ALLIED W8L 2011 TOWING WINCH WORKSHOP SERVICE MANUAL

Section 1: General ................................................
Introduction .............................................................
Description .............................................................
Unit Identifi cation .............................................
Serial Number Codes .......................................
Nameplate ........................................................
Warning and Maintenance Decals ....................
Gear Train ..............................................................
Operation and Control ............................................
Power Controls .................................................
Electronic Controls ...........................................
Description of Operations .................................
Capacities & Specifi cations ....................................
Recommended Oil List ......................................
Winch Drum Line Capacity ...............................
Winch Oil Capacity ............................................
Winch Weight ...................................................
Torque Specifi cations .......................................
Hydraulic Specifi cations ...................................
Section 2: Power/Cable Controls ........................
Hydraulic System ...................................................
Forward & Reverse Clutches ............................
Oil Brake ..........................................................
Hydraulic Control Valve ....................................
Hydraulic Control Relief Valve ...........................
Hydraulic Pump ................................................
Accumulators ...................................................
Accumulator Valve ............................................
Check Valve .....................................................
Cooling Oil Relief Valve .....................................
Sequence of Operation - BRAKE-ON ...............
Sequence of Operation - LINE-IN .....................
Sequence of Operation - LINE-OUT INCHING .
Sequence of Operation - LINE-OUT .................
Sequence of Operation - BRAKE OFF.............
Service ...................................................................
Maintenance Points ..........................................
Maintenance Schedule ....................................
Checks Before Operation .................................2
Checks During Operation .................................2
Checks and Adjustments .................................2
Control Cable Adjustments ..............................2
FREESPOOL Cable Adjustments ....................2
Hydraulic System Pressure Checks .................2
Preparation ......................................................
Pressure Gauges ...........................................
Brake Pressure Check ...................................
Cooling Oil Pressure Check ............................
Accumulator Pressure Check .........................
Forward Clutch Pressure Check and Forward
Modulator Valve Check ..................................
Reverse Clutch Pressure Check and Reverse
Modulator Valve Check ..................................
Control Valve Spool Travel Check ...................
Hydraulic Systems Pressure Tests Chart ........
Troubleshooting ....................................................
Troubleshooting Analysis Check Chart ...........
Troubleshooting Analysis Check Chart
for FREESPOOL Option ................................
Section 3: Electronic Controls ..........................
Hydraulic System..................................................
Valve Manifold Assembly
and Hydraulic Schematic...............................
Relief Valve.....................................................
Forward & Reverse Clutches...........................
Oil Brake.........................................................
Hydraulic Pump..............................................
Accumulator Valve..........................................
Check Valve...................................................
Sequence of Operation - BRAKE-ON .............
Sequence of Operation - LINE-IN ...................
Sequence of Operation - LINE-OUT ...............
Sequence of Operation - BRAKE OFF............
Sequence of Operation - FREESPOOL ..........
Electronic Control Module ....................................
LED States For Various Functions ..................
Input / Output Functions ..................................
Electronic Control Program Diagram ..............
DVC10 Electronic Schematic ..........................
Service .................................................................
Maintenance Points ........................................
Maintenance Schedule ..................................
Checks Before Operation ................................
Checks During Operation ................................
Joystick Detent Force Adjustment...................
Hydraulic System Pressure Check .................
Preparation.....................................................
Pressure Gauges ...........................................
Brake Pressure Check ....................................
Cooling Oil Pressure Check ............................
Accumulator Pressure Check .........................
Forward Clutch Pressure Check .....................
Reverse Clutch Pressure Check ......................
Hydraulic System Pressure Test Chart ............
Troubleshooting ......................................................
Troubleshooting Analysis Check Chart
for Operators ....................................................
Troubleshooting Analysis Check Chart
for Service Personnel .......................................3
Troubleshooting Chart
for Electronic Control Module ...........................3
Interfacing with the Electronic Control Modul ...3
DVC Controller Goes into Programming Mode
When Powered On ...........................................3
Re-Commissioning DVC Master Modules ........3
Section 4: Repairs ...............................................
General ..................................................................
Winch Removal ......................................................
Winch Disassembly ................................................
General Gear Arrangement ....................................
PTO Shaft Removal & Disassembly .......................
Oil Brake Removal & Disassembly .........................
Hydraulic Pump Removal & Disassembly ..............
Pump Disassembly ..........................................
Pump Inspection ..............................................
Pump Gear ................................................
Pump Front & Backplates...........................
Pump Body ...............................................
Clutch Shaft Removal & Disassembly .............
Repair of Reverse Clutch Gear.......................
Oil Clutch Disassembly ....................................
Brake Shaft Removal .......................................
Intermediate Shaft Removal, Non-Freespool ..
Intermediate Shaft Removal, Freespool ..........
Drum Shaft & Drum Removal ..........................
Winch Assembly ..............................................
Visual Inspection .......................................
Drum Shaft & Drum Installation .......................
Intermediate Shaft Installation, Non-Freespool
Intermediate Shaft Installation, Freespool .......
Brake Shaft Installation ....................................
Oil Clutch Reassembly ....................................
Clutch Shaft Reassembly & Installation ...........
Repair of Reverse Clutch Gear...................
Hydraulic Pump Reassembly & Installation .....
Pump Installation ......................................
Oil Brake Reassembly & Installation ................
PTO Shaft Reassembly & Installation ..............
Winch Installation ............................................
Special Tools