Allied H6G User manual

CUSTOMER
EDITION
P/N 599026W-H6GH1JE47 Printed in USA 10/28/2011
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 _________________________
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
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 and 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 seri-
ous 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 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 proce-
dures or practices that may improve equip-
ment 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 poten-
tial 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 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.
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, inspec-
tion, 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.
• 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.

ii
»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!
• 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).
KG
KG
KG
KG

iii
Safety Summary
• 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.
• 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 599027W-
H6GH1JE47.
• 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 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 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 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
Notes

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
Torque Specifications ................................................. 1-5
Gear Train ......................................................................... 1-6
FREESPOOL Operation............................................. 1-7
Operation and Control ....................................................... 1-8
Hydraulic System............................................................... 1-9
Planetary Reducer ..................................................... 1-9
Brake ........................................................................ 1-10
Motor ........................................................................ 1-11
Directional Control Manifold ..................................... 1-12
Logic Control Manifold.............................................. 1-12
HI-SPEED Limit Switch............................................ 1-12
Electronic Control Panel ........................................... 1-12
Sequence of Operation.................................................... 1-13
BRAKE-ON............................................................... 1-13
LINE-IN..................................................................... 1-14
HI-SPEED LINE-IN................................................... 1-16
LINE-OUT................................................................. 1-18
HI-SPEED LINE-OUT............................................... 1-20
FREESPOOL ........................................................... 1-22
Schematics...................................................................... 1-25
Troubleshooting ..................................................... 2-1
General.............................................................................. 2-1
Step-By-Step Pump & Controller Troubleshooting............. 2-2
Troubleshooting Analysis Check Chart.............................. 2-4
Service ......................................................................... 3-1
General ............................................................................. 3-1
Maintenance...................................................................... 3-1
Maintenance Points.................................................... 3-1
Maintenance Schedule............................................... 3-1
Checks Before Operation ........................................... 3-2
Checks During Operation........................................... 3-2
FREESPOOL Drag Adjustment......................................... 3-2
Hydraulic System Pressure Checks .................................. 3-2
Preparation................................................................. 3-2
Pressure Gauges ....................................................... 3-2
Standby Pilot Supply Pressure Check........................ 3-2
Maximum Pilot Supply Pressure Check ..................... 3-3
Counterbalance Valve Pressure Check...................... 3-3
Motor Supply Pressure Check.................................... 3-3
Brake Pressure Check................................................ 3-3
Brake Valve Pressure Check ...................................... 3-3
FREESPOOL Pressure Check................................... 3-4
High Speed Pressure Check...................................... 3-4
LINE-IN Pressure Check............................................ 3-5
LINE-OUT Pressure Check ........................................ 3-5
Valve Setting Procedures .................................................. 3-5
Load Sense Relief Valve ............................................ 3-5
Pilot Supply Reducing Valve ...................................... 3-5
Hydraulic System Pressure Tests Table............................. 3-6
Repairs ........................................................................ 4-1
General ............................................................................. 4-1
Winch Removal.................................................................. 4-1
Winch Disassembly ........................................................... 4-1
Intermediate & FREESPOOOL Shaft Removal.......... 4-2
Drum Shaft & Drum Removal..................................... 4-5
Hydraulic System Disassembly.................................. 4-9
Motor Shaft Removal & Disassembly ....................... 4-14
Motor Disassembly................................................... 4-17
Brake Disassembly................................................... 4-20
Planetary Reducer Disassembly .............................. 4-22
Winch Assembly .............................................................. 4-24
Visual Inspection ...................................................... 4-24
Planetary Reducer Assembly................................... 4-26
Brake Assembly ....................................................... 4-28
Motor Assembly........................................................ 4-30
Motor Shaft Assembly & Installation......................... 4-33
Hydraulic System Assembly..................................... 4-36
Drum & Drum Shaft Installation................................ 4-41
Intermediate & FREESPOOL Shaft Installation ....... 4-46
Winch Installation ............................................................ 4-50
Contents

vi
Notes

Section 1
1 - 1
General
Introduction
This service manual is for the H6G winch. 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 corrections.
Section 3. Maintenance provides a guide for peri-
odic maintenance, checks and adjustments.
Section 4. Repairs describes the removal, disas-
sembly, assembly, and installation of the winch.
Description
The H6G 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 hy-
draulic system. Oil flow and pressure are converted to
rotational energy by the winch motor. On the H6G, 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 auxiliary pump cir-
cuit and utilizes oil, filtration and cooling provided by the
tractor circuit. Flow to the winch is controlled by a control
lever and electrical switches located at the tractor’s control
station.
The H6G winch has a FREESPOOL function.The FREE-
SPOOL function permits the wire rope to be pulled from
the drum.
The H6G winch has a maximum rated line pull capacity
of 266,880N (60,000 lb.) when there is one layer or less
of wire rope on the drum. When there is more than one
layer of wire rope on the drum, the maximum rated line
pull is reduced.
Figure 1-1 H6G Winch
1. Drum
2. Access Cover for Motor and Winch Hydraulics
3. Plug to Drain Oil
4. Plug to Check Oil Level
6. Tie Rod
7. Fill Plug
9. Bearing Retainer for Intermediate Shaft
& Freespool drag Adjuster
10. Right Side Drum Shaft
11. Drawbar (Not Shown)
12. Breather

General
1 - 2
Unit Identification
Allied Winch S/N Nameplate Data For Tractor Mountings
H6G H 1 J 1501 E47
John Deere 850JR Tractor
Sequence Number
Internal Options
Winch Model
Hydraulic Operation Type
Gear Ratio Code
1 = 60:1
H = High Performance
(Hydraulic or Hydrostatic with 2-Speed)
J = External Pump, PFR, FS
with CARC Green Paint & 50mm Dia Pin Special Drawbar;
without Tractor Side Installation Parts
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.
Note:
H6G was previously known as WH6G.
The "W" designation has been dropped for simplicity.