Allied Systems W12E, 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 599012W 06 20 2018...

Page 2: ...06 20 2018 Printed in USA A Product of Allied Systems Company Sherwood Oregon USA Winch Model W12E Date Delivered Serial Number Date Installed Special Equipment or Attachments...

Page 3: ...t 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 inf...

Page 4: ...ble 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 interpret...

Page 5: ...ating Procedures 14 Power Operation 16 Troubleshooting Chart 18 Operation Electronic Controls Checks Before Operation 21 Checks During Operation 21 Operating Procedures 22 Power Operation 24 Troublesh...

Page 6: ...A Disabled Vehicle 46 Working on A Steep Slope 48 Tractor Is Down The Slope 48 Other Equipment Is Down The Slope 49 Operational Differences Optional Equipment Integral Arch 52 Fairlead 52 Drawbar 53...

Page 7: ...sed to emphasize 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 m...

Page 8: ...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 na...

Page 9: ...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 equipme...

Page 10: ...rs 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...

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...

Page 12: ...ed 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 5 Do not weld on any part of the winch Contact Allie...

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

Page 14: ...xii Notes...

Page 15: ...c 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 ad...

Page 16: ...e 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 hydraulic power is lost the brake remains applied and the...

Page 17: ...s 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...

Page 18: ...e drum A broken wire rope under high tension can return suddenly in the direction of the winch and cause injury and damage Figure 2 Drum Line Capacities WARNING The wire rope may disengage from the fe...

Page 19: ...n o r v e h C Caterpillar Multipurpose Tractor Oil MTO 13 to 104 25 to 40 0 5 o t 9 2 2 2 1 o t 0 2 a r t l U n a r T y H e s a C F C 0 3 o t 0 4 6 8 o t 0 4 T L d i u l F l i b o M l i b o M n o x x...

Page 20: ...ss Cover to Hydraulic System 5 Plug to Check Oil Level 6 Plug to Drain Oil 7 Tie Rod 8 Fill Plug 9 Cover for Oil Brake 11 Drum Shaft Bearing Retainer 12 Drawbar 13 Breather 14 Intermediate Shaft Retai...

Page 21: ...lead assembly To protect wire rope and frame from damage at odd pull angles Figure 5 W12E Towing Winch Optional Equipment Alternate gear ratio To allow better line speed control NOTE Not all optional...

Page 22: ...ronic Control Vehicle Code See Figure 6 N Non Freespool S HD Frame Non Freespool In addition to the serial number plate the serial number is stamped on the top left hand side of the frame Circled numb...

Page 23: ...ing Tractor Serial Number Where Applicable C O D E A Fiat Hitachi New Holland C Caterpillar G Terex H Dresser Dressta K Komatsu 59 D8R Series II 60 D275A 61 21C FD30 D8K PS 82 30 82 30B D750A TD25C PS...

Page 24: ...hi New Holland C Caterpillar G Terex H Dresser Dressta K Komatsu 64 FD30B C 594 Serial No 96V 62H TD25G H M D375A 1 65 FD40 D8L D9N D9R Clutch Br Steer TD40B C 66 D10N D10R 67 583R 68 D9R Diff Steerin...

Page 25: ...ractor Make Model and Starting Tractor Serial Number Where Applicable C O D E A Fiat Hitachi New Holland C Caterpillar G Terex H Dresser Dressta K Komatsu 74 583T D8T PL83 PL87 75 D9T 76 D10T 79 587T...

Page 26: ...IT LETTER MODIFICATION Z WINCH HAS BEEN UPGRADED TO USE MANIFOLD P N 2306547W ZV WINCH HAS BEEN UPGRADED TO USE MANIFOLD P N 2311887 X A KIT HAS BEEN INSTALLED THAT ADDS AN ACTIVATION SWITCH TO THE WI...

Page 27: ...perating hours See Figure 13 Maintenance Schedule on page 32 Check control lever adjustment Checks During Operation The Troubleshooting Chart at the end of this subsection can be used by the operator...

Page 28: ...tches brake and gear train The BRAKE OFF position is used when the operator has a load attached to the winch wire rope The operator can move the tractor forward without moving the load LINE OUT positi...

Page 29: ...e is released the clutch takes control and begins to move the load Inching LINE OUT This operation will release the brake as the reverse clutch is applied This permits the weight of the load with assi...

Page 30: ...tor READ OPERATING READ OPERATING INSTRUCTIONS INSTRUCTIONS 277276W READ OPERATING INSTRUCTIONS BRAKE OFF BRAKE ON LINE IN LINE OUT CONTROL LEVER POSITION LINE OUT position applies the LINE OUT clutch...

Page 31: ...slowly move a load toward the tractor The control valve will cause the oil pressure to slowly release the brake and slowly apply the LINE IN clutch As the brake is released the clutch takes control a...

Page 32: ...F position Run the engine at 1000 rpm 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 tro...

Page 33: ...ed suction strainer Check and clean or replace the suction strainer Defective or improperly adjusted oil relief valve See the Service Manual for additional troubleshooting Brake begins to release befo...

Page 34: ...not apply correctly at low PTO rpm Accumulator not charged Check accumulator PTO stalled 0 rpm Increase tractor rpm Worn or leaking pump Check pump and replace if necessary Winch stalls tractor engine...

Page 35: ...and 1 second off means system fault Light slow blink 3 second on and 3 second off means controls not active Note The winch oil should be warm approximately 80 F prior to operating a winch with a suspe...

Page 36: ...ver is used to select one of the following operations BRAKE OFF LINE OUT BRAKE ON LINE IN BRAKE OFF is the only detented position on the lever and the operator must pull the control lever to release i...

Page 37: ...23 Figure 10 Operator Electronic Controls Operation Electronic Controls...

Page 38: ...and gear train BRAKE OFF is used to move the tractor away from the load while keeping the cable tight LINE IN position applies the forward clutch and releases the brake The winch will wind the wire ro...

Page 39: ...the position of the power control lever Inching BRAKE OFF This operation is used to partially release a load For example when an operator wants to maintain the position of a load while climbing a slip...

Page 40: ...re increases proportionately as the control lever moves toward the fully engaged detented BRAKE OFF position allowing controlled slipping of the brake WARNING BRAKE OFF inching is not intended for hea...

Page 41: ...or additional troubleshooting Wrong oil Drain oil and replace with correct grade Refer to the approved oil list Hydraulic oil becomes too hot Winch is operated in the BRAKE OFF position for long perio...

Page 42: ...Manual for additional troubleshooting Low oil pressure Clutch does not apply correctly at low PTO rpm Accumulator not charged Check accumulator PTO stalled 0 rpm Increase tractor rpm Noisy buzz emana...

Page 43: ...Control module fault Check status indicator on module Red LED should not be illuminated If it is consult factory Coil open or shorted Check module output LEDs Flashing LED indicates open or shorted c...

Page 44: ...on Control lever is in detented position BRAKE OFF Move control lever out of detent Winch does not engage and tractor engine draws down in FWD or REV Plugged brake cartridge Replace cartridge Faulty b...

Page 45: ...e operating time Maintenance on the hour meter of the tractor to find the maintenance time for the winch Figure 12 Maintenance Points 1 Access Cover for Control Valve 2 Plug to Check Oil Level 3 Plug...

Page 46: ...te the rollers on the fairlead assembly if the winch is so equipped Use multi purpose grease with 2 4 molybdenum disulfide 250 hours or monthly b Check hydraulic system pressure See Service Manual for...

Page 47: ...and cover gasket When replacing be sure to lubricate filter seal ring between element and filter head 1000 hours or every 6 months Change the hydraulic oil Drain oil from plug item 3 Clean the oil str...

Page 48: ...e control lever with control valve in BRAKE ON The lever should be approximately vertical If not loosen nuts on U Bolt that clamps the control cable to the control lever housing Move U Bolt up or down...

Page 49: ...Used in 1993 2 Install cable adapter in groove on control lever cover and attach cover Figure 16 Control Cable Adjustments 1 Access Cover 2 Clevis 3 Tall Nut 4 Cotter Pin and Link Pin 5 Control Cable...

Page 50: ...screw inwards to increase detent force or outwards to decrease detent force 3 Move control lever from BRAKE ON to BRAKE OFF and back again If detent force is still unsatisfactory adjust setscrew again...

Page 51: ...37 Intentionally Blank Maintenance...

Page 52: ...tep 2 A load logs is connected to the wire rope The operator moves the control lever to the BRAKE ON position Operating Techniques READ OPERATING READ OPERATING INSTRUCTIONS INSTRUCTIONS 277276W READ...

Page 53: ...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 DETENT position This procedure will permit...

Page 54: ...ver is moved to the BRAKE OFF DETENT or LINE OUT position to loosen the wire rope The wire rope is then disconnected from the load READ OPERATING READ OPERATING INSTRUCTIONS INSTRUCTIONS 277276W READ...

Page 55: ...41 Operating Techniques Power Controls Intentionally Blank...

Page 56: ...tor turns on the activation switch and moves the control lever to the LINE OUT 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 ope...

Page 57: ...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 are...

Page 58: ...When the operator wants to disconnect from the load the vehicle is stopped and the control lever is moved to the BRAKE OFF DETENT or LINE OUT position to loosen the wire rope The wire rope is then di...

Page 59: ...45 Operating Techniques Electronic Controls Intentionally Blank...

Page 60: ...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 3 Use the LINE IN control lever to tighten...

Page 61: ...in 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 wire rope to the tow bar...

Page 62: ...n a steep slope can cause death or injury and loss of equipment Tractor is Down the Slope See Figure 20 Sometimes a tractor must work on a steep slope and can use a winch to give assistance when movin...

Page 63: ...g to prevent additional heat and wear 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 21 In this opera...

Page 64: ...l heat and wear 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 co...

Page 65: ...51 Operating Techniques General Intentionally Blank...

Page 66: ...tor 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 tract...

Page 67: ...olt 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 Ge...

Page 68: ...54 Notes...

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Page 70: ...599012W 06 20 2018 Printed in USA 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...