Please check the Allied Systems website regularly for updates to this manual. CUSTOMER EDITION

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1 Please check the Allied Systems website regularly for updates to this manual. CUSTOMER EDITION P/N W Printed in USA

2 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 wire rope breakage. 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 close to other machines. Avoid operating near anyone working or standing. Do not stand or permit others to stand in a bight (loop) of the wire rope. Do not stand or permit others to stand near the winch or wire rope when it is under tension. Do not work with a damaged wire rope (broken wire or strands, or a decrease in the diameter of a wire rope, are warning signs). Do not leave the tractor while the wire rope 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 wire rope and ferrule from the drum. When the ferrule is released, the cable may spring out with force. Winch serial number Date put into service

3 0-1 Index Ref Item Page 1 Frame/Covers/Decals/Mounting Parts Gear/Shaft Train Hydraulics/Controls Options Index-Numerical

4 0-2 Index - Master Description Page No. Arch Brake, Dry Disc Clutch Assembly Clutch Shaft Assembly Fairlead Frame/Covers Handlever Installation Hydraulic Group - H (High-Performance) Winch Hydraulic Group - T (Rescue) Winch Hydraulic Group - Conversion Kit Manifold - Bypass Manifold - Control Manifold - Directional Manifold - Logic Control Mounting Parts Motor, Hydraulic - One-Speed Motor, Hydraulic - Two-Speed Nameplate & Decals Numerical Index Oil Capacity Oil Specifi cations Optional Oil Cooler Installation Reducer, Planetary Shaft - Drum Shaft - Intermediate Shaft - Motor, H (High-Performance) Winch Shaft - Motor, T (Rescue) Winch Switch Panel Assembly Wire Rope Assemblies

5 0-3 Identification - Unit Allied Winch S/N Nameplate Data For Tractor Mountings H 1 B 1501 C81 Winch Model was previously known as W. The "W" designation has been dropped for simplicity. Hydraulic Operation Type H = High Performance: Winch Direction Valve, Variable or 2 Speed. T = Rescue: Tractor Direction Valve, Single Speed. Gear Ratio Code 1 = 60:1 2 = 75:1 3 = 70:1 4 = 88:1 Notes: Vehicle Code See Figure 1 Sequence Number Internal Options B = External Pump, PFR, FS, BRAKE-OFF Cluch E = External Pump, PFR, FS (Early Units Had Hydraulic BRAKE-OFF Where Motor Rotated) J = External Pump, PFR, FS; with CARC Green Paint & 50mm Dia Pin Drawbar; without Tractor Side Installation Parts 1. In Addition to the serial number plate, the serial number is stamped on the top left-hand side of the frame. 2. Circled numbers in Figure 1 indicate possible gear ratios. C O D E A New Holland & Fiat C Caterpillar E John Deere H Dressta K Komatsu R Case J850J D61EX J 81 D6N Figure 1 - Tractor or Skidder Identifi cation Codes and Available Gear Ratios

6 0-4 How to use the Illustrated Parts manual

7 0-5 When the part number and the next higher assembly is not known: 1. Determine the function and application of the part required. Turn to the illustrated index page immediately behind the front cover, and select the most appropriate area. 2. Use the table of contents at the beginning of each chapter to determine the assembly which would normally contain the part required. Proceed then to locate the part on the assembly breakdown page. When the part number is not known and the next higher assembly is known: 1. Determine the assembly the required part is used on. Turn to the master index (which immediately follows the illustrated index). 2. Locate the assembly on which the required part is used, and turn to the page indicated for that assembly. Proceed to locate the part on the assembly breakdown page. When the part number is known: Use the numerical index to fi nd the part number. Turn to the page listed and locate the part as indicated by the reference number. General: The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting the correct parts. Keys are used to show effective serial numbers for two or more similar assemblies, LH and RH assembly parts, etc. Select the appropriate key, A, B, C, or D and the corresponding quantity column to fi nd the required parts. Indent dots are used to indicate assemblies and sub-parts of assemblies. No dot indicates the major assembly. Part descriptions which are indented with dots are sub-parts of the major assembly shown above. Quantities shown are for one assembly. Note that when two assemblies are shown, but the quantity of the sub-parts is indicated as three, this means three per assembly - for a total of six. AR means As Required, and NSS indicates Not Sold Separately. Serial numbers are shown to allow for the most current parts information to be incorporated into the parts manual. See page 0-3 for serial number information. 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 SW Oregon Street Sherwood, OR USA Phone: Fax: Also see our website, 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.

8 0-6 Oil Specifications Oil Selection & Recommended Oil List The main consideration while selecting hydraulic fl uid is the estimated oil temperature extremes that will be experienced during service so the most suitable temperature- viscosity characteristics are obtained. VISCOSITY GRADE OIL OPERATING TEMPERATURE RANGE TYPICAL AMBIENT TEMPERATURE RANGE ISO SAE F C F C VG 22 10W -5 to to 60-5 to to 4 VG 32 15W 10 to to to to 13 VG to to to 70-7 to 21 VG to to to 90-1 to 32 VG to to to to 43 Figure 2 - Oil Selection Chart Factory fi ll is Exxon-Mobil 424. This is an ISO Viscosity Grade 46 to 68. For external pump winches (the winch pump uses tractor hydraulic fl uid) the hydraulic circuit and winch gear housing may have different fl uids. Note that some hydraulic system oils are not recommended for use inside the winch. For inside winch housing, use the following oils: HYDRAULIC SYSTEM (PUMP) WINCH CASE (GEAR TRAIN) Caterpillar Use Tractor Fluid TDTO TO-4 MTO John Deere Use Tractor Fluid Hy-Gard Komatsu Use Tractor Fluid Universal Tractor Fluid Chevron Use Tractor Fluid 1000 THF Exxon-Mobil Use Tractor Fluid Mobil Fluid 424 Case Use Tractor Fluid Hy-Tran Ultra New Holland Use Tractor Fluid Multitran Figure 3 - Recommended Oil List Oil Capacity The oil capacity for the winch is 8.5 quarts (8 liters).

9 1-1 Frame/Covers/Decals/Mounting Parts Frame/Covers - H (High-Performance) Winch & 1-3 Frame/Covers - T (Rescue) Winch & 1-5 Mounting Parts thru 1-17 Nameplate & Decals

10 1-2 Frame/Covers H (High-Performance) Winch A 11.1A

11 1-3 Frame/Covers H (High-Performance) Winch Item Part No. Description Qty Item Part No. Description Qty 1.1 NSS Frame, 1-3/4" Dia Pin Drawbar W Cover, Front W Gasket, Hose Seal W Rod, Tie W Cover W Pin W Screw, Flange W Fitting, O-Ring W Screw, Flange W Fitting W Screw, Flange W Screw, Flange W Cover, LH W Pin, Drawbar W Pin, Retaining W Cover, RH W Gasket, Top Cover RH W Plug, Breather W Cap, Breather W Fitting W Cover, Freespool W Gasket, Freespool W Top Plate, without Arch A W Top Plate, with Arch W Plate, Top Cover, without Arch A W Plate, Top Cover, with Arch W Plate, Cover W Plate, Cover W Gasket, Hose Cover 1

12 1-4 Frame/Covers T (Rescue) Winch A

13 1-5 Frame/Covers T (Rescue) Winch Item Part No. Description Qty Item Part No. Description Qty 1.1 NSS Frame W Cover, Freespool W Gasket, Freespool W Rod, Tie W Cover, Front W Pin W Gasket, Hose Seal W Fitting, O-Ring W Cover W Fitting W Screw, Flange W Screw, Flange W Pin, Drawbar W Screw, Flange W Pin, Retaining W Screw, Flange W Cover, LH W Cover, RH W Gasket, Top Cover RH W Plug, Breather W Cap, Breather W Fitting W Gasket W Plate, Top Cover, without Arch A W Plate, Top Cover, with Arch W Cover 1

14 1-6 Mounting Parts Caterpillar D6N

15 1-7 Mounting Parts Caterpillar D6N Item Part No. Description Qty Item Part No. Description Qty W Mounting Bracket, D5/6N W Guard, Bottom W Bracket, Filter W Washer 10 7 *a Y17C-1024 Capscrew W Washer W Harness Ext., Filter W Spacer W Capscrew W Washer W Mtg Bracket, Fuel/Water Separator 1 14 *b W Hose, Fuel W Clamp, Insulated Hose W Clamp W Fitting W Capscrew W Screw W Fitting W Bracket 1 22 *a W Capscrew W Washer *a W Stud W Washer W Nut 2 27 *a Capscrew 4 28 *a Stud W Nut W Nut 1 31 *b W Hose Assembly 1 32 *b W Hose Assembly W Capscrew W Washer W Fitting W Gasket, Fuel Primer Clamp Clamp Clamp W Plate W Nut W Plate, Mounting W Capscrew 2 44 *b W Hose Assembly 1 45 *b W Hose Assembly W Cover, Hose Guard 1 *a Use W Threadlock *b Included in Hose Kit

16 1-8 Mounting Parts John Deere 750J Last Used on S/N (without Arch), & on S/N (with Arch)

17 1-9 Mounting Parts John Deere 750J Last Used on S/N (without Arch), & on S/N (with Arch) A - Winch without Arch (Last Used on S/N -1107) B - Winch with Arch (Last Used on S/N -1108) Item Part No. Description Qty A B W Fitting W Wire Harness *a W Stud W Nut W Washer *a W Stud W Nut W Washer W Shim,.020 AR AR W Mounting Pad W Washer 4 4 Item Part No. Description Qty A B W Clamp *b W Hose Assembly *b W Hose Assembly W Cover, Hose Guard W Hose Guard W Capscrew W Washer W Hose Guard -- 1 *a Use W Loctite Kit *b Included in Hose Kit

18 1-10 Mounting Parts John Deere 750J First Used on S/N (without Arch), & on S/N (with Arch)

19 1-11 Mounting Parts John Deere 750J First Used on S/N (without Arch), & on S/N (with Arch) A - Winch without Arch (First Used on S/N -1108) B - Winch with Arch (First Use on S/N -1109) Item Part No. Description Qty A B W Fitting W Wire Harness *a W Stud W Nut W Washer *a W Stud W Nut W Washer W Shim,.020 AR AR W Mounting Pad W Washer W Clamp *b W Hose Assembly 1 1 Item Part No. Description Qty A B 16 *b W Hose Assembly Cover, Hose W Screw W Washer Cover, Hose Cover, Hose Guard W Hose Guard Cover, Hose Guard W Screw -- 6 *a Use W Loctite Kit *b Included in Hose Kit

20 1-12 Mounting Parts John Deere 850J Last Used on S/N (without Arch), & on S/N (with Arch)

21 1-13 Mounting Parts John Deere 850J Last Used on S/N (without Arch), & on S/N (with Arch) A - Winch without Arch (Last Used on S/N -1107) B - Winch with Arch (Last Used on S/N -1108) Item Part No. Description Qty A B W Fitting W Wire Harness *a W Stud W Nut W Washer *a W Stud W Nut W Washer W Shim,.020 AR AR W Mounting Pad W Washer Trim AR AR Item Part No. Description Qty A B W Clamp *b W Hose Assembly *b W Hose Assembly W Cover, Hose Guard W Hose Guard W Capscrew W Washer W Hose Guard -- 1 *a Use W Loctite Kit *b Included in Hose Kit

22 1-14 Mounting Parts John Deere 850J First Used on S/N (without Arch), & on S/N (with Arch)

23 1-15 Mounting Parts John Deere 850J First Used on S/N (without Arch), & on S/N (with Arch) A - Winch without Arch (First Used on S/N -1108) B - Winch with Arch (First Used on S/N -1109) Item Part No. Description Qty A B W Fitting W Wire Harness *a W Stud W Nut W Washer *a W Stud W Nut W Washer W Shim,.020 AR AR W Mounting Pad W Washer Trim AR AR W Clamp Item Part No. Description Qty A B 15 *b W Hose Assembly *b W Hose Assembly Cover, Hose W Screw W Washer Cover, Hose Cover, Hose Guard W Hose Guard Cover, Hose Guard W Screw -- 6 *a Use W Loctite Kit *b Included in Hose Kit

24 1-16 Mounting Parts Komatsu D61EX-15 First Used on S/N T-1092

25 1-17 Mounting Parts Komatsu D61EX-15 First Used on S/N T-1092 Item Part No. Description Qty Item Part No. Description Qty Mounting Bracket, Kom D61-RH Mounting Bracket, Kom D61-LH 1 3 *a W Washer 10 4 *a W Capscrew 10 5 *a W Stud W Washer 6 7 *a W Stud W Nut W Washer W Capscrew W Flange Screw Hose Guard Bracket, Bulkheads Bulkhead Bulkhead Bulkhead W Fitting 2 *a Use W Thread Lock

26 1-18 Nameplate & Decals Item Part No. Description Qty Item Part No. Description Qty W Decal, Warning W Screw Decal, Load & Wire Rope W Plate, Warning Decal, Maintenance (**B) Decal, Maintenance (**E) 1

27 2-1 Gear/Shaft Train Brake, Dry Disc Clutch Assembly Clutch Shaft Assembly Motor Shaft - H (High-Performance) Winch Motor Shaft - T (Rescue) Winch Reducer, Planetary Shaft - Drum Shaft - Intermediate Gear

28 2-2 Motor Shaft - H (High-Performance) Winch Item Part No. Description Qty Item Part No. Description Qty W Motor, Two-Speed (See p. 3-11) W Plate, Manifold Bracket W Planetary Reducer Assy (See p. 2-4) W Spacer W Gear Retainer W Capscrew W Capscrew W Reducer, Mounting W Seal Ring W O-Ring W O-Ring W Screw W Washer W Plate, Motor Shaft Mounting W Screw W Capscrew W O-Ring W O-Ring W Bracket W Capscrew W Nut W Washer W Brake, Dry Disk (see p. 2-5) W Stud W Nut W Nut W Capscrew 1

29 2-3 Motor Shaft - T (Rescue) Winch Item Part No. Description Qty Item Part No. Description Qty W Motor, One-Speed (See p. 3-10) W Plate, Manifold Bracket W Planetary Reducer Assy (See p. 2-4) W Spacer W Gear Retainer W Capscrew W Capscrew W Reducer, Mounting W Seal Ring W O-Ring W O-Ring W Screw W Washer W Plate, Motor Shaft Mounting W Screw W Capscrew W O-Ring W O-Ring W Bracket W Capscrew W Nut W Washer W Brake, Dry Disk (see p. 2-5) W Stud W Nut W Nut W Capscrew 1

30 2-4 Reducer, Planetary Item Part No. Description Qty Item Part No. Description Qty W Planetary Reducer Gear, Sun Assembly, Carrier Gear, Ring Cover Washer W. Fiiting W. Fitting W. Fitting Shaft Hub 1 11 *a Cone, Bearing 1 12 *a Cup, Bearing 1 13 *a Cone, Bearing 1 14 *a Cup, Bearing Washer 1 16 *a Kit, Retaining Ring 1 17 R Capscrew Washer *a W. HCE-98 Adhesive 1 *a Included in Reducer Rebuild Kit W

31 2-5 Brake, Dry Disc Item Part No. Description Qty Item Part No. Description Qty W Brake, Dry Disc W. Brake, Dry Disc 1 1 NSS.. Retaining Ring 1 2 NSS.. Retaining Ring 1 3 *c NSS.. Bearing 1 4 *b*c NSS.. Oil Seal 1 5 NSS.. Cover Plate 1 6 NSS.. Spline Shaft Assembly 1 7 NSS.. Bolt 4 8 *a NSS.. Primary Disc 1 9 *a NSS.. Rotor Disc 8 10 *a NSS.. Stator Disc 7 11 *a*b*c*d NSS.. Case Gasket 2 12 NSS.. Capscrew 4 13 NSS.. Dowel Pins 4 14 NSS.. Spring Plate 1 15 *d NSS.. Spring, Red NSS.. Piston 1 17 *b NSS.. Backup Ring 1 18 *b NSS.. O-Ring 1 19 *b NSS.. Backup Ring 1 20 *b NSS.. O-Ring 1 22 NSS.. Pressure Plate 1 23 NSS.. Capscrew 4 *a Included in Lining Kit *b Included in O-Ring Kit *c Included in Bearing Kit *d Included in Spring Kit

32 2-6 Clutch Shaft Assembly Item Part No. Description Qty Item Part No. Description Qty Housing, Clutch Shaft, Clutch Assembly, Clutch (Page 2-7) Piston, Clutch Ring, Seal Ring, Thrust 1 6 *a Ring, Thrust Support, Bearing W Cup, Roller Bearing W Cone, Roller Bearing W Cup, Roller Bearing W Cone, Roller Bearing W Locknut, Bearing W Lockwasher, Bearing W Bearing Bearing Washer Shim, Snap Ring, External W Snap Ring, External Snap Ring, External Snap Ring, Internal W O-Ring O-Ring W O-Ring W Pin W Spring Fitting 1 29 Y17C-0616 Capscrew W Washer Gear, Spider 1 *a Only Used on S/N -1090

33 2-7 Clutch Assembly Item Part No. Description Qty Item Part No. Description Qty Clutch Assembly Spring, Belleville Retainer, Spring Hub, Clutch Plate, Reaction Plate, Pressure 1 5 *a Plate, Pressure Disc, Friction Plate, Separator 8 8 Y17C Capscrew W. Washer W. Pin 3 *a Only Used on S/N -1090

34 2-8 Shaft - Drum ,21, Item Part No. Description Qty Item Part No. Description Qty W Drum 1 2 *a W Drum Shaft W Drum Retainer 1 4 *a 6607W Nut W Adapter W Capscrew W Thimble W Roller Bearing W Drum Gear W Capscrew W Washer W Retainer Plate W Flangescrew W Oil Seal W Spacer W O-Ring W Oil Seal W Piston Seal Ring W O-Ring W Shim,.020 AR W Shim,.007 AR W Shim,.005 AR 23 NI W Ferrule Keeper 1 24 NI 16829W Capscrew 1 *a Requires P/N W Sealant NI Not Illustrated

35 2-9 Shaft - Intermediate Gear With Freespool ,12 See Frames & Covers For Part Numbers , A - 60:1 Gear Ratio B - 75:1 Gear Ratio Item Part No. Description Qty A B W Capscrew W Piston Adjust W O-Ring W Housing, Freespool Adj W Intermediate Shaft W Pinion Gear W Dental Clutch W Washer W Screw W Nut W Bearing Cone 2 2 Item Part No. Description Qty A B W Bearing Cup *a W Freespool Shaft W Spring W Freespool Piston W Freespool Shifter Fork W O-Ring O-Ring W Intermediate Gear W Intermediate Gear -- 1 *a Apply W Threadlock to Threads

36 2-10 Intentionally Blank

37 3-1 Hydraulics/Controls Handlever Installation thru 3-17 Hydraulic Group - Conversion Kit & 3-9 Hydraulic Group - H (High-Performance) Winch thru 3-5 Hydraulic Group - T (Rescue) Winch & 3-7 Hydraulic Motor - One-Speed Hydraulic Motor - Two-Speed Manifold, Bypass Manifold, Control Manifold, Directional Manifold, Logic Control Optional Oil Cooler Installation Switch Panel Assembly thru 3-24

38 3-2 Hydraulic Group - H (High-Performance) Winch Page 1 of 4 (T) 40.47, 40.44, 40.19, (P) 40.39, 40.19, 40.44, (RI) 40.17, (RO) 40.17, , (P) 40.17, (T) 40.18, (LS) 40.17,

39 3-3 Hydraulic Group - H (High-Performance) Winch Page 2 of (2 PLCS) ORANGE WIRE (BRAKE-OFF) YELLOW WIRE (FREESPOOL) BLUE WIRE (HI-SPEED)

40 3-4 Hydraulic Group - H (High-Performance) Winch Page 3 of H*B H*E

41 3-5 Hydraulic Group - H (High-Performance) Winch Page 4 of 4 Item Part No. Description Qty Item Part No. Description Qty W Manifold, Logic Series II (Page 3-21) *e W Manifold, Directional (Page 3-18) *b W Cartridge, Valve Kit, Seal 1 *c W Cartridge, Counterbalance Valve Kit, Seal Assembly, Directional Valve W Switch, Pressure R Clip, Insulation *a W Flangescrew *a Y09G-0616 Capscrew W Wire Harness W Coupler, Quick Male *d Assembly, Fitting with.015 Orifi ce R Fitting R Fitting W Fitting R Fitting Fitting R Fitting R Fitting R Fitting R Fitting Fitting Fitting R Fitting Fitting R Fitting *f W Hose Assembly *f W Hose Assembly *f W Hose Assembly *f W Hose Assembly *f W Hose Assembly *f W Hose Assembly *f W Hose Assembly *f W Hose Assembly *f W Hose Assembly *f W Hose Assembly *f W Hose Assembly *f W Hose Assembly *f W Hose Assembly *f W Hose Assembly *f Hose Assembly *f Hose Assembly *f Hose Assembly *f Hose Assembly R Sleeve 6 Ft R Sleeve 4 Ft HSP Hose Protector-6" W Clamp, Strap R Fitting R Fitting Fitting *f Hose Assembly *f W Hose Assembly Fitting 2 *a Apply HCE-67 Medium Strength Thread Locker *b Last Used on S/N *c First Used on S/N *d First Used on S/N *e First Used on S/N *f Included in Hose Kit

42 3-6 Hydraulic Group - T (Rescue) Winch Page 1 of A A (3 PLCS) (2 PLCS) SECTION A-A , , , , OR

43 3-7 Hydraulic Group - T (Rescue) Winch Page 2 of 2 Item Part No. Description Qty Item Part No. Description Qty 50.1 *a 16741W Capscrew W Washer W Nut R Fitting W Coupler, Quick Male R Fitting W Tube Assembly *a Y09G-0616 Capscrew W Washer W Manifold, Relief W Valve, Relief R Fitting W Valve, Control (Page 3-19) Fitting Fitting R Fitting R Fitting R Fitting W Fitting W Manifold W Fitting W Fitting R Fitting Fitting Fitting *b W Hose Assembly *b W Hose Assembly *b W Hose Assembly *b W Hose Assembly *b W Hose Assembly *a Y01C-0432 Capscrew R Fitting *b W Hose Assembly Fitting R Fitting R Fitting W Switch, Temperature W Fitting W Fitting *b Cartridge, Valve Kit, Seal 1 *c W Valve, Counter Balance Cartridge, Valve 1 R Kit, Seal Valve Coil *d, *f W Hose Assembly 1 *e Fitting *e, *f Hose Assembly R Fitting Assembly, Directional Valve Assembly, Directional Valve 1 *a Apply HCE-67 Medium Strength Thread Locker *b Last Used on S/N *c First Used on S/N *d Last Used on S/N *e First Used on S/N *f Included in Hose Kit

44 3-8 Hydraulic Group - Conversion Kit Caterpillar D6N with Pilot Hydraulic Controls to Elect Hydraulic Controls Page 1 of VIEW FROM LEFT SIDE OF WINCH WITH COVER REMOVED.

45 3-9 Hydraulic Group - Conversion Kit Caterpillar D6N with Pilot Hydraulic Controls to Elect Hydraulic Controls Page 2 of 2 Item Part No. Description Qty Item Part No. Description Qty Conversion Kit, CAT D6N Pilot Hydraulid to Electronic Control Fitting Hose Assembly 1 3 R Hose Assembly Fitting 1 5 R Fitting Plug, Orifi ce Fitting 1 8 R Fitting Hose Assembly 1

46 3-10 Hydraulic Motor, One-Speed Item Part No. Description Qty Item Part No. Description Qty W Hydraulic Motor, One-Speed Vane 1 *a NSS. Snap Ring 1 2 *a NSS. Seal 1 3 *a NSS. Quad Ring 1 4 *a NSS. Seal Plate 1 5 *a NSS. O-Ring 1 6 NSS. Snap Ring 1 7 NSS. Bearing 1 8 NSS. Shaft 1 9 NSS. Bolt 4 10 NSS. Housing 1 11 NSS. Pin, Front Dowel 2 12 *a NSS. O-Ring 4 13 NSS. Ball Check 4 14 NSS. Screw 4 15 NSS. Timing Plate 2 16 NSS. Stator 1 17 NSS. Rotor 1 18 *b NSS. Vane, Rotor *b NSS. Spring, Outer *b NSS. Spring, Inner *b NSS. Vane, Stator 4 22 *b NSS. Spring, Vane 8 23 NSS. Pin, Rear Dowel 2 24 NSS. Rear Housing 1 *a Included in Seal Kit W *b Included in Vane & Spring Kit

47 3-11 Hydraulic Motor, Two-Speed Item Part No. Description Qty Item Part No. Description Qty W Hydraulic Motor, Two-Speed Vane 1 *a NSS. Snap Ring 1 2 *a NSS. Seal 1 3 *a NSS. Quad Ring 1 4 *a NSS. Seal Plate 1 5 *a NSS. O-Ring 1 6 NSS. Snap Ring 1 7 NSS. Bearing 1 8 NSS. Shaft 1 9 NSS. Bolt 4 10 NSS. Housing 1 11 NSS. Pin, Front Dowel 2 12 *a NSS. O-Ring 4 13 NSS. Ball Check 4 14 NSS. Screw 4 15 NSS. Timing Plate 2 16 NSS. Stator 1 17 NSS. Rotor 1 18 *b NSS. Vane, Rotor *b NSS. Spring, Outer *b NSS. Spring, Inner *b NSS. Vane, Stator 4 22 *b NSS. Spring, Vane 8 23 NSS. Pin, Rear Dowel 2 24 NSS. Rear Housing 1 25 NSS. Bearing, Needle 1 *a Included in Seal Kit W *b Included in Vane & Spring Kit

48 3-12 Handlever Installation Caterpillar D6N

49 3-13 Handlever Installation Caterpillar D6N Item Part No. Description Qty Item Part No. Description Qty W Valve Manifold Assembly W. Solenoid Cartridge W.. Valve, Cartridge Coil, Solenoid 1 R Kit, Seal 1 R Valve Body W Assembly, Switch Panel (See 3-22) W Decal - Switch Panel W Bolt W Nut W Washer W Decal - Winch In W Decal - Winch Out 1 9 R Fitting W Fitting W Wire Harness - Winch Console W Wire Harness - Winch 1 13 *a W Hose Assembly 1 14 *a W Hose Assembly 1 15 *a W Hose Assembly 1 16 *a W Hose Assembly 1 17 *a W Hose Assembly Fitting Fitting Fitting 2 21 R Fitting Fitting 1 23 Y01C-0428 Capscrew W Washer W Nut Receptacle Lock, Secondary W Plate, Mounting 1 *a Included in Hose Kit

50 3-14 Handlever Installation John Deere 750J Used on S/N thru Item Part No. Description Qty Item Part No. Description Qty 1 *b W Decal, Switch Panel 1 1 *c W Decal, Switch Panel W Decal, Winch In W Decal, Winch Out 1 4 *b W Assembly, Switch Panel (See 3-23) 1 4 *c W Assembly, Switch Panel (See 3-24) W Washer W Nut 2 7 *a W Capscrew W Bolt W Wire Harness, Console 1 12 R13661 Relay W Plate, Switch Mounting W Screw 2 *a Use W Threadlock *b Last Used on S/N *c First Used on S/N -1021

51 3-15 Handlever Installation John Deere 750J First Used on S/N Item Part No. Description Qty Item Part No. Description Qty W Decal, Switch Panel W Decal, Winch In W Decal, Winch Out W Assembly, Switch Panel (See 2-23) W Washer W Nut W Bolt W Wire Harness, Console 1 12 R13661 Relay W Plate, Switch Mounting W Screw 2

52 3-16 Handlever Installation John Deere 850J Used on S/N thru Item Part No. Description Qty Item Part No. Description Qty 1 *b W Decal, Switch Panel 1 1 *c W Decal, Switch Panel W Decal, Winch In W Decal, Winch Out 1 4 *b W Assembly, Switch Panel (See 3-23) 1 4 *c W Assembly, Switch Panel (See 3-24) W Washer W Nut 2 7 *a W Capscrew W Bolt W Wire Harness, Console 1 12 R13661 Relay W Plate, Switch Mounting W Screw 2 *a Use W Threadlock *b Last Used on S/N *c First Used on S/N -1021

53 3-17 Handlever Installation John Deere 850J First Used on S/N Item Part No. Description Qty Item Part No. Description Qty W Decal, Switch Panel W Decal, Winch In W Decal, Winch Out W Assembly, Switch Panel (See 3-23) W Washer W Nut W Bolt W Wire Harness, Console 1 12 R13661 Relay W Plate, Switch Mounting W Screw 2

54 3-18 Directional Manifold , 8 Item Part No. Description Qty Item Part No. Description Qty W Manifold, Directional W. Manifold Body W. Valve, Proportional Cartridge Spool W.. Kit, Seal W. Valve, Cartridge Check W.. Kit, Seal 1 6 *a, *b W. Screw 1 6 *c Fitting, Orifi ce W. Plug, Orifi ce W. Valve, Cartridge Relief W.. Kit, Seal W. Fitting, O-Ring W. Orifi ce W. Orifi ce 1 *a Use W Adhesive Sealant *b Last Used on S/N *c First Used on S/N -1201

55 3-19 Control Manifold Item Part No. Description Qty Item Part No. Description Qty W Control Manifold 1 NSS. Control Manifold Body W. Fitting W. Cartridge Shuttle Valve W.. Seal Kit 2 7 NSS. Expansion Plug 3

56 3-20 Bypass Manifold Item Part No. Description Qty Item Part No. Description Qty W Bypass Manifold W. Manifold Directional Valve W.. Kit, Seal Fitting 1

57 3-21 Logic Control Manifold Item Part No. Description Qty Item Part No. Description Qty W Logic Control Manifold W. Manifold Body W. Shuttle Valve W.. Seal Kit Cartridge, Valve Coil, Solenoid W. Fitting 3

58 3-22 Switch Panel Assembly Rescue Winch 9 (YELLOW LENS) (RED LENS) 10 4 Item Part No. Description Qty Item Part No. Description Qty W Switch Panel Assembly, Rescue Winch W. Plate, Switch Mounting Assembly, Switch 24V Frame, Mounting Assembly, Switch 1

59 3-23 Switch Panel Assembly Freespool and Hi-Speed Winch 9 11 (GREEN LENS) (YELLOW LENS) Item Part No. Description Qty Item Part No. Description Qty W Switch Panel Assembly, Freespool and Hi-Speed Winch Frame, Mounting W. Plate, Switch Mounting Cover, Blank Assembly, Switch 24V Assembly, Switch 3 Positions, 24V 1

60 3-24 Switch Panel Assembly (YELLOW LENS) (RED LENS) 1 12 (GREEN LENS) 7 Item Part No. Description Qty Item Part No. Description Qty W Switch Panel Assembly Frame, Mounting W. Plate, Switch Mounting Assembly, Switch 24V Assembly, Switch 3 Positions, 24V Assembly, Switch with Lock 1

61 3-25 Optional Oil Cooler Installation Caterpillar D6N Item Part No. Description Qty Item Part No. Description Qty W Capscrew W Washer W Bracket W Lower Bracket W Oil Cooler 1 6 R Fitting Fitting 1

62 3-26 Intentionally Blank

63 4-1 Optional Arch Fairlead Wire Rope Assemblies

64 4-2 Arch Item Part No. Description Qty Item Part No. Description Qty W Arch Assembly W. Weldment, Arch W. Roller W.. Bushing W. Washer W. Keeper W. Flange, Screw W. Roller W.. Bushing W. Fitting, Grease W. Washer W. Shaft W. Nut W. Shaft W. Shaft W. Roller W.. Bushing W Ear, RH W Lug, Wrapped W Pin W Keeper W Flange Screw W Ear, LH 1

65 4-3 Fairlead Item Part No. Description Qty Item Part No. Description Qty W Fairlead Assy., 4-Roller W. Frame W. Screw, Flange W. Keeper W. Fitting, Lube W. Roller W.. Bushing W. Washer W. Roller W.. Bushing W. Shaft W Bracket, RH W Bracket, LH W Shim A/R W Capscrew W Washer W Pin, Cotter W Spacer W Tie Bar 1

66 4-4 Wire Rope Assemblies Wire Rope Diameter Dia (in) Wire Rope Breaking Strength New (lbs) Tail Chain & Hook Working Load Limit (lbs) 3.5:1 Design Factor 3/4 58,800 34,200 7/8 79,600 34, ,400 47,700 Part No. Wire Diameter Length Ft (M) Part No. Wire Diameter Length Ft (M) WR6-263L 3/4" 263 (80) * WR6-399L 3/4" 399 (122) ** WR7-189L 7/8" 189 (58) * WR7-287L 7/8" 287 (87) ** WR8-147L 1" 147 (45) * WR8-223L 1" 223 (68) ** * Length to fi ll drum to 2/3 capacity (recommended) ** Length to fi ll drum to full capacity

67 5-1 Part No. Page No. Item Part No. Page No. Item Part No. Page No. Item Part No. Page No. Item Numerical Index W W W W - Y17C

68 5-2 Part No. Page No. Item Part No. Page No. Item Part No. Page No. Item Part No. Page No. Item W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W 1-7 8

69 5-3 Part No. Page No. Item Part No. Page No. Item Part No. Page No. Item Part No. Page No. Item W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W

70 5-4 Part No. Page No. Item Part No. Page No. Item Part No. Page No. Item Part No. Page No. Item W W A W A W A W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W HSP R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R WR6-263L 4-4 WR6-399L 4-4 WR7-189L 4-4 WR7-287L 4-4 WR8-147L 4-4 WR8-223L 4-4 Y01C Y01C Y09G Y09G Y17C Y17C Y17C

71

72 To fi nd a dealer in your area, Call: (503) , Fax: (503) , or or Visit our website: W Printed in USA

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