Allied H12E User manual

P/N 599049W Printed in U.S.A. 4/7/2020
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
H12E

Safety Precautions
Read, understand and observe the Safety Summary
on pages 0-3 through 0-5
to prevent injury to personnel and damage to equipment.
Winch serial number _________________________
Date put into service _________________________
NOTE: This publication may be translated to different languages for sole purpose
of easy reference in non-English speaking locations.
Should there be differences in interpretations to the text,
please refer to the English language edition published by Allied Systems Company
as the controlling document.

i
Safety Summary
General Safety Notices
The following pages contain general safety warnings
which supplement specific warnings and cautions
appearing 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 and terms are used to emphasize
safety precautions and notices in this manual:
The “DANGER” symbol indicates a
hazardous situation which, if not avoided,
will result in serious injury or death.
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 serious 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.
NOTICE
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
procedures or practices that 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 hazards that could
endanger personnel and/or damage the
equipment.
Safety Regulations
Each country has its own safety legislation. It is in the
operator’s own interest to be conversant with these
regulations 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.
Operation, Inspection, and Maintenance Warnings
Obey the following cautions and warnings
before using your winch to avoid equipment
damage, personal injury or death.
• Do not operate the winch unless your 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,
inspection, and maintenance instructions in this
manual.
• 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.
Safety Summary

ii
• 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 suddenly 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
machines.
• 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,
overloaded, 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. Refer to Parts Manual 599048W.
• 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 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 loading
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 pages 1-4 and 1-5.
• 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 hydraulics:
»Wear personal protective equipment, such as
gloves and safety glasses, whenever servicing
or checking a hydraulic system.
»Assume that all hydraulic hoses and components
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
cardboard to check for hydraulic leaks.
»Small hydraulic hose leaks are extremely
dangerous, 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.

v
Contents
Safety Summary .........................................................i
General ....................................................................1-1
Introduction...............................................................1-1
Description ...............................................................1-1
Unit Identification ...............................................1-2
Serial Number Codes.........................................1-3
Nameplate .........................................................1-3
Specifications ...........................................................1-4
Drum Wire Rope Capacities...............................1-4
Hydraulic Specifications.....................................1-4
Oil Specifications ...............................................1-4
Oil Capacity........................................................1-4
Maintenance Decal ............................................1-5
Torque Specifications.........................................1-5
Gear Train ................................................................1-6
Operation and Control ..............................................1-7
Hydraulic System......................................................1-8
Motor................................................................. 1-9
Brake................................................................1-10
Planetary Reducer ...........................................1-11
Counterbalance Relief Manifold .......................1-12
Control Manifold ...............................................1-13
Sequence of Operation...........................................1-14
Option Code B
BRAKE-ON ......................................................1-14
LINE-IN ............................................................1-16
LINE-OUT ........................................................1-18
BRAKE-OFF ....................................................1-20
Option Code D
BRAKE-ON ......................................................1-22
LINE-IN ............................................................1-24
LINE-IN Hi-Speed ............................................1-26
LINE-OUT ........................................................1-28
BRAKE-OFF ....................................................1-30
Komatsu D155AX-6/7 (K64)
BRAKE-ON ......................................................1-32
LINE-IN ............................................................1-34
LINE-OUT ........................................................1-36
BRAKE-OFF ....................................................1-38
Schematics.............................................................1-41
Troubleshooting......................................................2-1
General.....................................................................2-1
Mechanical/Hydraulic Troubleshooting Charts..........2-1
Service.....................................................................3-1
General ....................................................................3-1
Maintenance.............................................................3-1
Maintenance Points............................................3-1
Maintenance Schedule ......................................3-1
Hydraulic System Pressure Tests Ports .............3-2
Checks Before Operation...................................3-3
Checks During Operation...................................3-3
Hydraulic System Pressure Checks .........................3-3
Preparation.........................................................3-3
Pilot Supply Pressure Check..............................3-4
Motor Supply Pressure Check ...........................3-5
Brake Pressure Check .......................................3-6
BRAKE-OFF Pressure Check............................3-7
Brake Valve Pressure Check & Adjustment .......3-8
LINE-IN Pressure Check....................................3-9
LINE-OUT Pressure Check..............................3-10
PCOR Pressure Check ....................................3-11
Repairs ...................................................................4-1
General ....................................................................4-1
Winch Removal ........................................................4-1
Winch Disassembly ..................................................4-1
Intermediate Shaft Removal...............................4-2
Drum Shaft & Drum Removal.............................4-4
Hydraulic System Disassembly..........................4-8
Motor Shaft Removal & Disassembly...............4-10
BRAKE-OFF Clutch Disassembly....................4-14
Brake Disassembly ..........................................4-16
Planetary Reducer Disassembly......................4-18
Winch Assembly .....................................................4-20
Visual Inspection..............................................4-20
Brake Assembly ...............................................4-22
BRAKE-OFF Clutch Assembly.........................4-24
Motor Shaft Assembly & Installation ................4-28
Planetary Reducer Assembly...........................4-31
Hydraulic System Assembly.............................4-34
Drum & Drum Shaft Installation .......................4-36
Intermediate Shaft Installation .........................4-42
Contents

vi
Notes

Section 1
1 - 1
General
Introduction
This service manual is for the H12E hydraulic winch. The
following information is included in this manual:
Section 1. General includes operation descriptions
of systems and components as an aid for
troubleshooting and repair.
Section 2. Troubleshooting lists common problems
and the possible causes and corrections.
Section 3. Maintenance provides a guide for
periodic maintenance, checks and adjustments.
Section 4. Repairs describes the removal,
disassembly and assembly of the winch.
Description
The H12E Winch is a Power Forward (LINE-IN) and Power
Reverse (LINE-OUT) winch. The winch is powered by an
internal hydraulic motor connected to the tractor hydraulic
system. Oil flow and pressure are converted to rotational
energy by the winch motor. Motor torque is transmitted
through a holding brake, a planetary speed reducer and
two gear reductions to the drum. Hydraulic oil is supplied
by the tractor mounted pump. The tractor provides
hydraulic power, filtration and cooling. Operation of the
winch is controlled by a control lever and a BRAKE-OFF
switch located at the tractor’s control station.
The H12E winch BRAKE-OFF function permits the
wire rope to be pulled from the drum under increased
resistance.
The H12E winch has a maximum rated line pull capacity
of 150,000 lbs. (68,000 kg) when there is one layer of wire
rope on the drum. When there is more than one layer of
wire rope on the drum, the line pull is reduced.
Figure 1-1 H12E Winch
1
3
4
2
1
55
6
10
8
9
6
10
11
7
NAMEPLATE
2
NAMEPLATE
22
12
12
1. Drum
2. Access Cover for Motor and Hydraulics
3. Plug to Drain Oil
4. Plug to Check Oil Level
5. Tie Bar
6. Fill Plug
7. Bearing Retainer for Intermediate Shaft
8. Drum Shaft
9. Drawbar
10. Breather
11. Maintenance & Warning Decals
12. Serial Number Stamp

General
1 - 2
Unit Identification
Allied Winch S/N Nameplate Data For Tractor Mountings
Figure 1-2 Tractor Identification Codes and Available Gear Ratios for H12E Winch
Tractor Make Model and Starting Tractor Serial Number Where Applicable
H12E H 1 B 1001 K65
Sequence Number
Winch Model
Gear Ratio (Code #)
1 = 209:1
2 = 262:1
Hydraulic Operation Type
H = High Performance
Direction Control in Winch
T = Standard
Tractor Controls & Pump
Vehicle Code
See Figure 1-2
Internal Options
B = External Pump, PFR & BRAKE-OFF Clutch
D = External Pump, PFR, BRAKE-OFF Clutch
and Hi-Speed Control
1. In Addition to the serial number plate, the
serial number is stamped on the top left-
hand side of the frame. (See Figure 1-1
on page 1-1.)
2. Circled numbers in Figure 1-2 indicate
possible gear ratio.
Notes:
C
O
D
E
C
Caterpillar
E
John Deere
K
Komatsu
L
Liebherr
U
Shantui
50 D85-15

54 PR754

56 PR756

561 RL56

59 D8R Series II

64 D155AX-6/-7
 SD32DQ 
65 D275AX-5

74 D8T Tier 4

75 1050K

H12E = Standard
KH12E = Special