2300190W - Allied Systems Company
Contents
1. 14 Continued on next page Allied COMPANY Allied GOU Cal Operational Differences Optional Equipment Integral Arch EEE O aia ai a i E 41 Fairlead EE 41 Klee EE 42 Optional Gear Ratios rrrrrnnnrornnrennnnennnnennenen 42 Allied COMPANY Safety Summary Safety Summary The following pages contain general safety warnings which supplement specific warnings and cautions appearing elsewhere in this manual All electrical and hydraulic equipment is dangerous You must thoroughly review and understand the Safety Summary before attempting to operate troubleshoot or service this winch The following symbols terms are used to emphasize safety The CAUTION symbol appears where a hazardous situation which if not avoided could result i inor to moderate injur The DANGER symbol indicates a Se Garer nr d hazardous situation which if not avoided will result in death or serious injury Carefully read the message that follows to prevent serious injury or death The WARNING symbol appears wherever incorrect operating procedures or practices could cause serious injury or death Carefully read the message that follows to prevent serious injury or death lt Allied COMPANY e Should the recommendations in this manual deviate from those in the user country the national regulations should be followed This signal word alerts to a situation that is not related to person2. Operating Manual P N 2300190W 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 09 24 2015 Winch Model W3C Serial Number Date Delivered Date Installed Special Equipment or Attachments Allied Allied pr A Product of Allied Systems Company Sherwood Oregon USA 09 24 2015 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 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 attempts 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 Operating Manual contains basic information nec
3. 15 Contents sunnere ende jii Troubleshooting Analysis Chart 16 Safety Summary rrrorrrorrrnnnrerrrrnnnrrnrnnnnnenrnnnnnnnn V Maintenance Maintenance Points eee eee eee ea 19 General Maintenance Schedule a nnnnannnnannnennnnennnnnnnnnnnne 20 PEO CIC lo EE ions ali arat 1 Control Cable Adjustment PFO r rrranrnnnnonnnennnnnnn 21 How the Winch Operates cccceeceseeeesseeeeeeeeeaeees 1 Control Cable Adjustment PFR arrnnnnnnnnnennnnennnre 22 NAME 2 Direction Lever Adjustments eee 25 Wire Rope Gelechon eee eee 3 Approved Oil List amp Capacity rrnrnnnnnnnnnnnnnnnnnnnnnnnn 4 Operating Techniques PFO W3C Winch Descrpton eee 5 Tractor or Skidder Operation cc cccceseeeeeeeeees 27 Optional Eoupment eee eee eee eee 6 Serial Number CodeS eee 7 Operating Techniques PFR Tractor amp Skidder Identification Codes 8 Tractor or Skidder Operation cc ccccessseeeeeeees 31 Operation How To Move A DisabledVebhuce 35 Operating Procedures ccccssseeeeceeeeeeeeeeeeeeeens 11 Power Operation Power Forward Only PFO 11 Working on Steep Slope PFR Only Power Forward Reverse Operation Optional 12 Tractor Is Down The SlOp ccseeeeeeeeeees 37 FREESPOOL Operation ceeace cate sta 13 Other Equipment Is Down The Slope 38 FREESPOOL Drag Adjust cc nenea 13 Mechanical FREESPOOL Lock
4. has been done on the tractor and winch the direction lever to LINE OUT and the power lever Use only a wire rope that is in good to POWER IN OUT to control the speed of the tractor condition Make sure the wire rope and down the slope winch have enough capacity for the load Make sure the anchor for the wire rope has enough capacity for the load A failure of the tractor winch or wire rope 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 wire rope to the drawbar of another tractor a structure or a tree that has enough strength to hold the tractor on the slope Figure 19 Working on a Steep Slope Allied COMPANY a Allied GOU Cal B 1 38 Moving up the slope Set the throttle on the tractor for the required engine speed Put the direction lever in LINE IN and the power lever to POWER IN OUT to tighten the winch wire rope When the winch wire rope is tight put the tractor transmission in the FIRST speed range and REVERSE and engage the tracks or drive wheels At the same time put the direction lever in LINE IN and the power lever in POWER IN OUT Use the steering on the tractor to keep the travel of the tractor in line with the winch wire rope Fully engage LINE IN as necessary Do not permit the winch w
5. or perform maintenance on a machine that is in motion Allied COMPANY 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 Ifthe wire rope and ferrule must be removed from the drum make sure the end of the wire rope and ferrule are controlled when the ferrule is released The end of the wire rope can suddenly move from the drum like a compressed spring when the ferrule is released and cause an injury Stay in the operator s seat when operating the winch Do not stand on the vehicle when operating the winch Avoid winch operation near people or other machines Vil Allied GOU Cal 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 n
6. 227 ft 69 m 160 ft 49 m 3 4 in 19 mm NOTE Loosely or unevenly spooled line will reduce capacities Figure 2 Wire Rope Size and Capacities Allied COMPANY i Allied Oil ei Approved Oil List amp Capacity The type of oil used affects the line control Use the following oils in the W3C winch for improved performance Oil Company Oil Brand Amoco Oil Company Amoco 1000 Fluid Exxon Company Hydraul 560 John Deere Hy Gard Transmission amp Hydraulic Oil Sun Oil Company Sunfleet TH Universal Tractor Fluid Figure 3 Approved Oil List NOTE For operation in temperatures below 23 C 10 F use John Deere J20D Low Viscosity Hygard or equivalent The oil capacity for the W3C is 5 5 gallons 20 8 liters i Allied COMPANY General W3C Winch Description Frame Cover Front Cover LH Cover Brake Cover RH Knob FREESPOOL Drag Adjust Drum Oil Filler Breather Oil Strainer Cover 10 Oil Drain Plug 11 0il Level Check Plug 12 Control Lever P 2 3 4 5 6 TA 8 9 Figure 4 W3C Towing Winch Allied COMPANY Allied GOU Cal Optional Equipment e drawbar e power forward reverse PFR The W3C winch may be equipped with the following e mechanical FREESPOOL lock options extended heavy duty drawbar e fairlead assembly NOTE Not all optional equipment listed is available e alternate gear ratio for each model of tractor e integral arch Integral Ar
7. 850G H 2 AG GOE OOJO GOE FD amp FL5 b 450G 650G TD7E G D31 D37 F66 FD amp FL7 TC 450G TD8E G D39 21 21A F67C P H 650G DD e TD100E G KomSat I II H66 H67 NOG 125E G Muller TS22 TD7 8 9H D32 D38 650 850G H J170 TD7 8 9 10M D39 d TD9XP D3 4 5B amp C D85B D95B 650 750 850K 750 850L DC75 85 95 DOO D85B D95B 650 750 850K 750 850L DC75 85 95 OO i Allied COMPANY General D3 4 5C DC70 DC80 Hystat HO D4H PS Series I amp Il Series III XL LGP Tractor Make Model and SS Tractor Serial Number Where Applicable C A C H R V W O D Fiat Hitachi Caterpillar John Deere Dresser Case Ranger Daewoo E New Holand Dressta a For 11 tooth tractor spline b For 13 tooth tractor spline c The following tractor code pairs should be serviced identically C14 C11 C15 C34 and H14 H13 d All tractor codes included in this block are H13 e Gear ratio for 450G 650G DD is 6 only L Low PTO Input H High PTO Input Wide amp narrow mounting patterns are shown Figure 6 Tractor Identification Codes and Available Gear Ratios Allied COMPANY S GOU Cal Intentionally Blank W Allied COMPANY Operation Operation Operating Procedures A single control lever is used for PFO winch control see Figure 7 A second control lever may be used for PFR operation see Figure 8 The control levers are used to select one of the following operation
8. PIN amp COTTER CLEVIS STAR WASHER o o CITI De 1 4 NUT CABLE ADAPTER 1 4 CAPSCREW TORQUE 6 FT LBS 8 N m Figure 16 PFR Control Lever Disassembly and Adjustments Allied COMPANY Direction Lever Adjustments The direction control lever should stay in either the IN or OUT position If the direction lever doesn t travel equal distances into IN and OUT see Figure 15 its control cable must be adjusted 1 2 Remove the control lever assembly from the tractor Remove the aluminum bottom cover from the control lever housing by removing the two Phillips head screws see Figure 16 Remove the cotter and the clevis pin to free the clevis from the control lever Loosen the rear jam nut and adjust the nut inside the clevis by turning the clevis Adjusting the nut farther onto the cable will move the lever away from the operator Check adjustment by replacing the clevis pin and operating the lever Tighten the jam nut by holding the clevis Add grease to the clevis pin hole in the control lever base and install the clevis pin and cotter Test the lever operation before attaching the aluminum housing cover 10 11 Maintenance If the cable cannot be adjusted far enough the cable must be adjusted at the winch end Always adjust the cable at the control lever
9. parts manual 2300191W Maintain a minimum of three 3 complete wraps of wire rope on the drum for normal operation It may help to paint the last five wraps of wire rope a contrasting color to serve as a visual indicator Do not handle wire rope with bare hands Wear leather gloves at all times Align the tractor with the load to prevent side loading the winch and to maintain even spooling of the wire rope Allied COMPANY Allied GOU Cal 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 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 This winch is not rated for any application involved in the lifting or moving of personnel Use only the lubricants listed in the Recommended Oil List See Page 4 Do not weld on any part of the winch Contact Allied Systems if weld repairs are needed The hydraulic system must be kept clean and free of contamination at all times Be aware of the hazards of pressurized hydrauli
10. Detent gears damaged Replace gears Figure 11 Troubleshooting Analysis Chart 2 Allied COMPANY i GOU Cal Intentionally Blank ja Allied COMPANY Maintenance Maintenance The Maintenance Schedule is a program that includes maintenance time for the winch See Figure 12 for the periodic inspection and lubrication Use the operating maintenance points on the winch time on the hour meter of the tractor to determine the 1 Plug to Check Oil Level 2 Fill Plug and Breather 3 Plug to Drain Oil 4 Cover for Strainer Figure 12 W3C Winch Maintenance Points Allied COMPANY P INTERVAL PROCEDURE OR QUANTITY SPECIFICATION 50 hours or weekly Check oil level at plug item 1 Add oil as See Figure 3 Approved Oil List necessary through fill plug item 2 Do not operate tractor when checking the oil level Clean the breather item 6 Remove debris around breather Clean the breather with solvent if necessary Lubricate the rollers on the integral arch Use multi purpose grease with 2 4 or the fairlead assembly if the winch is molybdenum disulfide equipped with either of these options 500 hours or every 3 Clean the oil strainer Use liquid gasket See parts manual for oil strainer part months between the cover and strainer housing number item 4 Check the winch control lever linkage Check that the lever mounting bracket adjsutment and linkage are fastened correctly Tighten the bolts as necessary 1000 hours
11. INE IN to control the raising of the equipment down the slope Keep the equipment being raised in alignment with the winch and tractor Do not permit the winch wire rope to loosen and pass under the drive wheels or tracks of the tractor 39 GOU Cal 40 Intentionally Blank Allied COMPANY 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 vertical 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 of the line of action of the wire is higher than normal the tipping moment applied to the tractor is increased and the tractor will tip backwards at significantly lower line pulls 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 Fairlead A fairlead consists of a set of top and bottom horizontal rollers and side rollers that the wire rope passes between With this attachment if the direction of line pull is not wit
12. M LINE PULL BARE DRUM MAXIMUM WIRE ROPE DIAMETER LIMITED BY WIRE BREAKING STRENGTH MAY BE LOWER DUE TO AVAILABLE POWER FROM WINCH CARRIER CONTINUOUS LINE PULLS SHOULD BE LESS THAN WINCH CARRIER GVW 2315005 REV B C O MADE IN USA Figure 1 Nameplate Allied COMPANY Wire Rope Selection Each winch model can have a variety of wire rope sizes installed by the user The maximum wire rope size is shown on the nameplate See Figure 2 for approved wire rope sizes and drum capacities When a larger diameter wire rope is used the length of wire rope installed on the drum will be shorter In some situations 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 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 General For maximum wire rope strength there should be at least three wraps of wire rope on the drum Painting the last ten feet red will alert the operator that the wire rope is coming to the end of its length Wire Rope Diameter Drum Capacity 1 2 in 13 mm 234 ft 72 m 5 8 in 16 mm
13. 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 A V INCH 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
14. ake is also released FREESPOOL operation allows the wire rope to be pulled from the winch drum by hand FREESPOOL Drag Adjustment The FREESPOOL drag adjustment knob determines the resistance to rotation of the drum when in FREESPOOL The resistance to rotation is correct when the drum can be rotated by hand but the drum will not rotate more than one half revolution freely A knob on the right side of the frame see Figure 2 can be used to adjust the FREESPOOL drag Turn the knob clockwise to increase the drag or turn it counterclockwise to decrease the drag See Figure 9 Allied COMPANY fe GOU Cal Figure 9 FREESPOOL Drag Adjust Mechanical FREESPOOL Lock Some W3C winches are equipped with an optional manually operated mechanical FREESPOOL lock See Figure 10 FREESPOOL is hydraulically activated If the tractor engine is shut off while the winch is in FREESPOOL the hydraulic pressure will gradually leak off until the gears engage and returns the lever to BRAKE ON The optional FREESPOOL lock is a mechanical stop that prevents the gears from engaging This will keep the winch in FREESPOOL indefinitely even if the tractor engine is off The optional FREESPOOL lock is controlled from the operator s seat using a push pull cable Pulling up on the tee handle after the winch control lever has been shifted into FREESPOOL will mechanically lock the winch in FREESPOOL The engine may be shut off and the winch will stay i
15. al injury but may cause equipment damage NOTE The term NOTE highlights operating procedures or practices that may improve equipment reliability and or personnel performance Safety Regulations Each country has its own safety legislation It is in the operator s own interest to be conversant with these regulations and to comply with them in full This also applies to local bylaws and regulations in force on a particular worksite vi Allied COMPANY NOTE All possible safety hazards cannot be foreseen so as to be included in this manual Therefore you must always be alert to potential hazards that could endanger personnel and or damage the equipment The winch shall not be used for hoisting Use hearing protection when operating winches Operation Inspection and Maintenance Warnings Obey the following cautions and warnings before using your winch to avoid equipment damage personal injury or death Do not operate the winch unless 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 inspection 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
16. c system that controls the winch is inside the winch case When the PTO is operating a hydraulic pump 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 The PTO is connected to the winch s input shaft The input shaft turns the housing of the clutch When the clutch is applied power is transmitted by the gears to the drum As the drum rotates wire rope is pulled into the winch The W3C winch has the following operations e LINE IN For PFR Line in Line out e BRAKE ON e FREESPOOL e BRAKE OFF Allied COMPANY The winch has a gear assembly inside the drum The inner gear can slide on splines and is engaged with the outer gear by a spring When the control lever is in the FREESPOOL position the inner gear is disengaged from the outer gear by a hydraulically actuated piston Only the drum rotates when the gear assembly is disengaged The W3C winch has a maximum line pull of 41 200 Ibs rated at 30 000 Ibs Nameplate Each winch is shipped from the factory with a nameplate as shown in Figure 1 The rated capacity for the winch as it is equipped is shown on the nameplate Each winch must be operated within its rated capacity If the nameplate is missing or the wire rope does not match the information on the nameplate do not operate the winch until its capacity is known MODEL SERIAL NO MAXIMU
17. ch Fairlead Assembly Drawbar Figure 5 W3C Towing Winch Optional Equipment Allied COMPANY General Serial Number Codes The nameplate with the serial number code is found on A serial number indicates the following information the left front corner of the winch case A W3c P 1 A 1556 R11 Made By Lo Vehicle Code A Allied Systems Company See Figure 1 Winch Model Sequence Number W3C Standard K3C Special Applications Drive Type P Power Controlled Power Forward Only Power Forward Reverse Power Forward Only PFO Power Forward Reverse PFR Internal Options PFO with Freespool A PFR with Freespool B with Freespool Lock K with Freespool Lock L e SS Gear Ratio Code 1 30 0 1 Crawler Non Current 2 40 0 1 Crawler Non Current Notes 1 In Addition to the serial number plate 3 15 0 1 Skidder Non Current the serial number is stamped on the top right hand 4 21 0 1 Skidder side of the frame 5 39 0 1 Crawler 6 61 0 1 Crawler 2 Circled letter in Chart A indicates high PTO H or low PTO L See the following pages 3 Circled number in Chart A indicates available gear ratios Allied COMPANY Tractor Make Model and Starting Tractor Serial Number Where Applicable C E F H R V W Fiat Hitachi Caterpillar John Deere KMC Dresser Ranger Daewoo New Holand Dressta FD amp FL5 D3 D3B C 450 550G H F65C G DD80 80L FD amp FL7 a D4B C D5C
18. cs Wear personal protective equipment such as gloves and safety glasses whenever servicing or checking a hydraulic system Assume that all hydraulic hoses and components are pressurized Relieve all hydraulic pressure before disconnecting any hydraulic line Never try to stop or check for a hydraulic leak with any part of your body use a piece of cardboard to check for hydraulic leaks Small hydraulic hose leaks are extremely dangerous and can inject hydraulic oil under the skin even through gloves Infection and gangrene are possible when hydraulic oil penetrates the skin See a doctor immediately to prevent loss of limb or death Allied COMPANY Notes Safety Summary XI GOU Cal Notes xii Allied COMPANY General General Introduction This Operating Manual contains basic information necessary for the operation and maintenance of the W3C winch How the Winch Operates A winch is normally installed on a skidder or tractor to e increase the pulling power of the skidder or tractor e reach into an area where a skidder or tractor cannot go e make lift functions available when special attachments are installed The winch has a hydraulic clutch that is similar to a hydraulic powershift transmission Each tractor and skidder has a power take off PTO that is used to connect the power from the engine to the winch The SCH Self Contained Hydraulics indicates that the entire hydrauli
19. e Power Forward CONTROL Reverse option Two different levers are provided for FREESPOOL winches equipped with PFR the direction lever and the ee F power lever see Figure 8 BRAKE ON POWER DIRECTION LEVER LEVER DIRECTION LINE IN GE D READ OPERATING INSTRUCTIONS Figure 7 W3C Operator Controls PFO Figure 8 W3C Operator Controls PFR i Allied COMPANY The direction lever determines the direction of the winch drum rotation By moving the lever to the IN or OUT position a sliding gearset on the clutch shaft engages either the LINE IN gears or the LINE OUT gears This will give you either forward or reverse NOTE Never leave the direction lever in the centered position The lever should ALWAYS be as far into either the IN or OUT positions as possible When the direction lever is pushed into the IN position the LINE IN gears are engaged To start reeling wire rope in pull the power lever into the POWER IN OUT position When the direction lever is pushed into the OUT position the LINE OUT gears are engaged To start paying wire rope out pull the power lever into the POWER IN OUT position Operation FREESPOOL Operation Moving the lever into FREESPOOL while there is a load on the wire rope will cause sudden uncontrolled loss of load which can result in injury and damage When the control lever is moved into the FREESPOOL position the winch drum is disengaged from the gear train The br
20. e is routed smoothly and is not twisted To do this loosen the capscrews holding the cable to the control lever Allow the cable to rotate if it is under any strain If the cable rotates remove the cover and return to step 4 above Allied COMPANY 8 10 11 If the cable needs adjustment at the winch loosen the cover capscrews at the control lever and loosen the jam nut on the power control cable at the winch To adjust the cable rotate the metal cable jacket screwing the cable into or out of the winch Screwing the cable jacket into the winch will move the control lever towards the operator Apply grease to the clevis pin and reassemble the clevis pin and cotter Test the control lever operation before attaching the aluminum housing cover Be sure to rotate the cable inside the housing to remove any twisting caused by step 9 Tighten the cable jam nut at the winch and the cover capscrews at the control lever BRAKE ON SLOT SN Maintenance m POWER LEVER DIRECTION LEVER REVERSE POSITION MUSTBE I EQUAL DISTANCES FORWARD POSITION Figure 15 Proper Control Lever Alignment Allied COMPANY 23 ROUTE TO RIGHT LEVER JAM NUT FOR DIRECTION CONTROL CABLE 24 ROUTE TO LEFT LEVER JAM NUT FOR POWER CONTROL CABLE 1 4 NUT
21. e through the bad traction area without pulling the load at the same time ION R DIRECT LEVE AN READ OPERATING INSTRUCTIONS Step 5 When the vehicle is on firm ground the operator can move the direction lever to LINE IN and the power lever to POWER IN OUT to pull the load toward the vehicle Operating Techniques PFR POWER LEVER SPOO BRAKE OFF BRAKE O POWER IN OUT 2302316 ANY READ OPERATING INSTRUCTIONS DIRECTION LEVER Step 6 When the operator wants to disconnect from the load the vehicle is stopped and the power lever is moved to the FREESPOOL position to loosen the wire rope The wire rope is then disconnected from the load Allied COMPANY SS GOU Cal 34 Intentionally Blank Allied COMPANY 1 How to Move a disabled Vehicle How to Move a Disabled Vehicle A Atractor 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 Fasten the winch wire rope to a structure tow bar of another vehicle or a tree that has enough strength for the line pull The wire rope 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 ope
22. erator moves the control lever to the BRAKE the control lever to the FREESPOOL position so that ON position the wire rope can be pulled from the winch drum Allied COMPANY ei 28 ez BRAKE OFF Ne BRAKE ON 4 lt a Step 3 The operator can move the control lever to the LINE IN position If the load is less than approximately 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 the 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 WINCH CONTROL BRAKE OFF Ve Ee BRAKE ON 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 position This procedure will permit the vehicle to move through the bad traction area without pulling the load at the same time WINCH CONTROL nh FREESPOOL Ee u BRAKE OFF Ne BRAKE ON S LINE IN O Se da egy READ OPER Operating Techniques PFO FREESPOOL ef qa BRAKE OFF Ve BRAKE ON a LINE IN g ES ES Step 5 When the vehicle is on firm ground the Step 6 When the operator wants to disconnect from operator can move the control lever to LINE IN to the load the vehicle is stopped and the control lever pull the load toward the vehicle is moved to the FREESPOOL posi
23. ess cover Figure 14 Control Cable Adjustments Allied COMPANY al Allied Oil ei Control Cable Adjustment PFR Improper adjustment of the PFR control levers will cause damage to the winch Lever adjustment maintenance is necessary Power Lever Adjustment The power lever should align with the BRAKE ON slot when the winch is in BRAKE ON see Figure 15 If the power lever doesn t align with the slot its control cable must be adjusted 1 2 22 Remove the control lever assembly from the tractor Remove the aluminum bottom cover from the control lever housing by removing the two Phillips head screws see Figure 16 Remove the cotter and clevis pins to free the clevis from the control lever Loosen the rear jam nut and adjust the nut inside the clevis by turning the clevis Adjusting the nut farther onto the cable will move the lever away from the operator Check adjustment by replacing the clevis pin and operating the lever Adjust the cable until the lever aligns with the BRAKE ON slot Tighten the rear jam nut by holding the clevis Add grease to the clevis pin hole in the control lever base and install the clevis pin and cotter Test the lever operation before attaching the aluminum housing cover If the cable cannot be adjusted far enough the cable must be adjusted at the winch end Always adjust the cable at the control lever first Before adjusting the cable at the winch end ensure the cabl
24. essary for the operation and maintenance of a winch Optional 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 and copies of Parts Manual and Service Manual are always available Allied COMPANY Allied Oil ei NOTE For repairs and overhaul contact your Allied NOTE This publication may be translated to different winch dealer If you maintain your own equipment a languages for sole purpose of easy reference in service manual is available for your specific winch 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 Allied COMPANY Contents Contents Foreword eegene i Checks Before Operation ccccsscccseeeeeeeeeseees 15 Checks During Operation
25. first Before adjusting the cable at the winch end ensure the cable is routed smoothly and is not twisted To do this loosen the cover capscrews holding the cable to the control lever Allow the cable to rotate if it is under any strain If the cable rotates remove the cover and return to step 4 above If the cable needs adjustment at the winch loosen the cover capscrews at the control lever and loosen the jam nut on the power control cable at the winch To adjust the cable rotate the metal cable jacket screwing the cable into or out of the winch Screwing the cable jacket into the winch will move the control lever towards the operator Apply grease to the clevis pin and reassemble the clevis pin and cotter Test the control lever operation before attaching the aluminum housing cover Be sure to rotate the cable inside the housing to remove any twisting caused by step 9 Tighten the cable jam nut at the winch and the cover capscrews at the control lever Allied COMPANY GE GOU Cal 26 Intentionally Blank Allied COMPANY Operating Techniques PFO Operating Techniques PFO Tractor or Skidder Operation Gr Note Solid arrows indicate Gr FREESPOOL Ko da the positions of the control FREESPOOL lever BRAKE ON BRAKE ON 4 Sa LINE IN g e Step 1 The tractor or skidder is moved to an area Step 2 A load logs is connected to the wire rope where a load will be connected The operator moves The op
26. g 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 the vehicle An operator must be on the disabled vehicle to operate the steering and brakes as it is towed 1 Fasten the winch wire rope to the tow bar of the other vehicle The wire rope must be in a direction that is approximately 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 2 Putthe control lever in the LINE IN position to tighten the winch wire rope When the winch wire rope 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 wire rope tight so that the wire rope does not pass under the drive wheels or tracks of the vehicle being towed Figure 18 Moving a Disabled Vehicle Step B Pe Allied COMPANY Working on a Steep Slope PFR Only Working on a Steep Slope PFR Only 1 Setthe throttle on the tractor for the required engine The winch and the tractor must be in good speed condition for the following procedures Make sure that the required maintenance 2 Putthe tractor in FORWARD At the same time move
27. hin the small window of the fairlead 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 sul Allied GOU Cal 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 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 ge Allied COMPANY Operational Differences Optional Equipment Notes Allied COMPANY SS GOU Cal 44 Notes Allied COMPANY l NO MATTER HOW
28. ire rope to loosen and pass under the drive wheels or tracks of the tractor 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 equipment working on the steep slope A 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 Working on a Steep Slope PFR Only A Lowering the equipment on the slope 1 Set the throttle on the tractor for the required engine speed Keep the winch wire rope tightened between the tractor and the equipment being lowered down the slope Put the direction lever in the LINE OUT position and the power lever in the POWER IN OUT position to control the lowering of the equipment down the slope 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 operation so that the load is carefully controlled Keep the winch wire rope tightened between the tractor and the equipment being lowered down the slope Use L
29. n FREESPOOL lf FREESPOOL lock is on the control lever will not have any effect on the drum rotation MP Figure 10 FREESPOOL Lock De Allied COMPANY Checks Before Operation Check that the wire rope and hook are not worn or damaged Check that the periodic inspection and maintenance have been done at the recommended operating hours See the Maintenance Schedule for the W3C winch on page 20 Allied COMPANY Operation Checks During Operation The following Troubleshooting Chart can be used by the operator to identify a problem with the winch operation A trained service person is needed for additional troubleshooting and repair that requires disassembly of parts of the winch PROBLEM POSSIBLE CAUSE CORRECTION Operation is rough Hydraulic oil is too cold Put the control lever in the BRAKE OFF po or not regular sition Run the engine at 1000 rom to warm the oil to 80 F before operating the winch Low oil level Add hydraulic oil to the correct level Low oil pressure See the Service Manual for additional troubleshooting Wrong oil Drain oil and replace with correct grade Refer to the approved oil list Control cables need adjustment Check for correct adjustment Make sure the ends of the cables are fastened correctly Verify the handle is not contacting housing Hydraulic oil be Winch is operated in the BRAKE OFF position Use the BRAKE OFF position less When comes too hot for long periods
30. or every 6 Change the hydraulic oil Drain oil from plug See Figure 3 Approved Oil List months item 3 Clean the strainer Add 5 5 gallons 20 8 liters through fill plug item 2 Check the oil level at oil level check plug item 1 NOTE Clean the oil strainer screen after the first 50 hours on new and rebuilt winches Amount of oil may vary slightly with tractor Figure 13 Maintenance Schedule Allied COMPANY Control Cable Adjustment PFO Check the operation of the control lever to make sure it moves smoothly and will return to BRAKE ON position The control lever will stay in BRAKE OFF or FREESPOOL position as they are both detent positions Make sure the control lever does not hit the housing at the end of its travel Check that the positions of the control lever align with the position indicators on the control lever decal 1 Access Cover 2 Clevis 3 Tall Nut 4 Cotter Pin and Link Pin 5 Control Cable 6 Control Lever 7 Screw 8 Jam Nut 9 Screw Maintenance Remove the access cover on the housing to make adjustments Loosen the jam nut that keeps the adjustment nut and clevis from turning Remove the cotter pin and link pin from the clevis Turn the adjustment nut and clevis to adjust the length of the control cable 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 tighten the jam nut and install the acc
31. ot 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 Gei Always inspect wire rope tail chain and other rigging components for wear damage broken strands or abuse before use Never use wire rope tail chain or other rigging that is worn out damaged or abused Never overload wire rope tail chain or rigging Allied COMPANY Wire rope and tail chain will fail if worn out overloaded misused damaged improperly maintained or abused Wire rope or tail chain failure may cause serious injury or death Do not terminate wire rope to tail chain by the use of a knot Do not handle wire rope if the hook end is not free A load could break away suddenly tensioning the wire rope resulting in serious injury or death Stay clear of wire rope entry areas fairlead or arch rollers winch drum etc Safety Summary Make sure ground personnel are in plain view of the operator and at a distance of at least 17 times the working length of the wire rope Make sure that any hand signals used by ground personnel are clearly defined and understood by everyone involved Do not attempt to jerk or shock a load free Doing so can cause loads in excess of the rated capacity of the wire rope winch or mounting hardware Replace any parts only with genuine Allied Winch parts Refer to
32. rate 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 Put the control lever in the LINE IN position to tighten the winch wire rope When the winch wire rope 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 wire rope disengage the transmission until the winch wire rope is tightened again NOTE If the tracks or drive wheels on the vehicle stop turning the torque converter in the transmission 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 can cause the disabled vehicle or the tractor to slide slope can require additional distance to stop the vehicles Make sure the wire rope and tow chain have the capacity to do the job If the disabled vehicle does not have a tow pin or other equipment for towin
33. s e LINE IN For PFR LINE IN LINE OUT e BRAKE ON e FREESPOOL e BRAKE OFF Note 1 When the winch is in LINE IN operation the control lever is spring returned to BRAKE ON position 2 All other functions are Detented positions and the control lever must be returned to BRAKE ON position manually Power Operation Power Forward Only PFO Refer to Figure 7 BRAKE ON position is a neutral position The clutch is released and the brake is spring applied The winch drum will not turn LINE IN position applies the LINE IN clutch and releases the brake The winch will wind the wire rope at a speed controlled by the engine or torque converter RPM BRAKE OFF occurs when the operator moves the control lever towards the BRAKE OFF position The clutch is released and oil pressure releases the brake This position will permit the wire rope to unwind from the winch against the friction of the clutches brake and gear train as the tractor moves away from the load The BRAKE OFF position is used when the operator has a load on the winch wire rope and wants to move the tractor forward without moving the load while still Keeping the wire rope tight Wire rope cannot 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 Allied COMPANY D E 1 GOU Cal Power Forward Reverse Operation Optional Some W3C winches are equipped with th
34. the BRAKE OFF position is used the hydraulic oil flows continuously through the relief valve See the Service Manual for ad ditional troubleshooting Low oil level Add oil Clogged suction strainer Check and clean or replace the suction strainer Defective or improperly adjusted oil relief valve See the Service Manual for additional vr Figure 11 Troubleshooting Analysis Chart 1 la Allied COMPANY Operation PROBLEM POSSIBLE CAUSE CORRECTION Brake begins to Brake is worn or needs replacement See the Service Manual for additional release before the information clutch is applied Winch brake does See the Service Manual for additional not apply or release Control valve or control cable needs adjust information correctly Low oil Low oil pressure ss Clutch does not ap Accumulator not charged Check accumulator ply correctly at low PTO rom PTO speed stalled 0 rpm Increase tractor rom Worn or leaking pump Check pump and replace if necessary FREESPOOL does See the Service Manual for additional not operate correctly troubleshooting checks and adjustments Winch stalls tractor Not Not enough engine torque 0 Not enough engine torque 0 torque engine during winch l shift when tractor Low accumulator pressure See the Service Manual for additional RPM is low troubleshooting checks and adjustments Winch will not stay Handlever not adjusted Adjust levers in LINE IN or LINE OUT PFR only
35. tion to loosen the wire rope The wire rope is then disconnected from the load Allied COMPANY GE GOU Cal 30 Intentionally Blank Allied COMPANY Operating Techniques PFR Operating Techniques PFR Tractor or Skidder Operation Note Solid arrows indicate the positions of the control Step 1 The tractor or skidder is moved to an area Step 2 A load logs is connected to the wire rope where a load will be connected The operator moves The operator moves the power lever to the BRAKE the power lever into the FREESPOOL position so the ON position wire rope can be pulled from the winch drum Allied COMPANY al 32 SINN READ OPERATING INSTRUCTIONS Step 3 The operator moves the direction lever to the LINE IN position and the power lever to the POWER IN OUT position If the load is less than 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 the 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 DIRECTION LEVER 2302316A READ OPERATING FPN INSTRUCTIONS Step 4 Ifthe tractor or skidder must travel through an area with bad traction conditions the operator can move the power lever to the BRAKE OFF position This procedure will permit the vehicle to mov
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