Allied Systems H12A Guide

CUSTOMER
EDITION
P/N 599016W Printed in USA 09/27/2011
Please check the Allied Systems website
regularly for updates to this manual.
www.alliedsystems.com

Safety Precautions
Read, understand and observe the precautions on the following pages
to prevent injury to personnel and damage to equipment.
Winch serial number _________________________
Date put into service _________________________

i
Safety Summary
General Safety Notices
The following pages contain general safety warnings
which supplement specific warnings and cautions appear-
ing elsewhere in this manual. All electrical and hydraulic
equipment is dangerous. You must thoroughly review
and understand the Safety Summary before attempting
to operate, troubleshoot or service this winch.
The following symbols/terms are used to emphasize safety
precautions and notices in this manual:
DANGER
The “DANGER” symbol indicates a hazardous
situation which, if not avoided, will result in
death or serious injury. Carefully read the
message that follows to prevent serious injury
or death.
The “WARNING” symbol appears wherever
incorrect operating procedures or practices
could cause serious injury or death. Carefully
read the message that follows to prevent seri-
ous injury or death.
The “CAUTION” symbol appears where a
hazardous situation which, if not avoided,
could result in minor to moderate injury and
equipment damage.
This signal word alerts to a situation that is
not related to personal injury but may cause
equipment damage.
NOTE: …
The term “NOTE” highlights operating pro-
cedures or practices that may improve
equipment reliability and/or personnel per-
formance.
Safety Summary
Safety Regulations
Each country has its own safety legislation. It is in the
operator’s own interest to be conversant with these regu-
lations and to comply with them in full. This also applies
to local bylaws and regulations in force on a particular
worksite.
Should the recommendations in this manual deviate from
those in the user’ country, the national regulations should
be followed.
NOTE: All possible safety hazards cannot be
foreseen so as to be included in this manual.
Therefore, you must always be alert to poten-
tial hazards that could endanger personnel
and/or damage the equipment.
The winch shall not be used for hoisting.
Use hearing protection when operating
winches.
Winch protected with internal pressure relief
valves set to 3500 psi max.
Operation, Inspection, and Maintenance Warnings
Obey the following cautions and warn-
ings before using your winch to avoid
equipment damage, personal injury or
death.
• Do not operate the winch unless you are authorized
and trained to do so.
• Do not operate the winch unless the vehicle is
equipped with a screen to protect the operator if
the wire rope breaks.
• Read, understand, and follow the operating, inspec-
tion, and maintenance instructions in this Operating
Manual.

ii
• Do not use the control levers for hand holds when
entering or leaving the vehicle.
• Do not permit other people near the control area
when you inspect or repair a machine.
• Never inspect, repair, or perform maintenance on
a machine that is in motion.
• Inspect the winch before each use:
»Make sure that the controls and instruments
operate correctly.
»Report the need for repairs immediately.
»Do not work with a damaged or worn wire
rope.
»Do not use a winch that needs repairs.
»If the wire rope and ferrule must be removed
from the drum, make sure the end of the wire
rope and ferrule are controlled when the ferrule
is released. The end of the wire rope can sud-
denly move from the drum like a compressed
spring when the ferrule is released and cause
an injury.
• Stay in the operator’s seat when operating the
winch.
• Do not stand on the vehicle when operating the
winch.
• Avoid winch operation near people or other ma-
chines.
• Never stand nor permit others to stand in the bight
(loop) of a wire rope.
• Do not stand nor permit others to be near the
winch or wire rope when there is tension on the
wire rope.
• Observe jobsite rules.
• Be in complete control at all times.
• Do not use the control levers as hangers for clothes,
water bags, grease guns, lunch pails, etc.
• Do not leave the vehicle when the winch wire rope
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, which will cause damage.
• When the winch is not in use, make sure the control
lever is in BRAKE-ON position and the winch brake
is applied.
• Do not use winch as a hoist. Tractor and skidder
mounted winches are designed for towing.
• Always inspect wire rope, tail chain and other rigging
components for wear, damage, broken strands or
abuse before use.
• Never use wire rope, tail chain or other rigging that
is worn-out, damaged or abused.
• Never overload wire rope, tail chain or rigging.
• Wire rope and tail chain will fail if worn-out, over-
loaded, misused, damaged, improperly maintained
or abused. Wire rope or tail chain failure may cause
serious injury or death!
KG
KG
KG
KG
• Do not terminate wire rope to tail chain by the use
of a knot.
• Do not handle wire rope if the hook end is not free.
A load could break away, suddenly tensioning the
wire rope, resulting in serious injury or death.
• Stay clear of wire rope entry areas (fairlead or arch
rollers, winch drum etc).
• Make sure ground personnel are in plain view of the
operator, and at a distance of at least 1½ times the
working length of the wire rope.

iii
Safety Summary
• Make sure that any hand signals used by ground
personnel are clearly defined and understood by
everyone involved.
• Do not attempt to “jerk” or “shock” a load free. Doing
so can cause loads in excess of the rated capacity
of the wire rope, winch, or mounting hardware.
• Replace any parts only with genuine Allied Winch
parts.
• Maintain a minimum of three (3) complete wraps
of wire rope on the drum for normal operation. It
may help to paint the last five (5) wraps of wire rope
a contrasting color, to serve as a visual indicator.
• Do not handle wire rope with bare hands. Wear
leather gloves at all times.
• Align the tractor with the load to prevent side load-
ing the winch, and to maintain even spooling of the
wire rope.
• If applying tension to the wire rope manually during
spooling:
»Ensure that the operator is winching in slowly,
»Keep your hands and clothing well clear of any
rollers or the winch drum,
»Do not maintain tension by letting the wire rope
to slip through your hands,
»Use a hand-over-hand technique to maintain
tension.
• Be aware of the ground conditions, and make sure
the ground and tractor are stable enough to pull
the intended load.
• Do not attempt to pull loads in excess of the rated
capacity of the winch.
• Keep yourself informed of any applicable codes,
regulations and standards for the job.
• Your winch may have temperature shut-off system
for protection of tractor and winch. Manual override
of high temperature shut-off will cause damage to
tractor and winch.
• This winch is neither intended, designed, nor rated
for any application involved in the lifting or moving
of personnel.
• Use only the lubricants listed in the Recommended
Oil List. See Page 3-1 in Section 3.
• Do not weld on any part of the winch. Contact Allied
Systems if weld repairs are needed.
• The hydraulic system must be kept clean and free
of contamination at all times.
• Be aware of the hazards of pressurized hydrau-
lics:
»Wear personal protective equipment, such as
gloves and safety glasses, whenever servicing
or checking a hydraulic system.
»Assume that all hydraulic hoses and compo-
nents are pressurized. Relieve all hydraulic
pressure before disconnecting any hydraulic
line.
»Never try to stop or check for a hydraulic leak
with any part of your body; use a piece of card-
board to check for hydraulic leaks.
»Small hydraulic hose leaks are extremely dan-
gerous, and can inject hydraulic oil under the
skin, even through gloves.
»Infection and gangrene are possible when
hydraulic oil penetrates the skin. See a doctor
immediately to prevent loss of limb or death.

iv
Ordering Parts:
When ordering replacement parts, give the unit serial number,
part number, name of part and quantity required.
For any further information 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: [phone]
Fax: [phone]
E-Mail: par[email protected]
Also see our website, www.alliedsystems.com, where the most current copy of this manual is always available.
NOTE: This publication may be translated to different languages for sole
purpose of easy reference in non-English speaking locations. Should
there be differences in interpretations to the text, please refer to the
English language edition published by Allied Systems Company as the
controlling document.

v
Contents
Safety Summary .........................................................i
Section 1: General Introduction ...........................1-1
Unit Identification .....................................................1-1
Winch Components ..................................................1-2
Winch Wire Rope Capacity.......................................1-2
Winch General Arrangement....................................1-3
Section 2: Winch Operation ..................................2-1
Section 3: Installation............................................3-1
Winch Mounting........................................................3-1
Gear Cavity Lubrication............................................3-1
Lubrication For Storage ............................................3-1
Section 4: Hydraulic Components .......................4-1
Control Valve ............................................................4-1
Hoses .......................................................................4-1
Hydraulic Oils ...........................................................4-1
Hydraulic Circuit .......................................................4-1
Hydraulic Schematic.................................................4-3
Section 5: Start-Up Procedure..............................5-1
Section 6: Service and General Maintenance ......6-1
Bleeding Brake System ...........................................6-1
Gear Lubrication Schedule.......................................6-1
Maintenance Schedule.............................................6-1
Section 7: Disassembly and Assembly ................7-1
General Procedure Before Starting ..........................7-1
Removal Of Motor Assembly ....................................7-1
Disassembly Of Brake ..............................................7-1
Assembly Of Brake...................................................7-2
Disassembly Of Gear Reductions ............................7-2
Adjustment of Drum Bearings ..................................7-2
Section 8: Troubleshooting...................................8-1
Winch Will Not Pull Load ..........................................8-1
Considerable Reduction In Line Speed ....................8-2
Reverse Speed Is Slower Than Forward Speed.......8-2
Brake Will Not Hold In Neutral
When Pulling a Load......................................8-3
Brake Will Not Control Or
Stop Load When Lowering.............................8-3
Brake Vibrates When Lowering A Load ....................8-4
Contents

vi
Notes

Section 1
1 - 1
General Introduction
Unit Identification
Allied Winch S/N Nameplate Data For Tractor Mountings
H12A T 1 N 1501 K59
Vehicle Code
Sequence Number
Internal Option
Winch Model
Hydraulic Operation Type
Gear Ratio Code
1 = 144:1
2 = 192:1
See Figure 1-1
N = Non FREESPOOL
T = Uses Tractor Supplied Controls
C
O
D
E
A
New Holland
& Fiat
C
Caterpillar
E
John Deere
H
Dressta
K
Komatsu
R
Case
50
D85E/PX-15
(51)

59
D155AX-5

64
D155AX-6

65
D275AX-5

Figure 1-1 Tractor or Skidder Identification Codes and Available Gear Ratios
Tractor Make Model and Starting Tractor Serial Number Where Applicable
1. In addition to the nameplate, the serial number is
stamped on the top right-hand side of the frame.
2. Circled numbers in Figure 1-1 indicate possible gear
ratios.
Notes:

General
1 - 2
Barrel Diameter Wire Rope Diameter Ferrule
1 inch 1.12 inch 1.25 inch Name Length Diameter
12.50 in. 333 ft. 253 ft. 234 ft. Junior 2 3/8 in. 2 1/4 in.
Wire rope capacity of drum is based on SAE J1157 JAN 85
Figure 1-2 Winch Wire Rope Capacity
Winch Wire Rope Capacity
To supplement the following descriptions, consult the
Winch General Arrangement Drawings on pages 1-3
through 1-5.
Winch Components
This Allied Winch consists of the following components:
1. Motor – Two-speed vane with 15 in3 /rev. and 7.5 in3/
rev. displacements or two-speed vane with 9.5 in3/rev.
and 4.75 in3/rev. displacements
2. Clutch – Sprag (Cam) type one way
3. Brake – wet multi-disc type
4. Planetary gear reductions
5. Drive Shaft
6. Winch Drum
7. Winch Housing
This winch is “power in/power out” with equal speed in
both directions.

Section 1
1 - 3
Section 1
Figure 1-3 H12A General Arrangement - 1

General
1 - 4
Figure 1-4 H12A General Arrangement - 2

Section 1
1 - 5
Figure 1-5 H12A General Arrangement - 3

General
1 - 6
NotesNotes

Section 2
2 - 1
Winch Operation
The Allied H12A Winch is made up of these basic as-
semblies:
1. Hydraulic controls and motor
2. Primary drive: motor mount, spring applied/hydrau-
lically released fail-safe brake, primary planetary
reduction
3. Final reduction: 1 or 2 planetary reductions
4. Drum group: winch drum, winch housing, drive
shaft
The main hydraulic hoses from the tractor’s ripper circuit
supply oil to the two-speed motor for LINE-IN and LINE-
OUT functions. Pilot oil pressure is routed through an
electrically operated solenoid. The solenoid directs oil
flow to one of two ports, which then engages either a high
or low motor speed. An electrical switch located on the
operator’s compartment allows the operator to control the
solenoid and, therefore, the winch motor speed.
The hydraulic motor drives the sun gear of the primary
planetary reduction. The output of this reduction is trans-
mitted by the drive shaft that passes through the center
of the winch drum to the sun gear of the final planetary
reduction in the final drive gear housing. The output from
the final planetary reduction is transmitted directly to the
winch drum by a spline connecting the final drive planet
hub to the winch drum.
The primary drive also contains a wet multi-disc type
brake that runs in hydraulic oil. The brake is connected
to the sun gear of the primary planetary reduction by a
cam-type overrunning clutch. The brake is held engaged
by springs and is released by an annular hydraulic piston.
This brake piston is connected to the motor port, which
is pressurized during reverse (lowering) rotation, and be-
comes the exhaust port during forward (hoisting) rotation.
In this way the brake is held engaged at all times until the
winch is powered in reverse (lowering).
The brake hub forms the outer race of the sprag clutch.
The shaft of the primary sun gear forms the inner race
for the overrunning clutch. When the winch is powered
in forward (hoisting) rotation, the overrunning clutch per-
mits the sun gear to run free and the full power from the
hydraulic motor is transmitted to the winch drum. When
hydraulic oil is supplied to the motor for reverse (lowering)
rotation, the overrunning clutch will “lock up” and the motor
will not rotate until the pressure builds up and releases
the brake sufficiently to permit the primary sun gear and
brake plates to rotate together.
The winch can be used to lower any load (up to the
designed maximum load) with smooth acceleration and
deceleration. This is achieved by the special design of
the self-regulating friction brake. When a load is applied
to the cable on the winch drum it causes the overrunning
clutch to “lock up” and the load is held entirely by the fric-
tion brake. In order to lower the load, hydraulic pressure
is applied to the reversing side of the motor. The brake
piston also senses this pressure, and when the pressure
becomes high enough, the brake releases sufficiently to
allow itself to slip. If the load on the winch drum tries to
drive the motor faster than the supply of oil will permit (i.e.,
if the motor tries to act as a pump), the hydraulic pressure
will decrease in the brake piston, causing an increase in
braking effort. In this way a balanced pressure is supplied
to the brake piston according to the load on the winch
drum. The speed of the winch in either direction is depen-
dent on the volume of oil supplied to the motor through
the control valve and the selected motor speed.

Winch Operation
2 - 2
Notes

Section 3
3 - 1
Installation
Winch Mounting
Winch should be installed according to the installation
print supplied with the winch. All hardware should be
properly tightened.
Do not weld to any part of the winch.
Do not operate or perform any lubrication,
maintenance or repair on this product, until
you have read and understood the operation,
lubrication, maintenance and repair informa-
tion.
Gear Cavity Lubrication
The pour point of the oil should be lower than the lowest
expected starting temperature.
The following table gives the recommended viscosity in
relation to speed and ambient temperature:
Ambient Temperature
-10° to +15° C
+14° to +59° F
0° to +30° C
32° to +86° F
+10° to +50° C
+50° to +122° F
AGMA 3EP
ISO VG100
100 cSt at 40° C
AGMA 5EP
ISO VG220
220 cSt at 40° C
AGMA 6EP
ISO VG320
320 cSt at 40° C
Note: cSt is the same as mm2/s.
For special conditions consult factory for recommendations.
The recommended working temperature of the sump
should be between 50° and 70°C (122° to 158°F).
The intermittent peak temperature of the sump should
be no greater than 95°C (203°F).
The winch gear cavities are filled via the filler plug. Fill
with gear oil (est. 20 US gallons, or 75.7 liters) until it
reaches the filler/level plug. DO NOT OVERFILL as this
may cause the gear reductions to overheat. Use 85W-140
gear oils containing EP additives, which increase the oil
film load carrying capacity of the oil.
The winch gear cavity is supplied with a VENT (shown
on the right end of Figure 3-2). It is necessary that the
oil sump be vented at the highest possible point above
the oil level.
Lubrication For Storage
Allied routinely ships winches with a small amount of
vaporizing storage oil (oxidization inhibitor) in the drive
compartments to protect the components during shipping.
This protection is sufficient for temporary storage indoors
of up to two weeks prior to startup.
For storage up to two years indoors or up to six months
outdoors the following must be done (refer to Figure 3-2
for locations of plugs and vents):
• If stored outdoors, protect unit from any direct expo-
sure to weather.
• Replace vent and any plastic plugs with appropriate
metal plugs and O-Rings.
• Fill gear cavity to approximately 25% capacity (5 US
gallons, or 19 liters total) with Shell VSI circulating oil
68 (or equivalent rust inhibiting vaporizing oil).
• Fill brake completely via vent port with hydraulic oil.
• Fill brake piston cavity completely via the bleed port
with hydraulic oil.
• Seal off manifold ports with steel blanking plates that
have gaskets.
Figure 3-1 Gear Cavity Lubrication

Installation
3 - 2
Prior to Operation:
• Replace metal plugs with appropriate fittings, includ-
ing vent.
• Drain gear cavity of rust inhibiting oil and fill with gear
oil as per subsection of Gear Cavity Lubrication.
Figure 3-2 Winch Lubrication Ports
K50, K59 & K64*
(*Up to Serial Number 1004)
OIL FILL / OIL LEVEL PORT
SAE #16 O-RING BOSS
1-5/16-12 NF THREAD
LUBE OIL DRAIN
SAE #16 O-RING BOSS
1-5/16-12 NF THREAD
RELIEF VALVE
GEAR CAVITY OIL DRAIN
SAE #8 O-RING BOSS
3/4-16 NF THREAD
CIRCULATION PORT
SAE #8 O-RING BOSS
3/4-16 NF THREAD
BRAKE BLEED PORT
SAE #4 O-RING BOSS
7/16-20 NF THREAD
LINE-IN
BRAKE RELEASE PORT
SAE #4 O-RING BOSS
7/16-20 NF THREAD
LINE-OUT
LINE-IN PORT
PILOT RETURN,
CASE DRAIN
LINE-OUT
PORT
VENT PORT
SAE #8 O-RING BOSS
3/4-16 NF THREAD
BREATHER PILOT PRESSURE FOR
SPEED SELECTION MOTOR CASE
DRAIN
BRAKE PRESSURE
REGULATION VALVE
LOW SPEED
HIGH
SPEED
LINE-OUT
PRESSURE
TEST PORT
LINE-IN
PRESSURE
TEST PORT
Figure 3-3 Winch Lubrication Ports
K65 & K64*
(*Up to Serial Number 1004)

Section 3
3 - 3
Notes

Installation
3 - 4
Notes