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Section 4

4 - 9

Hydraulic System Disassembly, Rescue
Winch

Disconnecting the hoses is necessary in order to remove
the motor shaft assembly. For easier re-installation, be

Detail at Freespool

Shifter Fork

29 23

1,2,3

Detail at Counterbalance

Valve Manifold

Detail at Motor

and Brake

10,35

Detail at Cross Port

Relief Manifold

sure to clearly mark the hose ends of any hoses removed
with their corresponding ports.

Figure 4-3 Hydraulic System Components, Rescue Winch_1

Содержание Allied H6G Series

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 8: ...vi Notes...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 40: ...General 1 32 Notes...

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 51: ...Section 2 2 7 Notes...

Страница 52: ...Troubleshooting 2 8 Notes...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 60: ...Service 3 8 Notes...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 119: ...Section 4 4 59 Notes...

Страница 120: ...Repairs 4 60 Notes...

Страница 121: ......

Страница 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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