599030W - Allied Systems Company
Contents
1. Allied COMPANY Maintenance Maintenance The Maintenance Schedule is a program that includes on the hour meter of the tractor to find the maintenance periodic inspection and lubrication Use the operating time time for the winch A Access Cover for Control Valve Cover for Filter Plug to Check Oil Level Fill Plug Plug to Drain Oil Access Cover for Strainer Figure 12 W5B Winch Maintenance Points Allied COMPANY Si Allied WINCH INTERVAL PROCEDURE OR QUANTITY SPECIFICATION 50 hours or weekly Check oil level at plug item 2 Add oil as necessary See Figure 5 Recommended Oil List through fill plug item 5 Do not operate tractor when checking the oil level Check winch control lever See Figures 14 15 and Use SAE 30 oil on the linkage if needed 16 Check that the control cable and control housing are fastened correctly Tighten U bolts if required Clean the breather item 6 Remove debris around breather Lubricate the rollers on the fairlead assembly if the Use multi purpose grease with 2 4 molyb winch is so equipped denum disulfide 500 hours or every 3 Clean the oil suction screen and magnets Use a new gasket between the cover and the months suction tube Clean the breather Remove debris around breather Replace the filter See the Parts Manual for filter element and cover gasket When replacing be sure to lubricate filter seal ring between element and filter head 1000 hours2. Operation Figure 10 Troubleshooting Analysis Chart continued PROBLEM POSSIBLE CAUSE CORRECTION Low forward or reverse Leak in hydraulic system or loose Visually inspect winch for leaks and ensure hydraulic clutch pressure hydraulic connections connections are secure Leaky clutch circuit Perform clutch bleed down test on clutch circuit Broken seal rings on the bevel gear Replace seal rings NOTE A broken seal ring is the most common cause of a pressure differential between the two clutches Check preload on clutch brake shaft and adjust it if necessary to prevent additional breakage of seal rings Damaged bevel gear shaft seal ring Check grooves for taper scoring and rust Replace grooves or rebuild shaft if surfaces between the inner side of groove and seal ring are not flat Damaged bevel gear shaft bearing Check retainer for grooves Replace retainer if defec retainers tive or re sleeve Damaged clutch piston piston re Check piston and piston retainer cavity for dam tainer or O rings age Always replace both O rings when clutch is repaired Reverse pressure hose damaged by Remove cover and inspect bevel gear Allied COMPANY Allied WINCH Figure 10 Troubleshooting Analysis Chart continued PROBLEM POSSIBLE CAUSE CORRECTION Winch will not operate Accumulator system malfunction Check for while tracks are turning 1 Proper leakdown time as described in Figure 11 2 Leakin
3. Optional Gear Ratios Lower speed ratios allow better operator control of line speed They may also allow the winch to pull in excess of wire rope or winch rated capacity They do not increase the durability or damaging load limit of the winch Line pulls in excess of rated capacity will dramatically reduce the life of winch components ER Allied COMPANY Notes 47 48 Notes l NO MATTER HOW YOU SAY IT La Prudence Paye La Seguridad Paga Betriebssicherheit Macht Sich Bezahlt Passaa Olla Huolellinen Veiligheid Voor Alles S kerhet F rst Essere Sicuro Paga Seguran a Paga Sikkerhet F rst Pinter Be Awas arrera ate Rt tt yu NSF Et E To find a dealer in your area Call 503 625 2560 Fax 503 625 7269 or Email marketing alliedsystems com or Visit our website www alliedsystems com
4. 9 op 4 e NORMAL I i ZC OPERATION aa b BRAKE lo on md We S T G d Inching LINE IN This operation is used to slowly move a load toward the tractor The control valve will cause the Operation oil pressure to slowly release the brake and slowly apply the LINE IN clutch As the brake is released the clutch takes control and begins to move the load Ne EED E OPERATION GA wa FREESPOOL CONTROL A Inching LINE OUT This operation will release the brake before the LINE OUT clutch is applied This adjustment permits the weight of the load to unwind cable from the winch drum against the resistance of the brake The op erator controls the resistance of the brake by the position of the power control lever The LINE OUT clutch is not applied until the operator moves the power control lever more toward the LINE OUT position When the power control lever is moved so that the LINE OUT clutch is engaged the speed that the drum unwinds is controlled by the rom of the tractor PTO Allied COMPANY ei Allied WINCH FREESPOOL Operation The control lever normally cannot be moved to the FREESPOOL position if there is a load on the cable If enough force is used to disengage the gear train for the FREESPOOL operation an uncontrolled release of the load will occur Loss of the load can result in injury and damage Th
5. The winch has an intermediate gear assembly that provides a gear reduction and increases the available torque at the winch drum For winches equipped with the FREESPOOL option a sliding sleeve with splines engages the drum pinion gear and the intermediate gear When the control lever is in the FREESPOOL position the sliding sleeve disengages the drum pinion gear from the intermediate gear The gear train is disengaged from the clutch and brake shaft so that the cable can be pulled from the drum by hand Only the drum and drum pinion gear rotate when the cable is pulled from the drum during a FREESPOOL operation Shifting to FREESPOOL with a suspended load on the cable will cause the load to fall uncontrollably 2 Allied COMPANY W5B Winch Description The W5B winch is a power forward LINE IN and a power reverse LINE OUT winch used on tractors with a unidi rectional PTO This winch also has a FREESPOOL func tion so that cable can be pulled from the drum by hand The W5B winch has a maximum line pull capacity of 222 400 N 50 000 Ibf when there is one layer or less of cable on the drum Allied COMPANY General 1 Clutch 6 Intermediate Gear and 2 Pinion Freespool Assembly 3 Ring Gear 7 Drum gear 4 Clutch 8 Drum 5 Oil Brake Figure 1 W5B Winch Typical Gear Train Drum Shaft Access Cover for Filter Access Cover to Hydraulic Valve Access Cover to Clutch Shaft Plug to Check Oil Level Plug to Drain
6. agite da le ia jii Troubleshooting Chart 20 Safety Summary eee eee V Maintenance Maintenance Homte eee 31 General Maintenance Schedule rrrnnrrnnnnnnnnnnnnnnnnnnene 32 Mod EE 1 Control Cable Adiustment eee 33 How The Winch Operates eee 1 W5B Winch Description eee eee 3 Operating Techniques Nameplate EE EEE 5 Tractor or Skidder Operation ccmc eee 37 Wire Rope Gelechon eee eee eee 6 How To Move A Disabled Vehicle 40 Oil Capacity amp Recommended Oil List 7 Working on A Steep Slope c eee 42 Optional EqQuipPmeN EE 8 Tractor Is Down The Glope eee 42 Serial Number CodeS eee eee 9 Other Equipment Is Down The Slope 43 Tractor amp Skidder Identification Codes 10 Operational Differences Optional Equipment Operation Integral Arch EE 45 Checks Before Operation cccccsceceeeeeseeeeseees 13 FE 45 Checks During Operation 13 Ble oe EE IRRD PRI 46 Operating Procedures rrnnnrnnnnnavrnnnnvrnnnnnnnnnnennnnre 14 Optional Gear Ratios ccccccseeeeeeeeeeeeeeeeesseeees 46 Power Operation EE 16 Allied COMPANY ii Allied WINCH Intentionally Blank Allied COMPANY Safety Summary Safety Summary General Safety Notices A WARNING The following pages contain general safety warnings which supplement specific warnings and cautions appear The WARNING symbol appears wherever ing els
7. brake The winch will wind the cable at a speed con trolled by the PTO speed of the tractor N 3 GI LINE OUT position applies the LINE OUT clutch and releases the brake The winch will unwind the cable at a speed controlled by the PTO speed of the tractor and the weight of the load NORMAL thy OPERATION SC Ess N A BRAKE OFF position is a detent position The clutches are released and the oil pressure has released the brake This position will permit the cable to unwind from the winch against the friction of the clutches brake and gear train as the tractor moves away from the load 16 Allied COMPANY Inching is used for a fine control of the winch speed When the power control lever is slowly moved to a position between BRAKE ON and LINE IN or between BRAKE ON and LINE OUT inching occurs The normal adjust ment of inching for LINE IN is different from the adjustment for LINE OUT These adjustments can be modified by changing the overlap pressures of the modulator valves This change is necessary for some customer operations The following paragraphs describe the normal adjust ments for inching NOTE Inching will rapidly add heat and accelerate clutch amp brake wear Inching for more than a few seconds should be followed by several minutes of cooling recovery c m LINE Ne
8. 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 Allied COMPANY Vil Allied WINCH viii 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 Sei 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 dama
9. the U bolt that holds the freespool control cable Item 7 in the housing to adjust the control lever The linkage and cable must be adjusted so that the FREESPOOL shifter mechanism will slide the drum pinion gear to both posi tions Both positions have a detent 1 2 3 4 6 8 9 10 Figure 16 Control Cable Adjustments Allied COMPANY 2 36 Intentionally Blank Allied COMPANY Operating Techniques Operating Techniques Tractor or Skidder Operation PERATION GRANE ei ON Je IECH Ho p Cr Cr SE LINE e ELIN Cha NORMAL SE es ES Y OPERATION ei o OPERATION Step 1 The tractor or skidder is moved to an area where a load will be connected The operator Step 2 A load logs is connected to the cable The moves the control lever to the LINE OUT or the operator moves the FREESPOOL control lever to the FREESPOOL control lever into FREESPOOL posi NORMAL OPERATION position tion so that the cable can be pulled from the winch drum Allied COMPANY a Allied WINCH 38 NORMAL thy OPERATION Step 3 The operator can move the control lever to the LINE IN position If the load is less than approxi mately 75 of the maximum line pull the operator can begin traveling with the vehicle at the same time The winch will wind the load toward t
10. tractor in line with the winch cable Fully engage the LINE IN clutch as necessary and use minimal inching to prevent additional heat and wear Do not permit the winch cable to loosen and pass under the drive wheels or tracks of the trac tor Operating Techniques Other Equipment is Down the Slope See Figure 20 In this operation the tractor and winch are on stable ground and other equipment is working on a steep slope The winch is used to give additional control to the equip ment working on the steep slope winch with a fairlead option is recommended for this operation if alignment of the other equipment with the winch and tractor is a problem Make sure the tractor and winch are on stable ground and will not slide when the load is applied Align the tractor and winch with the load Apply the parking brake on the tractor Figure 20 Other Equipment on a Steep Slope Allied COMPANY o Allied WINCH A Lowering the equipment on the slope 1 44 Set the throttle on the tractor for the required engine speed Operator experience is required for this op eration so that the load is carefully controlled Keep the winch cable tightened between the tractor and the equipment being lowered down the slope Use the control lever in the LINE OUT position to control the lowering of the equipment down the slope Move the control lever between LINE OUT and BRAKE ON if inching is required Use minimum inching to prev
11. IVE ITEM PORT MENT POSITION ACTION REQUIRED Brake G4 Brake 400 psi BRAKE OFF 170 to 220 psi 1172 Adjust relief valve 2800 kPa to 1517 kPa gauge Cooling Gi Inlet 400 psi BRAKE ON At 1000 RPM 50 to Check plumbing for leakage 2800 kPa 85 psi 343 to 586 or blockage check bypass gauge kPa valve G4 Brake 400 psi BRAKE OFF 220 psi 1517 kPa Check hydraulic lines for 2800 kPa BRAKE ON None leaks SES Wait for ac None wait 1 Replace accumulator cumulator minute valve and cooling 140 psi 962 kPa Check for defective ac valves to immediately amp cumulators close 120 psi 828 kPa Stop Engine minimum after 30 BRAKE OFF seconds Repeat if required Accumulator ES Allied COMPANY Operation Figure 11 Hydraulic System Pressure Tests continued LINE IN G2 Forward 400 psi 220 psi 1517 kPa at Refer to Figure 10 for Low Forward 2800 kPa full lever travel Forward or Reverse Clutch gauge Pressure troubleshooting procedures on page 25 LINE OUT G3 Reverse 400 psi LINE OUT 220 psi 1517 kPa at Refer to Figure 10 for Low Reverse 2800 kPa full lever travel Forward or Reverse Clutch gauge Pressure troubleshooting procedures on page 25 NOTES 1 Clutch and brake pressure are modulated 0 220 psi in proportion to handlever travel 2 Maximum brake pressure in LINE IN and LINE OUT may not equal relief pressure Allied COMPANY E 30 Intentionally Blank
12. Maintenance Schedule for the W5B winch Checks During Operation The Troubleshooting Chart Figure 10 can be used by the operator to identify a problem with the winch operation A trained service person may be needed for additional troubleshooting and repair that requires disassembly of parts of the winch Allied COMPANY fe Allied WINCH Operating Procedures There are three different configurations of control levers to fit the variation in applications The control lever assembly has two control levers and the operation is the same in all configurations Both control levers are connected to the winch through control cables The power control lever is connected to the spool in the control valve This lever is used to select one of the following operations BRAKE OFF LINE OUT BRAKE ON LINE IN Except for the BRAKE OFF position the power control lever will return to the BRAKE ON position when the con trol lever is released A spring arrangement on the spool of the control valve returns the spool and control lever to the BRAKE ON position A ball and detent arrangement will hold the spool and control lever in the BRAKE OFF position The operator must pull the control lever from the BRAKE OFF position The BRAKE ON position is a neutral position No hydraulic pressure is applied to the brake or the clutches Springs apply the brake so that the winch drum will not rotate The BRAKE OFF position has a detent and is a neutral p
13. Oil Tie Rod Fill Plug and Breather Cover for Oil Brake Cover for Oil Strainer Bearing Retainer for Intermediate Shaft Access Cover for Drum Gear Freespool Adjust Standard on AW5B 1291 and above only Cover for Bevel Gear Adjust and Gear Box Figure 2 W5B Towing Winch Allied COMPANY General Nameplate Each winch is shipped from the factory with a nameplate as shown in Figure 3 The rated capacity for the winch as it api ALLIED SYSTEMS COMPANY is equipped is shown on the nameplate Each winch must 21433 SW OREGON STREET be operated within its rated capacity If the nameplate is NET SHERWOOD OREGON 97140 USA missing or the cable does not match the information on WWW ALLIEDSYSTEMS COM the nameplate do not operate the winch until its capacity is known MODEL SERIAL NO MAXIMUM RATED LINE PULL BARE DRUM MAX WIRE ROPE DIA WITH ARCH ZI Figure 3 Nameplate Made in USA 2311492 Rew B O Allied COMPANY Allied WINCH Wrie Rope Selection Each winch model can have a variety of wire rope sizes installed by the user The maximum wire rope size is A WARNING shown on the nameplate When a larger diameter wire rope is used the length of wire rope installed on the drum will be shorter The winch can create a tension in the wire rope that is greater than the strength of the wire rope The user must be careful to select a wire rope that has enough strength and length for the
14. Operating Manual Allied Towing Wincl This manual must be with the vehicle on which this winch is installed Please check the Allied Systems website regularly for updates to this manual www alliedsystems com P N 599030W 08 12 2010 Winch Model W5B Serial Number Date Delivered Date Installed Special Equipment or Attachments Allied Allied COMPANY MOE A Product of Allied Systems Company 08 12 2010 Sherwood Oregon USA Printed in USA Foreword Foreword The safe and efficient operation of a winch requires skill and alertness on the part of the operator To develop the skills required the operator must Receive training in the proper operation of the winch and the machine on which it is mounted Understand the capabilities and limitations of the winch and the machine on which it is mounted S Become familiar with the winch and the machine on which it is mounted and see that they are maintained in good condition Read and understand the SAFETY SUMMARY and OPERATING PROCEDURES contained in this Operating Manual In addition a qualified person experienced in the operation of the winch must guide a new operator through several load handling applications before the new operator at tempts to operate the equipment alone It is the employer s responsibility to make sure that the operator can see hear and has the physical and mental ability to operate the equipment safely This Operatin
15. anufacturer Oil Type F C F i Caterpillar ohn Deere xxonMobil hevron Recommended Oils Low Temperature Applications Note ExxonMobil and John Deere Oils are recommended for Inching Applications Ambient Temperature Range Oil Temperature Range Manufacturer Oil Type F C F C ohn Deere xxonMobil Chevron Note Use of a non recommended oil may void warranty Figure 5 Recommended Oil List Allied COMPANY Allied WINCH Optional Equipment The W5B winch may be equipped with the following op alternate gear ratio tions freespool function integral arch fairlead assembly drawbar NOTE Not all optional equipment listed is available for each model of tractor 1 Integral Arch 2 Fairlead Assembly 3 Drawbar Figure 6 W5B Towing Winch Optional Equipment Allied COMPANY Manufactured s JI A Allied Systems Company no A Hyster Company Winch Model Drive Type Unit Identification General Allied Winch S N Nameplate Data For Tractor Mountings A W5B P 4 B P Power Controlled Gear Ratio Code 1 25 621 2 32 27 1 3 40 33 1 4 41 31 1 5s LECHEN 6 69 92 1 T ASA 8 55 32 1 9 88 10 1 10 117 00 1 11 15 56 1 12 115 30 1 13 78 37 1 Allied COMPANY 1955 A34 TI Vehicle Code See Figure 7 Sequence Number Internal Options B Power Forward Reverse with Freespool NOTES 1 In Addition to the serial numb
16. bove with Exterior Drag Adjust The preload on the bearings of the intermediate shaft controls the resistance to rotation of the drum during the FREESPOOL operation The resistance to rotation is cor rect when the drum can be rotated by hand but the drum will not rotate more than one half revolution freely An adjusting screw is located in the center of the bearing retainer for the intermediate shaft please refer to Figure 9 This screw can be tightened or loosened to adjust the preload on the intermediate shaft The jam nut will main tain the FREESPOOL setting Adjusting Nut Jam Nut Figure 9 FREESPOOL Adjustments Allied COMPANY Operation Setting the preload on the intermediate shaft too tight will cause bearing overload Setting the preload too loose will allow shaft to not be parallel Use caution when adjusting De termine the correct preload by starting with the preload too loose and gradually increase the preload until the correct resistance to rotation is achieved see Page 18 Increase the preload by turning the adjusting screw by a maximum of 1 6 rotation 60 degrees and striking the housing with a hammer to make sure the bearing is sliding Check resistance to rotation after each adjustment Allied WINCH Figure 10 Troubleshooting Analysis Chart continued on next page PROBLEM POSSIBLE CAUSE CORRECTION Overheating Plugged pressure filter Replace filter Plugged suction filter Remove suction
17. d 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 Allied COMPANY Safety Summary XI Notes xii Allied COMPANY General General Introduction This Operating Manual is divided into separate sections to describe the various models of Allied winches Models that have similar operating characteristics are described in the same section How the Winch Operates A winch is normally installed on a skidder or tractor e to increase the pulling power of the skidder or tractor e to reach into an area where a skidder or tractor cannot go e to make lift functions available when special at tachments are installed The winch has hydraulic clutches that are similar to a hydraulic powershift transmission Most tractors and skidders have a power take off PTO that is used to connect the power from the engine to the winch The SCH Self Contained Hydraulics on the winch label in dicates that the hydraulic system for control of the winch is inside of the winch case When the PTO is operating a hydraulic pump
18. e power control lever must be in the BRAKE ON or BRAKE OFF positions to operate the FREESPOOL con trol lever When the FREESPOOL control lever is moved to the FREESPOOL position the winch drum is disengaged from the gear train The FREESPOOL operation permits the cable to be pulled from the winch drum by hand If the FREESPOOL control lever cannot be moved to en gage the gear train for power operation apply a clutch to move the gear train a small amount This action will align the splines in the sliding sleeve so that the intermediate gear can be engaged FREESPOOL Drag Adjustment For All W5B and AW5B 1290 and below without Exterior Drag Adjust The preload on the bearings of the intermediate shaft controls the resistance to rotation of the drum during the FREESPOOL operation The resistance to rotation is cor rect when the drum can be rotated by hand but the drum will not rotate more than one half revolution freely The addition or removal of shims for the preload on the bearings of the intermediate shaft requires the removal of the cover for the intermediate shaft This adjustment is normally only necessary if the winch has had an overhaul See the Service Manual if this adjustment is required GEAR N BRAKE ON rech S NN IN FREESPOOL Ae CINCEA Ze CONRO ieee NORMAL thy OPERATION SR Allied COMPANY FREESPOOL Drag Adjustment for AW5B 1291 and A
19. e tractor to slide A slope can require additional distance to stop the vehicles Make sure the cable and tow chain have the capacity to do the job If the disabled vehicle does not have a tow pin or other equipment for towing carefully fasten the tow chain around the axle of the disabled vehicle Make sure the tow chain is fastened so that the chain will not cause injury to people or damage to the vehicle An operator must be on the disabled vehicle to operate the steering and brakes when it is towed 1 Fasten the winch cable to the tow bar of the other vehicle The cable must be in a direction that is ap Allied COMPANY Operating Techniques proximately parallel to the direction of travel of the vehicle Apply the brakes on the tractor or skidder Use the throttle to set the engine speed at a power level to operate the winch Operator experience is required because the winch can use most of the engine power in some vehicles Use the LINE IN control lever to tighten the winch cable When the winch cable is tight use the power from the engine to the winch to pull the vehicle from the bad area If the disabled vehicle moves under its own power keep the towing cable tight so that the cable does not pass under the drive wheels or tracks of the vehicle being towed Figure 18 Moving a Disabled Vehicle Step B 41 Allied WINCH Working on a Steep Slope The winch and the tractor must be in good condition for t
20. ent additional heat and wear Allied COMPANY B Raising the equipment on the slope 1 Set the throttle on the tractor for the required engine speed Operator experience is required for this op eration so that the load is carefully controlled Keep the winch cable tightened between the tractor and the equipment being lowered down the slope Use the control lever in the LINE IN position to con trol the lowering of the equipment down the slope Move the control lever between LINE IN and BRAKE ON if inching is required Use minimal inching to prevent additional heat and wear Keep the equipment being raised in alignment with the winch and tractor Do not permit the winch cable to loosen and pass under the drive wheels or tracks of the tractor Operational Differences Optional Equipment Operational Differences Optional Equipment Integral Arch When using an integral arch the wire rope passes over a raised horizontal roller and between a set of smaller verti cal side rollers and an upper horizontal roller This causes the winch to pull upwards on loads In this way the load can be lifted slightly to reduce drag due to ground contact The side and top rollers act as fairleads to protect the wire rope from damage and from damaging the frame Because the line of action of the wire is higher than normal the tipping moment applied to the tractor is in creased and the tractor will tip backwards at significantly lower line pu
21. er plate the serial number is stamped on to the left hand side of the frame 2 Circled numbers in Figure 7 indicate possible gear ratios Allied WINCH Tractor Make Model and Starting Tractor Serial Number Where Applicable Fiat Hitachi Caterpillar John Deere Dresser Komatsu New Holland D41E 6 JD 750 750B w Cab 2 GI 9 JD 750 750B w Cab 2 JD 750 750B a w o Cab 00 000 D5E FL10C 9 TD 12B C D53 D58 D63 a D4BP 83J3553 amp up 47H1786 amp up 59J2553 amp up 7R926 amp up All 28X 51X 52X 69X 71X amp 77W Figure 7 Tractor or Skidder Identification Codes and Available Gear Ratios for W5B Winch 10 Allied Systems continued on next page General Tractor Make Model and Starting Tractor Serial Number Where Applicable C E H K R Fiat Hitachi Caterpillar John Deere Dresser Komatsu Case New Holland FL10E Challenger FD10E 65 75 2 2 750C 09 D4H PS UI Q III XL LGP Young Grapple Esco Grapple Figure 7 Tractor or Skidder Identification Codes and Available Gear Ratios for W5B Winch Allied COMPANY W Allied WINCH 12 Intentionally Blank Allied COMPANY Operation Operation Checks Before Operation Check the cable and hook for wear or damage Check that the periodic inspection and maintenance have been done at the recommended operating hours See Figure 12
22. evis to the control handle again and check the operation The linkage and cable must be adjusted so that the FREESPOOL shifter mechanism will slide the drum pinion gear to both positions Both positions have a detent When the adjustment is complete tighten the tall nuts and install the cover Allied COMPANY 6 Control Lever Clevis 7 Screw Tall Nut 8 Jam Nut Cotter Pin and Link Pin 9 Button Head Capscrew Control Cable Access Cover Figure 15 Control Cable Adjustments Maintenance C See Figure 16 This configuration was last used dur ing 1993 Check the operation of the power control lever Item 1 to make sure it moves smoothly and will return to the BRAKE ON position The power control lever will stay in the BRAKE OFF position when pushed into the detent position Check that the positions of the power control lever are the same as the position indicators on the decal Loosen the U bolt Item 6 that holds the power control cable Item 8 in the housing to adjust the control lever Make sure the control lever does not hit the housing at the end of its travel Check the operation of the FREESPOOL lever Item 2 for smooth operation Each of the two posi tions has detent Power Control Lever Freespool Control Lever Housing Locknut U Bolt Freespool Control Cable Power Control Cable Spacer Pivot Pin Make sure the positions of the FREESPOOL lever are the same as the position indicators on the decal Loosen
23. ewhere in this manual All electrical and hydraulic incorrect operating procedures or practices equipment is dangerous You must thoroughly review could cause serious injury or death Carefully and understand the Safety Summary before attempting read the message that follows to prevent seri to operate troubleshoot or service this winch ous injury or death The following symbols terms are used to emphasize safety A CAUTION precautions and notices in this manual The CAUTION symbol appears where a A DANGER hazardous situation which if not avoided could result in minor to moderate injury and The DANGER symbol indicates a hazardous equipment damage situation which if not avoided will result in death or serious injury Carefully read the message that follows to prevent serious injury or death Allied COMPANY Should the recommendations in this manual deviate from NOTICE those in the user country the national regulations should This signal word alerts to a situation that is BEES not related to personal injury but may cause equipment damage 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 NOTE The term NOTE highlights operating pro cedures or practices that may improve equipment reliability and or personnel per A WARNING formance The winc
24. filter clean and replace One or both clutches dragging Check by placing handlever in BRAKE OFF Nor mally drum will rotate slowly in the LINE IN direction If the reverse clutch is dragging the drum will rotate in the LINE OUT direction If forward clutch is drag ging the drum will rotate positively in the LINE IN direction and it will take more than 100 Ibs of line pull to prevent drum rotation valve to not return to BRAKE ON cable minimum bend redii 5 00 or replace cable Allied COMPANY Operation Figure 10 Troubleshooting Analysis Chart continued PROBLEM POSSIBLE CAUSE CORRECTION Operation is rough Hydraulic oil is too cold Put the control lever in the BRAKE OFF position Run the engine at 1000 rpm to warm the oil before operating the winch Low oil level Add hydraulic oil to the correct level Low system pressure See item on troubleshooting low oil pressure directly below Wrong oil Drain oil and replace with correct grade Refer to Figure 5 Recommended Oil List Accumulator malfunction Check accumulator and recharge replace as neces sary Tractor engine idling too low or PTO Increase tractor engine speed stalled Hydraulic system suction leaks Check the following for air leaks Observe oil exiting lube valve while 1 Suction hose to pump connection tractor is operating Suction leaks will 2 Pump shaft seal cause oil to foam 3 Suction filter cover and gasket 4 Suction h
25. g Manual contains basic information neces sary for the operation and maintenance of a winch Op tional equipment is sometimes installed that can change the characteristics described in this manual Make sure the necessary instructions are available and understood before operating the winch Some of the components described in this Operating Manual will NOT be installed on your winch If you have questions about any item on your winch or described in this Operating Manual contact your local winch dealer or contact Allied Systems Company Allied Systems Company 21433 SW Oregon Street Sherwood OR 97140 USA Phone 503 625 2560 Fax 503 625 7269 E Mail marketing alliedsystems com Also visit our website www alliedsystems com where the most current copy of this manual is always available Allied Systems i NOTE For repairs and overhaul contact your Allied NOTE This publication may be translated to differ winch dealer If you maintain your own equipment a ent languages for sole purpose of easy reference service manual is available for your specific winch 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 Allied COMPANY Contents Contents Freud 25444444 i FREESPOOL Operation une cocainei aere 18 FREESPOOL Adjustimeni n si coace aan ea ata dia 18 Contents vade d ae
26. g accumulator valve 3 Leak in accumulator lines 4 Damaged or defective accumulators Refer to Low Oil Pressure troubleshooting item above Defective PTO shaft Inspect PTO shaft and coupling clutch shaft bevel ring gear and PTO shaft pinion gear for wear or dam age Inspect magnetic suction screen Forward or reverse oil Low oil pressure See Low Oil Pressure troubleshooting item clutch not engaging above Low forward or reverse clutch pres See troubleshooting for Low Forward or Reverse sure Clutch Pressure item above Inadequate piston travel Remove the access cover and place the winch in gear while visually checking the clutch for piston movement Worn friction discs and separator Replace the friction discs and separator plates if too plates thin scored or distorted e Allied COMPANY Operation Figure 10 Troubleshooting Analysis Chart PROBLEM POSSIBLE CAUSE CORRECTION Forward or reverse oil Broken or weak release springs Check springs and replace as necessary clutch not releasing Warped frictions or separators Replace as necessary Lube pressure high Test and re set cooling oil relief valve Forward clutch engaging Improper orientation of forward Remove and reinstall shaft with proper alignment or releasing slowly clutch and clutch shaft Allied COMPANY a Figure 11 Hydraulic System Pressure Tests continued on next page TEST TEST CHECK EQUIP CONTROL CORRECT
27. ged or abused Never overload wire rope tail chain or rigging Allied COMPANY 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 Safety Summary 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 11 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 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 Allied COMPANY Allied WINCH Align the tractor with the load to prevent side load ing the winch and to mainta
28. h shall not be used for hoisting Safety Regulations A WARNING Each country has its own safety legislation It is in the Use hearing protection when operating operator s own interest to be conversant with these regu winches lations and to comply with them in full This also applies to local bylaws and regulations in force on a particular worksite vi Allied COMPANY 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 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 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
29. he following procedures Make sure that the required maintenance has been done on the tractor and winch Use only a cable that is in good condition Make sure the cable and winch have enough capacity for the load Make sure the anchor for the cable has enough capacity for the load A failure of the tractor winch or cable while working on a steep slope can cause death or injury and loss of equipment Tractor is Down the Slope See Figure 19 Sometimes a tractor must work on a steep slope and can use a winch to give assistance when moving on the slope Fasten the winch cable to the drawbar of another tractor a structure or a tree that has enough strength to hold the tractor on the slope A Moving down the slope 1 Setthe throttle on the tractor for the required engine speed 2 Put the tractor in FORWARD At the same time move the winch control lever to a position between BRAKE ON and LINE OUT inching to control the speed of the tractor down the slope Figure 19 Working on a Steep Slope SS Allied COMPANY B Moving up the slope 1 Set the throttle on the tractor for the required engine speed Use the LINE IN control lever to tighten the winch cable When the winch cable is tight put the tractor transmission in the FIRST speed range and RE VERSE and engage the tracks or drive wheels At the same time move the control lever on the winch to LINE IN Use the steering on the tractor to keep the travel of the
30. he vehicle as it travels If the load is nearly the capacity of the line pull the operator must move the load close to the vehicle before beginning to travel Allied COMPANY NORMAL fo hy OPERATION Step 4 If the tractor or skidder must travel through an area with bad traction conditions the operator can move the control lever to the BRAKE OFF DETENT position This procedure will permit the vehicle to move through the bad traction area without pulling the load at the same time Operating Techniques o or EG OR FREESPOOL CONTROL Step 5 When the vehicle is on firm ground the Step 6 When the operator wants to disconnect operator can move the control lever to LINE IN to from the load the vehicle is stopped and the control pull the load toward the vehicle levers are moved to the BRAKE OFF DETENT or FREESPOOL positions to loosen the cable The cable is then disconnected from the load Allied COMPANY SS Allied WINCH How to Move a Disabled Vehicle A A tractor or skidder often travels in areas where traction conditions are bad A vehicle equipped with a winch can be used to remove itself from mud or other areas where it cannot move using only the drive wheels or tracks See Figure 17 Use the following procedure 1 40 Fasten the winch cable to a structure
31. in 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 donot 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 7 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 Allied COMPANY 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 pressurize
32. in the winch case takes hydraulic oil from the winch sump and sends it to the hydraulic control valve The hydraulic control valve controls the operation of the winch Removable covers on the winch case allow access for repairs and adjustments The design of the winch cases permits a variation in the arrangement of PTO assemblies to fit the different tractors and skidders that use these winches The PTO is connected to the pinion assembly in the winch When the pinion rotates a sour gear turns the hydraulic pump and the pinion turns the ring gear bevel gear The bevel gear is connected to an oil clutch for the LINE IN power forward operation and another oil clutch for the LINE OUT power reverse direction Allied COMPANY l Allied WINCH The power through the winch to the drum for the cable is controlled by a LINE IN and a LINE OUT clutch When the LINE IN clutch is applied the drum rotates to pull the cable into the winch When the LINE OUT clutch is ap plied the drum rotates to permit the cable to be pulled from the winch at the speed controlled by the engine rpm When the control lever is in the BRAKE ON position an oil brake is automatically applied by a spring to hold the drum in its position If the control lever is moved to apply one of the clutches the brake is released by the same oil pressure that applies the clutch In the event that hy draulic power is lost the brake remains applied and the winch will not turn
33. job During operation of the winch the operator must know or estimate the line pull and make sure that the line pull is within the capacity of the winch and the specifications of the wire rope installed on the drum A broken wire rope under high tension can return suddenly in the direction of the winch and cause injury and damage 9 Allied COMPANY The wire rope may disengage from the ferrule pocket if there is a load on the wire with fewer than 3 complete wraps on the drum This will cause a loss of load and possible injury When spooling cable from the drum it is very diffi cult for the operator to know when nearing the end of the cable It is recommended that the last 5 wraps of wire be painted a contrasting color to alert the operator that the end of the usable wire has been reached Wire Rope Diameter Capacity for 216 mm 8 5 in Drum Diameter 16 mm 5 8 in 124 m 407 ft 19 mm 3 4 in 87 m 287 ft 22 mm 7 8 in 63 m 206 ft Figure 4 Drum Line Capacities for W5B Winch General Oil Capacity amp Recommended Oil List The oil capacity for W5B winch is 15 gallons 56 8 liters control Use the following oils in the W5B winch The type of oil used in Allied winches affects the line Recommended Oils All Applications Applications such as equipment rescue logging cable plow and inching applications such as pipe setting yo yo line sagging etc Ambient Temperature Range Oil Temperature Range M
34. lls The operator must exercise care to not pull more than the tractor can handle stably especially on side slopes Line pulls through the arch also exert higher loads on the fasteners holding the winch to the tractor For this reason the wire rope diameter is limited Refer to tag manual or consult the factory Fairlead A fairlead consists of a set of top and bottom horizontal rollers and side rollers that the wire rope is passed be tween With this attachment if the direction of line pull is not in alignment with the drum then the wire rope is pulled across one of the fairlead rollers instead of across the frame thus protecting both the frame and the wire rope from excessive wear Stability of the tractor is affected somewhat by the fact that the fairlead rollers are more rearward than the drum thus putting slightly more moment on the tractor during side pulls The operator must take care to assure stability on slopes Allied COMPANY SS Allied WINCH Drawbar Do not use the drawbar as an anchor point for a multipoint over puller line from the winch Loads applied to the drawbar are transmitted to the bolts holding the winch to the tractor Standard integral drawbars are designed to handle pulls of 66 of winch rated capacity bolt on drawbars are 60 Optional heavy duty and extended drawbars are available which increase the capacity of the drawbar and or move the pin farther back so it is not under the winch drum
35. ng item or winch stalls during low above RPM shift Pressure modulator set too low Turn modulator screw IN for earlier brake release mini 7 alia Accumulator system malfunction Check for Correct leakdown time as described in Figure 11 Leaking accumulator valve Leak in accumulator lines Damaged or defective accumulators Damaged brake piston piston hous Check piston and piston housing cavity for damage ing or seal rings Replace if scored or broken Always replace both seals when brake is repaired Low clutch pressure or low oil pump Refer to Low Forward or Reverse Clutch Pressure volume troubleshooting item below Oil brake slipping or drum Worn brake plates Check the required pressure to release the brake backspin on fast shift Replace friction discs and separator plates if pres from neutral to forward sure is too low Broken belleville spring Allied COMPANY ES Allied WINCH Figure 10 Troubleshooting Analysis Chart continued PROBLEM POSSIBLE CAUSE CORRECTION Brake releases before Modulator valve in control valve not Check forward modulator valve forward clutch engage functioning ment Low brake release pressure same See Oil Brake Slipping troubleshooting item as the above above Brake releases before Modulator valve in control valve not Check reverse modulator valve Adjust or replace reverse clutch engage functioning as necessary en Allied COMPANY
36. ntrol lever The linkage and cable must be adjusted so that the FREESPOOL shifter mechanism will slide the drum pinion gear to both positions Both positions Maintenance have a detent Install the cover when the adjustments are complete Freespool Control Lever Power Control Lever Freespool Control Cable U Bolt Power Control Cable Lock Nut Figure 14 Control Cable Adjustments Allied COMPANY SS Allied WINCH B See Figure 15 Make sure the positions of the power control lever are the same as the position indicators on the decal Remove the access cover Item 1 on the housing to make adjustments Loosen the jam nut Item 8 that keeps the tall nut Item 3 from turning and remove the button head capscrew Item 9 Remove the cotter pin and link pin Item 5 from the clevis Item 2 Turn the tall nut and clevis to adjust the length of the control cable Item 5 Use the link pin and cotter pin to connect the clevis to the control handle again and check the operation When the adjustment is complete install the access cover Check that the positions of the FREESPOOL lever are the same as the position indicators on the decal Remove the access cover on the housing Loosen the nut that keeps the tall nut from turning and remove the button head capscrew Remove the cotter pin and link pin from the clevis Turn the tall nut and clevis to adjust the length of the control cable Use the link pin and cotter pin to connect the cl
37. or every 6 Change the hydraulic oil Drain oil from plug item 3 See Figure 5 Recommended Oil List months Clean the oil strainer Through fill plug item 5 add 17 gallons 62 liters Check the oil level at item 2 NOTE Clean the oil strainer screen and change the oil filter after the first 250 hours on new and rebuilt winches t Amount of oil may vary slightly with tractor Figure 13 Maintenance Schedule E Allied COMPANY Control Cable Adjustment There are three configurations of operator controls nor mally used on the W5B winch Adjustments of the three configurations are described in the following paragraphs Check the operation of the power control lever to make sure it moves smoothly and will return to the BRAKE ON position The power control lever will stay in BRAKE OFF when pushed into DETENT position Make sure the control lever does not hit the handlever housing at the end of its travel A See Figure 14 Make sure the positions of the power control lever Item 2 are the same as the position indica tors on the control housing Remove the two capscrews and raise the cover Loosen the U bolt Item 4 that holds the power control cable Item 5 in the housing to adjust the hand lever Check that the positions of the FREESPOOL lever Item 1 are the same as the position indicators on the con trol housing Loosen the U Bolt Item 4 that holds the freespool control cable Item 3 in the housing to adjust the co
38. ose for cracks or collapsed sections Handlever Control cables need ad Make sure the ends of the cables are fastened correctly Double check push pull cable housing to ensure it is securely anchored on both ends Be sure that control lever has full movement and is not hitting housing Allied COMPANY Figure 10 Troubleshooting Analysis Chart continued PROBLEM POSSIBLE CAUSE CORRECTION Low oil pressure Leaking pressure hoses and fit Check for leaks and replace components where tings necessary Be sure hoses are not rubbing on any gears or winch components Defective or improperly adjusted oil Clean relief valve if no pressure then adjust Check relief valve poppet may be stuck relief valve with pressure gauge Replace if defec open tive Clogged suction strainer pressure Check and clean or replace suction strainer pres filter sure filter Oil brake leaking internally indicated Repair as required by low brake pressure Defective hydraulic pump Check pump pressure output only after all other checks have been made Worn pump indicated by pressure variation with engine RPM If pump is at fault replace Valve spool is not moving far Check to verify the control valve spool travel enough 22 Allied COMPANY Operation Figure 10 Troubleshooting Analysis Chart continued PROBLEM POSSIBLE CAUSE CORRECTION Brake does not release Low oil pressure Refer to Low Oil Pressure troubleshooti
39. osition for the clutches Hydraulic pressure is applied to release the brake The winch will not rotate easily because of friction in the clutches brake and gear train Cable can not be pulled from the winch by hand The BRAKE OFF position is different from the FREESPOOL position where the drum is disengaged from the gear train The BRAKE OFF position is used when the operator has a load on the winch cable The operator can move the tractor forward without moving the load and still keep the cable tight A second control lever engages and disengages a slid ing sleeve to control the FREESPOOL operation The FREESPOOL control lever has two positions NORMAL OPERATION and FREESPOOL The FREESPOOL con trol lever disengages the gear train so the cable can be pulled from the winch by hand 15 Allied COMPANY O wo RONS FREESPOOL CONTROL Figure 8 W5B Towing Winch Operator Controls Allied COMPANY Operation GE BRAKE QV o ON ej Greg FREESPOOL me Power Control Lever Freespool Lever Allied WINCH Power Operation GEAR N NORMAL eg OPERATION FREESPOOL CONTROL 5 BRAKE ON position is a neutral position Neither clutch is applied The brake is fully applied o FREESPOOL CONTROL A N EED LINE IN position applies the LINE IN clutch and releases the
40. tow bar of another vehicle or a tree that has enough strength for the line pull The cable must be in a direction that is approximately parallel to the direction of travel of the vehicle Use the throttle to set the engine speed at a power level to operate both the winch and the tracks or drive wheels Operator experience is required because the winch can use most of the engine power in some vehicles Use the LINE IN control lever to tighten the winch cable When the winch cable is tight put the vehicle transmission in REVERSE and engage the tracks or drive wheels Use the power from the engine to the winch and tracks together to remove the vehicle from the bad area 4 Ifthe vehicle travels faster than the winch winds the cable disengage the transmission until the winch cable is tightened again NOTE If the tracks or drive wheels on the vehicle stop turning the torque converter in the transmis sion has stalled and the winch will stop also If this happens put the vehicle in neutral to operate the winch Figure 17 Moving a Disabled Vehicle Step A Allied COMPANY B Atractor or skidder equipped with a winch can be used to pull another vehicle from mud or other areas where it cannot move using only the drive wheels or tracks See Figure 18 Use the following procedure Use extra care if the traction conditions are bad or if the vehicles are on a slope Bad traction conditions can cause the disabled vehicle or th
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