement pump relief set too low Check tractor hydraulic system settings Motor damaged Repair or replace motor BRAKE OFF clutch slipping See Troubleshooting for BRAKE OFF Clutch Slipping BRAKE OFF clutch will not operate No BRAKE OFF release pressure Control malfunction Valve not working Check solenoid valve operation Check electrical signal to solenoid valve Check...

Page 62: ...ance valve stuck open Repair or replace valve Brake not engaged or worn Repair brake Oil level too high in gear side cavity Too much oil added Drain excessive oil Check level to LEVEL plug on winch case Oil leaking from hydraulic supply into gear side cavity Locate leak Repair or replace faulty component No HI SPEED mode Option Code D X1 pressure not present at test port HI SPEED switch malfunctio...

Page 63: ...Troubleshooting 2 4 Notes ...

Page 64: ...d oil through fill plug item 4 Check the oil level at oil level check plug item 2 See Oil Specifications and Oil Capacity in Section 1 General This section provides the instructions for performing maintenance and making checks and adjustments Standard shop tools are used in doing the work described in this section Maintenance The Maintenance Schedule is a program that includes periodic inspection ...

Page 65: ...Service 3 2 Cross Port Relief Valve Cross Port Relief Valve Figure 3 2 Hydraulic Pressure Test Ports some items removed for clarity ...

Page 66: ...rformed with a bare drum no wire rope since the drum will rotate during the tests Always wear gloves when handling wire rope Dozer engine must be shut OFF before disconnecting drum wire rope Be careful when you remove the wire rope from the drum The end of the wire rope can move like a compressed spring causing an injury when the ferrule is released from the drum 2 Start the engine and place the w...

Page 67: ...dozer pilot test port see dozer Service Manual 6 Start dozer and set to high free idle 7 Check that the pressure reading is within the range shown for your dozer in Table 3 2 If the pressure is not as specified check for 1 Improper pilot supply valve setting or malfunction See dozer Service Manual 2 Pump pressure setting incorrect See dozer Service Manual 3 Leaking pressure hoses or fittings 4 Cor...

Page 68: ... 207 26 000 29 006 Komatsu D275AX 5 K65 3 781 4 179 26 069 28 813 3 781 4 179 26 069 28 813 Komatsu D85 15 K50 3 070 3 270 21 167 22 546 3 070 3 270 21 167 22 546 Liebherr PR754 L54 3 700 3 840 25 511 26 476 3 700 3 840 25 511 26 476 Liebherr PR756 L56 3 500 3 700 24 132 25 511 3 500 3 700 24 132 25 511 Liebherr RL56 L561 3 860 4 060 26 614 27 993 3 860 4 060 26 614 27 993 CAT D8R Series II C59 3 ...

Page 69: ...free idle 3 Operate the winch in LINE IN and LINE OUT 4 Check pressure The brake requires 300 psi to release Low pressure will result in premature wear of the friction discs and added heat generation If the brake pressure is not at least 300 psi check for 1 Improper pilot supply pressure 2 Malfunctioning control lever low RI and or RO pressure 3 Leaking pressure hoses or fittings 4 Restriction in ...

Page 70: ...ree idle 3 Measure pressure with the BRAKE OFF switch activated 4 The brake off clutch requires 355 psi to release Low pressure will result in premature wear of the friction discs and added heat generation If pressure is not at least 355 psi check for 1 Improper pilot supply pressure 2 Malfunctioning solenoid valve 3 Leaking pressure hoses or fittings 4 Restriction in pressure hose or manifold por...

Page 71: ... setting on the brake release valve will momentarily drive the motor against the brake before the brake releases Table 3 4 Hydraulic Pressure Readings 1000 PSI Gauge at TP BRAKE 1000 PSI Gauge at X1 Dozer Pressure in PSI kPa X1 BRAKE RELEASE PRESSURE TP BRAKE PILOT PRESSURE Komatsu D275AX 5 K65 130 150 896 1 034 500 570 3 447 3 930 Komatsu D85 15 K50 534 618 3 682 4 261 Liebherr PR754 L54 290 350 ...

Page 72: ... 3 Measure pressure with the control lever in the LINE IN position 4 Pressure should be as specified in Table 3 5 If the LINE IN pressure is not as specified in Table 3 5 check for 1 Improper pilot supply pressure 2 Malfunctioning control lever 3 Leaking pressure hoses or fittings 4 Restriction in pressure hose or manifold port Table 3 5 Hydraulic Pressure Readings Line In Hose RI Port Dozer Pilot...

Page 73: ... 3 Measure pressure with the control lever in the LINE OUT position 4 Pressure should be as specified in Table 3 6 If the LINE OUT pressure is not as specified in Table 3 6 check for 1 Improper pilot supply pressure 2 Malfunctioning control lever 3 Leaking pressure hoses or fittings 4 Restriction in pressure hose or manifold port Table 3 6 Pilot Pressure Readings Line Out Hose RO Port Dozer Pilot ...

Page 74: ...22 546 2 400 2 600 16 547 17 926 Liebherr PR754 L54 3 700 3 840 25 511 26 476 3 135 3 335 21 615 22 994 Liebherr PR756 L56 3 500 3 700 24 132 25 511 3 135 3 335 21 615 22 994 Liebherr RL56 L561 3 860 4 060 26 614 27 993 2 990 3 190 20 615 21 994 CAT D8R Series II C59 3 300 3 500 22 753 24 132 2 990 3 190 20 615 21 994 CAT D8T Tier 4 C74 3 430 3 532 23 649 24 352 2 990 3 190 20 615 21 994 John Deer...

Page 75: ...Service 3 12 Notes ...

Page 76: ...inch must be thoroughly cleaned to reduce the possibility of contamination Disconnected hoses should be plugged and open manifold fittings should be capped Winch Disassembly Most repairs require disassembly of the winch although many major assemblies can be removed from the winch with the winch still on the tractor The procedures in this section describe a complete unit overhaul with the winch rem...

Page 77: ... Winch is shown on its side in these illustrations Figure 4 1 Location of Intermediate Shaft Components Intermediate Shaft Removal 1 Shim 005 2 Shim 007 3 Shim 020 4 Intermediate Shaft Cover 5 Roller Bearing Cone 6 Roller Bearing Cup 7 Intermediate Gear 8 Drum Pinion Gear 9 Intermediate Shaft 10 Washer 11 Capscrew ...

Page 78: ...a 3 4 10 UNC slide hammer into the end of the intermediate shaft and partially pull it out Remove outer bearing cup and cone 4 Remove the cover and gasket Discard the gasket 5 Remove the intermediate shaft while ensuring that the intermediate gear does not fall 6 Remove the intermediate gear the drum pinion gear and the inner bearing cone Refer to Figure 4 1 for the location of components ...

Page 79: ...to remove heavy components such as the drum or drum gear by hand Always use a lifting device and the recommended attachments whenever possible Drum Shaft Drum Removal 1 Capscrew 2 Washer 3 O Ring 4 Seal Oil 5 Shim 005 6 Shim 007 7 Shim 020 8 O Ring 9 Thimble Tapered 10 Keeper 11 Capscrew 12 Washer 13 Seal Oil 14 Retainer Ring 15 Adapter 16 O Ring 17 Retainer Drum Shaft 18 Shaft Drum 19 Gear Drum 2...

Page 80: ...hen remove capscrews with thimbles leaving two located 180 apart 2 Remove drum shaft locknuts 3 Remove bearing retainer and shim pack NOTE Tagshimpackforreferenceduringreassembly 4 Remove retainer plate by removing retainer capscrews and washers ...

Page 81: ...sling around the drum and hoist until there is no slack then drive the shaft out the right hand side Support or sling the drum gear so that it does not fall during shaft removal 7 Remove two remaining drum capscrews mentioned in Step 1 8 Carefully remove the drum from winch frame Ensure that the adapter does not fall 9 Remove adapter Drum Shaft Drum Removal ...

Page 82: ...d roller bearing assembly from the left hand end of the drum Discard the oil seal NOTE Bearing cups and spacers are a matched set and must not be interchanged with other bearing set components NOTE Refer to Figure 4 2 on page 4 5 for location of components 12 Using a suitable lifting device the drum gear can now be removed 13 Remove and discard the oil seal from the right hand side of winch housin...

Page 83: ...y in order to remove the motor shaft assembly For easier re installation be sure to clearly mark the hose ends of any hoses removed with their corresponding ports Figure 4 3 Hydraulic System Components NOTE SOME COMPONENTS ARE NOT SHOWN FOR CLARITY Hydraulic System Disassembly ...

Page 84: ...overs as shown 3 Remove the control manifold assembly 4 Loosen the capscrews and remove the counterbalance relief CBR manifold assembly from the mounting bracket 2 Remove the hoses and tube assemblies shown below Tag hose ends and ports for reassembly ...

Page 85: ...l section Inspect all parts for damage and wear as specified in Figure 4 7 Figure 4 4 Motor Shaft Components 1 Planetary Reducer Kit 2 Brake Dry Disc D Mount 3 Housing Clutch 4 Piston Clutch 5 Snap Ring 6 Ring Thrust 7 Bearing Thrust Needle Roller 8 Cup Roller Bearing 9 Cone Roller Bearing 10 Snap Ring 11 Shaft Clutch 12 Ring Seal 13 Assembly Clutch 14 O Ring 15 O Ring 16 Spring 17 Pin 18 Gear Spi...

Page 86: ...r 3 Remove the manifold bracket plate and brake Remove Studs if damaged 4 Remove the bearing cover shims and the bearing 1 Remove the motor support from winch frame Brake Manifold Bracket Plate Studs NOTE Tagshimpackforreferenceduringreassembly ...

Page 87: ...any fittings that would prevent the reducer clutch housing assembly from being removed 7 Remove planetary reducer clutch housing assembly 8 Remove and discard the O ring 9 Remove the clutch housing from the reducer Motor Shaft Removal Disassembly ...

Page 88: ...s drift and remove clutch assembly 12 Pull the clutch assembly from clutch housing Spider Gear Shims Retaining Ring Bearings Shim Ring Snap 6mm Capscrew Seal Ring Clutch Piston Bearing Ring Thrust Ring Snap Bearing Cone Ring Snap Shaft Clutch Assembly Clutch Bearing Cup Clutch Housing Spring Dowel Pin Clutch Assembly 13 Remove clutch piston seal ring and other parts ...

Page 89: ... capscrews in a even cross pattern and replace with three M10 X 45MM long or longer capscrews and tighten alternately to compress spring 1 2 Remove the remaining smaller capscrews evenly Clutch will expand 1 3 Once the clutch has fully expanded remove all capscrews and lock washers 2 Remove pins from the clutch hub Mark the holes where the pins stay for reference when reassembly 3 Remove the clutc...

Page 90: ...Section 4 4 15 Intentionally Blank ...

Page 91: ...ttempting to repair it Figure 4 5 Brake Assembly Brake Disassembly 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 Capscrew 13 Dowel Pin 14 Spring Plate 15 Spring 16 Piston 17 Back Up Ring 18 O Ring 19 Back Up Ring 20 O Ring 22 Pressure Plate 23 Socket Head Screw N...

Page 92: ...n Do not remove shoulder bolts without pressurizing 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 disc is positioned by shoulder bolts item 7 and stator discs are positioned on dowel pins item 13 2 The minimum stack height of discs item 9 and item 10 is 1 173 8 Release pressure to brake before removing fo...

Page 93: ...cer malfunctions before its warranty period expires please contact Allied Systems Company first before attempting to repair it Figure 4 6 Planetary Reducer Assembly Planetary Reducer Disassembly 1 Sun Gear 2 Primary Carrier Assembly 3 Secondary Carrier Assembly 4 Ring Gear 5 Cover 6 Thrust Washer 7 Magnetic Fitting 8 Fitting 9 Fitting 10 Label 4 3 2 1 8 5 9 7 6 10 ...

Page 94: ...m 5 Thrust washer item 6 usually remains with cover item 5 2 Lift sun gear item 1 from primary carrier assembly item 2 3 Remove primary carrier assembly item 2 and secondary carrier assembly item 3 from ring gear item 4 4 Remove fittings items 7 8 9 from the cover item 5 ...

Page 95: ...using Replace damaged seals Inspect the brake motor shaft for wear or damage Replace a damaged shaft Check that the stator discs are flat free of damaged surfaces Replace damaged stator discs Inspect the piston for damage Make sure the seal groove and sealing surfaces are in good condition Replace a damaged piston Always replace the piston seals when the brake is repaired Planetary Reducer Assembl...

Page 96: ...eplace shaft if severely worn Check O ring groove and seal surface Dress groove or replace shaft if severely worn Check for crossthread or damaged threads Dress threads with thread chaser Drum Gear Check for broken or severely worn gear teeth Pay particular attention to leading edges of straight cut gear teeth Replace gear if teeth are broken or severely worn Drum Inspect quad ring groove for burr...

Page 97: ...ttempting to repair it Figure 4 8 Brake Assembly Brake Assembly 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 Capscrew 13 Dowel Pin 14 Spring Plate 15 Spring 16 Piston 17 Back Up Ring 18 O Ring 19 Back Up Ring 20 O Ring 22 Pressure Plate 23 Socket Head Screw Note...

Page 98: ...eaded 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 gaskets item 11 to pressure plate item 22 and spring plate item 14 12 Place unit on a press Using a fixture depress and install four socket head assembly bolts item 12 NOTE Apply two drops of Loctite 242...

Page 99: ...5 Install retainer to height C advancing retainer one tooth decreases height 0 004 6 Advance retainer three additional teeth align with hub splines 7 Draw a line across adjacent teeth with marker 8 Measure height D Figure 4 9 BRAKE OFF Clutch Assembly SECTION A A A A ALIGN SPLINES AS SHOWN RETAINER TOOTH 4 78 D 0 31 B 0 85 A 1 16 C NOTES APPLY LOCTITE 242 THREADLOCKER TORQUE TO 35 40 FT LBS 2 DIME...

Page 100: ...mble clutch 11 Assemble hub pressure plate 12 Install springs in series so that they oppose each other 13 Install retainer to height D use the number of turns required for removal align marks on teeth 14 Install frictions separators clutch plate 15 Insert pins into three equally spaced holes ...

Page 101: ...ecial fixturing external splines cannot be aligned precisely enough for spider gear to assemble This can be overcome by bench pressurizing fully assembled clutch and housing This will be described later 20 Apply Loctite 242 threadlocker to six 1 25mm long capscrews 21 Install three of these shorter capscrews in the open holes Torque to 35 40 ft lbs 48 54 N m 22 Alternately loosen the three longer ...

Page 102: ...Section 4 4 27 Intentionally Blank ...

Page 103: ...Intermediate Shaft and Gear see Intermediate Shaft Installation section 1 Planetary Reducer Kit 2 Brake Dry Disc D Mount 3 Housing Clutch 4 Piston Clutch 5 Snap Ring 6 Ring Thrust 7 Bearing Thrust Needle Roller 8 Cup Roller Bearing 9 Cone Roller Bearing 10 Snap Ring 11 Shaft Clutch 12 Ring Seal 13 Assembly Clutch 14 O Ring 15 O Ring 16 Spring 17 Pin 18 Gear Spider Clutch 19 Bearing Needle Heavy Du...

Page 104: ... stay in grooves and don t get pinched as piston and seal ring engage housing Gently tap with mallet to seat assembly 4 Lower clutch assembly vertically using jib hoist and M12x1 75 metric eyebolt Align paint marks on piston and clutch housing Position seal ring so three locking tabs align with slots in clutch housing and notch will align with 6mm capscrew after rotating Seal Ring Clutch Piston Be...

Page 105: ...ould begin to rotate by hand at about 360 psi 7 3 Increase pressure further clutch should reach full release at 420 psi 7 4 Increase pressure to 700 psi MAX and check for leaks 8 While clutch is released friction disks can be aligned by carefully assembling spider gear and aligning splines Use caution to prevent pinching fingers during spider installation splines are sharp and can cut Needle Beari...

Page 106: ...r item 1 into primary carrier assembly item 2 Sun gear should turn freely by hand 9 3 Clean mating surfaces and apply a bead of gasket eliminator to the face of the cover Item 5 that mates with the ring gear item 4 See instructions on sealant package 9 5 Secure thrust washer item 6 with tangs engaged in cover item 5 NOTE Washer can be secured to cover with a small amount of grease or silicone seal...

Page 107: ... O ring on brake 15 1 Install brake to reducer 15 2 Install manifold bracket to brake 15 3 Torque 3 4 hardware to 280 ft lbs 380 N m Torque M12 hardware to 66 ft lbs 90 N m 13 Apply bead of anaerobic sealant e g Loctite 515 to the RH cover plate Reinstall RH cover plate Torque capscrews to 165 ft lbs 225 N m Studs Brake Assembly Manifold Bracket Install O Ring Here O Ring VIEW A 17 Install the mot...

Page 108: ...Section 4 4 33 Intentionally Blank ...

Page 109: ...8 33 3 PLCS 34 CONNECT HARNESS TO BRAKE OFF SOLENOID LOWER SOLENOID AS INSTALLED IN WINCH 31 30 32 35 36 TOP SOLENOID 34 1 Assembly CBR Manifold 2 Capscrew 3 Washer 4 Assembly Tube Motor A 5 Assembly Tube Motor B 6 Kit Split Flange 7 Fitting 8 Fitting 9 Fitting 10 Fitting 11 Fitting 12 Fitting 13 Fitting 14 Coupler Quick Male 15 Assembly Control Manifold 16 Fitting 17 Fitting 18 Fitting 19 Coupler...

Page 110: ...ontrol manifold Torque capscrews to 28 ft lbs 38 N m 3 Reinstall hose and tube assemblies Alternately tighten connections to prevent placing motor tubes in a bind Adjust mounting bracket as necessary to align with manifold 4 Reinstall covers as shown Torque M12 hardware to 66 ft lbs 90 N m Torque M16 hardware to 165 ft lbs 225 N m ...

Page 111: ...t and motor shaft assembly Drum Drum Shaft Installation 1 Capscrew 2 Washer 3 O Ring 4 Seal Oil 5 Shim 005 6 Shim 007 7 Shim 020 8 O Ring 9 Thimble Tapered 10 Keeper 11 Capscrew 12 Washer 13 Seal Oil 14 Retainer Ring 15 Adapter 16 O Ring 17 Retainer Drum Shaft 18 Shaft Drum 19 Gear Drum 20 Drum 21 Spacer 22 Bearing Roller 24 Capscrew 25 Nut Blind 26 Washer 27 Capscrew 28 Fitting Lube ...

Page 112: ...e lip seal NOTE To prevent drum adapter from falling out insert eyebolt in one of the threaded holes then slip metal bar through eyebolt 3 Replace drum spacer O ring and install spacer in drum bore Install drum oil seal NOTE Smooth side of seal must face outboard 4 Lubricate right hand drum bore Coat right hand seal ring and groove with O ring lube Install new O ring ...

Page 113: ...himbles and screws Tighten progressively and evenly to ensure uniform compression of O ring Do not tighten to final torque until step 16 Drum Drum Shaft Installation 8 Align drum gear with adapter and temporarily secure the drum gear to the adapter using the retainer plate and two capscrews This will ensure that the gear will not fall during installation of the shaft ...

Page 114: ...Reinstall retainer plate using the eight special capscrews Tighten capscrews to 180 ft lbs 244 N m NOTE Capscrews cannot be installed unless drum gearanddrumadapterhavebeenalignedasindicated in Step 8 12 Set bearing retainer into place and tighten capscrews do not tighten to final torque Measure gap between retainer and winch frame in three places around the retainer Add the three indications and ...

Page 115: ...rum Shaft Installation 15 Coat shaft nut threads with anti seize Apply RTV sealant e g Loctite 593 RTV between the left drum nut and frame and between the right drum nut and drum retainer Install both shaft nuts and torque to 400 ft lbs 550 N m 16 Tighten drum to adapter capscrews to 180 ft lbs 244 N m torque ...

Page 116: ...Section 4 4 41 Intentionally Blank ...

Page 117: ...omponents Intermediate Shaft Installation 1 Shim 005 2 Shim 007 3 Shim 020 4 Intermediate Shaft Cover 5 Roller Bearing Cone 6 Roller Bearing Cup 7 Intermediate Gear 8 Drum Pinion Gear 9 Intermediate Shaft 10 Washer 11 Capscrew Intermediate Shaft Installation ...

Page 118: ...ermediate shaft NOTE Install intermediate gear with high shoulder as shown above 3 Install the outer bearing cup and cone Make sure that the cup is firmly seated against the bearing cone 4 Apply 1 8 bead of RTV sealant e g Loctite 593 RTV to the winch frame Install shim pack if necessary 5 Apply 1 8 bead of RTV sealant e g Loctite 593 RTV to the intermediate shaft cover Install intermediate shaft ...

Page 119: ...Repairs 4 44 Notes ...

Page 120: ......

Page 121: ...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 599049W 4 7 2020 Printed in U S A ...

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