Allied H6G Service Manual Download

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CUSTOMER

EDITION

P/N 599026W-H6GH1JE47

Printed in USA

10/28/2011

Please check the Allied Systems website

regularly for updates to this manual.

www.alliedsystems.com

Summary of Contents for H6G

Page 1: ...CUSTOMER EDITION P N 599026W H6GH1JE47 Printed in USA 10 28 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 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: ...ds cannot be foreseen 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 safety legislation It is in the operator s own interest to be conversant with these regu lations and to comply with them in full This also applies to local bylaws and regulations in f...

Page 4: ...le 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 Always inspect wire rope tail chain and othe...

Page 5: ...ure 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 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 Th...

Page 6: ...iv Notes ...

Page 7: ...FREESPOOL Drag Adjustment 3 2 Hydraulic System Pressure Checks 3 2 Preparation 3 2 Pressure Gauges 3 2 Standby Pilot Supply Pressure Check 3 2 Maximum Pilot Supply Pressure Check 3 3 Counterbalance Valve Pressure Check 3 3 Motor Supply Pressure Check 3 3 Brake Pressure Check 3 3 Brake Valve Pressure Check 3 3 FREESPOOL Pressure Check 3 4 High Speed Pressure Check 3 4 LINE IN Pressure Check 3 5 LIN...

Page 8: ...vi Notes ...

Page 9: ...H6G torque is transmitted 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 cooling provided by the tractor circuit Flow to the winch is controlled by a control lever and electrical switches located at the tractor s control station The H6G winch has a FREESPO...

Page 10: ...tio Code 1 60 1 H High Performance Hydraulic or Hydrostatic with 2 Speed J External Pump PFR FS with CARC Green Paint 50mm Dia Pin Special Drawbar without Tractor Side Installation Parts 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 Note H6G was previously known as WH6G The W designation has been dropped for si...

Page 11: ...e winch as it is equipped is shown on the nameplate Each winch is shipped from the factory with a nameplate as shown in Figure 1 2 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 If the win...

Page 12: ...uarts 8 liters Hydraulic Specifications Motor Dual displacement vane type Brake Dry multi disc spring applied Wire Rope Diameter H6G Capacity 29 mm 1 1 8 in 51 m 167 ft Note Loosely or unevenly spooled line will change capacities Use flexible wire rope with independent wire rope center Figure 1 4 Ferrule Size and Type for H6G Ferrule Size Type H6G Light Ferrule 2 1 4 x 2 0 Dia Hydraulic System Pum...

Page 13: ...Drum 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 Capscrews 7 16 UNC Gr 8 Directional Manifold Mounting Capscrews 3 8 UNC Gr 8 33 52 33 44 71 44 4 7 4 Torque Specifications ...

Page 14: ...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 output gear at 1 6th the speed An intermediate gear assembly gives further gear re duction to increase torque at the winch drum A dental clutch with splines engages the drum pinion gear and the intermediate gear The operator can disengage the dental clutch w...

Page 15: ...train When FREESPOOL is selected a hydraulically actuated sleeve disengages 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 uncontrolled release of the load will occur Loss of the load can result in injury and or equipment damage The yellow indicator pan...

Page 16: ...ving the lever a small amount results in slow wire rope movement for inching control Line speed increases proportionally as the lever is moved farther The switch panel contains two rocker switches to control FREESPOOL and HI SPEED The tractor must be running to supply hydraulic power to operate these functions A light shows when a switch is on The FREESPOOL switch incorporates a lock to prevent in...

Page 17: ...0 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 Washer 10 Retaining Ring 11 Ring Gear 12 Carrier Assembly 13 Sun Gear 14 Thrust Washer 15 Cover 16 Plug 17 Washer 18 Capscrew 19 Plug this housing is common to the gear side of the winch and output shaft rotation is the same as input shaft rotation at 1 6th th...

Page 18: ...g 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 Piston 17 Back Up Ring 18 O Ring 19 Back Up Ring 20 O Ring 21 Bearing 22 Presure Plate 23 Socket Head Screw springs to release the brake The separator plates have teeth that engage the splines inside the bra...

Page 19: ...e spool Output speed is proportional to input flow from the pump and inversely proportional to the motor displacement 1 Seal Plate Snap Ring 2 Seal Plate 3 Seal Shaft 4 Steel Plate 5 Seal Plate O Ring 6 Bearing Snap Ring 7 Ball Bearing 8 Shaft 9 Bolt 10 Front Housing Internal 11 Dowel Pins Front 12 O Ring 13 Ball Checks 14 Screw 15 Two Speed Plate 16 Stator 17 Rotor 18 Rotor Vane 19 Rotor Vane Spr...

Page 20: ...to send a pressure response to the brake when the winch is shifted to LINE IN or LINE OUT The two other shuttle valves allow communication between HI SPEED and FREESPOOL functions The brake valve provides pressure to the brake when the LINE IN or LINE OUT control pressure exceeds the pilot setting of the valve The HI SPEED and FREESPOOL valves are 3 way electric over hydraulic valves that communic...

Page 21: ...or 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 pressure on the control lines which are open to the tractor reservoir Similarly there is no pressure in the load sense line as it is vented back to the tractor reservoir through an orifice ...

Page 22: ...General 1 14 Figure 1 16 Hydraulic System LINE IN ...

Page 23: ...p 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 directional control spool and to the tractor reservoir Simultaneously pilot control pressure at the brake valve is connected to the brake release port and the brake is fully released Low pressure case drain oil flows from the hydraulic moto...

Page 24: ...General 1 16 Figure 1 17 Hydraulic System HI SPEED LINE IN ...

Page 25: ...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 so pressure at the hydraulic motor decreases a corresponding amount When the operator depresses the HI SPEED switch the HI SPEED solenoid valve in the logic manifold opens and pilot control pressure is communic...

Page 26: ...General 1 18 Figure 1 18 Hydraulic System LINE OUT ...

Page 27: ...through the directional control spool and to the tractor reservoir Si multaneously pilot control pressure at the brake valve is connected to the brake release port and the brake is fully released Low pressure case drain oil flows from the hydraulic motor back to the tractor reservoir This condition drives the winch drum in LINE OUT When the winch is operated in LINE OUT and a load pulls line from ...

Page 28: ...General 1 20 Figure 1 19 Hydraulic System HI SPEED LINE OUT ...

Page 29: ...f 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 relieves when pressure on the A port reaches 4500 psi When the winch is operated in LINE OUT and a load pulls line from the winch pressure builds on the A port of the motor up to the load sense relief setting When ...

Page 30: ...General 1 22 Figure 1 20 Hydraulic System FREESPOOL ...

Page 31: ...ntrol pressure communicates in the logic control manifold to release the brake open the bypass valve and shift the hydraulic motor to HI SPEED displacement Pilot control oil flow also saturates the inlet B port of the motor Pilot control pressure communicates to the FREESPOOL shifter fork allowing the dental clutch to disengage the drum pinion gear from the intermediate gear The gear train is dise...

Page 32: ...General 1 24 Notes ...

Page 33: ...Section 1 1 25 Figure 1 22 H6G Schematic ...

Page 34: ...General 1 26 Intentionally Blank ...

Page 35: ...er indicator 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 winch oil op erating temperature should not exceed 180 F 82 C Winch oil reservoir temperature is monitored at the dozer The John Deere 850JR warning light will come on at 200 F 93 C John Deere 850JR P...

Page 36: ...e 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 step 1 8 Yes Proceed to step 1 10 1 8 Is the pilot pressure 650 psi when the dozer blade is held over relief No Proceed to step 1 10 Yes Proceed to step 1 12 1 10 Can the pilot pressure be increased by ...

Page 37: ...ck for mechanical faults in the drive beyond the motor shaft Yes Operate the winch 2 Winch is sluggish or erratic 2 1 Is the control lever assembly in good condition Is there air in pilot lines No Repair or replace the control lever assembly If there is air in the pilot lines bleed them Yes Proceed to step 2 2 2 2 Is the brake fully released No Check brake release circuit or mechanism See shuttle ...

Page 38: ...ks and other sources of air 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 continues to rotate after control lever is returned to BRAKE ON Direction spool not shifting to cen tered position Direction spool sticking Clean or replace Control lever assembly ...

Page 39: ...r or replace motor refer to Section 4 FREESPOOL will not function or is difficult to engage FREESPOOL shifter fork or collar stuck Remove top covers and inspect shifter fork collar with control lever in FREESPOOL posi tion Repair parts if damaged Leakage at hydraulic connection or FREESPOOL shaft Remove top covers and inspect shifter fork with control lever in FREESPOOL position Replace seals if l...

Page 40: ...c system or loose hydraulic connections Visually inspect winch for leaks and ensure hydraulic connections are secure Line speed is abnormally slow for LINE IN LINE OUT or both 1 Poor pressure signal 2 Leak in the pilot controller unit in the control lever assembly Visually inspect to check for wear on control lever assembly Check for leaks in pilot control ler unit and replace if necessary Leak in...

Page 41: ...Section 2 2 7 Notes ...

Page 42: ...Troubleshooting 2 8 Notes ...

Page 43: ...gure 3 1 H6G Winch Maintenance Points INTERVAL PROCEDURE OR QUANTITY SPECIFICATION 50 hours or weekly Check oil level at plug item 2 Add oil MIL PRF 2105E as necessary through fill plug item 5 Do not operate tractor when checking the oil level See Oil Selection in Section 1 Clean the breather item 6 Remove debris around breather Clean the breather with solvent if necessary Lubricate the rollers on...

Page 44: ...her way to elevate the reservoir temperature is to hold the tractor blade over relief The oil temperature in the winch or tractor reservoir must be at least 20 C 70 F 3 Remove any dirt from the left side of the winch Re move control valve access plate 4 Stabilize engine speed at idle RPM for all tests 5 Leave test plugs securely installed unless testing that port 6 After completing all pressure ch...

Page 45: ...h adjust the load sense relief valve If it is too low proceed with pressure diagnostics to identify other possible problems A damaged motor or pump can cause low pressure at the motor Load Sense Valve Adjustment 1 Leave the brake pressure supply disconnected 2 Start the engine and operate the winch in LINE IN or LINE OUT 3 Measure the pressure at Motor Port A for LINE IN or Port B for LINE OUT 4 L...

Page 46: ...y pilot setting The FREESPOOL shift fork will shift at a minimum of 170 psi All pressures should be as specified in Figure 3 5 If pressures are not as specified in Figure 3 5 check for 1 Improper pilot supply pressure 2 Malfunctioning solenoid valve 3 Leaking pressure hoses or fittings 4 Restriction in pressure hose or manifold port 5 Loose DV lube orifice in B motor port block fitting Figure 3 4 ...

Page 47: ... manifold Start the engine and measure pressure with the control lever in the LINE IN position Pressure 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 speci fied in Figure 3 5 If the LINE IN pressure is not as specified in Figure 3 5 check for 1 Improper pilot supply pressure...

Page 48: ...nse Relief Valve Brake BR Brake 1000 psi 6895 kPa gauge LINE IN 275 650 psi Check plumbing for leakage Check brake for leakage Brake Valve BR Brake RI LINE IN 1000 psi 6895 kPa gauge LINE IN see Brake Valve Set ting Procedure BR 275 650 psi RI 140 160 psi Adjust brake valve FREESPOOL FS FREESPOOL BR Brake HS HI SPEED DV Pilot lube load sense 1000 psi 6895 kPa gauge FREESPOOL 275 650 psi Check plum...

Page 49: ...Section 3 3 7 Notes ...

Page 50: ...Service 3 8 Notes ...

Page 51: ...gure 3 1 H6G Winch Maintenance Points INTERVAL PROCEDURE OR QUANTITY SPECIFICATION 50 hours or weekly Check oil level at plug item 2 Add oil MIL PRF 2105E as necessary through fill plug item 5 Do not operate tractor when checking the oil level See Oil Selection in Section 1 Clean the breather item 6 Remove debris around breather Clean the breather with solvent if necessary Lubricate the rollers on...

Page 52: ...her way to elevate the reservoir temperature is to hold the tractor blade over relief The oil temperature in the winch or tractor reservoir must be at least 20 C 70 F 3 Remove any dirt from the left side of the winch Re move control valve access plate 4 Stabilize engine speed at idle RPM for all tests 5 Leave test plugs securely installed unless testing that port 6 After completing all pressure ch...

Page 53: ...h adjust the load sense relief valve If it is too low proceed with pressure diagnostics to identify other possible problems A damaged motor or pump can cause low pressure at the motor Load Sense Valve Adjustment 1 Leave the brake pressure supply disconnected 2 Start the engine and operate the winch in LINE IN or LINE OUT 3 Measure the pressure at Motor Port A for LINE IN or Port B for LINE OUT 4 L...

Page 54: ...y pilot setting The FREESPOOL shift fork will shift at a minimum of 170 psi All pressures should be as specified in Figure 3 5 If pressures are not as specified in Figure 3 5 check for 1 Improper pilot supply pressure 2 Malfunctioning solenoid valve 3 Leaking pressure hoses or fittings 4 Restriction in pressure hose or manifold port 5 Loose DV lube orifice in B motor port block fitting Figure 3 4 ...

Page 55: ... manifold Start the engine and measure pressure with the control lever in the LINE IN position Pressure 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 speci fied in Figure 3 5 If the LINE IN pressure is not as specified in Figure 3 5 check for 1 Improper pilot supply pressure...

Page 56: ...nse Relief Valve Brake BR Brake 1000 psi 6895 kPa gauge LINE IN 275 650 psi Check plumbing for leakage Check brake for leakage Brake Valve BR Brake RI LINE IN 1000 psi 6895 kPa gauge LINE IN see Brake Valve Set ting Procedure BR 275 650 psi RI 140 160 psi Adjust brake valve FREESPOOL FS FREESPOOL BR Brake HS HI SPEED DV Pilot lube load sense 1000 psi 6895 kPa gauge FREESPOOL 275 650 psi Check plum...

Page 57: ...Section 3 3 7 Notes ...

Page 58: ...Service 3 8 Notes ...

Page 59: ... Drain the oil MIL PRF 2105E 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 Remove the wire rope from the drum Clean the outside of the winch and the area where the winch contacts the tractor Be careful when you remove the wire rope from the drum The end of the wire rope can move ...

Page 60: ...inion 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 Spacer 21 Capscrew 22 Shifter Shaft Cover 23 Gasket Figure 4 1 Location of Intermediate and FREESPOOL Shaft Components Intermediate FREESPOOL Shaft Removal ...

Page 61: ... the tractor 1 Remove the capscrews securing the shifter shaft cover and take the cover off 2 Disconnect the hose assembly 3 Withdraw the shaft and remove the fork 4 Remove the intermediate shaft cover and FREESPOOL piston Shifter Shaft Cover Gasket Hose Assembly Freespool Shaft Freespool Fork Intermediate Shaft Cover Freespool Piston ...

Page 62: ... the location of compo nents 8 Remove bearing cup and cone and the intermediate shaft while ensuring that the intermediate gear does not fall 9 Remove intermediate gear NOTE Remove drum shaft retainer prior to removing intermediate gear See Drum Shaft and Drum Removal section that follows Outer Bearing Intermediate Shaft Drum Pinion Gear Inner Bearing Cone Intermediate Shaft Intermediate Gear Dent...

Page 63: ...ended 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 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 Roller Bearing 9 Drum Gear 10 Capscrew 11 Washer 12 Retainer Plate 13 Capscrew 14 Oil Se...

Page 64: ...0 apart 2 Remove both drum shaft locknut and the retainer capscrews 3 Remove bearing retainer and shim pack NOTE Tagshimpackforreferenceduringreassembly Locknut Capscrew Bearing Retainer Shim Pack Retainer Plate Capscrews 4 Remove retainer ring by removing retainer cap screws Drum Shaft Drum Removal ...

Page 65: ... the shaft out the right hand side NOTE Support or sling the drum gear so that it does not fall during shaft removal 7 Remove two remaining drum capscrews Note Part of frame shown removed for clarity Support Drum and Drum Gear Before Drum Shaft Removal Remove Adapter 8 Carefully remove the drum from winch frame Ensure that the adapter does not fall 9 Remove adapter ...

Page 66: ...11 Remove double tapered roller bearing assembly and drum seal spacer from the left hand end of the drum Remove and Discard NOTE RefertoFigure4 2forlocationofcomponents NOTE Bearing cones cups and spacer are matched set Drum Shaft Drum Removal 12 Remove and discard shaft seal from drum Seal lip should normally be pointed in 13 Using a suitable lifting device the drum gear can now be removed 14 Rem...

Page 67: ... 60 61 63 67 66 65 67 66 64 1 Directional Manifold 2 Counterbalance Valve Cartridge 3 Flangescrew 5 Fitting 6 Fitting 7 Fitting 8 Hose Assembly 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 Hose Assembly Logic Manifold HS Port to Motor 2 Speed Port Direc...

Page 68: ... Manifold PD Port to Tee Fit ting item 52 33 Hose Assembly Tee Fitting item 52 to Tractor Case 34 Fitting 35 O Ring 36 Pressure Switch 37 HoseAssembly DirectionalManifoldTPCPorttoPres sure Switch 38 Bypass Manifold 39 3 Port Manifold 40 Manifold 41 Fitting 42 Fitting Orifice 43 Check Valve 44 HoseAssembly BypassValve 3toBypassMotor Port B 45 HoseAssembly BypassValve 1AtoLogicMani fold DV Port 46 H...

Page 69: ...11 1 Drain oil MIL PRF 2105E 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 hoses ...

Page 70: ...ing the 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 manifold Hydraulic System Disassembly ...

Page 71: ...l manifold bracket from the motor 12 Remove the bypass 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 A and Port B bypass hoses can remain on motor during motor shaft removal procedures ...

Page 72: ... Gear first see Intermediate FREESPOOL Shaft Removal section Inspect all parts for damage and wear as specified in Figure 4 8 1 2 3 4 5 6 8 9 10 11 12 14 15 15 15 16 17 19 20 21 22 23 24 26 27 30 32 33 34 35 1 Motor 2 Manifold Bracket 3 Planetary Reducer 4 Spacer 5 Gear Retainer 6 Capscrew 8 Capscrew 9 Reducer Mounting 10 Seal Ring 11 O ring 12 O Ring 14 Flangescrew 15 Washer 16 Motor Shaft Mounti...

Page 73: ...Section 4 4 15 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 74: ...Repairs 4 16 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 75: ... 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 proper assembly paying careful attention that the cartridge will not be installed upside down Secure the motor prior to loosening the 5 8 11 bolts 4 Remove front housing NOTE Two 5 16 ball checks and ...

Page 76: ...8 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 cartridge Turn rotor stator cartridge over Repeat steps 11 12 11 Remove the rotor Remove both the rotor and stator vanes Motor Disassembly ...

Page 77: ...Section 4 4 19 12 Remove the spool assembly ...

Page 78: ... Company first before attempting 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 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 21 Bearing 22 Pressure Plate 23 Socket Head Screw Figure 4 6 ...

Page 79: ...e is useful to hold the brake in position 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 Primary disc is positioned by shoulder bolts item 7 and stator discs are positioned on dowel pins item 13 8 Release pressure to brake before removing four socket head capscrews ...

Page 80: ...s 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 Bearing Cone 9 Thrust Washer 10 Retaining Ring 11 Ring Gear 12 Carrier Assembly 13 Sun Gear 14 Thrust Washer 15 Cover 16 Plug 17 Washer 18 Capscrew 19 Plug Figure 4 7 Planetary Reducer Assembly Planetary ...

Page 81: ...from 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 from assembly Pull output shaft item 1 from hub item 6 NOTE To remove retaining ring use retaining ring expander tool 6 Remove oil seal item 2 and bearing cones items 3 8 from hub item 6 Inspect bea...

Page 82: ...eak 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 overheating or damaged surfaces Replace damaged separator plates Inspect the piston for damage Make sure the seal groove and sealing surfaces are in good condition Replace a damaged piston Always re...

Page 83: ...al Clutch Check for broken or worn teeth Replace dental clutch if teeth are broken or se verely worn Intermediate Shaft Check for deep scratches or scoring on bearing surfaces at each end of shaft Dress surface or replace shaft if severely worn Check for broken or severely worn splines Replace if splines are broken or severely worn Intermediate Gears Inspect both gears for broken or severely worn ...

Page 84: ...s 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 Bearing Cone 9 Thrust Washer 10 Retaining Ring 11 Ring Gear 12 Carrier Assembly 13 Sun Gear 14 Thrust Washer 15 Cover 16 Plug 17 Washer 18 Capscrew 19 Plug Figure 4 9 Planetary Reducer Assembly Planetary ...

Page 85: ...s installed 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 hub Be sure to align all bolt holes 7 Place carrier assembly item 12 into ring gear while aligning gear teeth Carrier splines mesh with splines on output shaft item 1 8 Place sun gear item 13 into ...

Page 86: ...y first before attempting 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 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 21 Bearing 22 Pressure Plate 23 Socket Head Screw Figure 4 10 Planet...

Page 87: ... pres sure plate item 22 Be sure piston is positioned so threaded holes in piston are in alignment with through holes in spring plate item 14 when in stalled 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 plate item 14 12 Place unit on a press Using a fixture depress and install four socket head asse...

Page 88: ...ch sta tor 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 Replace timing plate on rotor stator cartridge Install O ring and springs and install dowels pins Turn plate over and repeat NOTE Make sure springs are seated in the bottom of the spring pocket in both t...

Page 89: ...stall 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 MIL G 10924F over ball checks and O ring then wipe off excess grease MIL G 10924F 10 Install dowel pins into rotor stator cartridge Pour a small amount of clean oil MIL PRF 2105E into the cartridge then install front housing Make su...

Page 90: ...ns to assure that 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 oriented as shown Motor Assembly ...

Page 91: ...efore the FREESPOOL Shifter Fork and Intermediate Shaft and Gear see Intermediate Shaft Installation section 1 2 3 4 5 6 8 9 10 11 12 14 15 15 15 16 17 19 20 21 22 23 24 26 27 30 32 33 34 35 1 Motor 2 Manifold Bracket 3 Planetary Reducer 4 Spacer 5 Gear Retainer 6 Capscrew 8 Capscrew 9 Reducer Mounting 10 Seal Ring 11 O ring 12 O Ring 14 Flangescrew 15 Washer 16 Motor Shaft Mounting Plate 17 Flang...

Page 92: ...ucer 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 O rings on seal ring Motor Shaft Assembly Installation ...

Page 93: ...Section 4 4 35 7 Reinstall the brake 8 Install the brackets 9 Install the hydraulic motor NOTE Port A and Port B bypass hoses must be in stalled before placing motor in winch frame ...

Page 94: ...1 Directional Manifold 2 Counterbalance Valve Cartridge 3 Flangescrew 5 Fitting 6 Fitting 7 Fitting 8 Hose Assembly 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 Freespool Bulkhead 13 Hose Assembly Logic Manifold HS Port to Motor 2 Speed Port Directional Manifold PA Port to Lo...

Page 95: ...bly Directional Manifold Case to Tee Fitting item 52 32 Hose Assembly Logic Manifold PD Port to Tee Fitting item 52 33 Hose Assembly Tee Fitting item 52 to Tractor Case 34 Fitting 35 O Ring 36 Pressure Switch 37 HoseAssembly DirectionalManifoldTPCPorttoPres sure Switch 38 Bypass Manifold 39 3 Port Manifold 40 Manifold 41 Fitting 42 Fitting Orifice 43 Check Valve 44 HoseAssembly BypassValve 3toBypa...

Page 96: ... 2 Install 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 Install the logic manifold Hydraulic System Assembly ...

Page 97: ...nect 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 wire harness Wire Color Function Yellow Freespool Orange Bypass Blue High Speed ...

Page 98: ...Repairs 4 40 10 Connect the freespool hoses Figure 4 13 Hydraulic System Hydraulic System Assembly ...

Page 99: ...lation 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 Roller Bearing 9 Drum Gear 10 Capscrew 11 Washer 12 Retainer Plate 13 Capscrew 14 Oil Seal 15 Oil Seal 16 O Ring 17 Oil Seal 18 O Ring 19 O Ring 20 Shim 21 Shim 22 Shim ...

Page 100: ...tall drum seal Double Lip Seal NOTE Topreventdrumadapterfromfallingout insert eyebolt on marked hole then slip metal bar through eyebolt Drum Seal Roller Bearing Assembly Drum Drum Shaft Installation NOTE Smooth side of seal must face outboard 4 Lubricate the left hand drum bore with grease MIL G 10924F then install double tapered roller bearing assembly NOTE Bearing cones cups and spacer are matc...

Page 101: ...e drum spacer O ring and install spacer in drum bore Drum Spacer O Ring Seal Ring 7 Move the drum into position while being careful not to move the seal ring 8 Align adapter and drum holes then install the thim bles and screws Tighten progressively and evenly to ensure uniform compression of seal ring Do not tighten to final torque ...

Page 102: ...re 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 Retainer Plate Note Part of frame shown removed for clarity Note Part of frame shown removed for clarity Drum Drum Shaft Installation Do not hammer on drum shaft surface 12 Remove the retainer plate and install the bearing assembly ...

Page 103: ...en retainer and winch frame in three places around the retainer Add the three indications and divide by three to add obtain the average gap Assemble shim 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 intermediate shaft as sembly not installed install...

Page 104: ...on 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 Spacer 21 Capscrew 22 Shifter Shaft Cover 23 Gasket Figure 4 15 Location of Intermediate and Freespool Shaft Components Intermediate FREESPOOL Shaft Installation ...

Page 105: ...stall inner bearing assembly if previously removed Use a liberal amount of grease MIL G 10924F to hold the inner bearing cone in place 3 Place dental clutch on pinion gear Ensure chamfered ramp faces pinion 4 Position intermediate gear in housing NOTE Install intermediate gear with high shoulder down 5 Install intermediate shaft Inner Bearing Cone Drum Pinion Gear Dental Clutch Intermediate Gear I...

Page 106: ...ust cover 8 Coat the winch 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 the dental clutch and install the shifter shaft Intermediate FREESPOOL Shaft Installation Outer Bearing Cup Freespool Piston O Ring Freespool Adjust Cover Freespool Fork ...

Page 107: ...aft gear Nominal adjust ment should be recessed so two frame threads are exposed in frame Hose Assembly Shifter Shaft Cover Gasket Spring Freespool Shaft Apply adhesive sealant to threads 13 Secure the shifter shaft cover and the gasket with capscrews 14 Install cover Tighten capscrews on shifter shaft to 75 ft lbs 10 kg m Winch Frame FREESPOOL Shaft Two Threads ...

Page 108: ... 500 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 tractor 6 Secure the winch in place using the parts listed in the mounting kit instructions Tighten the nuts capscrews alternately at each side of the winch to pull the winch evenly against the tra...

Page 109: ...Section 4 4 51 Notes ...

Page 110: ...Repairs 4 52 Notes ...

Page 111: ......

Page 112: ...599026W H6GH1JE47 10 28 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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