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SERVICE MANUAL - Allied Systems Company

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1. 1 2 12 10 11 Q PLL lee im y i 4 N f LA Z NG y 5 fe f Y f E R i an 14 A 4 f Ek ER f A SY Ny 3 L LE WE EA Va TDR E EA L DD SEE WZ GE ZZ 1 ef a Da y GR E S e 17 Y ips AA DG N Gs ZZL LAL AA ly Es bg 21 f f 19 A 22 g f CF Y f 32 f Ne 27 f f 7 sul l TA e 23 A 31 Y Yu d 24 ZA LAX VIEWED FROM THE A DRUM END EES 26 NOTE Intermediate Shaft Assembly Shown Is Not Equipped with Freespool LH Winch Housing Drum O Ring Spacer Oil Seal Double Bearing Cup Qty 2 Seal Ring Capscrew Qty 10 Thimble Qty 10 10 Drum Adapter 11 Oil Seal 12 RH Winch Housing 13 Drum Gear 14 Sealing Capscrew amp Washer 15 Capscrew 16 Retainer Plate 17 Shaft Nut SS OO OI e 18 Drum Shaft 19 Bearing Cone Qty 4 20 Drum Retainer 21 Shims 22 Intermediate Gear 23 Capscrew amp Washer 24 Bearing Cup 25 Retaining Plate 26 Bearing Cone 27 shims 28 Intermediate Shaft 29 Drum Pinion Gear 30 Bearing Cone 31 Bearing Cup 32 Spacer Qty 2 33 O Ring Figure 4 20 Location of Drum and Drum Shaft Components Allied COMPANY Allied WINCH Alied Section 4 Drum Shaft amp Drum Removal Figure 4 18 shows the location of drum and drum shaft 3 Remove bearing retainer and shim pack components Do not attempt to remove heavy compo nents such as the drum or drum gear by hand Always use a lifting device and the recommended att
2. ea LT Se y g gt a 4 Ge SE N St g o d INTERMEDIATE 7 PUMP j SHAFT SH d Cl N A SC PUMP DRIVE GEAR Y q FORWARD Al N Es A CLUTCH REVERSE N CLUTCH A EZZZZA OR 7 N gt S N N m S ZA e EN PE AZ ES Ge WZ Sop SH O gt Gs Y ZA YES Z N Lemay yi N i en Y CLUTCH SHAFT Yj ibd caps i PESAS LLANE LL Allo N St dese 7 A LLL LLL LZ BRAKE SON AN aN A N 4 X CR S 4 z BR f N d BRAKE SHAFT f d N ud El LANES gt VE SI i N d D H SS 4 i f Y Ar SEDE IDA las Z SEDES EE genarr eps Figure 4 1 General Arrangement Non Freespool SR Allied COMPANY A 78 for W6F A 90 for W8L ALLEN HEAD PUSH PULL DETENT S ASSEMBLY CLUTCH SHAFT genarrfs pdf IN Section 4 SHIFTER FORK N SE ANN nN CROSS SHAFT d Ka ZA 7 d E BR AAA g d Z DENTAL CLUTCH O SECTION D D Figure 4 2 Freespool Arrangement PTO Shaft Removal and Disassembly Please refer to Figures 4 3 to 4 16 Before removing the PTO shaft assembly the winch must be removed from the tractor as explained above in Winch Removal SSW SIN Se So ee WN PTO Shaft with Removable Bevel Pinion Gear oldptos tif Snap Ring Bevel Pinion Gear Bearing Carrier O Ring Drilled Head Capscrew Oil Seal
3. 4 10 Accumulators src idad 1 15 Hydraulic Pump Removal amp Disassembly 4 13 Accumulator Control Valve cocco o 1 15 Pump Disassembly mercenaries 4 13 Cooling Oil Relief Valve ceccceeesseeeeeeeees 1 15 P mp INSO A 4 14 Sequence of Operation BRAKE ON 1 16 PUMO GO tries 4 14 Sequence of Operation LINE IN 1 17 Pump Front A Backplates cccccseseeeeeeeees 4 14 Sequence of Operation LINE OUT Pump A 4 14 INGRING auisoaracnnaneic rice 1 18 Clutch Shaft Removal amp Disassembly 4 15 Sequence of Operation BRAKE OFF 1 19 Oil Clutch Disassembly wesicnwvedscedecaesevsncieluzacaxwsechient 4 18 Sequence of Operation FREESPOOL 1 20 Brake Shaft Removal ooccccccccocccnncccconcnnccnnononnnnos 4 21 Intermediate Shaft Removal Non Freespoo 4 22 Section 2 Troubleshooting coocccccconnnnccncnnnnnnnnnns 2 1 Intermediate Shaft Removal Freespoo 4 24 E eege 2 1 Drum Shaft 8 Drum Removal c ooocccccccoccnnccon 4 26 Troubleshooting Analysis Check Chart 2 1 Assembly of the WINCH occcoccccccccnccccnccnnnnconcncnnos 4 30 Troubleshooting Analysis Check Chart for Visual INS CS Here Eet 4 30 FREE LEE 2 3 Drum Shaft amp Drum Installation 4 32 Intermediate Shaft Installation Non Freespoo 4 36 Section 32 Service EE 3 1
4. Repairs Brake Shaft Installation 4 Install right hand bearing assembly and retainer with 5 Adjust shaft endplay as follows out shim pack and tighten capscrews securely Do not tighten to final torque at this time Leave O ring a Using moderate pressure tap RH bearing retainer off retainer at this time to seat brake shaft components b Loosen the capscrews previously installed in Step 4 above Tighten capscrews finger tight only c Measure gap between retainer and winch frame in three places around retainer Add the three mea surements and divide by 3 to obtain the average gap Assemble shim pack 0 000 to 0 004 in 0 000 0 102 mm less than the average gap This will place the desired preload on the brake shaft bearings NOTE the clutch shaft and brake assembly must be installed prior to adjusting the brake shaft endplay See the following Oil Brake Reassembly and Instal lation section 6 Coat winch frame and retainer with sealing com pound Replace RH bearing retainer complete with final shim packs and O rings Use Loctite between shims for sealing in place Tighten six capscrews to 75 ft lbs 10 kg m torque 00 Oo o N A GE Allied COMPANY Allied S Section 4 Oil Clutch Reassembly 3 Install the spring retainer so holes are properly se A CAUTION quenced CAUTION Make certain all parts have been thoroughly cleaned prior to reassembly Dirt particles will seriously affect operati
5. Allied SERVICE IT MANUAL For Power Controlled Winches W6OF WSL W12E PP CUSTOMER EDITION 599787W 06 30 2010 Printed in USA Safety Precautions Observe the following precautions to prevent injury to personnel and damage to equipment Do not operate winch unless tractor is equipped with a rear screen for operator protection against cable break age Authorized operators only Report damage or erratic operation of the winch immediately Do not stand while operating the tractor or the winch Make sure that instruments and controls are operative before working the unit Do not use control levers or handles as machine mounting assists Do not use control levers or handles as hangers for clothes water bags grease guns lunch pails etc Do not permit personnel in the control area when working or making checks on the machine Do not allow riders on the machine or load Use extreme care when operating around other machines Avoid operating near anyone working or standing Do not stand or permit others to stand in a bight loop of the cable Do not stand or permit others to stand near the winch or cable when it is under tension Do not work with a damaged cable broken wire strands or a decrease in the diameter of a cable are warning signs Do not leave the tractor while the winch line is under tension Avoid pulling the hook over the drum and through the throat of the winch Do not anchor a double
6. Figure 1 6 Hydraulic System Hydraulic System See Fig 1 6 The operation of the winch is controlled by an internal hy draulic system When the tractor s PTO is operating this system provides pressure and directs the flow of oil for the main winch functions The hydraulic flow path of these various functions Is depicted in Figures 1 12 through 1 15 The suction strainer and pressure filter remove contami nants from the oil The hydraulic pump supplies pressur ized oil for the system The valve manifold assembly dis tributes and regulates the flow and pressure of hydraulic oil to the clutches and brake while maintaining the cooling oil flow It also controls the release of pressurized oil from the accumulators The accumulators provide pressurized oil for a limited amount of actuation if the hydraulic pump is not functioning This allows the release of the winch brake when the tractor engine or the hydraulic pump is not operating SS Allied COMPANY Forward and Reverse Clutches See Fig 1 7 and 1 8 The forward clutch Figure 1 7 and reverse clutch Figure 1 8 are multi disc types that are hydraulically applied and revclutch tif forwardclutch tif COVER SPIDER REVERSE A ROLLER BEARING BEARING CARRIER PLUG WASHER SNAP RING Section 1 spring released The clutches are cooled by the continu ous oil flow maintained during all operating conditions PISTON 2 RETAINER SS PISTON TC SPRING
7. PUSH ROD wn 0004 SPACER ae USED ONLY ON W6F ASA TS EECHER WITH METALLIC FRICTIONS D aT eri J Ak q oa ee nH i EE Iara SEPARATOR SES mais PLATES D A WS COVER gt COOLING OIL LINE ve V wf PISTON O RING BELLEVILLE A Km PISTON SPRING UW Ka HOUSING QTY 1 FOR W6 WSL S PRESSURE QTY 2 FOR W12E PLATE brakeassy tif CAGE Figure 1 10 Oil Brake Assmbly Oil Brake Assembly See Fig 1 10 The oil brake is a multi disc brake that is spring applied piston moves outward compressing the belleville spring and hydraulically released When pressurized oil is directed which then releases the brake into the cavity between the piston and piston housing the Allied COMPANY 1 13 General 11 12 NAL ZARZA NI ZZA Z Mee K lt SH SECTION B B g wut mg dla ILL ibe Lee mm LETI SH OTT LAX ALIG 7 A a Y AW ctrvalve eps SECTION A A Vo AM EROS ee LZZZZZZZ 77 f S Fer YU Gua eee mT L A man sata E UE ME Allied WINCH OS ot tl lee Ly Mh Valve Body Relief Cartridge Spool Assembly O Ring O Ring Fitting Spool Fitting Spool Spring Plug O Ring O Ring Fitting Nut Capscrew Fitting Oe Ol RN Figure 1 11 Hydraulic Control Valve Hydraulic Control Valve See Fig 1 11 The hydraulic control valve is a single spool valve installed inside the winch frame The flow of h
8. 4 2 3 4 5 6 7 8 9 Figure 1 10 Valve Manifold Assembly Valve Manifold Assembly See Fig 1 10 The valve manifold assembly controls the flow of hydrau lic oil to and from the clutches and brake Passages inside the valve body connect the oil flow with the functions that control the winch Various cartridge solenoid valves within the manifold cavity open and close passages to apply and release the clutches and brake Allied COMPANY Relief Valve A relief valve is part of the valve manifold assembly to prevent excessive hydraulic oil pressure It is a spring loaded poppet type valve mounted below the valve mani fold assembly s inlet port Cooling oil is distributed through the hydraulic lines to the brake and clutches to remove excess heat Oil from the relief valve is discharged directly to the inside of the winch housing When pressure starts to rise above 220 5 psi 1520 35 kPa at the inlet port passage the spring loaded poppet in the relief valve will bypass the excess flow to the cooling passage An orifice in the relief valve poppet prevents oil from becoming trapped behind the poppet and causing a hydraulic lock 1 11 General Capscrew Backplate Assembly O Ring Body Dowel Pin Drive Gear Assembly Idler Gear Assembly Key Seal Package Spring Ball Front Plate Assembly Shaft Seal 4 2 3 d 5 6 de 8 9 pump eps Figure 1 11 Hydraulic Pump Hydraulic Pum
9. INTERMEDIATE SHAFT RETAINER BRAKE SHAFT RETAINER siderightbw tif Figure 1 1 Model Views Winch Shown with Optional Fairlead Installed Allied COMPANY 1 1 General Unit Identification Allied Winch S N Nameplate Data For Tractor Mountings A WIZE E Manufactured By A Allied Systems Company Blank Indicates Hyster Winch Model Type Drive P Power Controlled Cable E Electronically Controlled 6 N 1995 C68 Lo Tractor See Table 1 1 Sequence Number Internal Option Non Freespool N Notes 1 In addition to the serial number plate the serial number is stamped into the top left hand side of the frame 2 Circled numbers in Table 1 1 indicate possible gear ratios Table 1 1 Tractor Identification and Gear Ratio for W12E Winch Tractor Make Model and Ces Tractor Serial Number Where Applicable D750A TD25C PS D800 TD25E G E 2 Gear Ratio 1 46 1 3 60 1 4 84 1 6 149 1 Fiat Hitachi New Holland 583 Serial No 78V 61A 594 Serial No 96V 62H D8L DON D9R Re Br Steer ES ES DOR Diff Steering 1 2 Allied COMPANY Allied Section 1 Nameplate The rated capacity for the 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 name Allied plate is missing or the cable does not match the informa tion on the nameplate do not operate the winc
10. 25 kg cm gauge Line Out Reverse C Reverse 1 400 psi 25 kg cm gauge Line Out Inching C Reverse D Brake EQUIPMENT REQUIRED CONTROL POSITION Brake Off Brake On Brake Off Brake On Stop engine Brake Off 5 Repeat if required Line In Vary between Brake On and Line In Vary between Brake On and Line Out 220 psi 15 5 kg cm Pressure not to exceed 250 psi 17 6 kg cm at high idle 8 11 psi 0 57 0 825 kg cm at full throttle 220 psi 15 5 kg cm None None wait 1 minute 145 psi 10 6 kg cm immediately amp 100 psi 7 kg cm minimum after 30 seconds 220 psi 15 5 kg cm Port B 50 psi 3 5 kg cm less than Port D Deere 750 755 amp Komatsu use 90 psi 6 3 kg cm 220 psi 15 5 kg cm Port C 120 psi 8 4 kg cm less than Port D Section 3 CORRECTIVE ACTION Adjust relief valve Check or replace cooling oil relief valve Check hydraulic lines for leaks Replace accumulator valve Check for defective accumulators Refer to Section 2 Table 2 1 for Low Forward or Reverse Clutch Pressure troubleshooting procedures Check or replace forward modulator valve Refer to Section 2 Table 2 1 for Low Forward or Reverse Clutch Pressure troubleshooting procedures Adjust reverse modulator The pressures specified are based on winches equipped with paper type friction materials in the brake
11. 22X 23X 26X D6D PS 3X 4X 5X 10K 76A D6D DD 3X 5X 14B PS 14 C do 14B 14C DD 977 750C FD14 DD 850C Gear Code Fwd Ratio Rev Ratio 1 45 10 1 19 47 1 6 106 40 1 45 9 1 2 56 40 1 24 3 1 7 27 90 1 12 1 1 3 64 90 1 28 1 1 8 85 20 1 36 8 1 4 81 00 1 35 0 1 9 55 6 1 45 9 1 5 44 00 1 19 0 1 ds Allied COMPANY Section 1 Table 1 2 Tractor Identification and Gear Ratio for W8L Winch Tractor Make Model and E Tractor Serial Number Where Car Fiat Hitachi E S SE Ka New Holland 16B PS TD20E G PS D80A 12 S N 10301 8 UP S 16B DD SE DD D85A 12 S N 10301 8 UP AB BD 20 PS D85E P 18 20B FL20 D85A E P 18 0000 983 38K D85E P 21 0000 FD FL20 D83 1 FP60 D85ESS 1 6 D85ESS 2 a Caterpillar D7 PS S N 92V 93E1752 8 UP 94N5660 amp UP 65V b Caterpillar D7 DD S N 91V 93N 64V 8 45W CG Caterpillar 572 40U 6J d Caterpillar prior to D8N S N 5TJ0001 same as C56 for AW8L 2293 4 up e Caterpillar DON S N 5TJ0001 UP T Komatsu D85ESS 2 Gear Ratio 1 amp 5 are both 90 1 1 Gear Code Forward Ratio Reverse Ratio 1 49 8 1 19 9 1 2 71 6 1 38 6 1 3 94 0 1 37 6 1 4 84 0 1 33 6 1 No Longer Available 5 90 1 1 36 0 1 No Longer Available 6 68 8 1 27 5 1 7 47 1 1 31 1 1 Allied COMPANY 1 3 General Table 1 3 Tractor Identification and Gear Ratio for W12E Winch Tractor Make Model and ge Tractor Serial Number Where Applicab
12. Faulty coil Replace coil if resistance is outside of 15 50Q range PWM C flashing Winch won t function or Joystick out of Replace joystick or send to factory for HSOUTx may be lit only allows one function calibration calibration but not flashing MS lit steady red Winch won t function Module fault Turn power off then on If MS light is still steady red replace module Interfacing with the Electronic Control Module ECM The ECM regulates the cartridge valves on the valve mani fold assembly based on joystick input and a preset com puter program Occasionally it may be necessary to down load a new control program for the ECM or perform higher level electronic control system troubleshooting through the ECM interface Should this be necessary a CD with the relevant software and a communication cable are avail able from Allied Systems The files may also be down loaded from Allied Systems e Commerce website Please contact a dealer or call Allied Systems for more informa tion 2 6 Allied COMPANY Section 3 Service General Maintenance This section provides the instructions for performing main The Maintenance Schedule is a program that includes tenance and making checks and adjustments Standard periodic inspection and lubrication Use the operating time shop tools are used in doing the work described in this on the hour meter of the tractor to determine the mainte section nance time for the winch aa
13. John Deere 850 Last Used on W6F 7143 amp AW6F 1000 mee 1 Bearing Carrier 15 Thrust Washer 2 Bearing Cup 17 Spacer 3 Bearing Cone 18 Spacer 4 Bearing Cup 19 Yoke 5 Bearing Cone 20 Shaft 6 Seal 21 PTO Shaft 7 Shim Pack 22 Gear 12 Washer 23 Capscrew 14 Capscrew 24 Washer 18 Of 5 21 g 2 1 4 5 6 24 15 23 es Wal Q N NN Si 22 a ES P 3 g EE S LMA d LY LLL ml gt Ma Y cong E G EZ A Se SN LAA Se T E Ces C 20 A EE 20 Ay NY UY A RN ACE ES ARS NN he A Le HN 3 A 4 pl 6 12 13 ge s t 17 16 1 7 John Deere 750 850 First Used on W6F 7144 amp AW6F 1001 John Deere 750 850B 750 850C Gear Ratios 1 amp 2 Onl John Deere 750 850A John Deere 750 8508 First Used on W6F 7144 8 AW6F 1001 Gear Ratios 3 4 6 8 9 Only John Deere750 850C Gear Ratios 6 8 amp 9 Only Figure 4 25 W6F John Deere PTO Shafts Allied COMPANY 4 39 Repairs PTO Shaft Reassembly amp Installation Spacer 8 Bearing Carrier PTO Shaft 9 Bearing Cup Snap Ring 10 Bevel Pinion Gear Capscrew 11 Locknut Gear 12 Lockwasher Bearing Cone 13 Lockwire 12 O Rin 14 Shim Pack KS be RY is E HINS AN pto komd85ess2 eps pto desstd25 eps 5 LT ARA Pta O Ring Countersunk Capscrew A L Spacer Washer EA H O Ring Shim Pack PTO Adapter Snap Ring Locknut PTO Shaft Lockwasher Ball Bearing Seal Bearing Carrier Figure 4 26 PTO Shaft on W8L for Komatsu D85ESS 2 Figure 4 27 P
14. Sequence of Operation LINE OUT LINE OUT or reverse is achieved by pushing the control lever to the reverse position thereby pulling the control spool out As the control spool moves the flow of oil to the cooling passage is blocked This allows pressure to build up in the inlet passage Oil flows from the inlet pas sage to the brake passage through an orifice producing a pressure drop between the inlet and brake passages de pending on the amount of oil flow As the brake port to sump is closed off by the spool the oil flow to sump is reduced allowing the brake pressure to build up As the brake pressure increases the reverse modulator valve will regulate the the oil pressure to the reverse clutch and main Allied COMPANY tain a constant 120 psi 827 kPa pressure differential be tween brake and clutch through inching mode At the end of spool travel a direct port to the reverse clutch is opened NOTE On a fast shift the spool moves into the full reverse position routing oil directly to the reverse clutch and bypassing the reverse modulator valve completely thereby avoiding any delay in opera tion 1 19 General PRESSURE MMMM COOLING SUCTION __ EA e FREESPOOL LEN INSTRUCTIGNS gt 271731W HANDLEVER POSITION REVERSE CLUTCH PRESSURE FILTER CONTROL CHECK VALVE i VALVE ME Li EE Eeer HYDRAULIC PUMP We SUCTION Y STRA
15. drum will rotate slowly in the LINE IN direction If the reverse clutch is dragging the drum will rotate in the LINE OUT direction If forward clutch is dragging the drum will rotate positively in the LINE IN direction and it will take more than 100 lbs of line pull to prevent drum rotation Low system pressure Adjust accordingly Low or high cooling oil pressure Check cooling oil pressure Replace relief valve if required Bevel shaft bearings set too tight Adjust accordingly Avoid continuous operation in the inching zone Low oil level Add oil Clogged suction strainer filter Check and clean or replace the suction strainer Winch will not operate Accumulator system malfunction Check for while tracks are turning 1 Correct leakdown time as described in Section 3 2 Leaking accumulator valve 3 Leak in accumulator lines 4 Damaged or defective accumulators Refer to Low Oil Pressure troubleshooting item above Defective PTO shaft Inspect PTO shaft and coupling clutch shaft bevel O ring gear and PTO shaft pinion gear for wear or damage Inspect magnetic suction screen Winch will not operate Joystick off center at startup Return joystick to neutral position and attempt Control module not powered Check fuse amp replace if necessary Joystick DC DC converter malfunction Replace converter if the red amp green LEDs are not lit Control module fault Check status indicator on module Red LED should not be il
16. wz re 00 st N mM Bearing Carrier Washer Roller Bearing Cup Locknut Bearing Roller Bearing Cone Oil Seal Spacer O Ring Shim Pack Input Shaft O Ring Gear O Ring Capscrew Spacer Washer O So Ol Ns Figure 4 5 PTO Shaft on W12E for Caterpillar D8 L DIN D10N Komatsu 375A 1 New Holland FH FD30B SCH Allied COMPANY oldjdpto1 tif John Deere 755 John Deere 750 Last Used on W6F 7143 amp AW6F 1000 O Or Po O 1 1 SSY E SS Ee 373008c eps haa LA ZN Sites MN RES S A N John Deere 750 850 First Used on W6F 7144 amp AW6F 1001 John Deere 750 850A NS d al A EA I NeR N W LLM gt Snap Ring Bevel Pinion Gear Bearing Carrier O Ring Capscrew amp Washer Oil Seal Ball Bearings Shim Pack Shaft Shaft with Integral Pinion Washer Yoke Nut Snap Ring DO SNOW OE 2 John Deere 855 1000 Thrust Washer Spacer Spacer Yoke Shaft PTO Shaft Gear Capscrew Washer Bearing Carrier Bearing Cup Bearing Cone Bearing Cup Bearing Cone Seal Shim Pack Washer Capscrew 23 A SG SCH 13 18 Only John Deere 750 8508 First Used on W6F 7144 amp AW6F 1001 Gear Ratios 3 4 6 8 8 9 Only John Deere750 850C Gear Ratios 6 8 9 Only Figure 4 6 W6F John Deere PTO Shafts Allied COMPANY 14 SH i BAR E BI AN
17. 3 Access Cover for Valve Manifold Assembly Cover for Filter Plug to Check Oil Level Fill Plug Plug to Drain Oil Breather w6 8 12maint tif Figure 3 1 W12E Maintenance Points Table 3 1 Maintenance Schedule weekly not operate the tractor when checking the oil level solvent if necessary Use multi purpose grease with 2 4 molybdenum assembly if the winch is equipped with either option disulfide 500 hours or Clean the oil suction screen and magnets Tilt the tractor approximately 15 to prevent loss of oil every 3 months when the cover is removed Use a new gasket between the cover and the suction tube Replace the filter See the Parts Manual for filter element and cover gasket When replacing be sure to lubricate filter seal ring between element and filter head 1000 hours or Change the hydraulic oil Drain oil from plug item 3 See Table 1 2 Approved Oil List every 6 months Clean the oil strainer Through fill plug item 5 add 22 gallons 83 liters of oil Check the oil level at item 2 NOTE Clean the oil strainer screen and change the oil filter after the first 50 hours on new and rebuilt winches t Amount of oil may vary slightly with tractor Allied COMPANY 3 1 Service KNOB SETSCREW LLAJ NIN at GE RR GE DETENT PIN NIN W a N Y Ny dli NR SUN Wd WL i DETENT PLATE gt TRS d joystick eps RETURN SPRING DUST FILTER JOYSTICK ASSEM
18. 50 psi 345 kPa pres sure differential between the brake and clutch through the inching mode At the end of the spool travel a direct port Allied COMPANY to the clutch is opened NOTE On a fast shift the spool moves into the full forward position routing oil directly to the forward clutch and bypassing the forward modulator valve completely thereby avoiding any delay in opera tion When pressure starts to rise above 220 5 psi 1520 35 kPa atthe inlet port passage the spring loaded poppet in the relief valve will bypass the excess flow to the cooling passage An orifice in the relief valve poppet prevents oil from becoming trapped behind the poppet and causing a hydraulic lock 1 17 General 5555555555555 E ECO O e NORMAL O OPERATION READ OPERATING INSTRUCTIONS 271731 w HANDLEVER POSITION PRESSURE FILTER CHECK VALVE WE ee eeh HYDRAULIC PUMP We SUCTION 3 STRAINER lineoutinching eps ACCUMULATOR VALVE ACCUMULATORS Allied WINCH SSS PRESSURE 220 psi 1517 kPa x N Ns CONTROLLED 10 220 psi 69 1517 kPa SS MODULATED 10 100 psi 69 690 kPa Be COOLING E SUCTION _ N REVERSE CLUTCH CONTROL VALVE FORWARD CLUTCH COOLING OIL MANIFOLD COOLING OIL RELIEF VALVE Figure 1 16 Hydraulic System LINE OUT INCHING Sequ
19. 8 Install joystick assembly on bracket Adjusting Joystick Detent Force 1 Remove screw on joystick knob Lift knob and boot from handlever 2 Using an Allen wrench turn the setscrew inwards to increase detent force or outwards to decrease de tent force 3 Move joystick from BRAKE ON to BRAKE OFF and back again If detent force is still unsatisfactory adjust setscrew again NOTE Detent force is different with knob in stalled since the compressed return spring works against the detent force 4 Place boot and knob over joystick assembly ensur ing boot is securely installed then install knob screw Allied COMPANY REVERSE FORWARD Section 3 ACCUMULATORS BYPASS VALVE 30 e O O KOK i E Ole Solon felt te REVERSE VALVE MANIFOLD CLUTCH ASSEMBLY VALVE BRAKE VALVE presscheck eps E LO FORWARD CLUTCH VALVE ACCUMULATOR VALVE Figure 3 3 Hydraulic Pressure Test Ports Hydraulic System Pressure Checks See Fig 3 3 The hydraulic oil and filter s should be maintained as in dicated in the Maintenance Schedule If any problems are found they should be corrected before operating the winch Preparation Prior to checking the hydraulic pressures perform the fol lowing 1 Remove cable from drum to prevent engtanglement during pressure checks since the drum will rotate during the tests Vehicle engine must be shut OFF before dis connecting drum cable Be carefu
20. HIGH PRESSURE CAN CAUSE SERIOUS INJURY TO EYES AND SKIN BEFORE SERVICING HYDRAULIC SYSTEM 1 SHUT ENGINE OFF a 2 MOVE CONTROL LEVER FROM BRAKE ON TO BRAKE OFF 8 TIMES 3 LOOSEN FITTING SLOWLY TO ASSURE NO PRESSURE IN SYSTEM 1321 sideleftbw tif siderightbw tif decalspnt eps Section 3 damaged install a new one in the location shown The W6F W8L and W12E model decals are used on both sides of the winch frame as shown Replace as neces sary a Ro Allied NAMEPLATE WINCH W6F OIL BRAKE d i E LEFT Ze s W6F SCH y Ya Mam RIGHT Figure 3 9 Decal Installaion Allied COMPANY 3 9 Notes 3 10 Allied COMPANY Allied WINCH Section 4 Repairs General This section includes the removal and disassembly of all major shaft assemblies inspection of components and reassembly and installation The wear points detailed in Table 4 1 should be inspected at the time of disassembly so that worn parts may be ordered and replaced prior to reassembly If the winch is to be completely overhauled perform the removal disassembly inspection and reas sembly procedures in the sequence of the following para graphs NOTE Always use the troubleshooting procedures given in Section 2 to locate a malfunction before performing a major overhaul of the unit Make all checks in a systematic manner Haphazard check ing wastes time and c
21. Ly VLA Dal Ys 7T ZL lA Y NSK Section 4 oldjdpto2 tif John Deere 850 Last Used on W6F 7143 amp AW6F 24 g 12 E SSY 2303691a eps 17 16 7 John Deere 750 850B amp 750 850C Gear Ratios 1 amp 2 Repairs PTO Disassembly Used on Gear Ratios 6 8 amp 9 Only ZZZ N GE AMY YA ZE aaa WALL LZ SSS Iesel vd pto cat527int eps Ball Bearing Snap Ring Interior Bearing Carrier Oil Seal O Ring Coupling Pin Spacer 8 Bearing Carrier PTO Shaft 9 Bearing Cup Snap Ring 10 Bevel Pinion Gear Capscrew 11 Locknut Gear 12 Lockwasher Bearing Cone 13 Lockwire O Ring 14 Shim Pack ERE gt gt D pto komd85ess2 eps Figure 4 8 PTO Shaft on W8L for Komatsu D85ESS 2 4 6 Allied WINCH Used on Gear Ratios 1 ZA Y SE pto cat527rem eps DG LLL PTO Shaft with Integral Bevel Pinion Gear Capscrew Lockwire O Ring PTO Shaft Gear Snap Ring Exterior El SS 4 ARSE Www EZZ ZN URGES RSS ARES 10 8 9 O Ring Countersunk Capscrew Spacer Washer O Ring Shim Pack PTO Adapter Snap Ring Locknut PTO Shaft Lockwasher Ball Bearing Seal Bearing Carrier pto drestd25 eps Figure 4 9 PTO Shaft on W12E for Dresser TD25E G Allied COMPANY kom d65drop eps 10 11 12 13 NY Ke PAR y o CX N N ZA V S Wp WY a es 31 30 29 28 P
22. RETAINER CLUTCH SHAFT O RING SETSCREW RELEASE SPRING SEPARATOR PLATE FRICTION CAPSCREW DISC DISC PLATE O RING PLUG PISTON O RING Vi PISTON RETAINER O RING O RING CLUTCH SHAFT ber O RING SETSCREW SPRING RETAINER COVER SPIDER GEAR ALIGNMENT DOWEL ae ROLLER BEARING BEARING CARRIER SNAP RING FORWARD PINION HUB CAPSCREW a tells h Oh CG a w Ge Ee wel A A wan a RELEASE SPRING COVER PLATE Figure 1 8 Forward Clutch Allied COMPANY General PUSH ROD ES e SST Sg FRICTION SN 7 PAX Oy TL TL Jegen DISC 7 5 oh EA E er TAN igs serararor AH d PLATES D OIL LINE COVER gt COOLING PISTON O RING STROKE LIMITER BELLEVILLE So A O PISTON SPRINGS y ES HOUSING PRESSURE PLATE brakeassy tif Figure 1 9 Oil Brake Assmbly Oil Brake Assembly See Fig 1 9 The multi disc oil brake is spring applied and hydraulically outward compressing the belleville springs which then released When pressurized oil is directed into the cavity releases the brake between the piston and piston housing the piston moves m Allied COMPANY Section 1 REVERSE FORWARD ACCUMULATORS BRAKE CLUTCH valveassy eps CLUTCH Valve Manifold Assembly Relief Valve Solenoid Poppet Valve Solenoid Spool Valve Solenoid Poppet Valve 24V Coil Coil Nut Plug Plug Plug s Plug Tab Washer Cavity Plug
23. Section 3 for procedure Move joystick out of detent Joystick is in detented position brake off Allied COMPANY 2 3 Troubleshooting Table 2 1 continued Troubleshooting Analysis Check Chart PROBLEM POSSIBLE CAUSE CORRECTION Winch does not Plugged brake valve Replace valve engage and tractor engine draws down in Faulty brake coil Replace coil LINE IN or LINE OUT Open or shorted brake circuit Check wiring harness See Winch will not operate in any function above Winch does not Plugged forward or reverse valve Replace valve engage and or load rolls out in LINE IN or Faulty forward or reverse coil Replace coil LINE OUT Open or shorted forward reverse circuit Check wiring harness See Winch will not operate in any function above Filter LED blinking Open or shorted coil See the Control Module Troubleshooting section in this chapter for more information Filter LED illuminated Filter is clogged Change filter and oil NOTE Change filter only after first 50 hours of operation when winch is new or freshly rebuilt Cold oil is causing filter bypass Monitor LED condition If LED remains illuminated after normal operating temperature has been reached change oil and filter Electrical short circuit Check filter bypass switch circuit of wiring harness SC Allied COMPANY Section 2 AAGA a A e WM A DIGITAL VALVE CONTROLLER MASTER
24. The pres sure at G6 should remain above 200 psi for several min utes Low accumulator gas pressures tend to stall the winch on a low engine rpm shift To determine if accumulators have any gas pressure remove valve stem protective cover and push genily on valve stem A ruptured bladder will emit oil Accumulators are not rebuildable Forward Clutch Pressure Check With the engine shut off connect a pressure gauge to Port G2 Start the engine and place joystick in BRAKE OFF to build up the accumulator system pressure Place joystick in LINE IN position and check forward clutch On a fast shift the clutch pressure should come up with the brake pressure If the pressure differential is too low the brake will not release soon enough and cause it to stall If the pressure differential is too high the brake will release too soon and cause backspinning of the drum If the forward clutch pressure is not as specified in Table 3 2 check for 1 Leaking pressure hoses or fittings Damaged or worn clutch piston seals Damaged or worn valve manifold assembly parts Broken seal rings on clutch shaft af o bh Damaged O rings on clutch shaft Troubleshooting information is given in Section 2 Reverse Clutch Pressure Check Shut off the engine and connect a pressure gauge to Re verse Clutch Port G3 Start the engine Place the joystick in LINE OUT and check reverse clutch pressure as indi cated in Table 3 2 On a fast LINE OUT sh
25. a power control lever for winch control See Fig 1 6 If the winch does not have the FREESPOOL function the second control lever is not used Both control levers are connected to the winch through control cables The power control lever is con nected to the spool in the control valve The power control lever is used to select one of the following operations e BRAKE OFF e LINE OUT e BRAKE ON e LINE IN Except for the BRAKE OFF position a spring arrange ment on the spool of the control valve returns the spool and power control lever to the BRAKE ON position A ball and detent arrangement will hold the spool and control lever in BRAKE OFF and the operator must pull the con trol lever to release it from that position The BRAKE ON position is a neutral position No hydrau lic pressure is applied to the brake or the clutches Springs apply the brake so that the winch drum will not rotate 1 10 The BRAKE OFF position has a detent and is a neutral position for the clutches Hydraulic pressure is applied to release the brake The winch will not rotate easily be cause of friction in the clutches brake and gear train Cable cannot be pulled from the winch by hand The BRAKE OFF position is different from the FREESPOOL position where the drum is disengaged from the gear train The BRAKE OFF position is used when the operator has a load on the winch cable The operator can move the tractor forward without moving the load A second
26. a pressure gauge to Port G1 Start the engine and see the Cooling section in Table 3 2 If the cooling oil pressure is too high or too low over heating can occur Accumulator Pressure Check With the engine shut off connect a pressure gauge to Port G4 This check determines if the accumulators are func tioning and have the correct nitrogen charge Observe the following while referring to the Accumulator section in Table 3 2 1 With engine running place joystick in BRAKE OFF and rev engine to maintain 220 psi 1520 kPa for one minute This will ensure the accumulators have a full supply of oil Return joystick to BRAKE ON Shut the engine off and wait one minute then turn key to the ON position but do not start the en gine 4 Place the joystick in the BRAKE OFF position This will release the oil in the accumulators Observe the initial pressure reading and the time for the pressure to drop below that specified in Table 3 2 If the leak down time is less than specified in Table 3 2 repeat steps 1 through 4 but do not delay in placing the joystick in BRAKE OFF after the engine is shut down If the leak down time is greater than that measured when waiting one minute there is probably a leak in the lines between the accumulators and the valve manifold assem bly Accumulator valve performance can be checked by con necting a gauge to Port G6 After ensuring the accumula tors are charged place the joystick in neutral
27. and clutches All WE8L and W12E winches are equipped with paper type friction materials in the brake and clutches The W6F models however used metal friction materials in early models which require different modulator pressure adjustments as follows PRESSURE DIFFERENTIAL BETWEEN SERIAL NUMBER FRICTION MATERIAL TYPE BRAKE amp CLUTCH SEQUENCE BREAKS 20 psi 14kglom 80 psi 56 kalom Prior to 1689 Pressure readings may vary 5 psi 0 4 kg cm NOTE All John Deere Mountings use paper frictions in clutches and brake regardless of serial number NOTE Engine 1000 rpm and oil temperature 70 F 20 C minimum Allied COMPANY Service Use 180 PSI for Komatsu D65 Turn the adjusting capscrew IN to decrease Reverse Clutch Pressure or OUT to increase pressure until Reverse Clutch Pressure is less than the brake pres sure by the amount shown in Table 3 2 Tighten locknut and recheck pressure Repeat steps 1 and 2 if necessary Allied WINCH Control Valve Spool Travel Check See Fig 3 8 lt may be necessary to check spool travel when control valve pressures do not meet specifications Figure 3 8 shows the correct travel for the various spool positions The control valve spool is self positioned to BRAKE ON The three other travel positions are determined by spool assembly internal stops and a detent assembly in the spool end cap If spool travel is found to be out of adjustment the spool assembl
28. between the two clutches Check preload on clutch brake shaft and adjust it if necessary to prevent additional breakage of seal rings refer to Section 4 Damaged bevel gear shaft seal ring grooves Check grooves for taper scoring and rust Replace or rebuild shaft if surfaces between the inner side of groove and seal ring are not flat defective or re sleeve Damaged clutch piston piston retainer or O Check piston and piston retainer cavity for damage Always repair both O rings when clutch is repaired Refer to Section 4 gear Coil for voltage backspin on fast shift discs and separator plates if too thin from neutral to forward Broken belleville spring Replace Refer to Section 4 Brake releases before Faulty forward clutch valve or coil Check forward clutch valve and coil forward clutch engagement reverse clutch replace as necessary engagement Noisy buzz emanating Air in relief valve This is not a detrimental condition Noise may be El O 1 Joystick will not detent Detent mechanism worn or broken Replace joystick assembly in brake off 2 Adjust detent spring force see Joystick amp Lubrication Adjustment in Section 3 for procedure Joystick does not Insufficient lubrication Lubricate detent pin see Joystick Lubrication amp return to neutral when Adjustment in Section 3 for procedure EES Excessive detent force Remove knob and adjust detent force see Joystick Lubrication Adjustment in
29. control lever disengages and engages a dental clutch to control the FREESPOOL operation The FREESPOOL control lever has two positions POWER and FREESPOOL The FREESPOOL control lever disen gages the gear train so that the cable can be pulled from the winch by hand Allied COMPANY TO OIL PRESSURE GAUGE SS GF SO DA d FORWARD CLUTCH A i SN H E 4 1 amp GE dote eil Zei Zeie 5 hydraulicsys tif Section 1 os H REVERSE EA CLUTCH PRESSURE FILTER SUCTION FILTER HOSES Figure 1 7 Hydraulic System Hydraulic System See Fig 1 7 The operation of the winch is controlled by an internal hy draulic system This system directs the flow of oil for winch control functions The suction and pressure filters remove contaminants from the oil The hydraulic pump supplies pressurized oil for the system The control valve is con nected by a cable to the control lever The control valve distributes and regulates the flow and pressure of hydrau lic oil to the clutches and brake while maintaining the cool ing oil flow A separate accumulator valve mounted on the front of the control valve body controls the release of pressurized oil from the accumulators The accumulators provide pres Allied COMPANY surized oil for a limited amount of actuation if the hydraulic pump is not functioning This allows the release of the winch brake when the tractor engine or the hydraulic pump is n
30. corrections Section 3 Service provides a guide for periodic maintenance checks and adjustments Section 4 Repairs describes the removal disas sembly assembly and installation of the winch W12E Electronic Controls Addendum provides the systems descriptions as well as troubleshooting and maintenance procedures for the W12E winch with Electronic Controls option W12EE NOTE Please refer to the addendum for all informa tion related to the W12EE winch SERIAL NUMBER PLATE e DRAWBAR DRAWBAR PIN w ke O Ki a 10 FILTER COVE Description The W6F W8L and W12E Winches are Power Forward LINE IN and Power Reverse LINE OUT winches used on trac tors with a constant running power takeoff PTO The winch utilizes a Self Contaned Hydraulic SCH system where all hydraulic power is produced internally inside the winch case The design of the winch case permits differ ent arrangements of PTO gear assemblies to fit different tractors that use these winches See Section 4 for the PTO gear assemblies The W6F W8L and W12E winches have a BRAKE OFF function which permits the cable to be pulled from the drum A FREESPOOL function is standard on the W6F winch except in Asia and is available as an option on the W8L winch The FREESPOOL function is not available on the W12E winch The W6F winch has a maximum line pull capacity of 266 880 N 60 000 Ibf when there is one layer or less of cable o
31. nuts or capscrews and lockwashers securing winch to tractor NOTE When removing the mounting nuts or capscrews loosen all nuts slightly then pry winch away from mounting pad Loosen all nuts again and pry winch again Continue this sequence until winch can be removed Disassembly of the winch 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 removed from the tractor However winch removal is not necessary for removal of individual shaft assemblies Dis assemble the winch as necessary to make repairs Figures 4 1 and 4 2 show the gears and components con tained within the winch housing Allied COMPANY 4 1 Repairs PTO Disassembly LEFT HAND SIDE RIGHT HAND SIDE DRUM pa eg y Seele o GE Y 4 f DRUM EY f ADAPTER NA Y Z S Y y O ES Y ASS ME X PIE E a ga U EEN
32. or two part line to the winch When not operating the winch always leave it in neutral with the brake on Never attempt to clean oil or adjust a machine while it is in motion Use extreme care when removing cable and ferrule from the drum When the ferrule is released the cable may spring out with force Winch serial number Date put into service Warning Warning Failure to follow these instructions can cause serious injury or death Authorized trained operator only Know the equipment Know the operating inspection and maintenance instruc tions in the operating manual Do not operate the winch unless the vehicle is equipped with a screen to protect the operator if the cable breaks Inspect the winch before use Make sure that the controls and instruments operate cor rectly Report the need for repairs immediately Do not work with a damaged or worn cable Do not use a winch that needs repairs If the ferrule and cable must be re moved from the drum make sure the end of the cable and ferrule are controlled when the cable is released The end of the cable can suddenly move from the drum like a compressed spring when the ferrule is released causing an injury Protect yourself Do not use the control levers for hand holds when enter ing or leaving the vehicle Do not permit other people near the control area when you inspect or repair a ma chine Never inspect repair or do maintenance on a machine that i
33. place 3 4 INCH SQUARE HOLE OR SIZE TO SUIT METRIC SOCKET DRIVE OR WELD 1 INCH 25mm NUT TO END CAP TO DRIVE WITH STANDARD SOCKET 2 36 60mm 22 6 mm 22 23 6mm 1 50 40mm 25 6mm 2 IN STD PIPE 2 92 74mm 22 6mm 22 23 6mm KEY STOCK 1 50 40mm 25 6mm 2 2 IN STD PIPE Figure 4 38 Clutch Shaft Locknut Socket PRESS FIT OR LOCTITE PIN 1 00 IN PLACE 25mm 0 30 7 62mm 0 30 7 62mm tool2 eps 9 16 INCH 15mm DIA DRILL 0 30 7 62mm Y a 30mm Figure 4 39 Clutch Shaft Driver Allied COMPANY Repairs Special Tools L gt Al Du Se 5 8 11 UNC NUT OR NUT TO MATCH PULLER 1 4 Z A TYP 4 PLACES 1 880 1 890 47 75 48 01mm 2 380 2 390 60 45 60 71mm 2 10 54mm 2 60 66 2 75 70mm 3 25 83 tool4 eps Figure 4 40 Clutch Shaft Puller may be used instead of Clutch Shaft Driver 1 INCH CUT WASHER 1 16 PIPE PLUG KA Q he O O se 1 4 20 X 3 8 UNC Figure 4 41 Lifting Eye 208 Allied COMPANY W12E Winch Electronic Controls Option oe CUSTOMER E EDITION Printed in USA Safety Precautions Observe the following precautions to prevent injury to personnel and damage to equipment Do not operate winch unless tractor is equipped with a rear screen for operator protection against cable breakage Authorized operators only Report damage or erratic operation of the winch immediately Do n
34. previously disassembled Install PTO and add or subtract shims to get heel to heel contact Tighten capscrews to 75 ft lbs 10 kg m Lockwire capscrews upon comple tion of shimming 22 Connect dial indicator as shown Add or subtract shims from the two clutch shaft bearing retainers to obtain zero endplay When zero endplay is obtained subtract 0 000 to 0 004 in 0 00 to 0 10 mm of shim s from the retainers This will provide the de sired preload on the clutch shaft N o O e Y Allied WINCH NOTE Adding or subtracting shims from these retainers will affect pinion to bevel gear backlash See step 23 23 Use dial indicator to check pinion to bevel gear back lash Backlash should be 0 006 0 014 in 0 152 0 356 mm If less than 0 006 in 0 152 mm remove shims from right hand bearing retainer as required Add same amount to left hand retainer to maintain endplay preload RH and LH shims are not interchangeable NOTE Prior to checking pinion to bevel gear backlash place the clutch shaft in a normal operat ing position by forcing the ring gear away from the pinion gear laterally along the clutch shaft Check the gear contact as shown in PTO Shaft Reassem bly and Installation section section step 5 24 Remove both bearing retainers and install the cast iron seal rings 25 Install a new O ring on the bearing retainer Lube bore and O ring Coat the shim packs with Loctite Carefully install bot
35. prior to in 5 Install snap ring on W6F and W8L The W12E uses a stallation of the brake assembly spacer 1 Lubricate and install two new O rings in piston It may be necessary to stretch inner O ring to hold it in place until piston is installed in piston housing r5 014 tif r5 009 tif ry CAUTION Make sure that snap ring is securely CAUTION Use only Allied Systems Company positioned in brake shaft groove approved O rings to ensure proper sealing 6 Install pressure plate Push plate against piston hous ee IP ISS ing Then install dowel pins 3 Ensure that the left hand bearing is securely installed over the brake shaft 4 Slide assembled piston and piston housing in place on studs KS bm r5 013 tif 5 7 Install hub E Piston Plate Ah CAUTION NOTE Make sure that bearing on brake shaft is CAUTION Do not reverse hub Dish must face properly positioned before installing housing out oe Allied COMPANY Allied S Section 4 8 Install snap ring 10 Install the friction discs and separator plates alter ZS l nately starting with a friction disc Align blanked out teeth on all friction discs 10 friction discs and 9 sepa rator plates are used r5 018 tif Separator Plates CAUTION For W6F winches prior to W6F 1689 equipped with 7 metallic friction discs the 6 separator plates are conical dished Face all AA CAUTION separator plates in the same direction Al
36. stored in the accumulators Brake Pressure Check With the engine shut off connect one high pressure gauge to Brake Port D with a JIC 37 flare female adapter Start the engine and refer to Table 3 2 Adequate brake pressure Is required to fully release the brake If the pres sure is not as specified check for 1 Improper relief valve setting or malfunction 2 Suction or pressure filter malfunction 3 Leaking pressure hoses or fittings 4 A defective hydraulic pump A defective pump is usu ally indicated by low pressure and pressure increases with increased engine RPMs Cooling Oil Pressure Check With the engine shut off connect one low pressure gauge to Port C Start the engine and see the Cooling section in Table 3 2 If the cooling oil pressure is too high it can stroke the clutch piston and drag the clutch pack The result is overheating Low cooling oil pressure will not produce enough cooling oil flow and cause overheating Check for a defective cooling oil relief valve Adjust relief valve as follows 1 Start engine and place handlever in BRAKE OFF 2 Loosen relief valve locknut Turn relief valve adjust ing capscrew IN to increase pressure and OUT to decrease pressure Adjust pressures as shown in Table 3 2 3 Tighten locknut after adjustment is completed 4 Recheck pressure reading and repeat steps 2 and 3 if necessary Accumulator Pressure Check With the engine shut off connect one low pres
37. the oil clutches 3 Remove the setscrews that lock the special Removal of the clutch assemblies is shown in the Clutch capscrews on the opposite side of the clutch Shaft Removal Disassembly section NOTE Disassembly is essentially the same for both l E the forward and reverse clutches The forward 4 Remove the special capscrews using the a hand im clutch is shown pact driver initially Hold firmly so as not to damage the clutch pack 1 Remove the snap ring from the pinion gear bore then remove and tag the roller bearing and carrier for ref erence during reassembly r3 007 tif r3 016 tif 2 Lift the spider pinion gear assembly from the clutch pack 5 Match mark position on cover plate and hub to aid in reassembly Lift cover plate from clutch assembly CH o o op _ r3 014 tif 6 Remove and tag shims SES Allied COMPANY Allied S Section 4 7 Remove the separator plates and friction discs from 9 Remove hub from piston housing Remove and dis the hub Inspect as described in Table 4 1 card O ring Friction Disc A r3 001 tif r2 036 tif 8 Remove and inspect the release springs Refer to Table 4 1 r2 034 tif o ben aal aal o N A NOTE Arrangement shown for paper type frictions Allied COMPANY 4 19 Repairs Oil Clutch Disassembly 12 Remove and discard the two O rings N mM o Y N NOT
38. up Remove brake assembly cover Remove cooling oil hose line eh Thrust Washer r5 019 tif Cooling Oil Line coversoff bw tif with metallic frictions 5 Remove friction discs and separator plates from the hub 2 Loosen the locknuts evenly then remove the brake assembly cover gt M Separator Plates gt JM E EAS NOTE Paper frictions are shown Earlier W6F models use metallic frictions SSES Allied COMPANY Allied S Section 4 6 iG vr 15 016 tif wy a Remove cage from studs lt may be necessary to 9 Remove snap ring from brake shaft on W6F and W8L tap cage with a soft hammer to loosen it A Pacer is used on the W12E Remove snap ring from brake shaft and pull hub off brakeshaft r5 014 tif 10 Slide the piston housing forward no more than one inch if only the clutch shaft bearing retainer is to be removed To service the piston housing or brake shaft remove the piston housing r5 015 tif Remove prosuo plate from SE CAUTION If the brake shaft is not to be re moved ensure that the bearing cup behind the piston housing remains in the winch case bore If the cup falls out the shaft will drop down and the right hand bearing will drop out of its cup P w 11 Pull the piston out of the housing using two 1 4 inch capscrews or pressurize housing with low pressure air Allied COMPANY 4 11 r5 013 tif Repairs Oil Brake Re
39. BLY y SXSSSSS PI e EA WASHER NUT e WIRING Figure 3 2 Joystick Checks Before Operation Check that the cable and hook are not worn or damaged Check that the periodic inspection and maintenance has been done at the recommended operating hours See Table 3 1 Maintenance Schedule Checks During Operation The troubleshooting charts in Section 2 can be used by the operator to identify a problem with the winch operation A trained service person is needed for additional trouble shooting and repair that requires disassembly of parts of the winch Joystick Lubrication amp Adjustment See Fig 3 2 A CAUTION Make sure vehicle engine is OFF before per forming any of these procedures 4h CAUTION Removing the Detent Plate from the joystick may cause a calibration error which will pre vent proper winch response Joystick Detent Pin Lubrication 1 Unscrew joystick assembly from bracket 2 Push down on knob to balance spring force and re 3 2 move screw on joystick knob Lift knob and boot from joystick Remove setscrew and detent spring Apply a few drops of oil on top of detent pin inside bore Install spring then setscrew Move joystick from BRAKE ON to BRAKE OFF and back to ensure detent force is satisfactory If not adjust detent force see Adjusting Joystick Detent Force below 7 Place boot and knob over joystick ensuring boot is securely installed then install knob screw
40. Coupling Pin CONOR Go bi ch 1 Remove sealing capscrews If winch is equipped with a drive adapter refer to Step 4 OZ pp ES Shaft L Ball Bearing Snap Ring GOEDD BBB EE O cath asst atl nati at ast aut mal PTO Shaft with Integral Bevel Pinion Gear Shaft amp Integral Pinion Gear Locknut Seal Spacer Lockring Shim Pack Figure 4 3 PTO Shafts Last Used on W6FP 3699 W6FX 3699 amp AW6F 1000 Last Used on W8LP 2099 amp AW8L 1000 Current on W12E Allied COMPANY Repairs PTO Disassembly SEA d H AEN eXL LN NT RK O a dE 1 Z el KE e Py e VLLLLLLLL ELE Sy MOD TX ky e rade zz a Ct ptoshaft1 eps ptoshaft2 eps PTO Shaft With PTO Shaft With Removable Bevel Integral Bevel Pinion Gear Pinion Gear Snap Ring Lockring Ball Bearing Spacer Bearing Carrier Oil Seal Capscrew O Ring Lockring Shim Pack O Ring PTO Shaft Pin Lockwire Coupling ON Ole SNe Figure 4 4 PTO Shafts First Used on AW6F 1001 8 AW8L 1001 2 Pull PTO shaft assembly straight out CAUTION Tag the shim pack so that the exact K Z A number of shims are re installed NRY Nas 3 Disassemble and inspect PTO shaft refer to Figures 4 3 through 4 9 4 If equipped with a drive adapter remove the drive adapter box first refer to Figures 4 10 through 4 16 then the bevel pinion gear and carrier Disas semble and inspect as required yy IP Oo Q Q
41. E For reassembly and setting of air gap refer to page 4 44 Step 11 Allied S Section 4 Brake Shaft Removal The brake shaft may not always be removed from the winch 4 Withdraw shaft from housing when mounted on the tractor Prior to removal of the brake shaft assembly perform the following a Remove the winch from the tractor see Winch Re moval section at the beginning of this chapter b Drain oil from winch c Remove all brake components as shown in the Oil Brake Removal and Disassembly section d Remove the brake shaft as shown in the following steps 1 Remove right hand bearing retainer Tag shims for reference during reassembly r2 004 tif Lg Si r2 008 tif 2 Pull brake shaft partially out of winch housing 3 Tap the left hand bearing off of shaft using reduction gear as driver i o y x 4 D e We vm 74 12 002 tif Allied COMPANY 4 21 WINCH Repairs Intermediate Shaft Removal Non Freespool pa Intermediate Shaft Removal Non Freespool The intermediate shaft can be removed with the winch 4 Remove the intermediate shaft while ensuring that mounted on the tractor the intermediate gear does not fall NOTE The following steps show the winch re moved from the tractor with the clutch shaft and brake shaft removed This is the normal sequence for complete unit overhaul but it is not necessary for the removal of the intermediate shaft only NOTE The instruct
42. E A 1 Jr Ir H fs bearingcone jpg fs intgear jog NOTE Install intermediate gear with high shoulder down 2 Position the freespool drum pinion in the housing 5 Install intermediate shaft D m 0 L o p H Allied COMPANY Allied S Section 4 6 Install the outer bearing cup and cone Make sure 6 Coatthe winch frame and retainer with Loctite or other that the cup is firmly seated against the bearing cone suitable sealing compound Install shim pack if nec essary and cover fs cup jpg fs fscover jpg NOTE The following step only applies to AW6F 4061 and below and AW8L 2032 and below without 7 Tighten the six capscrews to 75 ft lbs 1 0 kg m exterior freespool drag adjust l 7 To adjust the freespool drag loosen the bearing slightly as detailed in Step 6 of the Intermediate Shaft Removal Freespool section Place the winch in freespool and measure the rolling torque of the drum by placing 25 ft lb 3 5 kg m torque wrench on one of the eight drum nuts Keep the wrench handle pointed straight out from the drum center The torque should be 12 15 ft lbs 1 7 2 0 kg m Add or remove shims from the intermediate shaft retainer to reduce or increase torque respectively NOTE The following step only applies to AW6F 4062 and above and AW8L 2033 and above with exterior freespool drag adjust fs fscovercap jpg 8 Install new O ring on freespool piston and insta
43. INE OUT LINE OUT reverse operation is achieved by pushing the joystick forward from the BRAKE ON position which si multaneously closes the bypass valve and opens the ac cumulator valve Oil flow from the pump and accumulators increases pressure The brake dump valve closes so that brake pressure can increase The proportional brake and reverse clutch valves open according to the control mod Allied COMPANY ule program Modulated pressure to the clutch and brake is supplied during inching slight movement of the joystick from the BRAKE ON position Full pressure is applied to the clutch when the joystick is in full LINE OUT position Brake pressure is limited to just above brake release pres sure for faster response 1 15 General MODULATED PRESSURE HIGH PRESSURE MMMM LOW PRESSURE H SUCTION NO PRESSURE sid JOYSTICK POSITION VALVE MANIFOLD ASSEMBLY BYPASS VALVE PRESSURE FILTER CHECK VALVE H l Y zr SE Si HYDRAULIC N SUCTION PUMP N STRAINER N N ACCUMULATORS u T N J FORWARD OIL CLUTCH BRAKE e N ee Oo E oO 2 EE Sul N BRAKE DUMP VALVE a NN Figure 1 15 Hydraulic System BRAKE OFF Sequence of Operation BRAKE OFF BRAKE OFF is achieved by pushing the joystick to the left of the BRAKE ON position This position is detented 4h WARNING and the joystick must be moved manually to return it to the neutral position The bypass valve closes as the ac cumulator valve ope
44. INER Figure 1 18 Hydraulic System BRAKE OFF FORWARD CLUTCH y EA ee ACCUMULATOR VALVE COOLING ACCUMULATORS OIL MANIFOLD COOLING OIL RELIEF VALVE brakeoff eps Sequence of Operation BRAKE OFF BRAKE OFF is achieved by pushing the control lever to position oil flow to the clutches is blocked and high pres the BRAKE OFF position This position is detented and sure oil flows directly to the brake port to fully release the the control lever must be moved manually to return it to brake the neutral position With the control spool in BRAKE OFF SR Allied COMPANY Allied i Section 2 Troubleshooting General This section includes Tables 2 1 and 2 2 trouble analysis to normal operating condition Table 2 1 applies to all W6F check charts The charts list the most common troubles W8L and W12E winches and Table 2 2 applies to W6F that may be encountered A possible cause and recom and W8L winches equipped with optional FREESPOOL mended corrective action are listed to restore the winch Table 2 1 Troubleshooting Analysis Check Chart Operation is rough or Hydraulic oil is too cold Put the control lever in the BRAKE OFF position not regular AA Run the engine at 1000 rpm to warm the oil before operating the winch below approved oil list in Section 1 necessary Hydraulic system suction leaks Observe oil Check the following for air leaks exiting lube valve while tractor is operatin
45. Inside Nuts Castle Type with Cotter Hand Hand With Loctite Allied COMPANY ch O a O1 esch O a O1 N O1 Aa No NI SCHER NI ho NI O OH CH ala a a Ba olo O 00 O 0 150 225 400 200 70 40 mb mb Hand Hand Hand Hand Allied General Gear Train See Fig 1 3 amp 1 4 The gear train Figure 1 3 consists of Torque transfer during operation is shown in Figure 1 4 1 a PTO shaft assembly NOTE PTO Rotation is determined by standing 2 a clutch shaft assembly behind tractor and looking forward at the PTO shaft 3 a brake shaft assembly entering the winch case 4 an intermediate shaft assembly and 5 a drum shaft assembly INTERMEDIATE nan Ges Nica iv TI S CLUTCH SHAFT HU dr M shaftassy tif Figure 1 3 Gear Train O 10 E Ken O beer cC O ab X D L Bel Brake On Neutral Line In Forward Line Out Reverse Figure 1 4 Gear Train Rotation Torque Transfer Allied COMPANY Allied WINCH Freespool Operation W6F W8L Only See Fig 1 5 The FREESPOOL arrangement allows mechanical dis engagement of the drum gear from the remainder of the gear train When the FREESPOOL handlever is shifted the dental clutch engages or disengages the drum pinion and intermediate gear WARNING When the control lever is moved to the freespool position it will release the gear train and an
46. Intermediate Shaft Installation Freespool 4 38 E ial EE snasaannenmneacaraniears 3 1 Brake Shaft Installation 0000nnn00annenaaannnnnennennnaae 4 41 Maintenance mesial 3 1 Oil Clutch Reassembly A 4 43 Checks Before Operation ccccccccseeseeeeeees 3 2 Clutch Shaft Reassembly amp Installation 4 46 Checks During Operation snsaeeeneeneeneeeneen 3 2 Hydraulic Pump Reassembly amp Installation 4 52 Checks and adjustments ccccccccessseeeeeeeaeeeeeees 3 2 PURI installation ona 4 53 Control Cable Adjustment ccccssseeeeeeeees 3 2 Oil Brake Reassembly amp Installation 4 54 Freespool Cable Adjustments nnnennnenneaeenn 3 3 PTO Shaft Reassembly amp Installation 4 57 Freespool Drag Adjustment ees 3 3 Winch Installation ooenneaannnnnnnnnennnnennenennnnnnnnnennnnne 4 64 Hydraulic System Pressure Checks ccccccccnccnnccco 3 4 ee e 4 65 Preparation AA o 3 4 W12EE Addendum oocccccocnnccnonnnos See end of manual Allied Systems ji Notes Section 1 General Introduction This service manual is for the W6F W8L and W12E winches The following information is included in this manual Section 1 General includes operation descriptions of systems and components as an aid for trouble shooting and repair Section 2 Troubleshooting lists common problems and the possible causes and
47. MODULE SS DYC O HSOUT2 HSOUT4 HSOUTS STATUS O O O O O i Figure 2 1 Electronic Control Module Table 2 2 Electronic Control Module LED Description Chart See Figure 2 1 A Normal Powered Condition Module status Lit green after power up While downloading a program to the module MS and NS LEDs will flash in an alternating fashion Network status Lit or flashing after power up While downloading a program to the module MS and NS LEDs will flash in an alternating fashion DIG1 DIG8 Digital inputs PWM A FWD REV modulation Solid red to green in FWD or REV PWM B Brake modulation Solid red to green in FWD REV or Brake off PWM C Fault detection Solid at startup HSOUT 1 Forward output FWD operation HSOUT2 Reverse output REV operation HSOUT3 Brake output FWD REV or Brake off operation HSOUT4 Accumulator Cooling output FWD REV or Brake off operation HSOUT5 Freespool output Not used on W12E HSOUT6 Brake dump output FWD REV or Brake off operation STATUS Not used POWER Lit after power up Allied COMPANY 2 9 Troubleshooting Table 2 3 Electronic Control Module Troubleshooting Chart LED status LED status Fault description Probable cause PWM C lit Winch won t function Joystick off center at Center joystick startup PWM C amp HSOUTx Shorted or open output Wiring harness failure Check appropriate circuit from module to flashing circuit valve
48. PANY Section 1 Capscrew Backplate Assembly O Ring Body Dowel Pin Drive Gear Assembly Idler Gear Assembly Key Seal Package Spring Ball Front Plate Assembly Shaft Seal ee Ore ee Figure 1 12 Hydraulic Pump Accumulators Two accumulators joined by a tee fitting are connected to the hydraulic system The bladders have a nitrogen precharge so that the oil stored in the accumulators will be under pressure When released this oil will provide pressure for the hydraulic system during low engine rom shifts and if the PTO shaft stalls The W6F and W8L have two accumulators and the W12E has three accumulators They are charged with nitrogen to 100 psi Accumulator Valve The accumulator valve is mounted adjacent to the control valve and is actuated by the control valve spool cam As the hydraulic system builds up pressure oil can flow past the check ball in the valve to be stored in the accumula tors When the control valve spool is moved to the LINE IN or LINE OUT position a cam on the spool pushes up on the accumulator valve pin This pin lifts the check ball off its seat to release the oil stored in the accumulators If the PTO should stall so the hydraulic pump does not pro vide sufficient flow the stored oil will be released thus releasing the brake and applying the clutch This prevents further drag on the PTO shaft Cooling Oil Relief Valve See Figure 1 13 The cooling oil relief valve is a s
49. PANY Allied S Section 4 5 Using a depth gauge measure the distance from the 6 Coatthe winch frame and retainer with Loctite or other face of the bearing cup to the winch housing Add a suitable sealing compound Install finalized shim pack shim pack of 0 004 to 0 007 in 0 102 0 178 mm and retainer greater than the measured distance For example if the measured distance is 0 004 in 0 102 mm add a shim pack with a total thickness of 0 008 to 0 011 in 0 203 0 279 mm This will allow 0 004 to 0 007 in 0 102 to 0 178 mm endplay of the shaft 7 Tighten the six capscrews to 75 ft lbs 10 kg m pack of 0 020 in 0 510 mm are not uncommon Allied COMPANY 4 37 Repairs Intermediate Shaft Installation Freespool pa WINCH Intermediate Shaft Installation Freespool These figures show the winch removed from the tractor 3 Place dental clutch on pinion gear Ensure chamfered with the clutch shaft and brake shaft removed ramp faces pinion NOTE The winch is shown equipped with the optional freespool arrangement For instructions on how to install an intermediate shaft on a winch without freespool refer to the previous section Intermediate Shaft Installation Non Freespool 1 Install inner bearing assembly if previously removed Use a liberal amount of lubriplate or other light lube grease to hold the inner bearing cone in place fs dentalclutch jpg 4 Position intermediate gear in housing
50. PTO Shafts Last Used on W6FP 3699 W6FX 3699 amp AW6F 1000 Last Used on W8LP 2099 amp AW8L 1000 Current on W12E Allied COMPANY Repairs PTO Shaft Reassembly amp Installation dz E Ee i REE LLLLL APL LLLLLLLLLLA LLLP hh H gh i Sit YM gt II A LLLLIAALLLLLELLLLLL XD ptoshaft1 eps ptoshaft2 eps PTO Shaft With PTO Shaft With Removable Bevel Integral Bevel Pinion Gear Pinion Gear Snap Ring Lockring Ball Bearing Spacer Bearing Carrier Oil Seal Capscrew O Ring Lockring Shim Pack O Ring PTO Shaft Pin Lockwire Coupling ES ys Used on Gear Ratios 6 Used on Gear Ratios 1 8 amp 9 Only 3 zaa Ed E EE ST X _ O iS Ly e Be ie pto cat527int eps pto cat527rem eps Ball Bearing PTO Shaft with Integral Bevel Pinion Gear Snap Ring Interior Capscrew Bearing Carrier Lockwire Oil Seal O Ring O Ring PTO Shaft Coupling Gear Pin Snap Ring Exterior Figure 4 24 PTO Shaft on W6F for Caterpillar 527 Ge Allied COMPANY Section 4 1 Snap Ring 2 Bevel Pinion Gear 3 Bearing Carrier 1 4 O Ring TA 6 5 Capscrew 8 Washer Si O AS e 6 Oil Seal H DIAN 7 Ball Bearings 14 Wy WY is 4 8 Shim Pack 9 Shaft Uf d 10 Shaft with Integral Pinion UM iN 13 11 Washer 2 12 Yoke oi 3 13 Nut a 2 12 14 Snap Ring 3 John Deere 755 John Deere 855 John Deere 750 Last Used on W6F 7143 amp AW6F
51. Pin Bearing Cup Bearing Cone Snap Ring Bearing Cone Bearing Cup Carrier Seal Shim pack 383164g eps Sealing Capscrew PS DON D7R amp D8R Fitting Plug Gear 36T Plate Cover Capscrew Washer Ball Bearing Snap Ring Roller Bearing Cup Roller Bearing Cone Spacer Shim 005 Shim 007 Shim 020 Gear 36T Snap Ring Roller Bearing Cup Roller Bearing Cone Shaft Idler Pilot PTO Capscrew Shim 005 Shim 007 Shim 008 Shaft Input Seal Gear 37T Spacer Housing Gear Box Capscrew Washer Seal Shaft Lockwasher Bearing Carrier Snap Ring Ball Bearing Figure 4 17 Dropbox on W12E for Caterpillar 583R Last Used on S N AW12E 1103 Allied COMPANY Figure 4 16 Dropbox on W6F amp W8L for Caterpillar D6H R D7H cat583drop2 eps cat9rdroprev eps 53 54 52 3 17 5 salis WZ rN L 6 7 aah LLELLLLLLIA L KS oo NS y ASS lt q ASE SE War 56 i SH 60 TAI TY M5 f 51 CH d KEE SS 11 12 21 10 14 15 16 nie N St lt a KLLLL LLL LY e NN ELLZ INN lt lt Y NS YY V A AG 2 19 20 S 1 24 25 26 27 Fitting Plug Spacer Plate Cover Capscrew Washer Ball Bearing Snap Ring Roller Bearing Cup Roller Bearing Cone Spacer Shim Shim Shim Gear Snap Ring Roller Bearing Cup Roller Bearing Cone Shaft Idler Section 4 Pilot PTO Capscrew Shim Shim Shim Shaft Input Seal Gear Spacer H
52. Replace body if inner diameter of gear pocket ex ceeds 1 719 in 43 66 mm Allied COMPANY Allied S Section 4 Clutch Shaft Removal 8 Disassembly Figure 4 1 shows the location of clutch shaft components 4 Remove right hand bearing retainer and shim pack Removal of the clutch shaft and associated parts can usu Tag shims to aid in reassembly ally be accomplished with the winch mounted on the trac tor Prior to removal of the clutch shaft perform the follow ing a Drain oil from winch b Remove all brake components as shown in the Oil Brake Removal and Disassembly section steps 1 through 10 c If equipped with freespool option remove freespool shifter shaft and fork 1 Disconnect hydraulic lines from the left hand bear 5 Remove the two seal rings from each end of the clutch ing retainer shaft Expand the seal rings just enough to slip over the end of the shaft 2 Remove left hand bearing retainer and shim pack E 3 Seal Rings lt a A ses 13 037 tif 6 Straighten the lockwasher tang securing the locknut Use special tool illustrated in Figure 4 35 to remove the locknut 3 Remove hydraulic lines and fittings from the right hand bearing retainer 7 Remove the locknut and lockwashers O o Y gt Allied COMPANY 4 15 WINCH Repairs Clutch Shaft Removal amp Disassembly Allied 8 Remove the tapered roller bearing and thrust washer 11 Remove the lef
53. TO Shaft on W12E for Dresser TD25E G Pinion Bearing O Ring Shim Shim Oil Seal Yoke Washer O Ring Nut Snap Ring Shaft Keeper O Ring Snap Ring Gear Housing O Ring Snap Ring Bearing Idler Gear Bearing Cup Bearing Cone Shaft Bearing Cone Fitting Not Illustrated Capscrew Washer Plug Bearing Carrier Capscrew Washer 1020 3 Oo Dl SE A T ima a es H Greg SO K LLL WY 374814b eps Bearing Carrier Washer Roller Bearing Cup Locknut Bearing Roller Bearing Cone Oil Seal Spacer O Ring Shim Pack Input Shaft O Ring Gear O Ring Capscrew Spacer Washer 1 2 3 Se 6 ve 8 9 Figure 4 28 PTO Shaft on W12E for Caterpillar D8 L D9N amp D10N Komatsu 375A 1 New Holland FH FD30B Figure 4 29 Dropbox on W8Lfor Komatsu D85ESS 2 SC Allied COMPANY kom d85ess2drop eps Y N N 10 11 1213 N Y K N MLM Lf Lhd d Se VL LL f Li AY LAS 32 31 30 kom d65drop eps 29 Pinion Shaft Locknut Bevel Pinion Gear Bearing Carrier O Ring Shaft Ball Bearing Gear Housing Bearing Cone Pinion Bearing Cup O Ring es oe a a T dr 5 1131 Ke LD EZ OG CH Kul fe e 1305092 tif IL ZN gt FS GE YIIZ 28 Shim Pack Carrier Oil Seal Yoke O Ring Nut Washer Snap Ring Carrier Capscrew Keeper KX CSS ee 14 15 16 17 18 19 20 21 oldkomdropb
54. UMULATORS OIL BRAKE BRAKE DUMP VALVE MODULATED PRESSURE HIGH PRESSURE MAMMA LOW PRESSURE FH SUCTION ss NO PRESSURE si BYPASS VALVE PRESSURE FILTER ail CHECK VALVE me HYDRAULIC Figure 1 13 Hydraulic System LINE IN Forward Sequence of Operation LINE IN For LINE IN forward operation the operator pulls back on the joystick which simultaneously closes the bypass valve and opens the accumulator valve Oil flow from the pump and accumulators increases pressure The brake dump valve closes so brake pressure can increase The proportional brake and forward clutch valves open accord ing to the control module program Modulated pressure to 1 14 the clutch and brake is supplied during inching slight move ment of the joystick from the BRAKE ON position Full pressure is applied to the clutch when the joystick Is in full LINE IN position Brake pressure is limited to just above brake release pressure for faster response Allied COMPANY JOYSTICK POSITION VALVE MANIFOLD 6 ASSEMBLY O VLLLLLLL LLL FORWARD CLUTCH VLLLLLLLLL LL lineout eps LILLLLLLL CA E y SUCTION di STRAINER ACCUMULATORS OIL BRAKE BRAKE DUMP VALVE Section 1 MODULATED PRESSURE HIGH PRESSURE a LOW PRESSURE H SUCTION ss NO PRESSURE sid BYPASS VALVE PRESSURE FILTER CHECK VALVE Cs HYDRAULIC Figure 1 14 Hydraulic System LINE OUT INCHING Sequence of Operation L
55. YSTEM 7 LEFT W12E OIL BRAKE 2 sideleftbw tif siderightow tif decalspnt eps RIGHT Figure 3 4 Decal Installaion 3 6 Allied COMPANY To find a dealer in your area Call 503 625 2560 LI Fax 503 625 7269 or Allied Email marketing O alliedsystems com COMPAN Y Di l 599787W 06 30 2010 Visit our website http www alliedsystems com Printed in USA
56. a full supply of oil 2 Return handlever to BRAKE ON 3 Shut the engine off and wait one minute 4 Place the handlever in the BRAKE OFF position This will release the oil in the accumulators Observe the initial pressure reading and the time for the pressure to drop below that specified in Table 3 2 If the leak down time is less than specified in Table 3 2 repeat steps 1 through 4 but do not delay in placing the handlever in BRAKE OFF after the engine is shut down If the leak down time is greater than that measured when waiting one minute then there is either a leak in the lines between the accumulators and the accumulator valve or a leaking accumulator check valve Low accumulator gas pressures will tend to stall the winch on a low engine rpm shift To determine if accumulators have any gas pres sure remove valve stem protective cover and push gently on valve stem A ruptured bladder will emit oil Accumula tors are not rebuildable Forward Clutch Pressure Check and Forward Modu lator Valve Check With the engine shut off connect one low pressure gauge to Port B Start the engine and place handlever in BRAKE OFF to build up the accumulator system pressure Place handlever in LINE IN position and check FORWARD LINE IN clutch and LINE IN INCHING pressures as indicated in Table 3 2 On a fast shift the clutch pressure should come up with the brake pressure In LINE IN INCHING the clutch pressure should lag the brake release p
57. achments whenever possible Removal of the drum and drum shaft can be accomplished with the winch on the tractor To remove the drum gear it will be necessary to first remove the intermediate shaft see Intermediate Shaft Assembly Removal section and the clutch assembly see Clutch Shaft Removal and Disassembly section 1 Loosen the drum capscrews then remove capscrews with thimbles leaving two located 180 apart r1 033 tif NOTE Tag shim pack for reference during reassem bly 4 Remove retainer ring by removing retainer cap screws Y N o m m 2 Remove both drum shaft locknut and the retainer 5 Set bearing retainer removed in Step 3 back in place capscrews and screw locknut removed in Step 2 back in place This will allow the bearing retaining plate to be used as a fixture for pulling the shaft from the drum On W6F and W8L use 1 2 UNC jacking screws to break ei drum shaft free On W12E use two 5 8 UNC jacking AS screws to break drum shaft free NOTE Bearing assembly may be removed with the A H drum shaft if it is seized to the shaft Locknut e oo E mm 6 OnWG6F and WA8L install two 1 2 UNC ASTM F541 Eo i AC i Ed or equivalant eyebolts into the retainer 180 apart A E OnW12E screw two 5 8 UNC ASTM F541 or equiva lent eyebolts into retainer 180 apart 12 025 if Allied Systems 4 27 Repairs Drum Shaft amp Drum Removal NOTE Bearing
58. amaged brake piston piston housing or Check piston and piston housing cavity for damage seal rings Replace if scored or broken Always replace both seals when brake is repaired troubleshooting item below Allied COMPANY 2 1 Troubleshooting Table 2 1 continued Troubleshooting Analysis Check Chart PROBLEM POSSIBLE CAUSE CORRECTION Overheating Plugged pressure filter Replace filter Plugged suction filter Remove suction filter clean and replace One or both clutches dragging Check by placing handlever in BRAKE OFF Normally drum will rotate slowly in the LINE IN direction If the reverse clutch is dragging the drum will rotate in the LINE OUT direction If forward clutch is dragging the drum will rotate positively in the LINE IN direction and it will take more than 100 Ibs of line pull to prevent drum rotation Low Low system pressure pressure Adjust Adjust accordingly ao Low or K a a cooling oil pressure bn e e cooling oil pressure Replace cooling oil relief valve if required Bevel shaft bearings set too tight Adjust accordingly Control spool travel improperly adjusted Check and adjust as necessary Avoid continuous operation in the inching zone Oil brake slipping or Low brake release pressure Check brake release pressure Replace friction drum backspin on fast discs and separator plates if too thin shift from neutral to Broken belleville spring Replace Refer to Section 4 forward B
59. an cause further damage Review and perform any adjustments that may be the cause of a malfunction refer to Section 3 Use new seals gaskets and O rings when installing com ponents A CAUTION Cleanliness is of extreme importance in the repair and overhaul of any hydraulic unit Be fore attempting any repairs the exterior of the winch must be thoroughly cleaned to prevent the possibility of contamination Winch removal bh 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 N Remove the cable from the drum Clean the outside of the winch and the area where the winch contacts the tractor Be careful when you remove the cable from the drum The end of the cable can move like a compressed spring causing an injury when the ferrule is released from the drum Ge Move the control lever to the LINE IN position at least three times to discharge the pressure in the accu mulator 4 Remove the control valve cover 5 Disconnect control cable and freespool cable from winch 6 Connect slings and a crane or lifting device to the winch Install lifting eyes refer to Figure 4 38 into the lifting holes provided in the frame The slings and crane used to lift the winch must have a minimum lifting capacity of 1500 kg 3000 Ib 7 Drain the oil from the winch 8 Remove transmission cover 9 Remove mounting
60. ance to rotation of the drum during the FREESPOOL operation The resistance to rotation is cor rect when the drum can be rotated by hand but the drum will not rotate more than one half revolution freely The addition or removal of shims for the preload on the bearings of the intermediate shaft requires the removal of the cover for the intermediate shaft This adjustment is normally only necessary if the winch has had an over haul See Section 4 if this adjustment is required FREESPOOL Drag Adjustment for AW6F 4062 and above and AW8L 2033 and above with Exterior Drag Adjust See Figure 3 5 The preload on the bearings of the intermediate shaft con trols the resistance to rotation of the drum during the FREESPOOL operation The resistance to rotation is cor rect when the drum can be rotated by hand but the drum will not rotate more than one half revolution freely On W6F winches S N 4062 and above and W8L winches S N 2033 and above an adjusting screw is located in the center of the bearing retainer for the intermediate shaft please refer to Figure 3 5 This screw can be tightened or loosened to adjust the preload on the intermediate shaft The jam nut will maintain the FREESPOOL setting Adjusting Screw Jam Nut _ O a KA O o O O a YN _ UE Figure 3 6 FREESPOOL Adjustments Allied COMPANY oe Service Hydraulic System Pressure Checks Fig 3 7 The hydraulic oil and filter s should be maintain
61. aring Ball Bearing Inner Race Snap Ring O Ring Pin PS DON D7R 8 52 53 54 3 PTO Ref 41 Bearing Cup Bearing Cone Snap Ring Bearing Cone Bearing Cup Carrier Seal Shim pack Sealing Capscrew D8R 4 5 zal Sy Sy y 6 7 el ZAZ BOOT SES KZ SS 6 YA d S a M oss SS 3 ESA Y 55 lt S LEE Ge e CH 2 ORUMI fp SP Dr Ar NN ES EIB Le INN ag NYT 58 Hi lM SSSI 50 Z 10 11 12 V S i ZZ N Ge 21 13 14 15 16 17 18 19 20 41 40 N S Y Wl NG i RWW INN E ay O 23 7 24 25 26 27 Pinion Shaft Pinion Gear Ball Bearing Snap Ring Ball Bearing Oil Seal Idler Gear Input Gear Idler Shaft Input Shaft O Ring Gasket Carrier Bearing Retainer Shims Bushing Capscrew Torque to 40 Nm 30 ft lbs fiatdrop tif Figure 4 34 Dropbox on W6F for New Holland Construction ER E S A CA Al GG el Wee Vo E Tu q oe E ZC HES np CH Ab 10C 14B amp 14C FD14E Fitting Plug Gear 36T Plate Cover Capscrew Washer Ball Bearing Snap Ring Roller Bearing Cup Roller Bearing Cone Spacer Shim 005 Shim 007 Shim 020 Gear 36T Snap Ring Roller Bearing Cup Roller Bearing Cone Shaft Idler Pilot PTO Capscrew Shim 005 Shim 007 Shim 008 Shaft Input Seal Gear 37T Spacer Housing Gear Box Caps
62. assembly may be removed with the drum shaft if it is seized to the shaft 7 Attach a sling around the drum and hoist until there is no slack then drive the shaft out the right hand side NOTE support or sling the drum gear so that it does not fall during shaft removal 8 Remove two remaining drum capscrews 9 Carefully remove the drum from winch frame En sure that the adapter does not fall 10 Remove adapter _ r1 004A tif 11 Remove and discard adapter seal h o o w _ Allied WINCH NOTE This seal must be replaced with a new Allied Systems Company approved seal during reassem bly 12 Remove double tapered roller bearing assembly and seal spacer from the left hand end of the drum r1 009 tif E A ren ASG ba eG gt a f SS LES NOTE Refer to Figure 5 10 for location of compo nents 13 Remove and discard shaft seal from drum Seal lip should normally be pointed in wea N o o w Benn Allied COMPANY Allied S Section 4 14 Remove and discard adapter seal from winch hous 15 Using a suitable lifting device the drum gear can now Ing be removed r1 020 tif ee a N CH o y tT NM 5 Allied COMPANY 4 29 Repairs Ges WINCH Assembly of the Winch All components should be inspected for wear or damage may fail when placed under a load When in doubt it is as they are removed Refer to Table 4 1 V
63. bly This is due to insufficient clearance for installing the reduction gear when the bevel gear shaft is installed 1 Using lifting eye installed in the spider or in the pis ton housing oil hole lower the reverse clutch assem bly into the housing 9 2 Install new O rings on the clutch shaft and lubricate the entire shaft 3 r3 009 tif r3 013 tif N o op _ WINCH Position the clutch shaft so the blanked out tooth is up The pipe plug in the RH end of the shaft will be down Install ball bearing and bearing carrier Place the pump drive gear in the housing as shown The drive gear can be held in position by temporarily installing capscrews from the RH clutch shaft retainer into the two threaded holes provided in the gear Ensure that the dished side of the gear faces toward the brake compartment Install forward clutch assembly into the housing SCH Allied COMPANY Allied WINCH NOTE Keep the oil hole plug in the piston housing on top Scribe a vertical line on the housing for alignment with blanked out spline on shaft NOTE Ensure that the bearing and bearing carrier are installed as shown in the Oil Clutch Reassembly section Step 14 7 Install spacer next to forward clutch P r3 019 tif 8 Insert the ring gear H o N o op _ 9 r3 021 tif Section 4 Insert clutch shaft far enough to install spacer be tween bevel gear and bea
64. crew Washer Seal Shaft Lockwasher Bearing Carrier Snap Ring Ball Bearing Figure 4 35 Dropbox on W12E for Caterpillar 583R Last Used on AW12E 1103 Allied COMPANY cat583drop2 eps cat9rdroprev eps 53 54 52 3 17 NS 96 SF e SV 60 SS a RSS SEE SN NSS Six elt ss ESOS ct XG ya a Fitting 5 Plug Y Ba GE SH N Si et 6 7 SS SS OMA Spacer Plate Cover DU Capscrew Washer Ball Bearing Snap Ring Roller Bearing Cup Roller Bearing Cone Spacer Shim Shim Shim Gear Snap Ring Roller Bearing Cup Roller Bearing Cone Shaft Idler 51 11 12 21 10 14 15 16 51 18 SIS 25 26 27 Section 4 Pilot PTO Capscrew Shim Shim Shim Shaft Input Seal Gear Spacer Housing Gear Box Capscrew Washer Seal Shaft Lockwasher Bearing Carrier Snap Ring Ball Bearing Figure 4 36 Dropbox on W12E for Caterpillar 583R First Used on AW12E 1104 52 53 54 me yy ISS hE SSN OQ S N ZA 7 X RIN DA H N NES EN 17 s NZ ZA ELA Az Y SSA GY 161 ARS SR GY Y S Y gt a Niece SS o Z T H Zeg Cas gt Y a d CT 7 24 Figu SS ANNS SS 17 4 Fitting Plug Spacer Plate Cover Capscrew Washer Ball Bearing Snap Ring Roller Bearing Cup Roller Bearing Cone Spacer Shim 005 Shim 007 Shim 020 Gear 36T Snap Ring Roller Bearing Cup Roller Beari
65. d INTERMEDIATE 5 gum N haa T Lay V herp shaftassy tif Ee gt O ab z 2 ben 10 G O 0 a nl _ O Brake On Neutral Allied WINCH s Torque transfer during operation is shown in Figure 1 4 a drum shaft assembly NOTE PTO Rotation is determined by standing behind tractor and looking forward at the PTO shaft entering the winch case BRAKE SHAFT Ka a 777 CLUTCH SHAFT Figure 1 3 Gear Train Line In Forward Line Out Reverse Figure 1 4 Gear Train Rotation Torque Transfer Allied COMPANY 2304504W LE AA SSS A handleverinst eps Section 1 LINE OUT BRAKE OFF Electronic Joystick Filter amp Trouble Code Indicator Figure 1 5 Electronic Winch Controls Operation and Control See Fig 1 5 The electronic control assembly has one control lever see Figure 1 5 The control lever is connected to the winch through electrical wiring an electronic control module and a solenoid actuated valve manifold assembly This lever is used to select one of the following operations e BRAKE OFF LINE OUT e BRAKE ON LINE IN NOTE The filter LED on the joystick plate illumi nates momentarily at startup This is part of the normal system check Consultthe troubleshooting guide in Section 2 if the light does not turn off NOTE The winch will not operate until the joystick is briefly centered after startup BRAKE OFF is th
66. d parts as necessary Detent ball and spring loose damaged or Clean or replace as necessary sticking Winch will not Linkage improperly adjusted Check and adjust as necessary eee po0 Intermediate shaft assembly damaged rusted Adjust or repair as necessary Refer to Section 4 or preloaded Drum shaft assembly damaged rusted or Adjust or repair as necessary binding Winch freespools too Insufficient preload on intermediate shaft On winches with exterior Freespool Drag Adjust easily Tighten preload on the intermediate shaft On winches without exterior Freespool Drag Adjust Remove shims as required to preload shaft Refer to Section 4 Winch freespools too Too much preload on intermediate shaft On winches with exterior Freespool Drag Adjust hard Loosen preload on the intermediate shaft On winches without exterior Freespool Drag Adjust Add shims as required to preload shaft Refer to Section 4 NOTE It may be necessary to use a slide hammer on the shaft to unload the bearing race because of the fit in the bore Allied COMPANY 2 3 Notes Allied i Section 3 Service General Maintenance This section provides the instructions for performing main The Maintenance Schedule is a program that includes tenance and making checks and adjustments Standard periodic inspection and lubrication Use the operating time shop tools are used in doing the work described in this on the hour meter of the tractor to dete
67. e only detented position on the lever the operator must pull the control lever to release it from that position A collar and spring arrangement on the handlever returns the lever from the LINE IN and LINE OUT posi tions to the BRAKE ON position Do not use BRAKE OFF with a suspended load as fallback will occur BRAKE ON is a neutral position No hydraulic pressure is applied to the brake or the clutches Springs apply the brake so the winch drum will not rotate LINE IN position applies the forward clutch and releases the brake The winch will wind the cable at a speed con trolled by the PTO speed of the tractor LINE OUT position applies the reverse clutch and releases the brake The winch will unwind the cable at a speed con trolled by the PTO speed of the tractor and the weight of the load BRAKE OFF position releases the brake through oil pres sure but cable cannot be pulled from the winch by hand because of friction in the clutches brake and gear train BRAKE OFF is used to move the tractor away from the load while keeping the cable tight Moving the control lever with the engine OFF and the keyswitch ON may result in accumulator discharge and brake release which will cause load fallback Allied COMPANY 1 7 General VALVE MANIFOLD ASSEMBLY HYDRAULIC PUMP TO REVERSE CLUTCH TO FORWARD CLUTCH 2304896b 3 eps ACCUMULATORS PRESSURE FILTER SUCTION STRAINER BRAKE DUMP VALVE OIL BRAKE
68. e or blockage check bypass valve Check hydraulic lines for leaks Replace accumulator valve Check for defective accumulators Refer to Section 2 Table 2 1 for Low Forward or Reverse Clutch Pressure troubleshooting procedures Refer to Section 2 Table 2 1 for Low Forward or Reverse Clutch Pressure troubleshooting procedures Service Decal Nameplate and Service Plate Installa tion The unit nameplate a Warning Decal and a Filter Service The W12EE model decals are used on both sides of the Plate are located on the winch as illustrated in Figure 3 4 winch frame as shown Replace as necessary If any of these is damaged install new ones in the loca tions shown e Y LUBRICATION INSTRUCTIONS IMPORTANT USE ONLY AMOCO OI CO AMOCO20O00ELUID DEERE A CO HYGARD FLUID EXXONICOMPANY TORQUE FLUID Sp SUNIOIL CO SUNFLEET TH UNIVERSAL TRACTORIFLUID 50 HOURSIORIWEEKLY CHECKIOIL LEVEL WITHIENGINE OFF Ee NAMEPLATE miner EVERY 3 MONTHS REPLACE FILTER IF EQUIPPED 2000 HOURS OR YEARLY DRAIN FLUSH AND REFILL WITHINEWLOIL W12E OIL BRAKE Ne Allied A WARNING OIL UNDER HIGH PRESSURE CAN CAUSE SERIOUS INJURY TO EYES AND SKIN BEFORE SERVICING HYDRAULICISYSTEM 1 SHUT ENGINE OFF 2 MOVEICONTROL LEVER FROMIBRAKE ON TO BRAKE OFF 8 TIMES 3 LOOSEN FITTING i s SLOWLY TO ASSURE NOIPRESSUREIIN S
69. eck for broken or severely worn splines Replace if splines are broken or severely worn Intermediate Gears Inspect both gears for broken or severely Replace gears if teeth are broken or severely worn worn teeth Pay particular attention to leading edges of straight cut gear teeth Clutch worn Drum Shaft Dress surface or replace shaft if severely worn bearing surfaces Check O ring groove and seal surface Dress groove or replace shaft if severely worn Check for crossthreaded or damaged threads Drum Gear Check for broken or severely worn gear teeth Replace gear if teeth are broken or severely worn Pay particular attention to leading edges of straight cut gear teeth and rust ring will not seat properly for deep scratches burrs and rust Winch Frame Check area around drum and drum adapter Consult the factory for damage if cable has slipped between cable guard and winch frame Allied COMPANY 4 31 Repairs Drum Shaft amp Drum Installation Drum and Drum Shaft Installation If the drum gear was removed it must be installed prior to 3 Lubricate the left hand drum bore with Lubriplate or installation of the intermediate shaft and reverse clutch other light lube grease then install double tapered assembly roller bearing assembly 1 Lubricate seal bore with Lubriplate or other light lube grease Install double lip seal with smooth side to ward the drum in the right hand side of the frame 11 009 tif 4 Re
70. ed as in dicated in the Maintenance Schedule If any problems are found they should be corrected before operating the winch Preparation Prior to checking the hydraulic pressures perform the fol lowing 1 Remove cable from drum to prevent engtanglement during pressure checks since the drum will rotate during the tests Vehicle 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 like a compressed spring causing an injury when the ferrule is released from the drum Always wear gloves when handling cable 2 Startthe engine and place the winch in BRAKE OFF to raise the oil temperature to 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 1000 RPM for all tests 5 Leave test plugs securely installed unless testing that port 6 After completing all pressure checks and making the necessary adjustments ensure that all plugs and hoses are securely installed 7 Install control valve access plate and tighten capscrews Pressure gauges Two 400 psi 28 kg cm and one 30 psi 2 kg cm cali brated pressure test gauges are required to perform the hydraulic pressure checks NOTE Shut off the tractor engine when connecting and disconnecting test gauges Place handlever in BRAKE ON to prevent ac cidental discharge of pressurized oil
71. ence of Operation LINE OUT INCHING LINE OUT INCHING gradual brake release is achieved by slowly pushing the control lever ouf of the brake on neutral position towards the line out reverse position As the control spool moves the flow of oil to the cooling passage is blocked This allows pressure to build up in the inlet passage Oil flows from the inlet passage to the brake passage through an orifice producing a pressure drop between the inlet and brake passages depending on the 1 18 amount of oil flow As the brake port to sump is closed off by the spool the oil flow to sump is reduced allowing the brake pressure to build up As the brake pressure in creases the reverse modulator valve will regulate the oil pressure ot the reverse clutch and maintain a constant 120 psi 827 kPa pressure differential between the brake and the clutch through the inching mode Allied COMPANY NORMA Nk O OPERATION Dn FREESPOOL READ OPERATING Nes INSTRUCTIONS 271731 HANDLEVER POSITION PRESSURE y FILTER CHECK VALVE KE E ENEE HYDRAULIC PUMP Can Pe SUCTION 3 STRAINER lineout eps ACCUMULATOR VALVE ACCUMULATORS Section 1 PRESSURE MMM COOLING P SUCTION _ REVERSE CLUTCH g CONTROL VALVE FORWARD CLUTCH COOLING OIL MANIFOLD COOLING OIL RELIEF VALVE Figure 1 17 Hydraulic System LINE OUT Reverse
72. ernately at each side of the winch to pull the winch evenly against the tractor The two top inboard nuts should be snug then turned on to the next slot so that the cotter pin can be installed All outboard nuts should be tightened to 500 ft lbs 69 kg m Torque all nuts and capscrews as specified in Table 1 9 Install control lever assembly per mounting kit instruc tions Attach push pull cable s to control lever assembly Attach cable bracket s to winch Do not tighten fas teners at this time Allied WINCH 14 Attach push pull cable s to control valve clevis and freespool then tighten cable bracket s to winch Valve Spool Clevis r5 024 tif 15 Fill unit with oil 16 Adjust control cable and check hydraulic pressure settings as described in Section 3 17 After winch installation remove top cover and pry pinion towards tractor with a prybar to ensure the pinion is not jammed against the ring gear This avoids excessive noise during winch operation NOTE Pressure checks in accordance to table 3 2 should be taken with hydraulic oil at operating temperature Allied COMPANY Allied WINCH Special Tools The following are special tools that may be fabricated to facilitate the execution of the overhaul procedures tool1 eps Section 4 NOTE All dimensions in the following drawings are in inches with dimensions in millimeters enclosed by parantheses NOTE Fit end piece and weld in
73. evers as hangers for clothes wa ter bags grease guns lunch pails etc Do not leave the vehicle when the winch cable is under 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 and cause dam age When the winch is not in use make sure the control lever is in brake on position so that the winch brake is applied Indicates a condition that can cause personal injury A CAUTION Indicates a condition that can cause property damage NOTE Whenever information exists that requires additional emphasis beyond the standard text the term NOTE is used Notes Contents Contents Section 1 General mccciencnicccicinii li iad 1 1 Section 2 TroubleshootinNg cooocccccconncnncoconannnnnnnas 2 1 Idee fie M 1 1 A A 2 1 DESCAPIO iaa 1 1 Troubleshooting Analysis Check Chart 2 1 Serial Number CodeS cooooocccccccccccoocconononcnonanonnos 1 1 Electronic Control Module LED Description 2 5 Unit Identification comandancia 1 2 Electronic Control Module Troubleshooting 2 6 Namepla userinsatrapiot ene ta ninas 1 3 Interfacing With the Electronic Control Module 2 6 Capacities amp Specifications oocccccocccncconnnncnonos 1 4 Approved Oil List ccccoccccccoccnccccononiconcnnos 1 4 Section 3 Service conocccccnncccononncconcnnccenannnnonannne
74. ft Removal Non Freespool for instructions relevant to winches without the freespool option 1 Remove the capscrews securing the shifter shaft and the cover a PA O Shifter Shaft Z i fs shaft jpg 2 Remove the plug and spring from the freespool shifter fork D D 2 a 2 o p fs detentspr jpg 3 fs detentball jpg 4 fs shiftfork jpg Withdraw the shaft and remove the fork i Allied COMPANY Allied WINCH Allied WINCH 5 Remove the intermediate shaft cover D 2 DN S O op d Ka Section 4 7 Screw a 3 4 16 UNF slide hammer into the end of the intermediate shaft and partially pull it out W8L takes 3 4 10 UNC 8 Remove the drum pinion gear and the inner bearing cone Refer to Figure 4 2 for the location of compo nents 8 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 prior to remov ing intermediate gear See Drum Shaft and Drum Removal section that follows 6 Tag shims for reference during reassembly not shown NOTE The above step is relevant only to AW6F 4061 and below and AW8L 2032 and below without exterior freespool drag adjust Exterior freespool adjust covers do not require shims Allied COMPANY 4 25 Repairs Drum Shaft amp Drum Removal
75. g 1 Suction hose to pump connection Suction leaks will cause oil to foam 2 Pump shaft seal 3 Suction filter cover and gasket 4 Suction hose for cracks or collapsed sections Control cables need adjustment Check for correct adjustment as outlined in Section 3 Make sure the ends of the cables are fastened correctly Double check push pull cable housing to ensure it is securely anchored on both ends Be sure control lever has full movement and is not hitting housing Low oil pressure Check for leaks and replace components where necessary Be sure hoses are not rubbing on any gears or winch components Defective or improperly adjusted oil relief Clean relief valve if no pressure then adjust Check valve poppet may be stuck open relief valve with pressure gauge Replace if defective Clogged suction filter Check and clean or replace suction filter Oil brake leaking internally indicated by low Repair as required brake pressure Defective hydraulic pump Check pump pressure output only after all other checks have been made Worn pump indicated by pressure variation with engine RPM If pump is at fault replace Brake does not release Refer to Low Oil Pressure troubleshooting item or winch stalls during above Increase sequence differential Accumulator system malfunction Check for Correct leakdown time as described in Section 3 Leaking accumulator valve Leak in accumulator lines Damaged or defective accumulators D
76. h bearing retainers with their fi nalized shim packs E ke O sn o d w i NY i _ ps Allied COMPANY Allied S Section 4 26 Tighten capscrews on both bearing retainers to 75 ft lbs 10 kg m 27 Install clutch crossover hoses as shown and tighten securely Twist pressure hose to route away from bevel gear Lock in rotated position ko oi Kaes Oo Allied COMPANY 4 51 pump eps Repairs Hydraulic Pump Reassembly amp Installation pan WINCH Capscrew Backplate Assembly O Ring Body Dowel Pin Drive Gear Assembly Idler Gear Assembly Key Seal Package Spring Ball Front Plate Assembly Shaft Seal 1 2 3 4 5 6 7 8 9 Figure 4 19 Hydraulic Pump Hydraulic Pump Reassembly amp Installation de Replace as new parts seal kit 9 O Ring 3 and shaft seal 17 2 Tuck diaphragm seal 13 into grooves in front plate with open part of V section down 3 Press protector gasket 12 and back up gasket 11 into diaphragm seal 4 Drop steel balls 15 into respective seats and place springs 14 over balls 5 Place diaphragm 10 on top of back up gasket bronze face up 6 Entire diaphragm must fit inside raised rim of the dia phragm seal 7 Dip gear assembly into oil and slip into front plate bearings 8 Install dowel pins 9 Apply a thin coat of petroleum jelly to both milled gear pockets of body Slip body over gear
77. h until its COMPANY capacity is known and a new nameplate is installed Each winch must be operated within its rated capacity as shown MODEL on the nameplate SERIAL NUMBER MAXIMUM RATED LINE PULL Allied BARE DRUM LBS FULL DRUM LBS wnat MAXIMUM CABLE SIZE INCH DIA MAX CABLE SIZE WITH ARCH INCH DIA MANUFACTURED BY ALLIED SYSTEMS COMPANY SHERWOOD OREGON USA nameplate paf O 2300516RA Figure 1 2 Nameplate Allied COMPANY 1 3 General Capacities and Specifications Approved Oil List The type of oil used in current Allied winches affects line control Use ONLY the following oils in the W12EE winch Brand Amoco 1000 Fluid Torque Fluid 56 Hy Gard Transmission A Hydraulic Oil Sunfleet TH Universal Tractor Fluid Company Amoco Oil Company Exxon Company John Deere Sun Oil Company Table 1 2 Approved Oil List NOTE For operation in temperatures below 23 C 10 F use John Deere J20D Low Viscosity Hygard or equivalent Winch Drum Capacities Cable Diameter Capacity For 355 mm 14 in Drum Diameter Capacity For 235 mm 9 5 in Drum Diameter 28 mm 1 1 8 in 32 mm 1 1 4 in 67 m 220 ft 53 m 175 ft 84 m 276 ft 67 m 220 ft Loosely or unevenly spooled line will change capacities Use flexible cable with independent wire rope center Table 1 3 Drum Line Capacities for W12E Hydraulic Specifications Oil Capacity naciendo 22 0 Gal 83 L ey Gea
78. identificati n sssi 1 2 Accumulator Pressure Check 3 4 Serial Number Codes c occcccccocccnnnccncnccnncccnnancnnnnos 1 5 Forward Clutch Pressure Check and Forward Nameplate cetonas 1 5 Modulator Valve Check 3 5 Capacities Specifications coconccconnnccccnnnccnnnnos 1 6 Reverse Clutch Pressure Check and Reverse Approved QS usesicioessance as 1 6 Modulator Valve Check 3 6 Winch Capacities oooonccncccccnnonnccnonnnnncnnnons 1 6 Control Valve Spool Travel Check 3 6 Hydraulic Specifications occccccooncninnccnnonos 1 6 Hydraulic Systems Pressure Tests Chart 3 7 Winch Torque Specifications cccccoonnnnnccc 1 7 Decal Nameplate amp Service Plate 3 8 oea e 1 8 Freespool Operation ooccccccccoocccncccnconcnnncononnnons 1 9 Operation and Control occccccccccnnoncccconnnnnccnnnnnnns 1 10 leet E ATC 4 1 Hydraulic System aaannnneennnnnnnnnnnnnnnnnnnnnnnnnenne 1 11 General asinen a ai a aidin 4 1 Forward Reverse Clutches ooooccccco o 1 12 o e 4 1 Se 1 13 Disassembly Of the WINCH ooccccccccoccccncccconnnnnnnnnons 4 1 Hydraulic Control Valve ccccecsseeeeeeeeeeeeees 1 14 Gear Arrangement 4 3 Hydraulic Control Relief Valve 1 14 PTO Shaft Removal amp Disassembly o 4 3 Hydraulic PUMI seess 1 15 Oil Brake Removal amp Disassembly
79. ift the clutch pressure should come up with the brake pressure If the pressure differential is too low the brake will not release soon enough and cause drag If the pressure differential is too high the brake will release too soon and cause backspinning of the drum If the reverse clutch pressure is not as specified in Table 3 2 check for 1 Leaking pressure hoses or fittings Damaged or worn clutch piston seals Damaged or worn valve manifold assembly parts Broken seal rings on clutch shaft a en oO IN Damaged O rings on clutch shaft Troubleshooting information is given in Section 2 oe Allied COMPANY Section 3 Table 3 2 Hydraulic System Pressure Tests TEST EQUIPMENT TEST CHECK ITEM PORT REQUIRED Brake G4 Brake 400 psi 28 kg cm gauge CONTROL POSITION CORRECTIVE ACTION Brake Off 220 psi 15 5 kg cm Adjust relief valve Line In Forward Line Out Reverse 7 G1 Inlet G2 Forward G3 Reverse 400 psi 28 kg cm Brake On Less than 140 psi 10 kg cm gauge 400 psi Brake Off 220 psi 15 5 kg cm 28 kg cm Brake On None GE Stop engine 3 None wait 1 minute Brake Off 150 psi 11 kg cm immediately 8 100 psi 7 kg cm minimum after 30 seconds Repeat if required 220 psi 15 5 kg cm 220 psi 15 5 kg cm 400 psi 28 kg cm gauge 400 psi 28 kg cm gauge Allied COMPANY Check plumbing for leakag
80. in current Allied winches affects the line control Use ONLY the following oils in the W6F W8L and W12E winches Company Brand Amoco Oil Company Amoco 1000 Fluid Torque Fluid 56 Hy Gard Transmission amp Hydraulic Oil Sunfleet TH Universal Tractor Fluid Exxon Company John Deere Sun Oil Company Table 1 4 Approved Oil List NOTE For operation in temperatures below 23 C 10 F use John Deere J20D Low Viscosity Hygard or equivalent Winch Capacities Capacity For Capacity For 254 mm 10 in 178 mm 7 in Drum Diameter Drum Diameter Cable Diameter 19 mm 3 4 in 22 mm 7 8 in 89 m 293 ft 93 m 305 ft 25 mm 1 in 63 m 206 ft 72 m 237 ft NOTES Loosely or unevenly spooled line will change capacities Use flexible cable with independent wire rope center Table 1 5 Drum Line Capacities for W6F 113 m 307 ft 129m 425 ft Capacity For Capacity For 305 mm 12 in 203 mm 8 in Drum Diameter Drum Diameter Cable Diameter 22 mm 7 8 in 25 mm 1 in 28 6 mm 1 1 8 in 89 m 293 ft 63 m 206 tt 65 m 214 ft 93 m 305 ft 72 m 237 tt 68 m 224 ft NOTES Loosely or unevenly spooled line will change capacities Use flexible cable with independent wire rope center Table 1 6 Drum Line Capacities for W8L Allied WINCH Cable Diameter Capacity For Capacity For 355 mm 14 in 235 mm 9 5 in Drum Diameter Drum Diameter 84 m 276 ft 67 m 220 f
81. inion Shaft Locknut Bevel Pinion Gear Bearing Carrier O Ring Shaft Ball Bearing Carrier Oil Seal Yoke O Ring Nut Washer f 2 5 Z EE Shim Pack 14 15 16 f 17 18 19 20 21 kom d85ess2drop eps O Ring Snap Ring Snap Ring Housing Plug Gear O Ring e D i ANN N Oo ff SS N RY We N 4 gt n e S SS SES CX al BAA ESN ISS Kio SS WW wa K L NY Section 4 Pinion Bearing O Ring Shim Shim Oil Seal Yoke Washer O Ring Nut Snap Ring Shaft Keeper O Ring Snap Ring Gear Housing O Ring Snap Ring Bearing Idler Gear Bearing Cup Bearing Cone Shaft Bearing Cone Fitting Not Shown Capscrew Washer Plug Bearing Carrier Capscrew Washer A Ee E E NRO RO RS Or Irak 2a ll gl bech Zb al SHSODNAARONASOMNATRWNA O0 Bearing Cup Bearing Cone Lockwasher Gear Snap Ring Carrier Capscrew Keeper Gear Housing Bearing Cone Pinion Bearing Cup O Ring 1 2 3 4 S 6 e 8 9 Figure 4 11 Dropbox on W8Lfor Komatsu D85ESS 2 9 10 11 12 1314 15 16 S SISYSS Y wi Zei GH Y S URSS C po AO T x Ch A 19 d i s mpr EA E LLL ps 77 D A f H Pinion ae Pinion Gear Zeg Esa Ball Bearing 2 C ef ath d 13 vi de 9 WWJ A Ku a UL Ju l AAA No CO Roller Bearing Roller Bearing Oil Seal Idler Gear Input Gear Idler Shaft Input Shaft Snap Ring O Ring Carrier Shims Silicone Sealant Tighten
82. ions below appply only to a winch NOT equipped with the optional freespool arrangement Refer to the next section Intermediate Shaft Removal Freespool for instructions relevant to winches equipped with the freespool option 1 Remove the intermediate shaft cover 5 Remove the drum pinion gear and the inner bearing cone Intermediate mnie T N mM o w E f i AN Ge 2 Screw a 3 4 16 UNF slide hammer into the end of Ne w H the intermediate shaft and partially pull it out W8L e takes 3 4 10 UNC r1 028 tif 3 Remove bearing cup and cone r1 025 tif Bearing Cone Ta CH o w _ EE Allied COMPANY Allied WINCH 6 Remove drum shaft retainer prior to removing inter mediate gear See Drum Shaft and Drum Removal section that follows D ip aal o x lt peo _ Allied COMPANY Section 4 Repairs Intermediate Shaft Removal Freespool Intermediate Shaft Removal Freespool The intermediate shaft can be removed with the winch mounted on the tractor NOTE The following steps show the winch re moved from the tractor with the clutch shaft and brake shaft removed This is the normal sequence for complete unit overhaul but it is not necessary for the removal of the intermediate shaft only NOTE The instructions below appply only to a winch equipped with the optional freespool arrange ment Refer to the previous section Intermediate Sha
83. isual Inspec recommended to install a new bearing Any component tion All seals that were removed should be replaced dur that indicates excessive wear or damage should be re ing assembly Carefully inspect all bearings that have been placed The following reassembly and installation se removed Used bearings often appear satisfactory but quence assumes a complete winch overhaul Table 4 1 Visual Inspection PTO Shaft with Integral Check for broken or severely worn bevel gear Replace shaft if gear teeth are broken or severely Bevel Pinion teeth Also check splines for wear or twisting worn or if splines are not true Observe tooth contact wear pattern PTO Shaft with Check splines for wear or twisting Replace shaft if splines are severely worn or twisted Removable Bevel Pinion Bevel Pinion Check for broken or severely worn gear teeth Replace bevel pinion if teeth are broken or severely Removable worn Clutch Shaft Check for deep scratches or scoring on bearing surfaces at each end of shaft Inspect clutch shaft O ring grooves for taper scoring burrs and corrosion are not damaged Check for broken scored pitted and corroded cast iron seal rings Check threads on right hand end of clutch Dress threads with a thread chaser shaft for scoring or distortion of plugholes internal threads or locknut external Check for broken or severely worn splines Replace shaft if splines are broken or severely worn Inspect cast iron
84. l CAUTION Make sure that snap ring is securely dished sides must face either inward or out positioned in brake shaft groove ward 9 Install cage against pressure plate Then install 8 push 11 Install spacer in early W6F winches only not shown pins 12 Install thrust ring smooth side out N o LO _ E O S Q LO _ NOTE Holes in cage are sequenced so that cage can only be installed as shown Allied COMPANY 4 55 Repairs 13 Install belleville spring with curved side pointing out 15 Install winch covers ward W6F and W8L winches use one belleville spring whereas the W12E requires two Se o N o LO r5 020 tif 14 Install cover and secure with 8 nuts and washers Tighten nuts alternately to 130 ft lbs 18 kg m In stall the brake pressure and cooling lines removed during disassembly Se LO N o LO pas aoe Allied COMPANY Allied WINCH PTO Shaft Reassembly and Installation NOTE If equipped with a dropbox refer to Figures 4 27 to 4 34 for location of components Assembly of the PTO shaft is essentially the same for most tractors as shown in steps 1 through 5 1 Install new oil seal in the bearing carrier 2 Install bearing and secure with snap ring 3 Place the carrier on the shaft taking care not to dam age the seal 4 Place bevel pinion on shaft and secure with snap ring For low speed on W12E PTO shafts u
85. l when you remove the cable from the drum The end of the cable can move like a compressed spring causing an injury when the ferrule is released from the drum Always wear gloves when handling cable 2 Startthe engine and place the winch in BRAKE OFF to raise the oil temperature to at least 27 C 80 F 3 Remove any dirt from the left side of the winch Re move control valve access cover Stabilize engine speed at 1000 RPM for all tests Install control valve access cover and tighten capscrews Pressure gauges Two 400 psi 28 kg cm calibrated pressure test gauges are required to perform the hydraulic pressure checks NOTE Shut off the tractor engine when connecting and disconnecting test gauges Place joystick in BRAKE ON to prevent acci dental discharge of pressurized oil stored in the accumulators Allied COMPANY 3 3 Service Brake Pressure Check With the engine shut off connect a pressure gauge to Brake Port G4 Startthe engine and refer to Table 3 2 Adequate brake pressure is required to fully release the brake Ifthe pressure is not as specified check for 1 Improper relief valve setting or malfunction 2 Suction strainer or pressure filter malfunction 3 Leaking pressure hoses or fittings 4 A defective hydraulic pump A defective pump is usu ally indicated by low pressure and pressure increases with increased engine RPM Cooling Oil Pressure Check With the engine shut off connect
86. le Fiat Hitachi New Holland D8L DON D9R Clutch Br Steer Dresser TD25C PS TD25E PS TD25E G Komatsu D275A D155A 1 8 2 D355 Gear Code 1 46 10 1 3 60 40 1 4 83 60 1 Allied COMPANY Allied WINCH Serial Number Codes The serial number codes are described on page 1 2 of this manual The nameplate with the serial number code is found on the top left hand side of the winch case The serial number code is also stamped on the left hand side of the winch frame Nameplate The rated capacity for the 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 name plate is missing or the cable does not match the informa tion 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 winch is equipped with a log arch the maximum cable size may be reduced Refer to the nameplate for details nameplate pdf Section 1 MODEL SERIAL NUMBER MAXIMUM RATED LINE PULL BARE DRUM LBS FULL DRUM LBS MAXIMUM CABLE SIZE MAX CABLE SIZE WITH ARCH INCH DIA INCH DIA MANUFACTURED BY ALLIED SYSTEMS COMPANY SHERWOOD OREGON USA 2300516RA Figure 1 2 Nameplate Allied COMPANY General Capacities and Specifications Approved Oil List The type of oil used
87. ll pis 8 Position the freespool shifter fork on the dental clutch ton in freespool adjust cover and install the shifter shaft O 2 E Cc je S E oa Wa SD Allied COMPANY 4 39 Repairs 9 Install detent ball and spring into bore of the shifter 11 Lockwire as shown fork A A A A EAN P _ A D A Ob WS K g d CE e i Th a LIS a L 7 E d v e Se Shifter Fork Bore d W H D fs detentball jpg 13 Assemble crank shaft crank and freespool cable on cover as shown fs detentspr jpg Crank Shaft fs cover jpg 12 Install cover Tighten capscrews on shifter shaft to 10 Install plug securely 75 ft lbs 10 kg m Z aN S SE Shifter Shaft D 2 D 2 a 2 D p fs shaft jpg Allied S Section 4 Brake Shaft Installation The brake shaft and reduction gear must be installed be 2 Install reduction gear and bearing cone on the left fore installation of the clutch shaft assembly hand end of the shaft 1 Place shaft into winch housing and press pinion and bearing cone on right hand end of brake shaft r r2 002 tif CAUTION Install gear with the long hub side towards the left hand end of the shaft 3 Install left hand bearing cup into housing r2 004 tif 1 a ut e Brake Pinion 12 010 tif mm em ee NOTE Be careful not to bump shaft or cup will come out of bore r2 005 tif Allied COMPANY SE
88. luminated If it is consult factory Coil open or shorted 1 Check module output LEDs Flashing LED indicates open or shorted circuit Check wiring harness continuity Replace faulty coil Note A working coil will have 15 to 50Q resistance and will be magnetized when energized Cartridge valve plugged Replace valve if pressure at appropriate gauge port is not close to relief pressure with coil energized Relief pressure not being reached Check bypass coil amp valve replace faulty parts Forward or reverse Broken or weak release springs Check springs and replace as necessary clutch not releasing Warped frictions or separators Replace as necessary ae Allied COMPANY Section 2 Table 2 1 continued Troubleshooting Analysis Check Chart PROBLEM POSSIBLE CAUSE CORRECTION Forward or reverse See Low Oil Pressure troubleshooting item above dia ES See troubleshooting for Low Forward or Reverse Clutch Pressure item below Inadequate piston travel Remove the access cover and place the winch in A gear while visually checking the clutch for piston movement thin scored or distorted Refer to Section 4 Clutch does not apply Accumulator not charged Check accumulator dd MO PTO stalled 0 rpm Increase tractor rpm Low forward or reverse Broken seal rings on the bevel gear shaft Replace seal rings clutch pressure NOTE A broken seal ring is the most common cause of a pressure differential
89. moval amp Disassembly 12 Remove two O rings from the piston Discard O rings O o o LO NOTE Inspect all oil brake components as speci fied in Table 4 1 SC Allied COMPANY pump eps Section 4 Capscrew Backplate Assembly O Ring Body Dowel Pin Drive Gear Assembly Idler Gear Assembly Key Seal Package Diaphragm Back up gasket Protector gasket E SS OTC eI Diaphragm Seal Spring Ball Front Plate Assembly Shaft Seal Figure 4 19 Hydraulic Pump Hydraulic Pump Removal amp Disassembly To remove the hydraulic pump the winch must be removed from the tractor and the input carrier must be removed Cleanliness is extremely important when repairing these pumps Work in a clean area 1 Loosen suction hose at suction manifold Remove steel tube from valve to RH side of brake housing NB CH LO _ Loosen pressure hose from pump check valve Re move the two capscrews securing the pump then remove the pump See Figure 4 17 for an exploded view of the pump Pump Disassembly 1 Clean the pump thoroughly with solvent kerosene or other non corrosive cleaning fluid which will not affect rubber components Clamp pump in vise shaft down Scribe a line across the three sections of the pump to act as a guide in reassembly Remove capscrews Remove from vise Hold pump in hands and bump shaft against wooden block to separate front plate 16 fr
90. n 3 6 Allied Systems ji Notes Allied WINCH Section 1 General Introduction This service manual addendum is for W12E winches with electronic controls The following information Is included in this addendum Section 1 General includes operation descriptions of systems and components as an aid for trouble shooting and repair Section 2 Troubleshooting lists common problems and the possible causes and corrections Section 3 Service provides a guide for periodic maintenance checks and adjustments Description The W12E Electronic Winch W12EE is a Power Forward LINE IN and Power Reverse LINE OUT winch used on SERIAL NUMBER tractors with a constant running power takeoff PTO The winch utilizes a Self Contained Hydraulic SCH system where all hydraulic power is produced internally inside the winch case The design of the winch case permits differ ent arrangements of PTO gear assemblies to fit different tractors that use these winches The W12EE winch has a maximum bare drum line pull capacity of 533 760 N 120 000 Ibf Serial Number Codes The serial number codes are described on page 1 2 of this manual A nameplate with the serial number code is found on the top left hand side of the winch case The serial number code is also stamped on the left hand side of the winch frame DRUM SHAFT RETAINER CLUTCH SHAFT RETAINER Wize FILTER COVER DRAWBAR DRAWBAR PIN sideleftow tif
91. n the drum The W8L winch has a maximum line pull capacity of 355 480 N 80 000 Ibf when there is one layer or less of cable on the drum The W12E winch has a maximum line pull capacity of 533 760 N 120 000 Ibf when there is one layer or less of cable on the drum DRUM SHAFT RETAINER CLUTCH SHAFT RETAINER INTERMEDIATE SHAFT RETAINER FREESPOOL DRAG ADJUST BRAKE SHAFT RETAINER siderightbw tif Figure 1 1 Model Views Winch Shown with Optional Fairlead Installed Allied COMPANY 1 1 Allied General Unit Identification Allied Winch S N Nameplate Data For Tractor Mountings A W6F P 1 F 1995 H42 Lo Tractor See Tables 1 1 1 2 and 1 3 Sequence Number Winch Model Internal Option Freespool F Manufactured By A Allied Systems Company Blank Indicates Hyster Type Drive Non Freespool N P Power Controlled Horizontal Handlever Non Freespool M X Direct Drive Gear Drive Notes 1 In addition to the serial number plate i the serial number is stamped into the Gear Ratio top left hand side of the frame See Tables 1 1 1 2 and 1 3 2 Circled numbers in Tables 1 1 1 2 and 1 3 indicate possible gear ratios Table 1 1 Tractor Identification and Gear Ratio for W6F Winch Tractor Make Model and Starting Tractor Serial Number Where Applicable A C E F H K M R A New Holland Caterpillar John Deere FMC Dresser Komatsu Jl Case Xuanhua EI Fiat Hitachi D5B 24X 25X D5E PS 95J 96J D5B D53 DD
92. nananos 3 1 Winch ee eg 1 4 General sensores 3 1 Hydraulic Specifications ooooccccccnooncnncnnnonoos 1 4 NE 3 1 Winch Torque Specifications o coooooo 15 Checks Before Operation c ooccccoccccconccoccnncnnos 3 2 Elle OR T E T 1 6 Checks During Operation cooooonccnnnccoccoonnnnns 3 2 Operation and Control 1 7 Joystick Lubrication A Adiustmment no 3 2 Hydraulic SYStOM cc cece eecccceseeeseeeeseeeeeeeeeseeeeees 1 6 Joystick Detent Pin Lubrication a00nn000nnaa0nn 3 2 Forward amp Reverse Clutches sssneeennessnneeennn 1 9 Adjusting Joystick Detent Force 3 2 SE 1 10 Hydraulic System Pressure Checks ccoooccccccccooonos 3 3 Valve Manifold Assembly ssesssseeeeseeeennennn 1 11 Be lee ears ranna OO 3 3 Relief Valve ccoooccccconccocccccocccconcnoconnccnncnononos 1 11 Pressure gauges ccccsececeeseecesseceeeeeeeeeeseeeeens 3 3 Fiydraulic PONID EE 1 12 Brake Pressure Check 3 4 Accumulators cora 1 12 Cooling Oil Pressure Check 3 4 Sequence of Operation BRAKE ON 1 13 Accumulator Pressure Check 3 4 Sequence of Operation LINE IN 1 14 Forward Clutch Pressure Check 3 4 Sequence of Operation LINE OUT 1 15 Reverse Clutch Pressure Check 3 4 Sequence of Operation BRAKE OFF 1 16 Hydraulic System Pressure Tests Chart 3 5 Decal Nameplate Service Plate 00 00nnn000n000
93. nd attach cover 3 Check for complete lever travel Repeat steps 1 and 2 if adjustment is still incorrect oe Allied COMPANY Freespool Lever Power Control Lever Clevis Jam Nut U Bolt Power Control Cable Freespool Cable 2303167W paf Figure 3 4 Control Cable Adjustments this configuration used on W8L only _ O a N O H Cc O O 0 gt Access Cover i Control Lever Clevis Screw Tall Nut Jam Nut Cotter Pin and Link Pin Button Head Capscrew Control Cable Figure 3 5 Control Cable Adjustments FREESPOOL Cable Adjustment The only adjustment necessary is to position the handlever so that it allows the linkage to shift the FREESPOOL mechanism to normal and FREESPOOL positions Check the operation of the FREESPOOL lever for smooth op eration Each of the two positions has a detent Section 3 Check that the positions of the FREESPOOL lever are the same as the position indicators on the control hous ing Loosen the U bolt that holds the control cable in the housing to adjust the control lever Make sure the control lever does not hit the housing at the end of its travel The linkage and cable must be adjusted so that the FREESPOOL shifter mechanism will slide the drum pin ion gear to both detent positions FREESPOOL Drag Adjustment for AW6F 4061 and below and AW8L 2032 and below without Exterior Drag Adjust The preload on the bearings of the intermediate shaft con trols the resist
94. ng Cone Shaft Idler 10 11 12 21 13 14 15 16 50 1 40 18 AA Seege 25 26 27 re 4 37 Dropbox on W12E for Caterpillar D9R Allied COMPANY Pilot PTO Capscrew Shim 005 Shim 007 Shim 020 Shaft Input Seal Gear 37T Spacer Housing Capscrew Washer Seal Shaft Lockwasher Bearing Carrier Snap Ring Ball Bearing Repairs Winch Installation Winch installation 1 Thoroughly clean the mounting surfaces on the winch and the tractor Clean the mounting holes and hard ware of dirt grit and oil Lubricate the PTO shaft splines with grease where applicable Check the condition of the mounting studs on the vehicle Ensure that all studs are tight Replace any studs that are loose bent or otherwise damaged Minor thread damage may be dressed with a thread chaser Loctite all studs Install mounting adapter if required Attach sling or chain fall to lift points Raise the winch and align the splines on the tractor PTO with the splines of the PTO coupling 10 11 12 13 WARNING Make sure the lifting device has a minimum rated capacity of 6 000 Ibs 3 000 kg before lifting the winch Align the studs with the mounting holes to prevent thread damage Loosely install the two top nuts or capscrews before the winch is fully seated against the tractor Secure the winch in place using the parts listed in the mounting kit instructions Tighten the nuts capscrews alt
95. ns The brake dump valve closes so brake pressure can increase The proportional brake valve modulates brake pressure based on joystick position and the control program making brake off inching possible Brake off inching is not intended for heavy sus pended loads as unintended load fallback can occur 16 Allied COMPANY Allied Section 2 Troubleshooting General This section includes The charts list the most common troubles that may be e Table 2 1 a trouble analysis check chart encountered e Table 2 2 an electronic control module ECM LED description chart Table 2 3 a basic ECM troubleshooting chart Table 2 1 Troubleshooting Analysis Check Chart PROBLEM POSSIBLE CAUSE CORRECTION Operation is rough or Hydraulic oil is too cold Put the control lever in the BRAKE OFF position not regular Da Run the engine at 1000 rpm to warm the oil before operating the winch below approved oil list in Section 1 necessary Hydraulic system suction leaks Observe oil Check the following for air leaks exiting lube valve while tractor is operating 1 Suction hose to pump connection Suction leaks will cause oil to foam 2 Pump shaft seal 3 Suction filter cover and gasket 4 Suction hose for cracks or collapsed sections Low oil pressure Leaking pressure hoses and fittings Check for leaks and replace components where ie necessary Be sure hoses are not rubbing on any gears or winch components Defective or im
96. nut to 176 230 Nm 130 to 170 ft lbs Ball Bearing ay Ball Bearing ZZ E H zen e e a ey aL oldkomdropbox eps ser M Shaft Capscrew O Ring Bearing Cup Bearing Cone Shim pack Lockwasher Shim pack Snap Ring Locknut Bevel Pinion Gear Bearing Carrier O Ring Capscrew Gear Snap Ring Shaft Housing Bearing Cup 1305092 tif Slotted Nut Cotter Pin Washer 2 ete oe eS h Figure 4 13 Dropbox on W8L for Komatsu D83 1 amp D85ESS 2 Allied COMPANY Figure 4 14 Dropbox on W6F for Komatsu D65E 6 D65E 7 D65E 8 amp D68E 1 4 7 Repairs PTO Disassembly Pinion Shaft Pinion Gear Ball Bearing Snap Ring Ball Bearing Oil Seal Idler Gear Input Gear Idler Shaft Input Shaft O Ring Gasket Carrier Bearing Retainer Shims Bushing Capscrew Torque to 40 Nm 30 ft lbs Figure 4 15 Dropbox on W6F for New Holland Construction 59 E CD Y ALJ cat583rdrop eps E Si Ny ESSE SC SA A 57 ARQ 10C 14B 14C FD14E 52 53 54 4 lt I d 16 UNA KK fiatdrop tif 8 58 50 10 11 12 21 13 14 15 16 18 19 20 41 40 25 26 27 y el Ee Es AN Se L LC QC nl Ie Na geren ARA as aN A A GER Gg a Na M Y Ni ISSA RE QA SSI N N lt PX SS PTO Ref Drop Box Top Gear Idler Gear Ball Bearing Ball Bearing Inner Race Snap Ring O Ring
97. om backplate 2 Body 4 will remain with either front plate or backplate To separate body from section that remains place drive gear 6 in bearing and tap protruding end with plastic hammer Repairs Pump Removal amp Disassembly 10 Remove O Ring 3 from backplate assembly Remove diaphragm 10 from front plate by prying with O Ring pick Remove spring 14 and balls 15 from front plate Remove diaphragm seal 13 and shaft seal 17 from front plate Pump Inspection 1 Clean and dry all parts 2 Remove nicks and burrs from all parts Pump Gear 1 Inspect drive gear shaft 6 for broken keyway 2 Inspect all bearing points for excessive wear and rough surfaces 3 Replace gear assembly if shafts measure less than 6580 in 17 40 mm in bearing area 4 Inspect gear face for scoring and excessive wear 4 14 5 6 Allied WINCH Assure that snap rings are in grooves on either side of drive and idler gears If edge of gear teeth are sharp dull with emery cloth Pump Front and Backplates 1 Oil grooves in bearings should line up with dowel pin holes 2 Replace plate if inner diameter of bearings exceed 691 in 17 55 mm 3 Bearings in front plate should be flush with island in groove pattern 4 Check for scoring on face of backplate replace if wear exceeds 0015 in 038 mm Pump Body 1 Check inside gear pockets for excessive scoring or wear of body 2
98. on of the clutch assembly NOTE Reassembly is essentially the same for both the forward and reverse clutches 1 Install two new O rings in piston housing Lubricate piston cavity with O ring lube r2 037 tif 4 Install new O ring on the hub Lubricate with O ring lube r2 032 tif NOTE It may be necessary to stretch the large O ring so that it will stay in its groove during installa tion of the piston 2 Carefully install the piston in the housing Ta LO aal o N _ W Si e le x Allied COMPANY 4 43 Repairs Oil Clutch Reassembly 5 Install hub in piston housing Ensure that the holes NOTE Keep the blanked out teeth of the friction are properly sequenced with those in the piston hous discs in line ing 7 Install the release springs and 2 pins The W6F and W8L use 8 springs whereas the W12E uses 11 springs r2 036 tif 6 Starting with a separator plate on the hub alternately place the separator plates and the friction discs on 8 Install shims as tagged during removal the clutch hub The W6F uses 6 friction discs and separator plates while the W8L and W12E use 8 9 Install the cover plate and capscrews as marked friction discs and separator plates during disassembly The W6F uses 6 capscrews while the W8L and W12E require 8 Friction Disc om Ss Oo o op A NOTE For W6F winches equipped with metallic friction discs separat
99. or plates are slightly conical dished All the plates must be installed facing the same direction oe Allied COMPANY ber N O o Y op Allied S Section 4 10 Torque capscrews to 70 ft lbs 10 kg m 14 This step applies to the forward clutch only In stall roller bearing and carrier as tagged during re 11 Check clearance between the cover plate and fric moval Secure with snap ring in the pinion bore tion discs in two places Adjust shims refer to Step 8 only as necessary to produce a clearance of 0 140 0 180 3 6 4 6 mm for all winches with paper fric tions For W6F models with metallic frictions the clearance should be 0 085 0 125 inches 2 2 3 2 mm r3 004 tif CAUTION Cover plate must NOT extend above the face of hub regardless of specified clear ance Recheck clutch for proper assembly if this should occur r3 015 tif 12 Tighten setscrews to 40 ft lbs 6 kg m 13 Carefully place spider pinion assembly over clutch pack Ensure the friction discs do not move out of alignment Align blanked out teeth gt ES a Y oO SE SE o o lt lt lt lt ap ap A _ Allied COMPANY 4 45 Repairs Clutch Shaft Reassembly amp Installation fied Clutch Shaft Reassembly and Installation See Figure 4 1 for the location of clutch shaft components NOTE The reduction gear see Brake Shaft Installa tion Step 2 must be installed before installation of the clutch shaft assem
100. ot operating The operation of the winch is controlled by the clutches and the brake except when the intermediate shaft is dis engaged for FREESPOOL When the tractor s PTO is operating the hydraulic system provides pressure and flow The hydraulic flow path of the various functions is depicted in Fig 1 14 through Fig 1 18 1 11 Allied General Forward and Reverse Clutches See Fig 1 8 and 1 9 The forward clutch Figure 1 9 and reverse clutch 1 10 spring released Oil flow through the clutches is maintained are multi disc types that are hydraulically applied and under all operating conditions for cooling COVER SPIDER PISTON 7 RETAINER PISTON COVER Y HAE E SPRING PLATE ee E RETAINER SHIMS 3 CLUTCH E vet gr SHAFT PLUG gem E O RING SETSCREW ARNO A A RELEASE ROLLER o SS KE e SPRING BEARING E AN BEARING NS CARRIER 1 e SC J O RING super A LSS SEPARATOR WASHER SNAP PLATE Shee FRICTION CAPSCREW DISC revclutch tif Figure 1 8 Reverse Clutch FRICTION SEPARATOR COVER SPIDER DISC PLATE O RING d ALIGNMENT DOWEL PLUG Leg PISTON SS IT y ROLLER BEARING O RING Z PISTON S N i RETAINER E E A SNAP RING O RING A FORWARD O RING KR PINION e b CAPSCREW a en BS gt RELEASE SPRING CLUTCH E NN IN SHAFT Se ehm AN X COVER PLATE O RING SETSCREW SPRING RETAINER forwardclutch tif Figure 1 9 Forward Clutch i le Allied COMPANY Section 1
101. ot stand while operating the tractor or the winch Make sure that instruments and controls are operative before working the unit Do not use control levers or handles as machine mounting assists Do not use control levers or handles as hangers for clothes water bags grease guns lunch pails etc Do not permit personnel in the control area when working or making checks on the machine Do not allow riders on the machine or load Use extreme care when operating around other machines Avoid operating near anyone working or standing Do not stand or permit others to stand in a bight loop of the cable Do not stand or permit others to stand near the winch or cable when it is under tension Do not work with a damaged cable broken wire strands or a decrease in the diameter of a cable are warning signs Do not leave the tractor while the winch line is under tension Avoid pulling the hook over the drum and through the throat of the winch Do not anchor a double or two part line to the winch When not operating the winch always leave it in neutral with the brake on Never attempt to clean oil or adjust a machine while it is in motion Use extreme care when removing cable and ferrule from the drum When the ferrule is released the cable may spring out with force Winch serial number Date put into service Allied WINCH Warning Warning Failure to follow these instructions can cause serious injury or death Authori
102. ousing Gear Box Capscrew Washer Seal Shaft Lockwasher Bearing Carrier Snap Ring Ball Bearing Figure 4 18 Dropbox on W12E for Caterpillar 583R First Used on S N AW12E 1104 52 3 17 53 54 4 LEN Ns Zz DC WANN ES A DL Ei NSS NN SS CL Ce FS LF K SS AN 11 12 21 13 14 15 16 i 50 25 E 19 20 lize AE we GEE Yuu SC ES ANN D N KS SE LLLA K sm Fitting Plug Spacer Plate Cover Capscrew Washer Ball Bearing Snap Ring Roller Bearing Cup Roller Bearing Cone Spacer Shim 005 Shim 007 Shim 020 Gear 36T Snap Ring Roller Bearing Cup Roller Bearing Cone Shaft Idler Figure 4 19 Dropbox on W12E for Caterpillar D9R Allied COMPANY Pilot PTO Capscrew Shim 005 Shim 007 Shim 020 Shaft Input Seal Gear 37T Spacer Housing Capscrew Washer Seal Shaft Lockwasher Bearing Carrier Snap Ring Ball Bearing Repairs Oil Brake Removal amp Disassembly Oil Brake Removal 8 Disassembly Removal and disassembly of the brake can be accom 3 Remove belleville springs from cage assembly The plished while the winch is mounted on the tractor During W6F and W8L use 1 spring whereas the W12E uses disassembly place all parts in a clean container to protect 2 them from dust dirt and moisture Inspect all parts for damage and wear as specified in Table 4 1 1 Drain oil from winch or position winch with left hand side
103. ove Defective PTO shaft Inspect PTO shaft and coupling clutch shaft bevel ring gear and PTO shaft pinion gear for wear or damage Inspect magnetic suction screen a Allied COMPANY Section 2 Table 2 1 continued Troubleshooting Analysis Check Chart PROBLEM POSSIBLE CAUSE CORRECTION Forward or reverse oil See Low Oil Pressure troubleshooting item above O See troubleshooting for Low Forward or Reverse Clutch Pressure item above Inadequate piston travel Remove the access cover and place the winch in gear while visually checking the clutch for piston movement thin scored or distorted Refer to Section 4 en pas Warped frictions or separators Replace as necessary Lube pressure high Test and re set Table 2 2 Troubleshooting Analysis Check Chart for FREESPOOL Option PROBLEM POSSIBLE CAUSE CORRECTION Hard to shift Linkage binding or rusted Clean straighten repair or replace parts as necessary Shifting collar too tight on splines or splines Remove shifting collar dress splines with fine stone rough and replace parts if necessary Dental clutch installed backwards Install clutch so that chamfered ramp faces drum pinion gear Ball detent spring load too much Back off on spring plug Jumps out of gear Control linkage improperly adjusted Check and adjust as necessary Worn shifter fork Replace shifter fork and related parts as necessary Worn drum pinion gear bushing Replace bushing and relate
104. ox tif O Ring Snap Ring Snap Ring Housing Plug Gear O Ring Bearing Cup Bearing Cone Lockwasher Gear esch Pinion Pinion Gear Ball Bearing Ball Bearing Ball Bearing Roller Bearing Roller Bearing Oil Seal Idler Gear Input Gear Idler Shaft Input Shaft Snap Ring O Ring Carrier Shims Silicone Sealant Tighten nut to 176 to 230 Nm 130 to 170 ft lbs Figure 4 32 Dropbox on W8L for Komatsu D83 1 amp D85ESS 2 Allied COMPANY PS PRO ANO gi dh INO Locknut Bevel Pinion Gear Bearing Carrier O Ring Capscrew Gear Snap Ring Shaft Housing Bearing Cup NO A 9 10 11 12 13 14 ey gt ml Section 4 15 16 RSS pe NS Gear Bearing Cup Bearing Cone Carrier Oil Seal Yoke Slotted Nut Cotter Pin Washer D65E 8 amp D68E 1 Zu A YEN Shaft Capscrew O Ring Bearing Cup Bearing Cone Shim pack Lockwasher Shim pack Snap Ring Figure 4 31 Dropbox on W6F for Komatsu D65E 6 D65E 7 Repairs PTO Shaft Reassembly amp Installation 383164g eps Figure 4 33 Dropbox on W6F 8 W8L for Caterpillar D6H R D7H cat583rdrop eps 17 Drop Box Top Gear Idler Gear A Gi mE Y ES ES QQ AS ONIX SS NESS QUA Cd IDO IZLA 4 INGA AA A NY E E O AZ KE Ol LAY Y A 777 Y vee EAS Y Ge CH IZ Zi NY SS WN NS 4 X le NV Ar NN 1 N INSI BWW D y EEN 18 16 22 Ball Be
105. p See Fig 1 11 Accumulators The hydraulic pump is a fixed displacement gear pump Two accumulators are connected to the hydraulic system that supplies the hydaulic flow necessary for operation of The bladders are charged with nitrogen to 115 psi so the the winch The pump shaft is driven by a spur gear off of oil stored in the accumulators will be under pressure When the input shaft The pump inlet port is connected to the released this oil will provide pressure for the hydraulic winch suction filter The outlet is connected to the control system during low engine rpm shifts and if the PTO shaft valve inlet port via the pressure filter Stalls WE Allied COMPANY HIGH PRESSURE MA LOW PRESSURE FH SUCTION ss NO PRESSURE si JOYSTICK POSITION VALVE MANIFOLD BYPASS VALVE ASSEMBLY PRESSURE AK FILTER y CHECK VALVE Ur mE 2 HYDRAULIC SUCTION PANIE STRAINER H ACCUMULATORS FORWARD OIL CLUTCH EE Wal o Cc O E E E E BRAKE DUMP VALVE Figure 1 12 Hydraulic System BRAKE ON Neutral Sequence of Operation BRAKE ON Oil flows through the bypass valve to cool and lubricate the brake and clutch frictions The brake dump valve is open and ensures the brake is locked Allied COMPANY Section 1 eas General JOYSTICK POSITION VALVE MANIFOLD ASSEMBLY al S m v E FORWARD N CLUTCH i Ca X E Y mm W W SUCTION FREE STRAINER ACC
106. place drum spacer O ring and install spacer in drum bore r1 002 tif 2 Install drum adapter by pushing it through the double lip seal r1 011 tif r1 012 tif lt lt o O Bn Allied Section 4 5 Install drum seal 8 Align adapter and drum holes then install the thimbles and screws Tighten progressively and evenly to en sure uniform compression of seal ring Do not tighten to final torque Sa i t o S 9 Install drum gear NOTE Smooth side of seal must face outboard 6 Lubricate right hand drum bore Coat right hand seal ring and groove with O ring lube Install new seal ring TT are lt gt yr E 7 V aa al e a e s W E g S r1 020 tif 10 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 7 Move the drum into position while being careful not 11 Pour 2 quarts 2 liters of DEXRON oil into the drum to move the seal ring to ensure initial bearing lubrication Allied COMPANY 4 33 Repairs Drum Shaft Drum Installation 12 vue ur MOS tt i Get Ki Make sure that double tapered roller bearing seal and spacer are properly seated in the left hand side of the drum Then install the shaft until it bottoms solidly against
107. pound Install both shaft nuts and 150 ft lbs W12E torque to 400 ft lbs 55 kg m a Sep t mM o ka Eh u e A E PS P ty A T BIE 19 Tighten drum to adapter capscrews to 200 ft lbs 27 kg m torque Allied COMPANY 4 35 Repairs Intermediate Shaft Installation Non Freespool Intermediate Shaft Installation Non Freespool These figures show the winch removed from the tractor 3 Position the pinion gear so that the teeth are splined with the clutch shaft and brake shaft removed to the intermediate shaft NOTE The winch is shown equipped without the optional freespool arrangement For instructions on how to install an intermediate shaft on a freespool winch refer to the next section Intermediate Shaft Installation Freespool 1 Install inner bearing assembly if previously removed Use a liberal amount of lubriplate or other light lube grease to hold the inner bearing cone in place Drum Gear 4 Install the outer bearing assembly Make sure that the cup is firmly seated against the bearing cone r1 025 tif 2 Position intermediate gear in housing Install inter mediate shaft far enough to support the gear OI o bj SE CH o w KN High Shoulder Down r1 027a tif NOTE Install intermediate gear with high shoulder down towards the drum gear to set enough clear ance between the intermediate gear and the drum gear GE Allied COM
108. pring loaded poppet type valve The valve is mounted in the control valve dump port Allied COMPANY and maintains cooling oil pressure at 8 psi 0 6 kg cm Cooling oil is distributed through the hydraulic lines to the brake and clutches to remove excess heat Oil from the relief valve is discharged directly into the inside of the winch housing Turning the center cap clockwise will increase pressure Newer units have holes drilled into the valve body flats for access to the cap s threads Threads can be upset with a punch when correct pressure is obtained therefore lock ing the cap into position VALVE BODY SE T gt Ve 2 D Be Figure 1 13 Cooling Oil Relief Valve 1 15 General PRESSURE MM COOLING HN SUCTION __ e NORA FREESPOOL READ OPERATING A CONTROL HANDLEVER CLUTCH PRESSURE y FILTER CHECK VALVE Se TZ 1 a a ee ee eS HYDRAULIC PUMP FORWARD CLUTCH yee EAS ACCUMULATOR g VALVE COOLING ACCUMULATORS OIL MANIFOLD Sa COOLING OIL RELIEF VALVE lt 7 SUCTION 3 STRAINER Figure 1 14 Hydraulic System BRAKE ON Neutral Sequence of Operation BRAKE ON brakeon eps The control valve spool is spring centered to neutral In Sage at 8 psi 55 kPa Cooling oil flows out of the cooling this position oil entering the open center valve flows into oil manifold to lubricate and cool
109. properly adjusted oil relief Clean relief valve if no pressure then adjust Check valve poppet may be stuck open relief valve with pressure gauge Replace if defective Clogged suction strainer suction strainer Check and clean or replace suction strainer Oil brake leaking internally E ci by low Repair as required brake pressure Defective hydraulic pump Check pump pressure output only after all other checks have been made Worn pump indicated by pressure variation with engine RPM If pump is at fault replace Brake does not release Low oil pressure Refer to Low Oil Pressure troubleshooting item or winch stalls during above low RPM shift Accumulator system malfunction Check for 1 Correct leakdown time as described in Section 3 2 Leaking accumulator valve Leak in accumulator lines Damaged or defective accumulators 4 Damaged brake piston piston housing or Check piston and piston housing cavity for damage Replace if scored or broken Always replace both seals when brake is repaired Refer to Low Forward or Reverse Clutch Pressure troubleshooting item below Allied COMPANY 2 1 Troubleshooting Table 2 1 continued Troubleshooting Analysis Check Chart PROBLEM POSSIBLE CAUSE CORRECTION Overheating Plugged pressure filter Replace filter Plugged suction filter Remove suction filter clean and replace One or both clutches dragging Check by placing joystick in BRAKE OFF Normally
110. r Type 10 13 gpm 38 50 l min at 1000 rom Operating pressure occcccccccccnnccno 220 psi 1 517 kPa VE Cartridge valve manifold assembly SI Full flow magnetic strainer 16 micron synthetic fiber cartridge ii Allied COMPANY Allied WINCH Winch Torque Specifications NOTE Unless otherwise specified torque 1 2 UNC to 50 ft lbs 7 kg m 3 8 UNC to 25 ft lbs 4 kg m NOTE All torque values given with threads lubricated ITEM TORQUE VALUES PTO Shaft Assembly Bearing Carrier Capscrews 75 10 Clutch Shaft Assembly Bearing Retainer Capscrews 75 10 Bearing Locknut 200 28 Pump Mounting Capscrews Brake Shaft Assembly Bearing Retainer Capscrews 75 10 Intermediate Shaft Assembly Bearing Retainer Capscrews 75 10 Freespool Shift Shaft Drum Shaft Assembly RH Bearing Retainer Capscrews Drum Gear to Adapter Capscrews Drum Shaft Nuts Drum to Adapter Capscrews Clutch Assembly Clutch Piston Housing Capscrews 70 10 Clutch Piston Housing Setscrews 40 6 Brake Assembly Cover Nuts 200 28 Control Valve Mounting Capscrews Winch Mounting to Tractor Studs Capscrews Nuts All Except Inside Nuts Inside Nuts Castle Type with Cotter With Loctite Table 1 4 Torque Specifications Allied COMPANY Section 1 General Gear Train See Fig 1 3 1 4 The gear train Figure 1 3 consists of 1 a PTO shaft assembly 2 a clutch shaft assembly 3 abrake shaft assembly d an intermediate shaft assembly an
111. r in LINE OUT and check reverse clutch and LINE OUT INCHING pressures as indicated in Table 3 2 Ona fast LINE OUT shift the clutch pressure should come up with the brake pressure In LINE OUT INCHING the clutch pressure should lag the brake release pressure as shown in Table 3 2 If the pressure differential is too low the brake will not release soon enough and cause drag If the pres sure differential is too high the brake will release too soon and cause backspinning of the drum If the reverse clutch pressure is not as specified in Table 3 2 check for 1 Leaking pressure hoses or fittings 2 Damaged or worn clutch piston seals 3 Improper control valve spool movement 4 Broken seal rings on clutch shaft 5 Damaged O rings on clutch shaft Troubleshooting information is given in Section 2 If the LINE OUT INCHING pressure differential is not as specified in Table 3 2 proceed as follows 1 Loosen the reverse modulator adjustment locknut and start engine Move the handlever towards LINE OUT until the brake pressure reads 140 PSI 9 8 kg cm 3 6 Allied COMPANY Table 3 2 Hydraulic System Pressure Tests TEST ITEM CHECK FUNCTION PORT Brake D Brake 1 400 psi 25 kg cm gauge C Cooling 1 30 psi gauge Accumulator D Brake 1 400 psi 25 kg cm gauge Line In B Forward 1 400 psi Forward 25 kg cm gauge B Forward D Brake Line In Inching 2 400 psi
112. rake releases before Modulator valve in control valve not Check forward modulator valve forward clutch functioning engagement Low brake release Low brake release pressure See Oil Brake See Oil Brake Slipping troubleshooting item above troubleshooting item above Brake releases before on a ee valve in control valve not E cti forward modulator valve Adjust or replace as reverse clutch functioning necessary engagement Low forward or reverse Broken seal rings on the bevel gear shaft Replace seal rings clutch pressure NOTE A broken seal ring is the most common cause of a pressure differential between the two clutches Check preload on clutch brake shaft and adjust it if necessary to prevent additional breakage of seal rings refer to Section 4 Damaged bevel gear shaft seal ring grooves Check grooves for taper scoring and rust Replace or rebuild shaft if surfaces between the inner side of groove and seal ring are not flat defective or re sleeve Damaged clutch piston piston retainer or O Check piston and piston retainer cavity for damage Always repair both O rings when clutch is repaired Refer to Section 4 gear Winch will not operate Accumulator system malfunction Check for while tracks are turning 1 Correct leakdown time as described in Section 3 2 Leaking accumulator valve Leak in accumulator lines Damaged or defective accumulators 4 Refer to Low Oil Pressure troubleshooting item ab
113. ressure as shown in Table 3 2 If the pressure differential is too low the brake will not release soon enough and cause it to Stall If the pressure differential is too high the brake will release too soon and cause backspinning of the drum If the forward clutch pressure is not as specified in Table 3 2 check for 1 Leaking pressure hoses or fittings 2 Damaged or worn clutch piston seals 3 Improper control valve spool movement 4 _ Broken seal rings on clutch shaft 5 Damaged O rings on clutch shaft Troubleshooting in formation is given in Section 2 If the LINE IN INCHING pressure differential is not as specified in Table 3 2 remove the forward modulator valve and check for defective or dirty parts To adjust the modu lator valve proceed as follows 1 Loosen the forward modulator adjustment locknut With engine running move the handlever toward LINE IN until the brake pressure reads 140 PSI 9 5 kg cm Use 180 PSI 12 7 kg cm for Komatsu D65 2 Turn the adjusting capscrew IN to decrease Forward Clutch Pressure or OUT to increase pressure until the Forward Clutch Pressure is less than the brake pressure by the amount specified in Table 3 2 3 Tighten locknut and recheck pressure Repeat steps 1 and 2 if necessary Reverse Clutch Pressure Check and Reverse Modu lator Valve Adjustment Shut off the engine and connect the high pressure gauge to Reverse Clutch Port C Start the engine Place the handleve
114. ring and carrier NOTE Bevel gear and spacers are shown for clockwise PTO shaft rotation as viewed from behind tractor For D65 D75 Fiat Hitachi New Holland tractors install bevel gear as shown in Figure 4 1 10 be Le e QA oOo op _ To install the clutch shaft in the forward clutch as sembly the blanked out tooth on the shaft spline must engage the alignment dowel in the forward clutch hub Mark the right hand end of the shaft to indicate the position of the blanked out tooth Rotate the clutch shaft so that the blanked out tooth on the shaft is facing up and therefore in alignment with the oil plug hole in the clutch piston housing refer to Step 6 Using the capscrew in the pump drive gear position the gear so that the shaft can be pushed through the clutch assembly and gear Use a pry bar to hold the forward clutch to the right so that the shaft can be pushed through far enough to facilitate lining the pump gear up on the shaft Allied COMPANY AA WINCH Repairs Clutch Shaft Reassembly amp Installation pes 14 Install the thrust washer over the right hand end of A CAUTION ine shai CAUTION Be sure to replace the pipe plug if it is removed from piston housing oil hole in order to install the lifting eye 11 Remove capscrews from pump drive gear and in stall tapered roller bearing cone on left hand end of the clutch shaft 15 Install the tapered roller bearing 13 P
115. rmine the mainte section nance time for the winch EE a A lt 3 Access Cover for Control Valve Cover for Filter Plug to Check Oil Level Fill Plug Plug to Drain Oil Breather w6 8 12maint tif Figure 3 1 W6F W8L amp W12E Maintenance Points Table 3 1 Maintenance Schedule INTERVAL PROCEDURE OR QUANTITY SPECIFICATION 50 hours or Check oil level at plug item 2 Add oil as necessary Do See Table 1 4 Approved Oil List weekly not operate the tractor when checking the oil level Use SAE 30 oil on the linkage as needed Check that the control lever control cable and control housing are fastened correctly Tighten U bolts if required solvent if necessary Lubricate the rollers on the cable guide rolls integral arch Use multi purpose grease with 2 4 molybdenum or fairlead assembly if the winch is equipped with this disulfide option 500 hours or Clean the oil suction screen and magnets Tilt the tractor approximately 15 to prevent loss of oil every 3 months when the cover is removed Use a new gasket between the cover and the suction tube Clean the breather in the fill plug Clean the breather with solvent Replace the filter See the Parts Manual for filter element and cover gasket When replacing be sure to lubricate filter seal ring between element and filter head 1000 hours or Change the hydraulic oil Drain oil from plug item 3 See Table 1 4 Approved Oil List every 6 month
116. s Clean the oil strainer Through fill plug item 5 add e 14 5 gallons 55 liters for W6F e 20 gallons 76 liters for W8L e 22 gallons 83 liters for W12E Check the oil level at item 2 NOTE Clean the oil strainer screen and change the oil filter after the first 50 hours on new and rebuilt winches t Amount of oil may vary slightly with tractor Allied COMPANY 3 1 Service Freespool Control Lever Power Control Lever Freespool Control Cable U Bolt Power Control Cable Lock Nut x O O lt D 2 O O _ D gt O Figure 3 2 Control Cable Adjustments Checks Before Operation Check that the cable and hook are not worn or damaged Check that the periodic inspection and maintenance has been done at the recommended operating hours See Table 3 1 Maintenance Schedule Checks During Operation The Troubleshooting Chart in Section 2 can be used by the operator to identify a problem with the winch opera tion A trained service person is needed for additional troubleshooting and repair that requires disassembly of parts of the winch Checks and adjustments The checks and adjustments for the winch are as follows e Control Cable Adjustments e Freespool adjustment e Hydraulic system checks Control Cable Adjustments A single control cable connects the power lever to the hy draulic control valve spool Check the operation of the power control lever to make sure it moves smoothly and will return
117. s in motion Stay in the operator s seat Do not stand on the vehicle when operating the winch Allied COMPANY Keep a clear work area Avoid winch operation near people or other machines Never stand or permit others to stand in a bight loop of the cable Do not stand nor permit others to be near the winch or cable when there is tension on the cable Ob serve jobsite rules Be in complete control at all times Use common sense Do not use the control levers as hangers for clothes wa ter bags grease guns lunch pails etc Do not leave the vehicle when the winch cable is under 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 and cause dam age When the winch is not in use make sure the control lever is in brake on position so that the winch brake is applied Indicates a condition that can cause personal injury 44 CAUTION Indicates a condition that can cause property damage NOTE Whenever information exists that requires additional emphasis beyond the standard text the term NOTE is used Notes Contents Contents Section 1 General orina nenna 1 1 Pressure gauges ccccoooccnncccnoncnnnconnancnnononanennncnnnns 3 4 MroduUCiON E 1 1 Brake Pressure Check 3 4 Description occcccccnnccncccnonnonccnonnconononannnnnnonanennnnnnans 1 1 Cooling Oil Pressure Check 3 4 Unit
118. s onto front plate with half moon port cavities in body facing backplate Check if scribed location mark lines up 4 52 10 Install O Ring 3 in groove of backplate 11 Slide backplate over gear shafts until dowel pins are engaged Line up scribed location mark 12 Place pump in vise shaft down and install capscrews 1 Torque evenly 25 to 28 Ib ft 33 9 to 38 0 Nm 13 Oil shaft seal 17 with petroleum jelly and work shaft seal over drive gear shaft taking care not to cut rub ber sealing lip 14 Seat shaft seal carefully by tapping with plastic ham mer 15 Add a generous portion of clean oil to both ports to ensure that the pump is adequately lubricated Ro tate pumpshaft by hand Pump will have small amount of drag but should turn freely after short pe riod of use 16 Replace the driveshaft key 15 NOTE To prime the pump fill it with heavy oil such as SAE 90W prior to installation This is important to protect the pump from aeration during initial opera tion Allied COMPANY Allied S Section 4 Pump Installation 2 Install hoses and tube Ensure they are tightened se curely 1 Position pump in winch housing and secure with the two capscrews Tighten capscrews to 25 ft lbs 4 kg NOTE Install hose before installing tube Allied COMPANY 4 53 Repairs Oil Brake Reassembly amp Installation Oil Brake Reassembly and Installation Make sure the clutch shaft has been installed
119. se Loctite and torque to 100 ft lbs 13 8 kg m 5 Assemble shim pack and install PTO shaft as de scribed in the Clutch Shaft Reassembly and Instal lation section steps 21 through 23 Coat the ring gear teeth with Prussian Blue and rotate the PTO shaft to check the gear contact NOTE If equipped with a dropbox the PTO shaft assembly should be assembled and installed as described in the Clutch Shaft Reassembly and Installation section step 21 After the PTO shaft is installed the adapter box can be placed over the PTO shaft assembly and secured with the winch N a NY MMs NV ST Ke EN O ly rt NN PTO Shaft with Removable Bevel Pinion Gear ut GA O o D O Snap Ring Bevel Pinion Gear Bearing Carrier O Ring Drilled Head Capscrew Oil Seal Coupling Pin 00 JO Om P ON Figure 4 22 Section 4 Correct Incorrect tooth contact A high contact indicates pinion is too far out Set the pin ion to the correct depth by removing shims from the car rier A low contact indicates pinion is too deep Set the pinion to the correct depth by adding shims to the carrier 6 Install PTO coupling on shaft and secure with lockpin and spiral snap ring Ensure that the snap ring is installed securely r4 006 tif l e T Ki PTO Shaft with Integral Bevel Pinion Gear Ball Bearing Snap Ring Shaft amp Integral Pinion Gear Locknut Seal Spacer Lockring Shim Pack
120. seal ring grooves for Dress grooves or replace shaft if seal will not seat damage properly Check for damage on enlarged plugs in the Replace plugs if damaged shaft ends Clutch Shaft Bearing Check retainer seal ring bore for grooves Replace if scored or rusted May be bushed if Retainers scoring and rust scored Clutch Shaft Spacers Inspect spacer ends for scoring or corrosion Replace if damaged in any way Bevel Gear Check for broken or worn teeth Replace if teeth are broken or severely worn Inspect gear hub faces for scoring wear or The gear should be replaced if the hub faces are corrosion Check rivets between gear and defective in any way hub for tightness Forward and Reverse Check for plugged oil holes in clutch hub Clean oil holes as necessary Clutch Assemblies l SC l SC TE Carefully inspect friction discs for facing wear Replace friction disc s if oil grooves are worn from distortion and damaged teeth facing or if distorted in any way Carefully inspect separator plates to verify Replace separator plates if surfaces are warped or that surfaces are not worn excessively or scored Paper friction separators are flat Bronze unevenly friction separators are dished Inspect piston retainer plate O ring grooves Replace piston retainer plate if damaged piston cavity and center bore for scoring burrs and corrosion Look for any internal cracks Check for wear or collapsed release springs Replace spring s if di
121. storted or damaged in any way Inspect spider gear for broken or worn gear Replace gear if teeth are broken or severely worn teeth Be sure pinion gear is secured to or if pinion gear has broken free from spider gear spider gear Inspect bearing bore for scoring Replace gear if bearing bore is badly scored or galling SES Allied COMPANY Section 4 Table 4 1 Visual Inspection continued ITEM INSPECTION REQUIREMENTS CORRECTIVE ACTION spring s cracks or warping contact with belleville spring Carefully inspect friction discs for facing wear Replace friction discs if oil grooves are worn from distortion and damaged teeth facing or distorted in any way Replace if brake release pressure is low Carefully inspect separator plates to verify Replace separator plates if surfaces are warped or that surfaces are not worn excessively or scored unevenly Inspect piston housing O ring grooves and center bore for scoring burrs and corrosion Inspect brake cage for wear scoring burrs and cracks cracked Inspect brake hub for wear scoring burrs and cracks cracked mushrooming and end faces out of square diameter length or end squareness is distorted and distortion misalignment bearing surfaces at each end of shaft Check for spline straightness particular attention to leading edges of straight cut gear teeth Intermediate Shaft Check for deep scratches or scoring on bearing surfaces at each end of shaft Ch
122. sure gauge to Port D This check determines if the accumulators are functioning and have the correct nitrogen charge Observe Se Allied COMPANY Wal pun W i Bes O uN uN oa presscheck tif Section 3 240 220 200 A TUN O A O A TI SR DI RELIEF PRESSURE CG INLET MI INLET Q a W SERIES PRESSURE DIAGRAM 240 TER N LCC ee V PAN uo 2 140 A la ttt te Na Y ll any 7 EEN Cie AE E Y 100 100 300 o MN TTT AT Y Jl H LLL STITT TG III UI TI BN R EEN Beer BEES 0 75 0 7 E TRAVEL RE 50 PSI MODULATOR SETTING C 100 PSI MODULATOR SETTING BRAKE OFF BRAKE INCHING FORWARD ON FORWARD MOD ADJUSTMENT RELIEF ACCUMULATOR VALVE VALVE JAM NUT RELIEF VALVE ef SE Z ADJUSTING CAPSCREW SPOOL A N n N EE N N e REVERSE SCH YY I CLUTCH e Zeg REVERSE PRESSURE e y LU OS e ST R LINE COOLING UT CAPSCREW OIL RELIEF Y REVERSE VALVE REVERSE CLUTCH MODULATOR COOLING VALVE OIL LINE COOLING INLET OIL FORWARD FORWARD OIL LINE MANIFOLD CLUTCH BRAKE CLUTCH BRAKE COOLING PRESSURE PRESSURE COOLING OIL LINE LINE LINE OIL LINE Figure 3 7 Hydraulic System Pressure Checks Allied COMPANY 3 9 Service the following while referring to the accumulator section in Table 3 2 1 With engine running place handlever in BRAKE OFF and rev engine to maintain 220 psi 1520 kPa for one minute This will ensure that the accumulators will have
123. t 28 mm 1 1 8 in 32 mm 1 1 4 in 67 m 220 ft 53 m 175 ft NOTES Loosely or unevenly spooled line will change capacities Use flexible cable with independent wire rope center Table 1 7 Drum Line Capacities for W12E Winch Model ol Capacity 14 5 Gal 65L 20 0 Gal 76 L 22 0 Gal 83L Table 1 8 Winch Oil Capacities Hydraulic Specifications A eee Gear Type 10 13 gpm 38 50 l min at 1000 rpm Operating pressure cccoocncccoccncconcns 225 psi 1 550 kPa HU One Spool FIS EE Full flow magnetic strainer 20 micron paper cartridge 6 Allied COMPANY Allied WINCH Winch Torque Specifications NOTE Unless otherwise specified torque 1 2 UNC to 50 ft lbs 7 kg m 3 8 UNC to 25 ft Ibs 4 kg m NOTE All torque values given with threads lubricated Section 1 Table 1 9 Torque Specifications ITEM PTO Shaft Assembly Bearing Carrier Capscrews Clutch Shaft Assembly Bearing Retainer Capscrews Bearing Locknut Pump Mounting Capscrews Brake Shaft Assembly Bearing Retainer Capscrews Intermediate Shaft Assembly Bearing Retainer Capscrews Freespool Shift Shaft Drum Shaft Assembly RH Bearing Retainer Capscrews Drum Gear to Adapter Capscrews Drum Shaft Nuts Drum to Adapter Capscrews Clutch Assembly Clutch Piston Housing Capscrews Clutch Piston Housing Setscrews Control Valve Mounting Capscrews Winch Mounting to Tractor Studs Capscrews Nuts All Except Inside Nuts
124. t hand tapered roller bearing Wrap end of shaft with tin or cardboard so gear will slide off end of shaft r3 030 tif 12 Attach puller to clutch shaft on right hand side using special tool held in place with the bearing locknut or using special drift drive shaft from the left side 13 Pull the clutch shaft out far enough to remove the e spacer between the bevel ring gear and the forward Thr stWasher e clutch assembly 9 Remove the internal snap ring from the reverse spi der gear bore 10 Remove the external snap ring form the left hand end of the clutch shaft 14 Remove the bevel ring gear and RH spacer Remove the PTO pinion gear if splined gear or remove PTO before removing clutch assembly SE CH CH o op _ SCH Allied COMPANY Allied S Section 4 15 Install lifting eye see Figure 4 38 in the 1 16 inch 17 Remove the ball bearing and carrier pipe tap hole of the forward clutch pack and lift out 7 For the W8L and W12E a nylon rope sling may be Twas r3 009 tif 3 017 tit 18 Install the 1 4 inch tapped hole lifting eye refer to Figure 4 38 and remove the reverse clutch assem bly For the W8L and W12E a nylon rope sling may 16 Secure the reverse clutch pack with heavy wire ora be used lifting eye Then carefully withdraw the shaft Allied COMPANY See Repairs Oil Clutch Disassembly Oil Clutch Disassembly This section details the disassembly of
125. the brake and clutch as the low pressure core passages The cooling oil relief semblies Excess flow goes directly to the sump valve maintains hydraulic pressure in the cooling oil pas ZER Allied COMPANY O thy NORMAL PERATION READ OPERATING A INSTRUCTIONS 271731 HANDLEVER POSITION e PRESSURE FILTER CHECK VALVE ME Li E E E HYDRAULIC PUMP cn E SUCTION y STRAINER linein eps VALVE ACCUMULATORS A Section 1 PRESSURE MMMM COOLING P SUCTION __ REVERSE CLUTCH F CONTROL VALVE FORWARD CLUTCH ACCUMULATOR COOLING OIL MANIFOLD C COOLING OIL RELIEF VALVE Figure 1 15 Hydraulic System LINE IN Forward Sequence of Operation LINE IN For LINE IN forward operation the operator pulls back on the lever which causes the spool to move into the valve closing off the flow of oil to the cooling passage This allows a pressure buildup in the inlet passage Oil flows from the inlet passage to the brake passage through an orifice producing a pressure drop between the inlet and brake passage depending on the amount of oil flow As the brake port to sump is closed off by the spool the oil flow to sump is reduced allowing the brake pressure to build up As the brake pressure increases the forward modulator valve will regulate the oil pressure to the for ward clutch and maintain a constant
126. the left hand tapered roller bearing Tighten left hand nut 13 CAUTION Do not hammer on drum shaft sur face Remove the retainer plate and install the bearing assembly NOTE Bearings go in reverse order from that shown above 4 34 WARNING Make sure the drum gear does not fall off the adapter 14 r1 024 tif Allied WINCH Install retainer plate using the eight special capscrews Tighten capscrews on W6F 75 ft lbs 10 kg m W8L 146 ft lbs 20 kg m and W12E 225 ft lbs 31 kg m tis E E ai AUTE AL NOTE Capscrews cannot be installed unless drum gear and drum adapter have been aligned as indi cated in Step 8 15 16 Set bearing retainer into place and securely 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 divide by three to add obtain the average gap As semble shim pack to provide a net fit with 0 005 inch 0 1288 mm tolerance Coat winch frame and bearing retainer with Loctite Install finalized shim pack determined in step 15 If intermediate shaft assembly not installed install be fore retainer t Se LO baal o _ Allied COMPANY lli Section 4 17 Secure retainer with capscrews and lockwashers 18 Coat shaft nut threads with John Crane or other suit Tighten capscrews to 75 ft lbs W6F and W8L or able sealing com
127. to the BRAKE ON position The power control lever will stay in BRAKE OFF when pushed into DETENTED position Cable adjustment is not necessary except to ensure full spool travel To adjust handlevers depicted in Figures 3 2 through 3 4 proceed as follows Allied WINCH leverconfig4 tif Power Control Lever Freespool Control Lever Housing Locknut U Bolt Freespool Control Cable Power Control Cable Spacer Pivot Pin 1 2 3 4 6 de 8 9 4 O Figure 3 3 Control Cable Adjustments this configuration last used in 1993 1 Ensure that the cable bracket at winch end of control cable is securely attached to the winch housing 2 Check the position of the handlever with control valve in BRAKE ON The lever should be approximately vertical If not loosen nuts on U Bolt that clamps the control cable to the handlever housing Move U Bolt up or down the elongated slots to improve position of handlever Tighten nuts securely 3 Move handlever to LINE IN and BRAKE OFF posi tions and ensure that the lever holds in the BRAKE OFF position Check to ensure that the handlever does not hit the housing in either position If interfer ence is found repeat step 2 To adjust the handlever depicted in Figure 3 5 proceed as follows refer to Fig 3 5 1 Adjust handlever position so full valve spool stroke is attained by screwing cable in or out of tall nut 2 Install cable adapter in groove on handlever cover a
128. ull shaft back towards the right Install the roller bearing and carrier in the reverse clutch assembly 16 Install the lock ring and special nut as shown and secure with the internal snap ring baal o a oe Allied COMPANY Allied WINCH 17 Use special tool specified in Figure 4 35 to tighten 19 the locknut to 200 ft lbs 28 kg m Bend two lockring tangs over flats of locknut 18 If removed install bearing cup in the left hand re tainer Assemble an approximately 0 025 in 0 635 mm shim pack on the left hand bearing retainer then install retainer Tighten capscrews securely Do not tighten to final torque or install cast iron seal rings at this time N CH o op r4 011 tif 20 Section 4 If removed install bearing cup and O ring in the right hand retainer Assemble a shim pack approximately 0 040 in 1 02 mm thick on the right hand bearing retainer and install retainer Do not install cast iron seals Tighten capscrews securely Do not tighten to final torque at this time Bearing Cup em Apply air pressure to oil port on each end of the shaft and check clutch piston for movement When air pres sure is applied piston should move approximately 1 8 inch 3 mm to 3 19 inch 5 mm Allied COMPANY 4 49 Repairs Clutch Shaft Reassembly amp Installation 21 Assemble PTO shaft as described in the PTO Shaft Reassembly and Installation section if
129. y load that may be on the cable An uncontrolled release of the load may oc cur Loss of the load can result in injury and damage The power control lever must be in the BRAKE ON or BRAKE OFF positions to operate the FREESPOOL con INTERMEDIATE GEAR J s L Y A PR DENTAL CLUTCH freespool tif DISENGAGED Section 1 trol lever When the FREESPOOL control lever is moved to the FREESPOOL position the sliding sleeve disengages the drum pinion gear from the intermediate gear The gear train is disengaged from the drum gear so that the cable can be pulled from the drum by hand Only the drum and drum pinion gear rotates when the cable is pulled during FREESPOOL operation The resistance to rotation by the drum during FREESPOOL is controlled by the preload on the bearings for the intermediate shaft If the FREESPOOL control lever cannot be moved to en gage the gear train for power operation apply the clutch to move the gear train a small amount This action will align the splines in the dental clutch so that the intermedi ate gear can be engaged FREESPOOL ARRANGEMENT Figure 1 5 Freespool Allied COMPANY 1 9 General O Q Q D KA Lo EN O o be O 0 jo y ar N Wu _ Wi gt O Cc lt Allied WINCH Power Control Lever Freespool Lever Figure 1 6 Typical Winch Controls Operation and Control See Fig 1 6 The control lever assembly has
130. y or complete control valve assembly should be replaced Ensure that the spool end cap is in stalled securely then perform the check for smooth return of handlever to neutral from any other position Any bind ing or sticking should be investigated by removing the spool cap and examining parts for wear NOTE The spool is detented in BRAKE OFF If spool does not lock up in this position examine the detent parts inside the spool end cap and repair or replace as necessary DETERMINE THIS POSITION BRAKE ON FIRST AS A REFERENCE ON o gt _ O O oa Kal BRAKE OFF Figure 3 8 Control Valve Spool Travel Allied COMPANY Decal Nameplate and Service Plate Installa tion The unit nameplate a Warning Decal and a Filter Service Plate are located on the winch as shown in Figure 3 9 If the nameplate has been damaged obtain a new one and install the new nameplate in the location shown in Figure 3 8 If the Warning Decal or Filter Service Plate have been LUBRICATION INSTRUCTIONS IMPORTANT USE ONLY AMOCO OIL CO AMOCO 1000 FLUID DEERE amp CO HYGARD FLUID EXXON COMPANY TORQUE FLUID 56 SUN OIL CO SUNFLEET TH UNIVERSAL TRACTOR FLUID 50 HOURS OR WEEKLY CHECK OIL LEVEL WITH ENGINE OFF 500 HOURS OR EVERY 3 MONTHS CLEAN OR REPLACE SUCTION STRAINER REPLACE FILTER IF EQUIPPED DRAIN FLUSH AND REFILL WITH NEW OIL 2000 HOURS OR YEARLY 1321666RO A WARNING OIL UNDER
131. ydraulic oil to and from the clutches and brake is controlled by the control valve Passages inside the valve body connect the oil flow and pressure with the functions that control the winch The control valve spool opens and closes passages to apply and release the clutches and brake The control valve spool is connected by a cable to the control lever for operator operation Built in pressure modu lators automatically ensure positive clutch engagement before the brake is fully released The forward modulator and reverse modulator are adjustable The control valve spool is spring loaded in the BRAKE ON position and has a detented position to hold it in the BRAKE OFF position 1 14 Hydraulic Control Relief Valve A relief valve is in the control valve to prevent excessive hydraulic oil pressure The valve is a spring loaded pop pet type valve mounted in the control valve dump port Cooling oil is distributed through the hydraulic lines to the brake and clutches to remove excess heat Oil from the relief valve is discharged directly to the inside of winch housing Hydraulic Pump See Fig 1 12 The hydraulic pump is a fixed displacement gear pump that supplies the hydaulic flow necessary for operation of the winch The pump shaft is driven by a spur gear off of the input shaft The pump inlet port is connected to the winch suction filter The outlet is connected through the pressure filter to the control valve inlet port Allied COM
132. zed trained operator only Know the equipment Know the operating inspection and maintenance instruc tions in the operating manual Do not operate the winch unless the vehicle is equipped with a screen to protect the operator if the cable breaks Inspect the winch before use Make sure that the controls and instruments operate cor rectly Report the need for repairs immediately Do not work with a damaged or worn cable Do not use a winch that needs repairs If the ferrule and cable must be re moved from the drum make sure the end of the cable and ferrule are controlled when the cable is released The end of the cable can suddenly move from the drum like a compressed spring when the ferrule is released causing an injury Protect yourself Do not use the control levers for hand holds when enter ing or leaving the vehicle Do not permit other people near the control area when you inspect or repair a ma chine Never inspect repair or do maintenance on a machine that is in motion Stay in the operator s seat Do not stand on the vehicle when operating the winch Allied COMPANY Keep a clear work area Avoid winch operation near people or other machines Never stand or permit others to stand in a bight loop of the cable Do not stand nor permit others to be near the winch or cable when there is tension on the cable Ob serve jobsite rules Be in complete control at all times Use common sense Do not use the control l

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