Allied H12E, Service Manual

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Contents
Safety Summary ......................................................... i
General ....................................................................1-1
Introduction ...............................................................1-1
Description ...............................................................1-1
Unit
Identifi cation ...............................................1-2
Serial Number Codes .........................................1-3
Nameplate .........................................................1-3
Specifi cations ...........................................................1-4
Drum Wire Rope Capacities ...............................1-4
Hydraulic Specifi cations .....................................1-4
Oil Specifi cations ...............................................1-4
Oil Capacity ........................................................1-4
Maintenance Decal ............................................1-5
Torque Specifi cations .........................................1-5
Gear Train ................................................................1-6
Operation and Control ..............................................1-7
Hydraulic System ......................................................1-8
Motor
................................................................. 1-9
Brake ................................................................1-10
Planetary Reducer ...........................................1-11
Counterbalance Relief Manifold .......................1-12
Control Manifold ...............................................1-13
Sequence of Operation ...........................................1-14
Option Code B
BRAKE-ON ......................................................1-14
LINE-IN ............................................................1-16
LINE-OUT ........................................................1-18
BRAKE-OFF ....................................................1-20
Option Code D
BRAKE-ON ......................................................1-22
LINE-IN ............................................................1-24
LINE-IN Hi-Speed ............................................1-26
LINE-OUT ........................................................1-28
BRAKE-OFF ....................................................1-30
Komatsu D155AX-6/7 (K64)
BRAKE-ON ......................................................1-32
LINE-IN ............................................................1-34
LINE-OUT ........................................................1-36
BRAKE-OFF ....................................................1-38
Schematics .............................................................1-41
Troubleshooting ......................................................2-1
General .....................................................................2-1
Mechanical/Hydraulic Troubleshooting Charts ..........2-1
Service .....................................................................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-IN Pressure Check ....................................3-9
LINE-OUT Pressure Check ..............................3-10
PCOR Pressure Check ....................................3-11
Repairs ...................................................................4-1
General ....................................................................4-1
Winch Removal ........................................................4-1
Winch Disassembly ..................................................4-1
Intermediate Shaft Removal...............................4-2
Drum Shaft & Drum Removal.............................4-4
Hydraulic System Disassembly ..........................4-8
Motor Shaft Removal & Disassembly...............4-10
BRAKE-OFF Clutch Disassembly ....................4-14
Brake Disassembly ..........................................4-16
Planetary Reducer Disassembly ......................4-18
Winch Assembly .....................................................4-20
Visual
Inspection ..............................................4-20
Brake Assembly ...............................................4-22
BRAKE-OFF Clutch Assembly .........................4-24
Motor Shaft Assembly & Installation ................4-28
Planetary Reducer Assembly ...........................4-31
Hydraulic System Assembly .............................4-34
Drum & Drum Shaft Installation .......................4-36
Intermediate Shaft Installation .........................4-42
Contents