Allied Systems AW3CP1A1556R11, Operating Manual

Page 1: ...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 2300190W 09 24 2015 ...

Page 2: ...09 24 2015 Printed in USA A Product of Allied Systems Company Sherwood Oregon USA Winch Model W3C Date Delivered Serial Number Date Installed Special Equipment or Attachments ...

Page 3: ...oyer 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 necessary 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 ...

Page 4: ...able for your specific winch NOTE This publication may be translated to different languages for sole purpose of easy reference in non English speaking locations Should there be differences in interpretations to the text please refer to the English language edition published by Allied Systems Company as the controlling document ...

Page 5: ...EESPOOL Operation 13 FREESPOOL Drag Adjust 13 Mechanical FREESPOOL Lock 14 Checks Before Operation 15 Checks During Operation 15 Troubleshooting Analysis Chart 16 Maintenance Maintenance Points 19 Maintenance Schedule 20 Control Cable Adjustment PFO 21 Control Cable Adjustment PFR 22 Direction Lever Adjustments 25 Operating Techniques PFO Tractor or Skidder Operation 27 Operating Techniques PFR Tr...

Page 6: ...iv Operational Differences Optional Equipment Integral Arch 41 Fairlead 41 Drawbar 42 Optional Gear Ratios 42 ...

Page 7: ...ze safety precautions and notices in this manual DANGER The DANGER symbol indicates a 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 WARNING The WARNING symbol appears wherever incorrect operating procedures or practices could cause serious injury or death Carefully read the message that fol...

Page 8: ... with these regulations and to comply with them in full This also applies to local bylaws and regulations in force on a particular worksite Should the recommendations in this manual deviate from those in the user country the national regulations should be followed NOTE All possible safety hazards cannot be foreseen so as to be included in this manual Therefore you must always be alert to potential...

Page 9: ...n operating the winch Avoid winch operation near people or other machines 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 operato...

Page 10: ...ers on the vehicle or load Do not use the winch as an anchor for a double or two part line Do not pull the hook through the throat or over the drum which will cause damage When the winch is not in use make sure the control lever is in BRAKE ON position and the winch brake is applied Do not use winch as a hoist Tractor and skidder mounted winches are designed for towing Always inspect wire rope tai...

Page 11: ...orking length of the wire rope Make sure that any hand signals used by ground personnel are clearly defined and understood by everyone involved Do not attempt to jerk or shock a load free Doing so can cause loads in excess of the rated capacity of the wire rope winch or mounting hardware Replace any parts only with genuine Allied Winch parts Refer to parts manual 2300191W Maintain a minimum of thr...

Page 12: ...icants 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 hydraulics Wear personal protective equipment such as gloves and safety glasses whenever servicing or checking a hydraulic system Assumethatal...

Page 13: ...xi Safety Summary Notes ...

Page 14: ...xii Notes ...

Page 15: ...at is used to connect the power from the engine to the winch The SCH Self Contained Hydraulics indicates that the entire hydraulic 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 ...

Page 16: ...y the drum rotates when the gear assembly is disengaged The W3C winch has a maximum line pull of 41 200 lbs rated at 30 000 lbs 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 ...

Page 17: ...RNING 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 For maximum wire rope strength there should be at least three wraps ...

Page 18: ...oved Oil List NOTE For operation in temperatures below 23 C 10 F use John Deere J20D LowViscosity Hygard or equivalent Oil Company Oil Brand Amoco Oil Company Amoco 1000 Fluid Exxon Company Hydraul 560 John Deere Hy Gard Transmission Hydraulic Oil Sun Oil Company Sunfleet TH Universal Tractor Fluid The oil capacity for the W3C is 5 5 gallons 20 8 liters ...

Page 19: ...h 1 Frame 2 Cover Front 3 Cover LH 4 Cover Brake 5 Cover RH 6 Knob FREESPOOL Drag Adjust 7 Drum 8 Oil Filler Breather 9 Oil Strainer Cover 10 Oil Drain Plug 11 Oil Level Check Plug 12 Control Lever General W3C Winch Description ...

Page 20: ...C winch may be equipped with the following options fairlead assembly alternate gear ratio integral arch drawbar power forward reverse PFR mechanical FREESPOOL lock extended heavy duty drawbar NOTE Not all optional equipment listed is available for each model of tractor Integral Arch Drawbar ...

Page 21: ...llied Systems Company P Power Controlled See Figure 1 Power Forward Only PFO with Freespool A Power Forward Reverse PFR with Freespool B Power Forward Only PFO with Freespool Lock K Power Forward Reverse PFR with Freespool Lock L H In Addition to the serial number plate the serial number is stamped on the top right hand side of the frame Circled letter in Chart A indicates high PTO or low PTO See ...

Page 22: ...D4B C D5C H 1000 H D31 D37 H 450 550G H 850G H L F65C G DD80 80L H 12 FD FL5 b FD FL7 L 450G 650G TC 450G 650G DD e H TD7E G TD8E G TD100E G 125E G H D31 D37 D39 21 21A KomSat I II H F66 F67C P H H66 H67 Muller TS22 13 TD7 8 9H TD7 8 9 10M TD9XP H D32 D38 D39 d 650 850G H L J170 14 D3 4 5B C DD c H TD8H DD c H D85B D95B 650 750 850K 750 850L DC75 85 95 H 15 DC 100 H D4E DD c L D85B D95B 650 750 85...

Page 23: ... Daewoo 16 FD80 DC70 DC80 H D3 4 5C Hystat H 30 D5M H 34 D4D D4E H 360 D4H PS Series I II H 361 D4H DD H 362 D4H PS Series III XL LGP H Note Wide narrow mounting patterns are shown 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 f...

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Page 25: ...lied 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 t...

Page 26: ...ard Reverse Operation Optional SomeW3C winches are equipped with the Power Forward Reverse option Two different levers are provided for winches equipped with PFR the direction lever and the power lever see Figure 8 Figure 8 W3C Operator Controls PFR ...

Page 27: ...f 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 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 y...

Page 28: ...mechanical stop that Figure 9 FREESPOOL Drag Adjust 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 Th...

Page 29: ...done at the recommended operating hours See the Maintenance Schedule for the W3C winch on page 20 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 ...

Page 30: ...e 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 comes too hot Winch is operated in the BRAKE OFF position for long periods Use the BRAKE OFF position less When the BRAKE OFF position is used the hydraulic oil flows continuously through the relief valv...

Page 31: ...ly correctly at low PTO rpm Accumulator not charged Check accumulator PTO speed stalled 0 rpm Increase tractor rpm Worn or leaking pump Check pump and replace if necessary FREESPOOL does not operate correctly See the Service Manual for additional troubleshooting checks and adjustments Winch stalls tractor engine during winch shift when tractor RPM is low Not enough engine torque Increase engine rp...

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Page 33: ...erating time on the hour meter of the tractor to determine the Maintenance Figure 12 W3C Winch Maintenance Points Maintenance 1 Plug to Check Oil Level 2 Fill Plug and Breather 3 Plug to Drain Oil 4 Cover for Strainer maintenance time for the winch See Figure 12 for the maintenance points on the winch ...

Page 34: ... hours or every 3 months Clean the oil strainer Use liquid gasket between the cover and strainer housing item 4 See parts manual for oil strainer part number Check the winch control lever linkage adjsutment Check that the lever mounting bracket and linkage are fastened correctly Tighten the bolts as necessary 1000 hours or every 6 months Change the hydraulic oil Drain oil from plug item 3 Clean th...

Page 35: ...ntrol lever decal Figure 14 Control Cable Adjustments 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 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...

Page 36: ...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 5 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 ope...

Page 37: ...et screwing the cable into or out of the winch Screwing the cable jacket into the winch will move the control lever towards the operator 10 Apply grease to the clevis pin and reassemble the clevis pin and cotter Test the control lever operation before attaching the aluminum housing cover 11 Be sure to rotate the cable inside the housing to remove any twisting caused by step 9 Tighten the cable jam...

Page 38: ...24 Figure 16 PFR Control Lever Disassembly and Adjustments ...

Page 39: ... cover 6 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 7 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 re...

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Page 41: ...moves the control lever to the FREESPOOL position so that the wire rope can be pulled from the winch drum Step 2 A load logs is connected to the wire rope The operator moves the control lever to the BRAKE ON position Operating Techniques PFO Operating Techniques PFO Note Solid arrows indicate the positions of the control lever ...

Page 42: ...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 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 wi...

Page 43: ...can move the control lever to LINE IN to pull the load toward the vehicle Step 6 When the operator wants to disconnect from the load the vehicle is stopped and the control lever is moved to the FREESPOOL position to loosen the wire rope The wire rope is then disconnected from the load ...

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Page 45: ...or moves the power lever into the FREESPOOL position so the wire rope can be pulled from the winch drum Step 2 A load logs is connected to the wire rope The operator moves the power lever to the BRAKE ON position Operating Techniques PFR Operating Techniques PFR Note Solid arrows indicate the positions of the control lever ...

Page 46: ...ill 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 Step 4 If the 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 move through the bad ...

Page 47: ... the power lever to POWER IN OUT to pull the load toward the vehicle 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 Operating Techniques PFR ...

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Page 49: ...erience is required because the winch can use most of the engine power in some vehicles 3 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 If the vehicle t...

Page 50: ... 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 t...

Page 51: ... 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 A Moving down the slope 1 Set the throttle on the tractor f...

Page 52: ...age LINE IN as necessary Do not permit the winch wire 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 opti...

Page 53: ... the equipment down the slope 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 2 Keep the winch wire rope tightened between the tractor and the equipment being lowered down the slope Use LINE IN to control the raising of the equipment down the slope 3 Keep...

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Page 55: ...ll 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...

Page 56: ...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 ...

Page 57: ...43 Operational Differences Optional Equipment Notes ...

Page 58: ...44 Notes ...

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Page 60: ...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 2300190W 09 24 2015 Printed in USA ...