Allied Systems W8L, 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 599018W 05 10 2017...

Page 2: ...05 10 2017 Printed in U S A A Product of Allied Systems Company Sherwood Oregon U S A Winch Model W8L Date Delivered Serial Number Date Installed Special Equipment or Attachments...

Page 3: ...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 info...

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: ...Operation 11 Operating Procedures 11 Power Operation 13 Troubleshooting Chart 15 Operation Electronic Controls Checks Before Operation 19 Checks During Operation 19 Operating Procedures 20 Power Opera...

Page 6: ...Down The Slope 48 Operational Differences Optional Equipment Fairlead 50 Drawbar 50 Optional Gear Ratios 50 Appendix A FREESPOOL Description 51 Checks before Operation 52 Checks during Operation 52 O...

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: ...nd 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 s country th...

Page 9: ...bsite 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 Obey the following cautions and warnings before using your w...

Page 10: ...ied Do not use winch as a hoist Tractor and skidder mounted winches are designed for towing Always inspect wire rope tail chain and other rigging components for wear damage broken strands or abuse bef...

Page 11: ...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...

Page 12: ...ective equipment such as gloves and safety glasses whenever servicing or checking a hydraulic system x x Assume that all hydraulic hoses and components are pressurized Relieve all hydraulic pressure b...

Page 13: ...ntrols the operation of the winch Removable covers on the winch case allow access for repairs and adjustments When PTO is rotating the hydraulic pump shaft is also rotating Oil from the hydraulic pump...

Page 14: ...s stamped with winch model winch serial number maximum bare drum line pull maximum wire rope diameter DO NOT operate the winch with larger diameter wire rope If the nameplate is missing DO NOT operate...

Page 15: ...ension can suddenly whip back towards the winch causing injury or product damage Be sure the operator knows the capacity of the wire rope and the winch WARNING Load loss hazard A loaded wire rope with...

Page 16: ...illar Multipurpose Tractor Oil MTO 13 to 104 25 to 40 Case Hy Tran Ultra 20 to 122 30 to 50 F C ExxonMobil Mobil Fluid LT 40 to 86 40 to 30 John Deere Low Viscosity Hy Gard 40 to 86 40 to 30 Chevron T...

Page 17: ...Access Cover to Hydraulic Valve 4 Access 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 10 Intermediate Shaft Bearing Retainer 11...

Page 18: ...ns Fairlead assembly To protect wire rope and frame from damage at odd pull angles Alternate gear ratio To allow better line speed control Electronic controls Line control NOTE Not all optional equipm...

Page 19: ...1 49 8 19 9 Winch x 1 38 Gearbox 7 47 1 1 31 1 1 8 125 1 190 1 94 143 Winch x 1 33 Gearbox 9 94 1 102 1 10 125 1 136 1 94 102 Winch x 1 33 Gearbox 11 85 4 1 34 1 1 49 8 19 9 Winch x 1 71 Gearbox A Al...

Page 20: ...ex H Dresser K Komatsu M MF N Zoomlion 48 D68ESS 12 50 D85E PX 15 51 16B PS S N 10301 UP D7F a D7G PS D700A 82 20B 82 20 TD20E G H PS TD20M D80A 12 D700C D700D TEREX 52 16B DD S N 10301 UP D7F DD D7G...

Page 21: ...er Where Applicable C O D E A Fiat Hitachi New Holland C Caterpillar G Terex H Dresser K Komatsu M MF N Zoomlion 56 DX255 FD255 D255 D8N e D8R D135A 57 D7R PS D85ESS 2 f ZD220 58 D8R D87E 2 59 D8R SER...

Page 22: ...on 83 D7G SERIES II 983 983 Track Loader S N 38K a Caterpillar D7F S N 94N5660 UP b Caterpillar D7 DD S N 91V 93N 64V 45W c Caterpillar 572 S N 40U 6J d Caterpillar prior to D8N S N 5TJ0001 same as C5...

Page 23: ...position No hydraulic pressure is applied to the brake or the clutches Springs apply the brake so that the winch drum will not rotate Checks Before Operation Check that the cable and hook are not wor...

Page 24: ...ch will not rotate easily because of friction in the clutches the brake and the gear train Wire rope cannot be pulled from the winch by hand The BRAKE OFF position is used when the operator has a load...

Page 25: ...tractor LINE OUT position applies the LINE OUT clutch and releases the brake The winch will unwind the wire rope at a speed controlled by the PTO speed of the tractor and the weight of the load BRAKE...

Page 26: ...tion is used to 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...

Page 27: ...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 troubleshooting Wrong oil Drain...

Page 28: ...ve inching Allow time for oil to cool after inching Clogged suction strainer Check and clean or replace the suction strainer Defective or improperly adjusted oil relief valve See the Service Manual fo...

Page 29: ...pply 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 duri...

Page 30: ...18 Intentionally Blank...

Page 31: ...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 suspended load Checks During Operation Ch...

Page 32: ...l lever is used to select one of the following operations BRAKE OFF LINE OUT BRAKE ON LINE IN The BRAKE OFF position is detented the control lever must be pulled back to the BRAKE ON neutral position...

Page 33: ...21 Operation Electronic Controls Figure 11 1 Control Levers NON CURRENT CURRENT 3 NON CURRENT...

Page 34: ...22 Figure 11 2 Operator Electronic Controls...

Page 35: ...erse clutch and releases the brake The winch will unwind the wire rope at a speed controlled by the PTO rpm of the tractor and the weight of the load BRAKE OFF is a detented position Oil pressure has...

Page 36: ...erse clutch is applied This permits the weight of the load with assistance from the reverse clutch to unwind wire rope from the winch drum against the resistance of the brake The reverse clutch is com...

Page 37: ...oil Drain oil and replace with correct grade Refer to Figure 3 Recommended Oil List Hydraulic oil becomes too hot Winch is operated in the BRAKE OFF position for long periods Use the BRAKE OFF positio...

Page 38: ...nual for additional troubleshooting checks and adjustments Control valve failure Low oil pressure Clutch does not apply correctly at low PTO rpm Accumulator not charged Check accumulator PTO stalled 0...

Page 39: ...return to BRAKE ON position when released Defective return spring worn detent parts or lubricant evacuation See the Service Manual for additional troubleshooting Control lever is in detented position...

Page 40: ...hould not be illuminated If it is consult factory Coil open or shorted Check module output LEDs Flashing LED indicates open or shorted circuit Check wiring harness continuity Replace faulty coil Note...

Page 41: ...aring grease Winch does not engage and tractor engine draws down in LINE IN or LINE OUT Plugged brake cartridge Replace cartridge Faulty brake coil Replace coil Open or shorted brake circuit Check wir...

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Page 43: ...Maintenance time on the hour meter of the tractor to determine the maintenance time for the winch Figure 14 W8L Winch Maintenance Points Maintenance 1 Access Cover for Control Valve 2 Plug to Check Oi...

Page 44: ...rs on the fairlead assembly if the winch is so equipped Use multi purpose grease with 2 4 molybdenum disulfide 250 hours or monthly There may be a gear box fastened to the front of the winch which has...

Page 45: ...Recommended Oil List Check control lever See Control Lever Detent Force Adjustment NOTE Clean the oil strainer screen and change the oil filter after the first 250 hours on new and rebuilt winches Amo...

Page 46: ...ol 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 hi...

Page 47: ...n 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 Remove the cotter pin and link pin Item 5 from the c...

Page 48: ...power control lever Item 1 are the same as the position indicators on the decal Loosen the U bolt Item 4 that holds the power control cable Item 5 in place Turn the jam nut Item 3 to adjust the power...

Page 49: ...trol 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 operator moves the control level to the BRAKE ON positi...

Page 50: ...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 trav...

Page 51: ...ve the control lever to LINE IN position 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 BRA...

Page 52: ...40 Intentionally Blank...

Page 53: ...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 operator moves the...

Page 54: ...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 ba...

Page 55: ...ition 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 BRAKE OFF position to loosen the wire...

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Page 57: ...is required because the winch can use most of the engine power in some vehicles 3 Put the control lever in the LINE IN positionto tighten the winch wire rope When the winch wire rope is tight put the...

Page 58: ...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 t...

Page 59: ...have enough capacity for the load Make sure the anchor for the wire rope has enough capacity for the load Tractor is Down the Slope See Figure 21 Sometimes a tractor must work on a steep slope and can...

Page 60: ...and use minimal inching 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 F...

Page 61: ...onal 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...

Page 62: ...ead 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 Drawbar Do not use the drawbar...

Page 63: ...rator can disengage the sliding sleeve with a control lever for the FREESPOOL operation when there FREESPOOL is no load on the wire rope When the control lever is in the FREESPOOL position the sliding...

Page 64: ...e 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 Operating Procedu...

Page 65: ...r cannot be moved to engage 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 ge...

Page 66: ...justing Start with the preload too loose and gradually increase the preload until the correct resistance to rotation is achieved Increase the preload by turning the adjusting screw by a maximum of 1 6...

Page 67: ...OOL control cable Item 3 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 positions Bot...

Page 68: ...Loosen the nut that keeps the tall nut from turning 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 cotte...

Page 69: ...cable Item 9 in place Turn the jam nut to adjust the FREESPOOL cable The linkage and cable must be adjusted so that the FREESPOOL shifter mechanism will slide the drum pinion gear to both positions B...

Page 70: ...e LINE OUT position or the FREESPOOL control lever into 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 t...

Page 71: ...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 t...

Page 72: ...l 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 BRAKE OFF DETENT position or LINE OUT position to...

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Page 74: ...599018W 05 10 2017 Printed in U S A 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...