Related Manuals for Allied Systems W12E
Summary of Contents for Allied Systems W12E
- 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 W12E Serial Number Winch Model Date Installed Date Delivered Special Equipment or Attachments A Product of Allied Systems Company 06/20/2018 Sherwood, Oregon USA Printed in USA...
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Page 3: Foreword
Operating Manual, contact your local winch dealer, in good condition. or contact Allied Systems Company: • Read and understand the SAFETY SUMMARY and OPERATING PROCEDURES contained in this Allied Systems Company Operating Manual. - Page 4 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 specifi c winch. non-English speaking locations.
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Page 5: Table Of Contents
Contents Contents Foreword ..............i Operation, Electronic Controls Checks Before Operation ........21 Contents ..............iii Checks During Operation ........21 Operating Procedures ..........22 Safety Summary ............. v Power Operation .............24 Troubleshooting Chart ..........27 General Maintenance Introduction ...............1 How The Winch Operates .........1 Maintenance ............31 Nameplate ..............3 Maintenance Points ...........31... -
Page 6: Contents
Contents (continued) Operating Techniques, General Operational Differences, Optional Equipment How To Move A Disabled Vehicle......46 Integral Arch ............52 Working on A Steep Slope ........48 Fairlead ..............52 Tractor Is Down The Slope .........48 Drawbar ..............53 Other Equipment Is Down The Slope ....49 Optional Gear Ratios ..........53... -
Page 7: Safety Summary
Safety Summary Safety Summary General Safety Notices WARNING The following pages contain general safety warnings which supplement specific warnings and cautions T h e “ WA R N I N G ” s y m b o l a p p e a rs appearing elsewhere in this manual. - Page 8 NOTE: All possible safety hazards cannot NOTICE be foreseen so as to be included in this manual. Therefore, you must always be alert to potential hazards that could This signal word alerts to a situation that endanger personnel and/or damage the is not related to personal injury but may equipment.
- Page 9 Safety Summary Operation, Inspection, and Maintenance Warnings • Inspect the winch before each use: » Make sure that the controls and instruments Obey the following cautions and operate correctly. warnings before using your winch to » Report the need for repairs immediately. avoid equipment damage, personal »...
- Page 10 • Never stand nor permit others to stand in the bight • Do not use winch as a hoist. Tractor and skidder (loop) of a wire rope. mounted winches are designed for towing. • Do not stand nor permit others to be near the winch or wire rope when there is tension on the wire rope.
- Page 11 Safety Summary • Wire rope and tail chain will fail if worn-out, • Make sure ground personnel are in plain view of the overloaded, misused, damaged, improperly operator, and at a distance of at least 1½ times the maintained or abused. Wire rope or tail chain failure working length of the wire rope.
- Page 12 • If applying tension to the wire rope manually during • Use only the lubricants listed in the Recommended spooling: Oil List. See Page 5. » ensure that the operator is winching in slowly, • Do not weld on any part of the winch. Contact Allied »...
- Page 13 Safety Summary Notes...
- Page 14 Notes...
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Page 15: General
W12E winch. valve. The hydraulic control valve controls the operation of the winch. Removable covers on the winch case allow How the Winch Operates access for repairs and adjustments. - Page 16 When the control lever is in the BRAKE-ON position, an The W12E winch has a rated line pull capacity of 533,800 oil brake is automatically applied by a spring to hold the N (120,000 lbf) when there is one layer of wire rope on drum in its position.
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Page 17: Nameplate
General 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. -
Page 18: Wire Rope Selection
Wire Rope Selection WARNING Each winch model can have a variety of wire rope sizes The wire rope may disengage from the installed by the user. The maximum wire rope size is shown ferrule pocket if there is a load on the wire on the nameplate. -
Page 19: Recommended Oil List
General Recommended Oil List The type of oil used in Allied winches affects the line control. Use the following oils in the W12E winch: Recommended Oils* - General Conditions Ambient Temperature Range Manufacturer Oil Type °F °C ExxonMobil Mobil Fluid 424 (Factory fill) - Page 20 Drum Shaft Bearing Retainer Access Cover to Hydraulic Valve Drawbar Access Cover to Hydraulic System Breather Plug to Check Oil Level Intermediate Shaft Retainer Plug to Drain Oil Brake Shaft Retainer Tie Rod Nameplate Fill Plug Drawbar Pin Figure 4 - W12E Winch...
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Page 21: Optional Equipment
General Optional Equipment The W12E winch may be equipped with the following • Alternate gear ratio - To allow better line speed control. options: • Fairlead assembly - To protect wire rope and frame NOTE: Not all optional equipment listed is available for each model of tractor. -
Page 22: Serial Number Codes
A serial number indicates the following information: A W12E 1555 Manufactured By With Upgraded A = Made by Allied Systems Company eControl Kit (Without "A" indicates made by Hyster) See Figure 7 if a letter or letters is stamped. Winch Model... -
Page 23: Tractor & Skidder Identifi Cation Codes
General Figure 6 - Tractor or Skidder Identifi cation and Gear Ratio (Continued on next page) Tractor Make Model and Starting Tractor Serial Number Where Applicable Fiat-Hitachi/ Caterpillar Terex Dresser/ Komatsu New Holland Dressta D8R Series II D275A 82-30, 82-30B, ... - Page 24 Figure 6 - Tractor or Skidder Identifi cation and Gear Ratio (Continued on next page) Tractor Make Model and Starting Tractor Serial Number Where Applicable Fiat-Hitachi/ Caterpillar Terex Dresser/ Komatsu New Holland Dressta FD30B/C TD25G/H/M D375A-1 Serial No. 96V 62H ...
- Page 25 General Figure 6 - Tractor or Skidder Identifi cation and Gear Ratio Tractor Make Model and Starting Tractor Serial Number Where Applicable Fiat-Hitachi/ Caterpillar Terex Dresser/ Komatsu New Holland Dressta 583T, D8T PL83/PL87 , , D10T , 587T , ...
- Page 26 Figure 7 - Winch eControls Modifi cation Status A LETTER AT THE END OF THE WINCH SERIAL NUMBER CODE INDICATES THAT THE WINCH HAS BEEN MODIFIED WITH AN UPGRADED eCONTROL KIT. LETTER MODIFICATION WINCH HAS BEEN UPGRADED TO USE MANIFOLD P/N 2306547W WINCH HAS BEEN UPGRADED TO USE MANIFOLD P/N 2311887 A KIT HAS BEEN INSTALLED THAT ADDS AN ACTIVATION...
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Page 27: Operation, Power Controls
Operation, Power Controls Operation, Power Controls Checks Before Operation Checks During Operation • Check that the wire rope and hook are not worn or The Troubleshooting Chart at the end of this subsection damaged. Check that the periodic inspection and can be used by the operator to identify a problem with maintenance have been done at the recommended the winch operation. -
Page 28: Operating Procedures
Operating Procedures LINE-OUT position applies the reverse clutch and releases the brake. The winch will unwind the wire rope The control lever assembly has a power control lever for at a speed controlled by the PTO speed of the tractor and winch control. - Page 29 Operation, Power Controls Inching (LINE-IN). This operation is used to slowly move Inching (LINE-OUT). This operation will release the brake a load toward the tractor. As the control lever is moved as the reverse clutch is applied. This permits the weight of gradually towards the LINE-IN position, the control valve the load, with assistance from the reverse clutch, to unwind will cause the oil pressure to slowly release the brake and...
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Page 30: Power Operation
Power Operation BRAKE BRAKE CONTROL LEVER LINE LINE POSITION CONTROL LEVER BRAKE BRAKE POSITION LINE LINE READ OPERATING READ OPERATING READ OPERATING READ OPERATING READ OPERATING READ OPERATING INSTRUCTIONS INSTRUCTIONS INSTRUCTIONS 277276W INSTRUCTIONS INSTRUCTIONS INSTRUCTIONS 277276W BRAKE-ON position is a neutral position. Neither clutch LINE-OUT position applies the LINE-OUT clutch and is applied. - Page 31 Operation, Power Controls Inching is used for a fi ne control of the winch speed. When the power control lever is slowly moved to a BRAKE position between BRAKE-ON and LINE-IN or between LINE BRAKE-ON and LINE-OUT, inching occurs. The normal CONTROL LEVER POSITION adjustment of inching for LINE-IN is different from the...
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Page 32: Troubleshooting Chart
Troubleshooting Chart PROBLEM POSSIBLE CAUSE CORRECTION Operation is rough or not regular. Hydraulic oil is too cold. Put the control lever in the BRAKE-OFF position. Run the engine at 1000 rpm to warm the oil to 80°F before operating the winch. - Page 33 Operation, Power Controls PROBLEM POSSIBLE CAUSE CORRECTION Hydraulic oil becomes too hot. Winch is operated in the BRAKE-OFF Use the BRAKE-OFF position less. When position for long periods. the BRAKE-OFF position is used, the hydraulic oil fl ows continuously through the relief valve.
- Page 34 PROBLEM POSSIBLE CAUSE CORRECTION Clutch does not apply correctly. Worn or damaged clutch. See the Service Manual for additional troubleshooting, checks and Control valve or control cable needs adjustments. adjustment. Low oil pressure. Clutch does not apply correctly at Accumulator not charged. Check accumulator.
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Page 35: Operation, Electronic Controls
Operation, Electronic Controls Operation, Electronic Controls Checks Before Operation Checks During Operation • Check that the wire rope and hook are not worn or • Check the winch indication light: damaged. - Light steady on after oil warmup means • Check that the periodic inspection and maintenance problem(s) exist. -
Page 36: Operating Procedures
Operating Procedures NOTE: The fi lter LED illuminates briefl y at startup. This is part of the normal system check. Consult the The electronic control assembly has one control lever. The troubleshooting guide (see Figure 11) if the light does control lever is connected to the winch through electrical not turn off. - Page 37 Operation, Electronic Controls Figure 10 - Operator Electronic Controls...
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Page 38: Power Operation
Power Operation CONTROL LEVER POSITION CONTROL LEVER POSITION BRAKE-ON is a neutral position. No hydraulic pressure LINE-OUT position applies the reverse clutch and is applied to the brake or the clutches. Springs apply the releases the brake. The winch will unwind the wire rope brake so the winch drum will not rotate. - Page 39 BRAKE- ON and LINE-IN or between BRAKE-ON and LINE-OUT, inching occurs. Any adjustments require computer program changes and may be necessary for some customer operations. Contact Allied Systems Company if inching needs adjustment. The following paragraphs describe the normal procedures for inching.
- Page 40 stationary as the tractor climbs the hill. Brake pressure WARNING increases proportionately as the control lever moves toward the fully engaged (detented) BRAKE-OFF position, BRAKE-OFF inching is not intended for allowing controlled slipping of the brake. heavy suspended loads, as unintended load fallback can occur.
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Page 41: Troubleshooting Chart
Operation, Electronic Controls Troubleshooting Chart PROBLEM POSSIBLE CAUSE CORRECTION Operation is rough or not regular. Hydraulic oil is too cold. Put the control lever in the BRAKE- OFF position. Run the engine at 1000 rpm to warm the oil before operating the winch. - Page 42 PROBLEM POSSIBLE CAUSE CORRECTION Winch brake does not apply or release Brake is worn. See the Service Manual for additional correctly. troubleshooting. Low oil pressure. Clutch does not apply correctly. Worn or damaged clutch. See the Service Manual for additional troubleshooting, checks Control valve failure.
- Page 43 Operation, Electronic Controls PROBLEM POSSIBLE CAUSE CORRECTION Winch will not operate in any function. Control lever off-center at startup. Return control lever to neutral position and attempt function again. Control module not powered. Check fuse & replace if necessary. Control lever DC-DC converter Replace converter if the red &...
- Page 44 PROBLEM POSSIBLE CAUSE CORRECTION Control lever will not detent in BRAKE- Detent mechanism worn or broken. 1. Replace control lever assembly. OFF. 2. Lubricate detent pin (see Service Control lever does not return to neutral Defective return spring, worn detent Manual for procedure).
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Page 45: Maintenance
Maintenance Maintenance The Maintenance Schedule is a program that includes on the hour meter of the tractor to fi nd the maintenance periodic inspection and lubrication. Use the operating time time for the winch. Maintenance Points Access Cover for Control Valve Cover for Filter Plug to Check Oil Level Fill Plug... -
Page 46: Maintenance Schedule
Maintenance Schedule INTERVAL PROCEDURE OR QUANTITY SPECIFICATION 50 hours or Check oil level at plug (item 2). Add oil as necessary See Figure 3 – Recommended Oil List. weekly through fi ll plug (item 5). Do not operate tractor when checking the oil level. - Page 47 Maintenance INTERVAL PROCEDURE OR QUANTITY SPECIFICATION 500 hours or Clean the oil suction screen and magnets. Use a new gasket between the cover and the suction tube. every 3 months Clean the breather in the fi ll plug. Clean the breather with solvent if needed. Replace the fi...
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Page 48: Control Cable Adjustment
Control Cable Adjustments A single control cable connects the power control lever to Power Control Lever the hydraulic control valve spool. Check the operation of U-Bolt Power Control Cable the power control lever to make sure it moves smoothly Lock Nut and will return to the BRAKE-ON position. - Page 49 Maintenance Access Cover Clevis Tall Nut Cotter Pin and Link Pin Control Cable Control Lever Screw Jam Nut Button Head Capscrew Power Control Lever Housing Locknut U-Bolt Power Control Cable Spacer Pivot Pin Figure 15 Control Cable Adjustments Figure 16 Control Cable Adjustments (This Confi...
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Page 50: Control Lever Force Adjustment
Control Lever Detent Force Adjustment 4. Place boot and knob over control lever assembly, ensuring boot is securely installed, then install knob/ handle screw. CAUTION Make sure vehicle engine is OFF before performing any of these procedures. CAUTION Removing the Detent Plate from the control Lever may cause a calibration error, which will prevent proper winch response. - Page 51 Maintenance Intentionally Blank...
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Page 52: Tractor Or Skidder Operation
Operating Techniques Tractor or Skidder Operation BRAKE BRAKE CONTROL LEVER LINE LINE POSITION CONTROL LEVER BRAKE BRAKE POSITION LINE LINE READ OPERATING READ OPERATING READ OPERATING READ OPERATING READ OPERATING READ OPERATING INSTRUCTIONS INSTRUCTIONS INSTRUCTIONS INSTRUCTIONS INSTRUCTIONS INSTRUCTIONS 277276W 277276W Step 1. - Page 53 Operating Techniques, Power Controls CONTROL LEVER BRAKE BRAKE POSITION LINE LINE BRAKE BRAKE CONTROL LEVER LINE LINE POSITION READ OPERATING READ OPERATING READ OPERATING READ OPERATING READ OPERATING READ OPERATING INSTRUCTIONS INSTRUCTIONS INSTRUCTIONS INSTRUCTIONS INSTRUCTIONS INSTRUCTIONS 277276W 277276W Step 3. The operator can move the control lever Step 4.
- Page 54 CONTROL LEVER BRAKE BRAKE POSITION LINE LINE BRAKE BRAKE CONTROL LEVER LINE LINE POSITION READ OPERATING READ OPERATING READ OPERATING READ OPERATING READ OPERATING READ OPERATING INSTRUCTIONS INSTRUCTIONS INSTRUCTIONS INSTRUCTIONS INSTRUCTIONS INSTRUCTIONS 277276W 277276W Step 5. When the vehicle is on fi rm ground, the Step 6.
- Page 55 Operating Techniques, Power Controls Intentionally Blank...
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Page 56: Tractor Or Skidder Operation
Operating Techniques Tractor or Skidder Operation CONTROL LEVER POSITION CONTROL LEVER POSITION 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 turns The operator moves the control lever to the BRAKE- on the activation switch, and moves the control lever ON position. - Page 57 Operating Techniques, Electronic Controls CONTROL LEVER POSITION CONTROL LEVER POSITION Step 3. The operator can move the control lever Step 4. If the tractor or skidder must travel through to the LINE-IN position. If the load is less than an area with bad traction conditions, the operator approximately 75% of the maximum line pull, the can move the control lever to the BRAKE-OFF operator can begin traveling with the vehicle at the...
- Page 58 CONTROL LEVER POSITION CONTROL LEVER POSITION Step 5. When the vehicle is on fi rm 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.
- Page 59 Operating Techniques, Electronic Controls Intentionally Blank...
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Page 60: How To Move A Disabled Vehicle
How to Move a Disabled Vehicle If the vehicle travels faster than the winch winds the A. A tractor or skidder often travels in areas where traction wire rope, disengage the transmission until the winch conditions are bad. A vehicle equipped with a winch can wire rope is tightened again. - Page 61 Operating Techniques, General Fasten the winch wire rope to the tow bar of the other B. A tractor or skidder equipped with a winch can be used vehicle. The wire rope must be in a direction that is to pull another vehicle from mud or other areas where it approximately parallel to the direction of travel of the cannot move using only the drive wheels or tracks.
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Page 62: Working On A Steep Slope
A. Moving down the slope: Working on a Steep Slope Set the throttle on the tractor for the required engine WARNING speed. The winch and the tractor must be in good Put the tractor in FORWARD. At the same time, condition for the following procedures. -
Page 63: Other Equipment Is Down The Slope
Operating Techniques, General B. Moving up the slope: Other Equipment is Down the Slope (See Figure 21). Set the throttle on the tractor for the required engine In this operation, the tractor and winch are on stable speed. ground and other equipment is working on a steep slope. - Page 64 A. Lowering the equipment on the slope: B. Raising the equipment on the slope: Set the throttle on the tractor for the required engine Set the throttle on the tractor for the required engine speed. Operator experience is required for this speed.
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Page 66: Operational Differences, Optional Equipment
Operational Differences, Optional Equipment Integral Arch Fairlead When using an integral arch, the wire rope is routed over A fairlead consists of a set of top and bottom horizontal a raised horizontal roller and through a set of smaller rollers and side rollers that the wire rope is fed through. vertical side rollers and an upper horizontal roller. -
Page 67: Drawbar
Operational Differences, Optional Equipment Drawbar Optional Gear Ratios Do not use the drawbar as an anchor point for a multipoint Lower speed ratios allow better operator control of line (over puller) line from the winch. Loads applied to the speed. They may also allow the winch to pull in excess of drawbar are transmitted to the bolts holding the winch wire rope or winch rated capacity. - Page 68 Notes...
- Page 70 To fi nd a dealer in your area, Call: 503.625.2560, Fax: 503.625.7269, or 599012W 06/20/2018 Printed in USA Email: marketing@alliedsystems.com, or Visit our website: www.alliedsystems.com...
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