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Allied Systems W5C Operating Manual

Power controlled & electronic controlled towing winch
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Operating Manual
A Product of
A Product of
Sherwood, OR USA
W5C
Power Controlled &
Electronic Controlled
Towing Winch
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 599005W
Printed in U.S.A.
11/08/2024

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Summary of Contents for Allied Systems W5C

  • Page 1 Power Controlled & Electronic Controlled Towing Winch 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. A Product of A Product of www.alliedsystems.com Sherwood, OR USA P/N 599005W Printed in U.S.A.
  • Page 2 Serial Number Winch Model Date Installed Date Delivered Special Equipment or Attachments A Product of Allied Systems Company 11/08/2024 Sherwood, Oregon Printed in U.S.A. U.S.A.
  • Page 3 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 specific winch. non-English speaking locations.
  • Page 5 Checks During Operation ........29 Wire Rope Installation ..........7 Operating Procedures ..........30 Oil Capacity & Recommended Oil List .....9 Power Operation .............34 W5C Winch Description .......... 10 FREESPOOL Operation .........36 Optional Equipment ..........11 FREESPOOL Drag Adjustment ......36 Serial Number Codes ..........12 Troubleshooting Analysis Chart ......38...
  • Page 6 Contents (continued) Maintenance Operating Techniques, General Maintenance Points ..........43 How To Move A Disabled Vehicle ......57 Maintenance Schedule ........44 Working on A Steep Slope ........59 Operator Control Adjustment ........46 Dozer Is Down The Slope ........59 Other Equipment Is Down The Slope ....60 Operating Techniques, Power Controls Dozer or Skidder Operation ........49 Operational Differences, Optional Equipment...
  • Page 7 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 ” sy 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 This signal word alerts to a situation that be alert to potential hazards that could is not related to personal injury but may endanger personnel and/or damage the cause equipment damage.
  • Page 9 Safety Summary » • Do not operate the winch unless you are authorized If the wire rope and ferrule must be removed and trained to do so. from the drum, make sure the end of the wire rope and ferrule are controlled when •...
  • Page 10 • Do not leave the vehicle when the winch wire rope • Always inspect wire rope, tail chain and other rigging is under tension. components for wear, damage, broken strands or abuse before use. • Do not permit riders on the vehicle or load. •...
  • Page 11 Safety Summary • Stay clear of wire rope entry areas (fairlead or arch • If applying tension to the wire rope manually during rollers, winch drum etc). spooling: » • Make sure ground personnel are in plain view of the ensure that the operator is winching in slowly, operator, and at a distance of at least 1½...
  • Page 12 • Use only the lubricants listed in the Recommended Oil List. See Page 9. • 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.
  • Page 13 Note Notes...
  • Page 14 Notes...
  • Page 15 This Operating Manual is divided into separate sections to describe the various operating characteristics of the The hydraulic control valve controls the operation of the W5C winch. winch. Removable covers on the winch case allow access for repairs and adjustments. The design of the winch...
  • Page 16 The W5C winch has a maximum line pull capacity of The winch has an intermediate gear assembly that 62,500 lbf (278,000 N) when there is one layer or less of provides a gear reduction and increases the available wire rope on the drum.
  • Page 17 General Nameplate Each winch is shipped from the factory with a nameplate as shown in Figure 1. The nameplate is stamped with: • winch model • winch serial number • maximum rated bare drum line pull • maximum wire rope diameter DO NOT operate the winch with larger diameter wire rope.
  • Page 18 Wire Rope Selection WARNING Each winch model can have a variety of wire rope sizes, Load loss hazard. lengths, or grades installed by the user. The maximum wire rope size is shown on the nameplate. The maximum A wire rope that breaks under high tension can rated line pull stamped into the nameplate is based on the suddenly whip back towards the winch, causing maximum wire rope size, EEIPS grade.
  • Page 19 EIPS EEIPS Wire Rope Capacity for Capacity for Maximum Maximum Diameter Full Drum Fill 2/3 Drum Fill Rated Line Pull Rated Line Pull in (mm) ft (m) ft (m) Lbs (N) Lbs (N) 5/8 (16) 423 (129) 279 (85) 29,400 (130,700) 32,400 (144,100) 3/4 (19) 298 (91)
  • Page 20 Wire Rope Reel When the wire rope is transferred from a reel to the drum, derwind winches, as shown in Figure 3, to avoid putting or from the drum back onto a reel, it must go from “top to a reverse bend into the wire rope. top”...
  • Page 21 Wire Rope Installation Keeper WARNING Ferrule Gloves should be worn when working with or near wire rope to prevent cuts and abrasions. NOTE: The illustrations in this section show a winch with an “overwind” configuration, which is standard. Some winches are configured for “underwind” , with the wire rope spooling onto the bottom of the drum instead of the top.
  • Page 22 Another method is to use the tines of a forklift to bear against the reel flange(s). Again, the friction generated between the tines and the flange(s) will create tension in the wire rope. Finally, the end of the wire rope may be fastened to a fork- lift.
  • Page 23 Oil Capacity & Recommended Oil List control. Use the following oils in the W5C winch: The oil capacity for W5C winch is 14.5 gallons (54.9 liters). The type of oil used in Allied winches affects the line Recommended Oils* - General Conditions...
  • Page 24 W5C Winch Description Drum Right Side Drum Shaft Access Cover for Filter Drawbar Access Cover to Hydraulic Valve Bearing Retainer for Idler Shaft Plug to Check Oil Level Bearing Retainer for Brake/Clutch Shaft Plug to Drain Oil Access Cover for Strainer...
  • Page 25 General Optional Equipment • alternate gear ratios The W5C winch may be equipped with the following • electronic controls options: • underwind • integral arch NOTE: Not all optional equipment listed is available • fairlead assembly for each model of dozer.
  • Page 26 A serial number indicates the following information: 1555 Vehicle Code Manufactured By See Figure 10 A = Allied Systems Company Sequence Number Winch Model Internal Option Drive Type Power Forward and Reverse with FREESPOOL = B...
  • Page 27 General Figure 10 Dozer or Skidder Identification Codes and Available Gear Ratios Dozer Make Model and Starting Dozer Serial Number Where Applicable Komatsu Case* Ranger Fiat-Hitachi/ Caterpillar John Deere Dresser/ New Holland Dressta D41E-6  D5N* (Mechanical Dozer Controls)  D5M, D6M ...
  • Page 28 Dozer Make Model and Starting Dozer Serial Number Where Applicable Komatsu Case* Ranger Fiat-Hitachi/ Caterpillar John Deere Dresser/ New Holland Dressta D4H Series I & II  Holland 1150K  DC130  D4H III, D5H PS, XL, LGP;  1150M ...
  • Page 29 Dozer Make Model and Starting Dozer Serial Number Where Applicable Komatsu Case* Ranger Fiat-Hitachi/ Caterpillar John Deere Dresser/ New Holland Dressta D6H/R W/ ESCO Grapple  Fiat/Hitachi FD/FL10E, 700J  FD/DX145  Challenger 65 - 69  700K  700L ...
  • Page 30 Dozer Make Model and Starting Dozer Serial Number Where Applicable Komatsu Case* Ranger Fiat-Hitachi/ Caterpillar John Deere Dresser/ New Holland Dressta Holland 700H 1650L   DC150  750C I & II  750K  750L  D6N* (Mechanical D61EX-12 Dozer ...
  • Page 31 Dozer Make Model and Starting Dozer Serial Number Where Applicable Komatsu Case* Ranger Fiat-Hitachi/ Caterpillar John Deere Dresser/ New Holland Dressta D5N** (Pilot Hydr. Dozer Controls)  D6N** (Pilot Hydr. Dozer Controls)  D6N*** (Diff-Steer after Sep. 2005)  D6N*** Tier 4i ...
  • Page 32 * Dozers (C28 & C47) with mechanical controls, ** Dozers (C77 & C78) with pilot hydraulic controls, and *** Dozers (C81 & C810) with pilot hydraulic controls were effective with the following dozer serial numbers: Dozer Model Dozer Code Dozer Serial Number AGG00000 to AGG01334 AKD00000 to AKD01134 AGG01335 and higher...
  • Page 33 Operation, Power Controls Operation, Power Controls Checks Before Operation Checks During Operation • Check the wire rope and hook for wear or damage. • Check FREESPOOL drag adjustment if equipped. Check that the periodic inspection and maintenance have been done at the recommended operating hours. The Troubleshooting Chart at the end of this section can be See Maintenance Schedule, Figure 20 on page 44 used by the operator to identify a problem with the winch...
  • Page 34 Operating Procedures The BRAKE-OFF position has a detent and is a neutral position for the clutches. Hydraulic pressure is applied to The control lever assembly has two control levers and the release the brake. The winch will not rotate easily because operation is the same in all configurations.
  • Page 35 Operation, Power Controls STANDARD FREESPOOL OPTION Power Control Lever Freespool Lever Figure 11 W5C Towing Winch Operator Controls...
  • Page 36 Power Operation BRAKE-ON position is a neutral position. Neither clutch LINE-OUT position applies the LINE-OUT clutch and is applied. The brake is fully applied. releases the brake. The winch will unwind the wire rope at a speed controlled by the PTO speed of the dozer and the weight of the load.
  • Page 37 Operation, Power Controls Inching is used for a fine control of the winch speed. Inching (LINE-IN). This operation is used to slowly move When the power control lever is slowly moved to a a load toward the dozer. The control valve will cause the position between BRAKE-ON and LINE-IN or between oil pressure to slowly release the brake and slowly apply BRAKE-ON and LINE-OUT, inching occurs.
  • Page 38 FREESPOOL Operation WARNING The control lever normally cannot be moved to the FREESPOOL position if there is a load on the wire rope. If enough force is used to disengage the gear train for the FREESPOOL operation, an FREESPOOL Drag Adjustment uncontrolled release of the load will occur.
  • Page 39 Operation, Power Controls CAUTION Setting the preload on the intermediate shaft too tight will cause bearing overload. Setting the preload too loose will allow shaft to not be parallel. Use caution when adjusting. Determine the correct preload by starting with the preload too loose, and gradually increase the preload until the correct resistance to rotation is achieved (see Page 24).
  • Page 40 Figure 13 Troubleshooting Analysis Chart (Continued on next page) PROBLEM POSSIBLE CAUSE CORRECTION Operation is rough or Hydraulic oil is too cold. Put the control lever in the BRAKE-OFF position. irregular. Run the engine at 1000 rpm to warm the oil before operating the winch.
  • Page 41 Operation, Power Controls Figure 13 Troubleshooting Analysis Chart PROBLEM POSSIBLE CAUSE CORRECTION Brake begins to Brake is worn or needs adjustment. See the Service Manual for additional release before clutch troubleshooting. Pressure modulator needs repair or is applied. adjustment. Winch brake does See the Service Manual for additional Brake is worn or needs adjustment.
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  • Page 43 Operation, Electronic Controls Operation, Electronic Controls Checks Before Operation Checks During Operation • Check the wire rope and hook for wear or damage. • Check the winch indication light: • Check that the periodic inspection and maintenance - Light steady on after oil warmup means some have been done at the recommended operating problem(s).
  • Page 44 Operating Procedures must pull the control lever from the BRAKE-OFF or FREESPOOL position. The electronic control assembly has one control lever. The control lever is connected to the winch through electrical The BRAKE-ON position is a neutral position. No hydraulic pressure is applied to the brake or the clutches.
  • Page 45 NOTE: The filter LED is used to signal a shorted or open valve coil circuit. This LED will also illuminate momentarily as a self-test on startup. Figure 14 W5C Towing Winch Operator Electronic Controls (Old Style)
  • Page 46 IS NOT BEING USED BRAKE-ON LINE-IN WARNING Moving the control lever with the engine OFF and the keyswitch ON may result in accumulator discharge and brake release which will cause loss of load. Figure 15 W5C Towing Winch Operator Electronic Controls (New Style)
  • Page 47 1/2 SECOND ON 1 SECOND OFF 3 SECONDS ON 3 SECONDS OFF Figure 16 Winch Indicator Light Blink Codes...
  • Page 48 Power Operation CONTROL LEVER POSITION CONTROL LEVER POSITION LINE-OUT position applies the reverse clutch and releases BRAKE-ON is a neutral position. Neither clutch is applied. the brake. The winch will unwind the wire rope at a speed The brake is fully applied. controlled by the PTO rpm of the dozer and the weight of the load.
  • Page 49 BRAKE-ON and LINE-IN or between BRAKE- takes control and begins to move the load. 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 CONTROL LEVER paragraphs describe the normal procedures for inching.
  • Page 50 FREESPOOL Operation WARNING CONTROL LEVER POSITION Moving the lever into FREESPOOL while there is a load on the wire rope will cause sudden loss of load which can result in injury and damage. When the control lever is moved to the FREESPOOL Inching (BRAKE-OFF).
  • Page 51 Operation, Electronic Controls CAUTION Setting the preload on the intermediate shaft too tight will cause bearing overload. Setting the preload too loose will allow shaft to not be parallel. Use caution when adjusting. Determine the correct preload by starting with the preload too loose, and CONTROL LEVER POSITION gradually increase the preload until the...
  • Page 52 Figure 18 Troubleshooting Analysis Chart (Continued on next page) PROBLEM POSSIBLE CAUSE CORRECTION Operation is rough or irregular. 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. Low oil level.
  • Page 53 Operation, Electronic Controls Figure 16 Troubleshooting Analysis Chart (Continued...) PROBLEM POSSIBLE CAUSE CORRECTION Brake begins to release before Brake is worn. See the Service Manual for additional clutch is applied. troubleshooting. Winch brake does not apply or Brake is worn. See the Service Manual for additional release correctly.
  • Page 54 Figure 16 Troubleshooting Analysis Chart (Continued...) PROBLEM POSSIBLE CAUSE CORRECTION Filter light blinking. Control module fault or controls not Check Service Manual. activated. FREESPOOL does not operate See the Service Manual for additional correctly. troubleshooting, checks and adjustments. Winch will not freespool. Inadequate freespool piston pressure.
  • Page 55 Operation, Electronic Controls Figure 16 Troubleshooting Analysis Chart (Continued...) Winch will not operate in any Control lever off-center at startup. Return Control lever to BRAKE-ON position function. and attempt function again. Control module not powered. Check fuse & replace if necessary. Control lever DC-DC conver ter Check fuse &...
  • Page 56 Figure 16 Troubleshooting Analysis Chart PROBLEM POSSIBLE CAUSE CORRECTION Noisy buzz emanating from Air in relief cartridge. This is not a detrimental condition. Noise winch. may be intermittent. Control lever will not detent in Detent pin, plate, or spring worn or Replace appropriate parts.
  • Page 57 Use the operating time time for the winch. Access Cover for Filter Access Cover for Hydraulic Valve and Oil Fill Plug to Check Oil Plug to Drain Oil Breather Access Cover for Strainer Figure 19 W5C Winch Maintenance Points...
  • Page 58 INTERVAL PROCEDURE OR QUANTITY SPECIFICATION 5 0 h o u rs o r Check oil level at plug (item 2). Add oil as See Figure 7 – Recommended Oil List. weekly*. necessary. Do not operate the dozer when checking the oil level. Lubricate the winch control lever and the Use SAE 30 oil on the linkage as needed.
  • Page 59 Maintenance INTERVAL PROCEDURE OR QUANTITY SPECIFICATION 1000 hours or Change the hydraulic oil. Drain oil from plug See Figure 7 – Recommended Oil List. every 6 months. (item 4). Clean the oil strainer. Add 14.5 gallons (54.9 liters) † through cover plug (item 2). Check the oil level at item 3.
  • Page 60 There are three configurations of operator controls so that the FREESPOOL shifter mechanism will slide normally used on the W5C winch. Two configurations have the drum pinion gear to both positions. Both positions cable controls and the third is electronic. The electronic have a detent.
  • Page 61 Maintenance B. See Figure 23. Make sure the positions of the power control lever are the same as the position indicators on 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.
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  • Page 63 Operating Techniques, Power Controls Operating Techniques, Power Controls Dozer or Skidder Operation Step 1. The dozer 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 The operator moves the FREESPOOL control lever moves the control lever to the LINE-OUT or the to the NORMAL OPERATION position.
  • Page 64 Step 3. The operator can move the control lever Step 4. If the dozer or skidder must travel through an to the LINE-IN position. If the load is less than area with bad traction conditions, the operator can approximately 75% of the maximum line pull, the move the control lever to the BRAKE-OFF position.
  • Page 65 Operating Techniques, Power Controls 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 levers pull the load toward the vehicle.
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  • Page 67 Operating Techniques, Electronic Controls Operating Techniques, Electronic Controls Dozer or Skidder Operation CONTROL LEVER POSITION CONTROL LEVER POSITION CONTROL LEVER POSITION Step 1. The dozer or skidder is moved to an area Step 2. A load (logs) is connected to the wire rope. where a load will be connected.
  • Page 68 CONTROL LEVER POSITION CONTROL LEVER POSITION Step 4. If the dozer or skidder must travel through an Step 3. The operator can move the control lever to the LINE-IN position. If the load is less than area with bad traction conditions, the operator can move the control lever to the BRAKE-OFF (DETENT) approximately 75% of the maximum line pull, the position.
  • Page 69 Operating Techniques, Electronic Controls CONTROL LEVER POSITION CONTROL LEVER POSITION CONTROL LEVER POSITION Step 5. When the vehicle is on firm ground, the Step 6. When the operator wants to disconnect operator can move the control lever to LINE-IN to from the load, the vehicle is stopped and the control pull the load toward the vehicle.
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  • Page 71 Operating Techniques, General Operating Techniques, General How to Move a Disabled Vehicle engine to the winch and tracks together to remove the vehicle from the bad area. A. A dozer or skidder often travels in areas where traction conditions are bad. A vehicle equipped with a winch can If the vehicle travels faster than the winch winds the be used to remove itself from mud or other areas where wire rope, disengage the transmission until the winch...
  • Page 72 B. A dozer or skidder equipped with a winch can be used Fasten the winch wire rope to the tow bar of the other to pull another vehicle from mud or other areas where it vehicle. The wire rope must be in a direction that is cannot move using only the drive wheels or tracks.
  • Page 73 Operating Techniques, General A. Moving down the slope: Working on a Steep Slope Set the throttle on the dozer for the required engine WARNING speed. The winch and the dozer must be in good Put the dozer in FORWARD. At the same time, condition for the following procedures.
  • Page 74 B. Moving up the slope: Other Equipment is Down the Slope (See Figure 27). Set the throttle on the dozer for the required engine In this operation, the dozer and winch are on stable ground speed. and other equipment is working on a steep slope. The winch is used to give additional control to the equipment Use the LINE-IN control lever to tighten the winch working on the steep slope.
  • Page 75 Operating Techniques, General A. Lowering the equipment on the slope: B. Raising the equipment on the slope: Set the throttle on the dozer for the required engine Set the throttle on the dozer for the required engine speed. Operator experience is required for this speed.
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  • Page 77 Operational Differences, Optional Equipment Operational Differences, Optional Equipment Integral Arch Fairlead When using an integral arch, the wire rope passes over A fairlead consists of a set of top and bottom horizontal a raised horizontal roller and between a set of smaller rollers and side rollers that the wire rope is passed vertical side rollers and an upper horizontal roller.
  • Page 78 Drawbar Alternate 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 80 To find a dealer in your area, Call: 503.625.2560, Fax: 503.625.7269, or Email: marketing@alliedsystems.com, or 599005W 11/08/2024 Printed in U.S.A. Visit our website: www.alliedsystems.com...