Allied Systems H5C Series, Service Manual

Page 1: ...16 2020 Hydraulic Winch Please check the Allied Systems website regularly for updates to this manual www alliedsystems com A Product of Sherwood OR USA Service Manual H5C Applicable to winches with se...

Page 2: ...____________________ Date put into service _________________________ NOTE This publication may be translated to different languages for sole purpose of easy reference in non English speaking locations...

Page 3: ...t may improve equipment reliability and or personnel performance NOTE All possible safety hazards cannot be foreseen so as to be included in this manual Therefore you must always be alert to potential...

Page 4: ...tension Do not permit riders on the vehicle or load Do not use the winch as an anchor for a double or two part line Do not pull the hook through the throat or over the drum which will cause damage Whe...

Page 5: ...d Do not attempt to pull loads in excess of the rated capacity of the winch Keep yourself informed of any applicable codes regulations and standards for the job Your winch may have temperature shut of...

Page 6: ...ormation on parts service or ordering consult your local winch dealer or contact Allied Systems Company Allied Systems Company 21433 SW Oregon Street Sherwood OR 97140 USA Phone 503 625 2560 Fax 503 6...

Page 7: ...cks During Operation 3 2 FREESPOOL Drag Adjustment 3 2 Hydraulic System Pressure Checks 3 2 Preparation 3 2 Pilot Supply Pressure Check 3 4 Installations without Optional DRAG BRAKE Motor Supply Press...

Page 8: ...vi Notes...

Page 9: ...rgy by the winch motor Motor torque is transmitted through a holding brake and two gear reductions to the drum Hydraulic oil is supplied by the tractor mounted auxiliary pump circuit or designated win...

Page 10: ...n Type T Standard Tractor Direction Valve Single or 2 Speed Vehicle Code See Figure 1 2 Internal Options D External Pump PFR FS Overwind 2 Speed Rescue G External Pump PFR FS Overwind 2 Speed Rescue D...

Page 11: ...igure 1 3 If the nameplate is missing or the wire rope does not match the information on the nameplate do not operate the winch until its capacity is known and a new nameplate is installed Each winch...

Page 12: ...ar case is filled with hydraulic transmission oil and is separate from the tractor hydraulic system Factory fill for the gear case is Exxon Mobil 424 For proper operation only oils shown in Figure 1 5...

Page 13: ...operating manual for low temperature oils and other details Tractor final drive oils may be used in winch if used more than once a day perform overhaul if used less than once a day remove covers and c...

Page 14: ...n When oil is supplied to the hydraulic motor the brake is simultaneously released with pilot control pressure The hydraulic motor can operate at half displacement when the operator selects the HI SPE...

Page 15: ...emainder of the gear train When FREESPOOL is selected a hydraulically actuated sleeve disengages the dental clutch from the intermediate shaft The drum is now disconnected from the brake and the winch...

Page 16: ...uses it to return to the BRAKE ON position which stops the drum rotation and applies the holding brake By moving the lever a small amount slow wire rope movement is achieved for inching control Line s...

Page 17: ...Section 1 1 9 Figure 1 12 Winch Controls Installation on Komatsu D51 24 shown Your controls may vary LINE IN LINE OUT Figure 1 13 Winch Controls Installation on CAT D6K2 shown Your controls may vary...

Page 18: ...e brake housing and are held stationary Teeth in the friction discs engage the splines on the motor shaft and rotate with the hub Figure 1 14 Brake 1 Brake Mounting Plate 2 Brake Housing 3 Capscrew 4...

Page 19: ...Ring 13 Ball Checks 14 Screw 15 Timing Plate 16 Stator 17 Rotor 18 Rotor Vane 19 Rotor Vane Spring Outer 20 Rotor Vane Spring Inner 21 Stator Vane 22 Stator Vane Spring 23 Needle Bearing 24 Rear Housi...

Page 20: ...nt supply pressure drops below a set point in LINE OUT mode The counterbalance valve allows oil to free flow in the LINE IN mode through a check valve The high pressure relief valves act as an overloa...

Page 21: ...Valves Brake Valve Port RI Port PP Port 2 Port PD Port RO Port RI Port RO Port BR Port DV Port HS Port X1 Port FS Figure 1 18 Control Manifold Installations with DRAG BRAKE Control Manifold on Instal...

Page 22: ...OUT Control Manifold CBR Manifold Freespool Shifter Fork 2 Speed Hydraulic Motor Parking Brake Typical In Cab Controls Your Installation may vary Brake TP Freespool TP Motor Port A TP Motor Port B TP...

Page 23: ...K371 and L39 With control lever centered the tractor ripper valve blocks flow to the winch Pilot pressure is present at the control manifold All control lines are open to tank The spring applied hold...

Page 24: ...during High Speed Control Manifold CBR Manifold Freespool Shifter Fork 2 Speed Hydraulic Motor Parking Brake Typical In Cab Controls Your Installation may vary Brake TP Freespool TP Motor Port A TP M...

Page 25: ...e operator selects HI SPEED mode by the rocker switch on the control panel an electric solenoid valve on the control manifold sends pilot pressure to the C port on the motor The spool shifts to close...

Page 26: ...during High Speed Control Manifold CBR Manifold Freespool Shifter Fork 2 Speed Hydraulic Motor Parking Brake Typical In Cab Controls Your Installation may vary Brake TP Freespool TP Motor Port A TP Mo...

Page 27: ...r port A to the counterbalance relief manifold is controlled by the counterbalance valve The counterbalance valve maintains sufficient pressure in the motor outlet A line to prevent uncontrolled lower...

Page 28: ...OUT Control Manifold CBR Manifold Freespool Shifter Fork 2 Speed Hydraulic Motor Parking Brake Typical In Cab Controls Your Installation may vary Brake TP Freespool TP Motor Port A TP Motor Port B TP...

Page 29: ...fork allowing the dental clutch to disengage the drum pinion gear from the intermediate gear The gear train is disengaged from the drum gear so the wire rope can be pulled from the drum by hand The de...

Page 30: ...Manifold CBR Manifold Freespool Shifter Fork 2 Speed Hydraulic Motor Parking Brake Typical In Cab Controls Your Installation may vary Brake TP Freespool TP Motor Port A TP Motor Port B TP High Pressu...

Page 31: ...C805 R371 R42 With control lever centered the tractor ripper valve blocks flow to the winch Pilot pressure is present at the control manifold All control lines are open to tank The spring applied hold...

Page 32: ...Manifold Freespool Shifter Fork 2 Speed Hydraulic Motor Parking Brake Typical In Cab Controls Your Installation may vary Energized during High Speed Brake TP Freespool TP Motor Port A TP Motor Port B...

Page 33: ...selects HI SPEED mode by the rocker switch on the control panel an electric solenoid valve on the control manifold sends pilot pressure to the C port on the motor The spool shifts to close half of th...

Page 34: ...Manifold Freespool Shifter Fork 2 Speed Hydraulic Motor Parking Brake Typical In Cab Controls Your Installation may vary Energized during High Speed Brake TP Freespool TP Motor Port A TP Motor Port B...

Page 35: ...r port A to the counterbalance relief manifold is controlled by the counterbalance valve The counterbalance valve maintains sufficient pressure in the motor outlet A line to prevent uncontrolled lower...

Page 36: ...Manifold CBR Manifold Freespool Shifter Fork 2 Speed Hydraulic Motor Parking Brake Typical In Cab Controls Your Installation may vary Brake TP Freespool TP Motor Port A TP Motor Port B TP High Pressur...

Page 37: ...fork allowing the dental clutch to disengage the drum pinion gear from the intermediate gear The gear train is disengaged from the drum gear so the wire rope can be pulled from the drum by hand The de...

Page 38: ...nifold CBR Manifold Freespool Shifter Fork 2 Speed Hydraulic Motor Parking Brake Drag Brake Housing A B C A B A1 B Brake FS X1 HS DV BR RI RO PP PD TP A TP B High Pressure Low Pressure Back Pressure D...

Page 39: ...E ON Y46F With control lever centered the tractor ripper valve blocks flow to the winch Pilot pressure is present at the control manifold All control lines are open to tank The spring applied holding...

Page 40: ...nifold Freespool Shifter Fork 2 Speed Hydraulic Motor Parking Brake Drag Brake Housing Engergized During HI SPEED A B C A B A1 B Brake FS X1 HS DV BR RI RO PP PD TP A TP B High Pressure Low Pressure B...

Page 41: ...tor selects HI SPEED mode an electric solenoid valve on the control manifold sends pilot pressure to the C port on the motor The spool shifts to close half of the power cavities in the motor Full pump...

Page 42: ...ifold Freespool Shifter Fork 2 Speed Hydraulic Motor Parking Brake Drag Brake Housing Engergized During HI SPEED A B C A B A1 B Brake FS X1 HS DV BR RI RO PP PD TP A TP B High Pressure Low Pressure Ba...

Page 43: ...ort A to the counterbalance relief manifold is controlled by the counterbalance valve The counterbalance valve maintains sufficient pressure in the motor outlet A line to prevent uncontrolled lowering...

Page 44: ...ifold CBR Manifold Freespool Shifter Fork 2 Speed Hydraulic Motor Parking Brake Drag Brake Housing A B C A B A1 B Brake FS X1 HS DV BR RI RO PP PD TP A TP B High Pressure Low Pressure Back Pressure Dr...

Page 45: ...ge the drum pinion gear from the inter mediate gear The gear train is disengaged from the drum gear so the wire rope can be pulled from the drum by hand The dental collar may not fully re engage until...

Page 46: ...ifold CBR Manifold Freespool Shifter Fork 2 Speed Hydraulic Motor Parking Brake Drag Brake Housing A B C A B A1 B Brake FS X1 HS DV BR RI RO PP PD TP A TP B High Pressure Low Pressure Back Pressure Dr...

Page 47: ...fter fork allowing the dental clutch to disengage the drum pinion gear from the intermediate gear The gear train is disengaged from the drum gear Pilot control pressure engages the drag brake This sup...

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

Page 49: ...Section 1 1 41 H5CT C805 2 SPEED CAT D6K2 T4F Figure 1 32 H5C Hydraulic Electrical Schematic Caterpillar D6K2 T4f C805...

Page 50: ...Section 1 1 42 H5CT K371 2 SPEED KOM D51 24 Figure 1 33 H5C Hydraulic Electrical Schematic Komatsu D51 24 K371...

Page 51: ...Section 1 1 43 H5CT L39 2 SPEED LIEBHERR PR716 Figure 1 34 H5C Hydraulic Electrical Schematic Liebherr PR716 L39...

Page 52: ...Section 1 1 44 H5CT R42 2 SPEED CNH 1650M H5CT R371 2 SPEED CNH 1150M Figure 1 35 H5C Hydraulic Electrical Schematic Case 1650M R42 1150M R371...

Page 53: ...Section 1 1 45 H5CT Y46 2 SPEED TIGERCAT 920 WITH DRAG BRAKE Figure 1 36 H5C Hydraulic Electrical Schematic Tigercat 920 Y46F...

Page 54: ...ng supplied to winch Tractor work equipment lever is in locked position Unlock tractor work equipment lever Improper winch hose routing Verify hose connections are in accordance with hydraulic schemat...

Page 55: ...ntrol lever or insuf ficient pilot supply pressure See Step By Step Pump and Controller Troubleshooting section in this chapter If brake is leaking repair as needed Brake shuttle valve stuck Clean or...

Page 56: ...d by foaming or milky colored oil Inspect for leaks and other sources of air induction Incorrect oil used Drain reservoir and re fill with correct oil refer to tractor oil specifications Motor damaged...

Page 57: ...tuck Remove covers and inspect shifter fork collar with switch in FREESPOOL position Repair parts if damaged Leakage at hydraulic connec tion or FREESPOOL shaft Remove covers and inspect shifter fork...

Page 58: ...hydraulic system or loose hydraulic connections Visually inspect winch for leaks and ensure hydraulic connections are secure Lever handle turns Handle parts loose Tighten all lever handle parts LEDs i...

Page 59: ...Troubleshooting 2 6 Notes...

Page 60: ...ug item 3 Add oil through fill plug item 5 Check the oil level at oil level check plug item 2 See Oil Specifications and Oil Capacity in Section 1 General This section provides the instructions for pe...

Page 61: ...f the winch has had an overhaul Hydraulic System Pressure Checks The hydraulic oil and filter s should be maintained as indicated in the dozer Service Manual If any problems are found they should be c...

Page 62: ...Pressure Test Ports Units without optional DRAG BRAKE Motor A Test Port Motor B Test Port Brake Test Port Freespool Test Port Figure 3 4 Hydraulic Pressure Test Ports Units with optional DRAG BRAKE M...

Page 63: ...quipment lever to locked position 5 Connect a 1000 psi gauge to the dozer pilot test port see dozer Service Manual 6 Start dozer and set to high free idle 7 Check that the pressure reading is within t...

Page 64: ...e 3 6 Test Equipment Setup Table 3 3 Hydraulic Pressure Readings Dozer Full Supply Pressure in PSI kPa Motor Port A Motor Port B Komatsu D51 24 K371 3 350 3 500 23 097 24 132 3 350 3 500 23 097 24 132...

Page 65: ...and LINE OUT 4 Check pressure The pressure at this port should be equal to the pilot supply pressure from the dozer The brake begins to release at 200 psi and fully releases at 300 psi Low pressure wi...

Page 66: ...RAKE PILOT PRESSURE Komatsu D51 24 K371 100 120 689 827 300 400 2 068 2 758 CAT D6K2 T4F C805 80 100 552 689 400 435 2 758 2 999 CNH 1650M R42 80 100 552 689 350 370 2 413 2 551 CNH 1150M R371 80 100...

Page 67: ...e The pressure at this port should be equal to the pilot supply pressure from the dozer FREESPOOL requires 170 psi to release Low pressure will not allow for full disengagement of gears for FREESPOOL...

Page 68: ...to high free idle 3 Measure pressure with the control lever in the LINE IN position 4 Pressure should be as specified in Table 3 5 If the LINE IN pressure is not as specified in Table 3 5 check for 1...

Page 69: ...to high free idle 3 Measure pressure with the control lever in the LINE OUT position 4 Pressure should be as specified in Table 3 6 If the LINE OUT pressure is not as specified in Table 3 6 check for...

Page 70: ...ck is complete remove gauge and reconnect brake release hose Motor Supply Pressure Check All installations with optional DRAG BRAKE Figure 3 12 Test Equipment Setup Table 3 7 Hydraulic Pressure Readin...

Page 71: ...OUT 4 Check pressure The pressure at this port should be equal to the pilot supply pressure from the dozer The brake begins to release at 200 psi and fully releases at 300 psi Low pressure will result...

Page 72: ...ssure in PSI kPa RI BRAKE RELEASE PRESSURE TP BRAKE PILOT PRESSURE TigerCat 920 Y46F 80 100 552 689 350 400 2 413 2 758 5 Check pressure as indicated in Table 3 8 The brake valve sets the overlap betw...

Page 73: ...ated 4 Check pressure The pressure at this port should be equal to the pilot supply pressure from the dozer FREESPOOL requires 170 psi to release Low pressure will not allow for full disengagement of...

Page 74: ...s 1 With the engine shut off connect pressure gauge in line on the RI hose at the control manifold 2 Start dozer and set to high free idle 3 Measure pressure with the control lever in the LINE IN posi...

Page 75: ...t pressure gauge in line on the RO hose at the control manifold 2 Start dozer and set to high free idle 3 Measure pressure with the control lever in the LINE OUT position 4 Pressure should be as speci...

Page 76: ...ssure with the DRAG BRAKE switch activated 4 The drag brake requires 350 psi to fully engage Low pressure will result in premature wear of the friction discs and added heat generation If pressure is n...

Page 77: ...Service 3 18 Notes...

Page 78: ...he 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 2 Remove the wire rope from the drum Clean the outside of the...

Page 79: ...ngescrew 8 Washer 9 Capscrew 10 Oil Seal 11 Retainer 12 Oil Seal 13 Drum Gear 14 Spacer 15 Roller Bearing Cone 16 Roller Bearing Cup 17 Drum Shaft 18 Snap Ring 19 Roller Bearing 20 Drum Shaft 21 O Rin...

Page 80: ...ol 3 O Ring 4 Capscrew 5 Freespool Shaft 6 Freespool Adjust Piston 7 O Ring 8 Bearing Cone 9 Roller Bearing Cup 10 Pinion Shaft 11 Roller Bearing Cone 12 Roller Bearing Cup 13 Nut 14 Screw 15 Intermed...

Page 81: ...winch from tractor 3 Position winch on its left side and block securely 4 Remove right hand side cover front cover and top cover 5 Remove all hoses wiring harnesses and tube as semblies Tag hose ends...

Page 82: ...ractor 3 Position winch on its left side and block securely 4 Remove right hand side cover front cover and top cover 5 Remove all hoses wiring harnesses and tube as semblies Tag hose ends and ports fo...

Page 83: ...and ball bearing out of front housing Motor Disassembly NOTE Disassembling the motor while it s still under its warranty period immediately invalidates the war ranty If the motor malfunctions before...

Page 84: ...the rear housing 8 Place cartridge on any object which will hold it off the table Remove screws and timing plate 9 Remove O ring and springs with a small screwdriver Remove dowels pins 10 Replace pla...

Page 85: ...which obviously show excessive wear or damage 15 Vanes Normal wear results in slight flattening of vane tips which does not impair motor performance Replace vane if radius is reduced by 50 Clearance...

Page 86: ...Section 4 4 9 Intentionally Blank...

Page 87: ...it in posi tion 4 On the left side cover remove the freespool adjust ment housing freespool adjustment piston the bear ing cup and cone 5 Remove the left hand frame side cover Note Be aware that the f...

Page 88: ...m the motor shaft 8 Remove the pinion shaft Freespool Shaft Bearing Snap Ring Gear Motor Shaft Ref Pinion Shaft Motor Shaft Ref Shift Fork Spring Intermediate Gear Dental Clutch 10 Remove the capscrew...

Page 89: ...ounting plate and the motor shaft 13 The oil seals are contained in the brake mounting plate Inspect the seals for damage and note the direction they are installed 14 To remove the internal snap ring...

Page 90: ...eleased 16 Inspect the friction disc for wear and the separator plates for wear and flatness Note Care should be taken to keep the friction disc free from oil contamination Any oil on the fric tion di...

Page 91: ...f the friction discs are contaminated with oil the brake will greatly reduce holding power and the brake discs must be replaced 4 Remove the external snap ring and sleeve from brake housing 5 Using a...

Page 92: ...dozer if necessary 2 Clean the exterior of the left side of the winch 3 Slowly remove the capscrews and drag brake flange 4 Remove and discard the gasket 5 Clean the area around the open fittings on...

Page 93: ...and covers for leakage or damage Replace component if sealing surfaces or splines are damaged Check the friction discs for wear distortion or damage The discs should be free of hydraulic oil The minim...

Page 94: ...Check for broken or worn teeth Replace dental clutch if teeth are broken or severely worn I n t e r m e d i a t e Shaft Check for deep scratches or scoring on bearing surfaces at each end of shaft Dr...

Page 95: ...e discs starting with a separator disc and then alternate with a friction disc You should start and end with a separator disc 5 Manually align the internal teeth on the friction discs 6 Install the in...

Page 96: ...nd tighten all four cap screws evenly Then tighten one turn at a time in rotation until mounting plate is flat against the brake housing Torque capscrews to 285 lbs ft 6 Reinstall the motor replace o...

Page 97: ...ting You should end with a separator plate There should be a total of 8 separator plates and 7 friction discs Note Care should be taken to keep the friction disc free from oil contamination Any oil on...

Page 98: ...eals with a very light coat of hydraulic oil Do not get any oil in the brake housing where the brake discs are 7 Install the roller bearing in to the mounting plate to help guide the seals over the sh...

Page 99: ...e freespool shaft and the capscrew Recon nect the hydraulic hose from the shift fork to the fitting on the winch frame 14 Install the pinion shaft 15 Install the gear on the motor shaft install both s...

Page 100: ...ote Back adjustment screw out until there is no pressure on the piston This will be adjusted when winch is mounted and on the tractor 19 Refill the winch case with an approved oil listed in the servic...

Page 101: ...tor NOTE Make sure that the radiused edge of each sta tor vane points to the rotor and the radiused edge of each rotor vane points to the stator 3 Place cartridge on any object which will hold it off...

Page 102: ...l dowel pins and ballchecks into rear housing Install main body O ring 9 Install main body O ring and ball checks into front housing Place a small amount of grease over ball checks and O ring then wip...

Page 103: ...h directions to assure that the shaft turns smoothly Torque motor to 190 ft lbs Rotate shaft again in both directions to assure that the shaft turns smoothly 13 Reassemble the spool assembly Ensure sp...

Page 104: ...Section 4 4 27 Intentionally Blank...

Page 105: ...d control manifolds in their original positions and hand tighten fasteners only 3 Reinstall all tube assemblies hose assemblies and wiring harnesses 4 Tighten the fasteners used to mount the CBR and c...

Page 106: ...tighten fasteners only 3 Reinstall CBR manifold in its original position and hand tighten fasteners only 4 Reinstall all tube assemblies hose assemblies and wiring harnesses 5 Tighten the fasteners us...

Page 107: ...500 kg 3 500 lbs before lifting the winch 4 Align the studs with the mounting holes to prevent thread damage 5 Loosely install the two top nuts or capscrews before the winch is fully seated against th...

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Page 109: ...To find a dealer in your area Call 503 625 2560 Fax 503 625 7269 or Email marketing alliedsystems com or Visit our website http www alliedsystems com 599028W 12 16 2020 Printed in U S A...