599024W - Allied Systems Company
Contents
1. Qaz j o o T Wl C It lt GZ S o Io One Solid Arrow indicates lever travel direction Step 1 The tractor or skidder is moved to an area where a load will be connected The operator moves the control lever to the LINE OUT position or acti vates the FREESPOOL switch so that the wire rope can be pulled from the winch drum ma ale WINCHIN Step 2 A load logs is connected to the wire rope If FREESPOOL was used the operator must deac tivate the FREESPOOL switch 31 os SE p o Sila ES S CH d e GE ce Solid Arrow indicates lever travel direction Step 3 The operator can move the control lever to Step 4 Ifthe tractor or skidder must travel through the LINE IN position If the load is less than approxi an area with bad traction conditions the operator can mately 50 of the maximum line pull the operator activate the BRAKE OFF switch This will permit the can begin traveling with the vehicle at the same time vehicle to move slowly through the bad traction area The winch will wind the load toward the vehicle as without pulling the load at the same time it travels If the load is nearly the capacity of the line pull the operator must move the load close to t2. Align the tractor with the load to prevent side load ing the winch and to maintain even spooling of the wire rope If applying tension to the wire rope manually during spooling ensure that the operator is winching in slowly keep your hands and clothing well clear of any rollers or the winch drum do not maintain tension by letting the wire rope to slip through your hands use a hand over hand technique to maintain tension Be aware of the ground conditions and make sure the ground and tractor are stable enough to pull the intended load Do not attempt to pull loads in excess of the rated capacity of the winch Keep yourself informed of any applicable codes regulations and standards for the job Your winch may have temperature shut off system for protection of tractor and winch Manual override of high temperature shut off will cause damage to tractor and winch This winch is neither intended designed nor rated for any application involved in the lifting or moving of personnel Use only the lubricants listed in the Recommended Oil List See Pages 8 and 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 Safety Summary Be aware of the hazards of pressurized hydrau lics Wear personal protective equipment such as gloves and safety glasses whenever servicing
3. Operating Manual P N 599024W This manual must be with the vehicle on which this winch is installed Please check the Allied Systems websit regularly for updates to this manua www alliedsystems co 02 22 2013 Winch Model HSC amp H6G Serial Number Date Delivered Date Installed Special Equipment or Attachments Allied A Product of Allied Systems Company 02 22 2013 Sherwood Oregon USA Printed in USA 2 WINCH Foreword Foreword The safe and efficient operation of a winch requires skill and alertness on the part of the operator To develop the skills required the operator must Receive training in the proper operation of the winch and the machine on which it is mounted Understand the capabilities and limitations of the winch and the machine on which it is mounted Become familiar with the winch and the machine on which it is mounted and see that they are maintained in good condition e Read and understand the SAFETY SUMMARY and OPERATING PROCEDURES contained in this Operating Manual In addition a qualified person experienced in the operation of the winch must guide a new operator through several load handling applications before the new operator at tempts to operate the equipment 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 bas
4. TEMP SHUT OFF OVER RIDE switches incorporate a lock to prevent inadvertent actuation The slide lock must be released before the switch can be turned on BRAKE OFF is available as an option only to High Performance winches The HI TEMP SHUT OFF OVERRIDE feature is available as an option to both Rescue and High Performance winches The tractor must be running to supply hydraulic power to operate these functions A WARNING FREESPOOL should not be used if there is a load on the wire rope An uncontrolled release of the load will occur Loss of the load can result in injury and or equipment damage The yellow indicator panel on the selector switch lights when the winch is in FREESPOOL If equipped with BRAKE OFF the red indicator in the BRAKE OFF switch will also light even though that switch is in the off position When FREESPOOL is selected a hydraulically actuated sleeve disengages the drum pinion from the intermediate shaft The drum is now disconnected from the brake and the winch cannot support a load The control lever will still operate the winch motor but the drum will not turn When the BRAKE OFF switch is selected the holding brake is released allowing the tractor to move away from a towed load The tractor must be operated at a slow speed within the range of the first transmission setting The HI SPEED switch is a dual action momentary switch Pushing it towards the operator allows the winch to operate at low speed w
5. from the drum make sure the end of the wire rope and ferrule are controlled when the ferrule is released The end of the wire rope can sud denly move from the drum like a compressed spring when the ferrule is released and cause an injury Stay in the operators seat when operating the winch Do not stand on the vehicle when operating the winch Avoid winch operation near people or other ma chines vii Allied viii Never stand nor permit others to stand in the bight loop of a wire rope Do not stand nor permit others to be near the winch or wire rope when there is tension on the wire rope Observe jobsite 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 Do not leave the vehicle when the winch wire rope is under tension Do not permit riders 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 ko KG Always inspect wire rope tail chain and other rigging components for wear damage broken strands or abuse before use Never use wire rope tail cha
6. installed on the drum will be shorter In some situations very difficult for the operator to know when the winch can create a tension in the wire rope that is nearing the end of the wire rope It is recom greater than the strength of the wire rope The user must mended that the last 5 wraps of wire rope be be careful to select a wire rope that has enough strength painted a contrasting color to alert the opera REESEN tor that the end of the usable wire rope has been reached A WARNING Wire Rope Diameter H5C Capacity During operation of the winch the operator 16mm 5 8 in 129 m 423 ft must know or estimate the line pull and make 19mm 3 4 in 91 m 298 ft sure that the line pull is within the capacity of 22mm 7 8 in 66 m 215 ft the winch and the specifications of the wire rope installed on the drum A broken wire Note Loosely or unevenly spooled line will change rope under high tension can return suddenly capacities Use flexible cable with independent wire in the direction of the winch and cause injury rope center and damage Figure 2 H5C Drum Line Capacities General Wire Rope Diameter H6G Capacity Drum 10 in Ferrule Size amp Type SE Ge s ES oe e HSC Light Ferrule 2 1 4 x 2 0 Dia H6G Light Ferrule 2 1 4 x 2 0 Dia 25mm 1 0 in 68 m 223 ft ight Ferrule 2 1 4 x 2 0 Dia Note Loosely or unevenly spooled line will change Figure 4 Ferrule Size and Type Tor R
7. reducer and two gear reductions to the drum On the H5C torque is transmitted through a holding brake and three gear reductions to the drum Hydraulic oil is supplied by the tractor mounted pump The winch utilizes oil filtration and cooling provided by the tractor circuit Power to the winch is controlled by a control lever and electrical switches located at the trac tor s control station The tractor must be running and the auxiliary hydraulic function switch if equipped must be on LINE IN LINE OUT and BRAKE ON are controlled by a proportional control lever When the control lever is in the BRAKE ON or centered position the holding brake is automatically applied Pushing the lever away from the operator releases the brake and reels wire rope off the drum LINE OUT Pulling the lever towards the operator releases the brake and reels wire rope onto the drum LINE IN Releasing the lever causes it to return to the BRAKE ON position which stops the drum rotation and applies the holding brake Moving the lever a small amount results in slow wire rope movement for inching control Line speed increases proportionally as the lever is moved farther Allied The switch panel may contain up to four rocker switches to control FREESPOOL BRAKE OFF HI SPEED and HI TEMP SHUT OFF OVERRIDE Not every winch is equipped with all four A light shows when a switch is on except for HI TEMP SHUT OFF OVERRIDE The FREE SPOOL BRAKE OFF and HI
8. RRECTION Operation is rough or not regu lar Hydraulic oil is too cold Allow tractor hydraulics to warm up Low oil level Add oil Hydraulic oil becomes too hot Winch is operated for long periods Allow unit to rest Ensure cooler is installed Low oil level Add oil Brake begins to release before the motor moves the drum Brake is worn or needs replacement Brake valve is out of adjustment See the Service Manual for additional information Winch brake does not apply or release correctly Brake is worn Brake valve is out of adjustment or low pressure See the Service Manual for additional information FREESPOOL does not operate correctly Low pressure Load on wire rope See the Service Manual for additional information Oil is coming out of the breather Leak in FREESPOOL hose or shift fork See the Service Manual for additional information 26 Figure 15 Troubleshooting Analysis Chart Maintenance Maintenance The Maintenance Schedule is a program that includes on the hour meter of the tractor to find the maintenance periodic inspection and lubrication Use the operating time time for the winch Maintenance Points 1 Access Cover for Motor and Winch Hydraulics 5 Oil Fill Plug 2 Plug to Check Oil Level 6 Breather 3 Plug to Drain Oil Figure 16 H5C Winch Maintenance Points Allied Sys
9. SC and HEG capacities Use flexible cable with independent wire rope center Figure 3 H6G Drum Line Capacities Allied WINCH Oil Selection The main consideration while selecting hydraulic fluid is the estimated oil temperature extremes that will be expe rienced during service so the most suitable temperature viscosity characteristics are obtained VISCOSITY OIL OPERATING TYPICAL AMBIENT GRADE TEMPERATURE RANGE TEMPERATURE RANGE ISO SAE F Se F Se VG22 10W_ 5 to 140 20 to 60 5 to 40 20 to 4 VG 32 15w 10to 160 12 to 71 10 to 55 12 to 13 VG 46 20 20 to 180 7 to 82 20 to 70 7 to 21 VG68 20 30 to 200 1 to 93 30 to 90 1 to 32 VG 100 30 40 to 220 4 to 104 40 to 110 4 to 43 Figure 5 Oil Selection Chart Factory fill is Exxon Mobil 424 which has an ISO Viscosity Grade 46 to 68 For external pump winches the winch pump uses tractor hydraulic fluid the hydraulic circuit and winch gear housing may have different fluids Note that some hydraulic system oils are not recommended for use inside the winch For inside winch housing use the following oils HYDRAULIC SYSTEM PUMP WINCH CASE GEAR TRAIN Caterpillar Use Tractor Fluid TDTO TO 4 MTO John Deere Use Tractor Fluid Hy Gard Komatsu Use Tractor Fluid Universal Tractor Fluid Chevron Use Tractor Fluid 1000 THF Exxon Mobil Use Tractor Fluid Mobil Fluid 424 C
10. The winch is used to give additional control to the equip ment working on the steep slope A winch with a fairlead option is recommended for this operation if alignment of the other equipment with the winch and tractor is a problem Make sure the tractor and winch are on stable ground and will not slide when the load is applied Align the tractor and winch with the load Apply the parking brake on the tractor Figure 22 Other Equipment on a Steep Slope Allied Systems 37 Allied A Lowering the equipment on the slope 1 38 Set the throttle on the tractor for the required engine speed Operator experience is required for this op eration so that the load is carefully controlled Keep the winch wire rope tightened between the tractor and the equipment being lowered down the slope Use the control lever in the LINE OUT position to control the lowering of the equipment down the slope Move the control lever between LINE OUT and BRAKE ON if inching is required 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 op eration so that the load is carefully controlled Keep the winch wire rope tightened between the trac tor and the equipment being raised up the slope Use the control lever in the LINE IN position to control the raising of the equipment up the slope Move the control lever between LINE IN an
11. Winch Model JI doo Vehicle Code H6G was previously known as WH6G See Figure 11 The W designation has been dropped for simplicity Sequence Number Hydraulic Operation Type H High Performance Internal Options Winch Direction Valve variable or 2 Speed T Rescue Eternal Pump PFR FS BRAKE OFF Clutch B Tractor Direction Valve Single Speed External Pump PFR FS E Early Units had Hydraulic BRAKE OFF Where Motor Rotated External Pump PFR FS J with CARC Green Paint amp 50mm Dia Pin Drawbar Gear Ratio Code 1 60 1 without Tractor Side Installation Parts ae ico Notes 1 In Addition to the serial number S os plate the serial numberis stamped on the top left hand side of the frame 2 Circled numbers in Figure 11 indi cate possible gear ratios Wei Allied Systems Tractor Make Model and Starting Tractor Serial Number Where Applicable General A C E H K o D New Holland Caterpillar John Deere Dressta Komatsu Case E amp Fiat 47 750J 850J D61EX 15 OG O 750J 48 D6N 81 0O Figure 11 Tractor or Skidder Identification Codes and Available Gear Ratios for H6G Winch 17 WINCH Intentionally Blank 18 Allied Systems Operation Operation Checks Before Operation Check the wire rope and hook for wear or damage Check that the periodic inspection and maintenance have been done at the recommended operating hours See Fi
12. ase Use Tractor Fluid Hy Tran Ultra New Holland Use Tractor Fluid Multitran Oil Capacity Figure 6 Recommended Oil List The oil capacity for H5C winch is 17 quarts 16 liters The oil capacity for H6G winch is 8 5 quarts 8 liters General Allied WINCH H5C and H6G Winch Descriptions SERIAL NUMBER PLATE 1 Drum 9 Bearing Retainer for Intermediate Shaft 2 Access Cover for Motor and Winch Hydraulics amp FREESPOOL drag Adjuster 3 Plug to Drain Oil 10 Right Side Drum Shaft 4 Plug to Check Oil Level 11 Drawbar Not Shown 6 Tie Bar 12 Breather 7 EI Plug Figure 7 H5C Towing Winch 19 Allied Systems General NOPON gt 1 SERIAL NUMBER PLATE L SERIAL NUMBER STAMP 7 10 Drum 9 Access Cover for Motor and Winch Hydraulics Plug to Drain Oil 10 Plug to Check Oil Level 11 Tie Bar 12 Breather Fill Plug Bearing Retainer for Intermediate Shaft amp FREESPOOL drag Adjuster Right Side Drum Shaft Drawbar Not Shown Figure 8 H6G Towing Winch 11 Allied Optional Equipment The H5C and H6G winches may be equipped with the NOTE Not all optional equipment listed is available for following options each model of tractor Integral arch See the nameplate for the max wire rope size with arch e Fairlead assembly e Heavy duty extended drawbar e Optional gear ratios for H6G winch I
13. cks or drive wheels Operator experience is required because the winch can use most of the engine power in some vehicles 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 If the vehicle travels faster than the winch winds the wire rope disengage the transmission until the winch wire rope is tightened again Do not drive over the wire rope Figure 19 Moving a Disabled Vehicle Step A B A tractor or skidder equipped with a winch can be used 1 to pull another vehicle from mud or other areas where it cannot move using only the drive wheels or tracks See Figure 20 Use the following procedure Use extra care if traction conditions are bad or if the vehicles are on a slope Bad traction can cause the disabled vehicle or the tractor to slide A slope can require additional distance to stop the vehicles Operating Techniques 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 to set the engine speed at a power level to operate the winch Operator experience is required because the
14. d BRAKE ON if inching is required Keep the equipment being raised in alignment with the winch and tractor Do not permit the winch wire rope to loosen and pass under the drive wheels or tracks of the tractor Operational Differences Optional Equipment Operational Differences Optional Equipment Integral Arch When using an integral arch the wire rope is routed over a raised horizontal roller and through a set of smaller vertical side rollers and an upper horizontal roller This enables the winch to pull upwards versus horizontally on loads In this way the load can be lifted slightly to reduce drag due to ground contact The side and top rollers act as fairleads to protect the wire rope from damage and from damaging the frame Because the line of action of the wire rope is higher than normal the tipping moment applied to the tractor is in creased and the tractor will tip backwards at significantly lower line pulls The operator 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 tractor For this reason the wire rope diameter is limited Refer to tag manual or consult the factory Fairlead A fairlead consists of a set of top and bottom horizontal rollers and side rollers that the wire rope is fed through With this attachment if the direction of line pull is not directly behin
15. d the fairlead rollers instead of across the frame thus protecting both the frame and the wire rope from excessive wear Stability of the tractor is affected somewhat by the fact that the fairlead 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 Allied Systems S Allied Drawbar Do not use the drawbar as an anchor point for a multipoint over puller line from the winch Loads applied to the drawbar are transmitted to the bolts holding the winch to the tractor Standard integral drawbars are designed to handle pulls of 66 of winch rated capacity bolt 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 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 the winch Line pulls in excess of rated capacity will dramatically reduce the life of winch components Allied Systems Notes Notes 41 WINCH 42 Notes NO MATTER HOW YOU SAY IT La Prudence Paye La Seguridad Paga Betriebssicherheit Macht Sich Bezahlt Passaa Olla Huolellinen Veiligheid Voor Alles Sakerhet Forst Ess
16. e However the holding brake is locked out and the winch will not hold a suspended load or a load that can slide away When the BRAKE OFF switch is selected the brake off clutch is disengaged allowing the tractor to move away from a towed load BRAKE OFF is controlled by the rocker switch with a red indicator A safety lock prevents the switch from accidentally being turned on To operate the switch slide the locking tab first then push the rocker switch The BRAKE OFF position is used when there s a load on the winch wire rope It allows the operator to slowly move the tractor away from the load while spooling wire rope off the drum in a controlled manner In BRAKE OFF hydraulic pressure is applied to release the brake off clutch As wire rope is pulled from the winch the turning drum back drives the winch gear train to the brake off clutch The winch motor brake and planetary reducer remain stationary Mechanical drag through the gear train and viscous drag in the brake off clutch keep the wire rope from bird nesting as it is spooled off the drum Allied Systems A WARNING BRAKE OFF should not be used if there is a load on the wire rope An uncontrolled release of the load will occur Loss of the load can result in injury and or equipment damage FREESPOOL Operation A WARNING The winch motor will activate if the lever is moved but the drum will not be in control A WARNING Freespool should not be used if t
17. e BRAKE OFF switch BRAKE OFF mode is simultaneously activated in FREESPOOL to allow re engagement of the gear train when FREESPOOL is turned off 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 informa tion on the nameplate do not operate the winch until its capacity is known The serial number of your winch is stamped both into the nameplate and into the frame as shown in Figures 7 and 8 General Allied ALLIED SYSTEMS COMPANY 21433 SW OREGON STREET SHERWOOD OREGON 97140 USA MUS WWW ALLIEDSYSTEMS COM MODEL SERIAL NO MAXIMUM RATED LINE PULL BARE DRUM MAX WIRE ROPE DIA WITH ARCH O w in usa zte2nevs UO Figure 1 Nameplate Allied Wire Rope Selection A WARNING Each winch model can have a variety of wire rope sizes The wire rope may disengage from the ferrule installed by the user The maximum wire rope size is pocket if there is a load on the wire rope with shown on the nameplate See Figure 2 and Figure 3 for fewer than 3 complete wraps on the drum This approved wire rope sizes and drum capacities When a will cause a loss of load and possible injury larger diameter wire rope is used the length of wire rope When spooling wire rope from the drum it is
18. ere Sicuro Paga Seguran a Paga Sikkerhet F rst Pinter Be Awas mamma a ar A yI F E SAFETY PAYS LELAS LILI lt 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
19. ew can be tightened or loosened to adjust the preload on the intermediate shaft The jam nut will maintain the FREESPOOL setting A 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 Extreme care must be used when adjusting FREESPOOL drag 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 23 Increase the preload by turning the adjusting screw by a maximum of 1 6 rotation 60 degrees and striking the housing with a hammer to make sure the bear ing is sliding Check resistance to rotation after each adjustment HI SPEED Operation On two speed winches the nearest rocker switch selects the HI SPEED mode When activated a green indicator will be lit To achieve high speed the hydraulic winch motor operates at reduced displacement and the same pump flow turns the motor faster producing higher line speed HI SPEED approximately doubles the line speed Note that while operating in HI SPEED the amount of force the winch can pull is reduced The winch speed can be switched from low to high speed or back to low speed while the winch is moving The opera tor may notice a momentary increase in motor noise during the transition This is normal If line pull exceeds a certain percentage of the rated load the wi
20. g procedures or practices equipment is dangerous You must thoroughly review and could cause serious injury or death Carefully understand the Safety Summary before attempting to read the message that follows to prevent seri operate troubleshoot or service this winch ous injury or death The following symbols terms are used to emphasize safety A CAUTION precautions and notices in this manual The CAUTION symbol appears where a A DANGER hazardous situation which if not avoided could result in minor to moderate injury and The DANGER symbol indicates a hazardous equipment damage situation which if not avoided will result in death or serious injury Carefully read the message that follows to prevent serious injury or death WINCH A WARNING This signal word alerts to a situation that is The winch shall not be used for hoisting not related to personal injury but may cause equipment damage A WARNING NOTE The term NOTE highlights operating pro Use hearing protection when operating cedures or practices that may improve winches equipment reliability and or personnel per formance A WARNING Safety Regulations Maximum winch system permissible pressure 650 PSI Control Pressure Each country has its own safety legislation It is in the 3 500 PSI Working Pressure operator s own interest to be conversant with these regu lations and to comply with them in full This also applies NOTE All poss
21. gure 18 the Maintenance Schedule on page 29 Checks During Operation The Troubleshooting Chart Figure 15 on page 26 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 Allied Systems 13 Allied Operating Procedures The H5C and H6G winches are designed to operate on a load sense pilot operated hydraulic system When the tractor is running the winch is ready to operate but no oil is flowing to the winch Pilot pressure is present at the winch The control lever and electrical switches are used to select the following operations not all winches are equipped with all options BRAKE ON spring centered position LINE IN LINE OUT BRAKE OFF optional FREESPOOL HI SPEED either LINE IN or LINE OUT optional HI TEMP SHUT OFF OVERRIDE optional The operator must reset the switches to deactivate the FREESPOOL and BRAKE OFF functions The tractor mounted lever controls LINE IN LINE OUT and BRAKE ON functions When the lever is in the neutral or spring centered position the winch is in BRAKE ON mode In the BRAKE ON position no oil is directed to the motor and the spring applied holding brake prevents drum movement unless BRAKE OFF or FREESPOOL are selected Moving the lever directs a pilot signal to the directional control valve which in turn controls oil f
22. he 0 AWARNING vehicle before beginning to travel A WARNING Drive away speed is limited to 1 0 on speed sele tor or damage to the winch motor can occur Allied Systems WINGH OUT E EE Solid Arrow indicates lever travel direction Step 5 When the vehicle is on firm ground the operator can deactivate the BRAKE OFF switch and move the control lever to LINE IN to pull the load toward the vehicle Operating Techniques Oo we ES Step 6 When the operator wants to disconnect from the load the vehicle is stopped and the FREE SPOOL switch is activated to loosen the wire rope The wire rope is then disconnected from the load Allied Systems Allied How to Move a Disabled Vehicle A A tractor or skidder often travels in areas where traction conditions are bad A vehicle equipped with a winch can be used to remove itself from mud or other areas where it cannot move using only the drive wheels or tracks See Figure 19 Use the following procedure 1 34 Fasten the winch wire rope to a structure tow bar of another vehicle or a tree that has enough strength for the line pull The wire rope must be in a direction that is approximately parallel to the direction of travel of the vehicle Use the throttle to set the engine speed at a power level to operate both the winch and the tra
23. here is a load on the wire rope An uncontrolled release of the load will occur Loss of the load can result in injury and or equipment damage FREESPOOL is controlled by the rocker switch with a yellow indicator A safety lock prevents the switch from being accidentally turned on To operate the switch slide the locking tab first then push the rocker switch Operation FREESPOOL mechanically disengages the winch drum from the drive train so wire rope can be pulled from the winch by hand It also releases the brake to allow re engagement of the gear train when FREESPOOL is turned off When the FREESPOOL switch is turned on the yellow indicator will light as well as the red indicator on the BRAKE OFF switch if so equipped This is because the brake is also released in FREESPOOL mode FREESPOOL must be disengaged by the operator or it will stay on Turn the switch off to disengage 1 Adjusting Nut 2 2 Jam Nut Figure 13 FREESPOOL Adjustments Allied Systems Allied FREESPOOL Drag Adjustment The preload on the bearings of the intermediate shaft controls the resistance to rotation of the drum during the FREESPOOL operation The resistance to rotation is correct when the drum can be rotated by hand but the drum will not rotate more than one half revolution freely An adjusting screw is located in the center of the bearing retainer for the intermediate shaft please refer to Figure 13 This scr
24. hile pushing the switch away from the opera tor activates HI SPEED When in HI SPEED mode green light on the winch will automatically shift to low speed when the load exceeds a certain percentage of the rated load For heavy loads or when better control is desired the winch should be operated in the normal speed For light loads and faster wire rope speed operate the winch in HI SPEED mode Allied Systems 2 Operating Principles of HSC High Performance Winches for Caterpillar D6K C80 and Komatsu D51EX PX 22 K37 Tractors The H5C High Performance winch is designed to oper ate on a hydrostatic pilot operated hydraulic system The winch has a high pressure pump and motor similar to a hydrostatic transmission The charge pump inside the main pump circulates oil to the filter winch control valve control lever and charge circuit of the pump Excess flow from the charge system is sent through the pump and motor for cooling When the tractor is running the winch is ready to operate but no oil is flowing to the winch motor Pilot pres sure is present at the winch control valve A filter bypass indicator light is located near the winch operator controls An illuminated filter bypass indicator light indicates either the oil is too thick or the filter should be replaced If the oil is too thick it is either too cold or an incorrect viscosity grade is being used To warm cold oil operate the tractor at a low to mid throttle setting The
25. ible safety hazards cannot be to local bylaws and regulations in force on a particular foreseen so as to be included in this manual worksite Therefore you must always be alert to poten tial hazards that could endanger personnel Should the recommendations in this manual deviate from and or damage the equipment those in the user country the national regulations should be followed vi Allied Systems Operation Inspection and Maintenance Warnings Obey the following cautions and warn ings 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 operator if the wire rope breaks Read understand and follow the operating inspec tion and maintenance instructions in this Operating Manual Do not use the control levers for hand holds when entering or leaving the vehicle Do not permit other people near the control area when you inspect or repair a machine Never inspect repair or perform maintenance on a machine that is in motion Safety Summary Inspect the winch before each use Make sure that the controls and instruments operate correctly Report the need for repairs immediately Do not work with a damaged or worn wire rope Do not use a winch that needs repairs If the wire rope and ferrule must be removed
26. ic information neces sary for the operation and maintenance of a winch Op tional equipment is sometimes installed that can change the characteristics described in this manual Make sure the necessary instructions are available and understood before operating the winch Some of the components described in this Operating Manual will NOT be installed on your winch If you have questions about any item on your winch or described in this Operating Manual contact your local winch dealer or contact Allied Systems Company Allied Systems Company 21433 SW Oregon Street Sherwood OR 97140 USA Phone 503 625 2560 Fax 503 625 7269 E Mail marketing alliedsystems com Also visit our website www alliedsystems com where the most current copy of this manual is always available Allied Sy illied Systems l COMPANY Allied WINCH NOTE For repairs and overhaul contact your Allied NOTE This publication may be translated to differ winch dealer H you maintain your own equipment a ent languages for sole purpose of easy reference service manual is available for your specific winch 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 Contents Contents FOTW ORG esaa eene Geesse i HI SPEED Operation 24 HI TEMP SHUT OFF OVERRIDE Operation 25 COMENS eebe egegiege he S
27. in or other rigging that is worn out damaged or abused Never overload wire rope tail chain or rigging Wire rope and tail chain will fail if worn out over loaded misused damaged improperly maintained or abused Wire rope or tail chain failure may cause serious injury or death Do not terminate wire rope to tail chain by the use of a knot Do not handle wire rope if the hook end is not free A load could break away suddenly tensioning the wire rope resulting in serious injury or death Stay clear of wire rope entry areas fairlead or arch rollers winch drum etc Safety Summary Make sure ground personnel are in plain view of the operator and at a distance of at least 11 2 times the working 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 Manuals 599029W for H5C winch and 599027W for H6G winch Maintain a minimum of three 3 complete wraps of wire rope on the drum for normal operation It may help to paint 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 Allied
28. low to the hydraulic winch motor Pilot pressure is sequenced to release the holding brake as the directional valve begins supplying flow to the motor Moving the lever toward the operator causes the drum to begin turning and reeling in wire rope The lever is a proportional controller the amount of flow is proportional to the amount of lever movement Mov ing the lever a small amount turns the drum slowly the speed increases as the lever is moved further Gradually releasing the lever slows the line speed until the drum stops When the drum stops the brake is automatically set Inching control of the line can be achieved by small movements of the lever 8 Allied Systems Operation CONTRLLEVER FREESPOOL BRAKE OFF SWITCH SWITCH YELLOW RED DECAL LINE OUT DECAL HIGH PERFORMANCE HI SPEED SWITCH GREEN LINE IN DECAL Figure 12 HSC and H6G Towing Winch Operator Controls Allied Systems SS Allied LINE OUT LINE OUT is controlled in the same manner as LINE IN except the lever is moved away from the operator LINE OUT speed is also proportional to lever movement When the lever is returned to the BRAKE ON position the brake is automatically applied BRAKE OFF BRAKE OFF should not be used to lower a suspended load or a load that can slide down a slope A WARNING If the operator leaves the winch in BRAKE OFF mode the LINE IN and LINE OUT control of the winch will still operat
29. nch will automatically shift to slow speed When in high speed the motor will exhibit an increased level of noise than when used in low speed ES Allied Systems HI TEMP SHUT OFF OVERRIDE Operation A WARNING Winches equipped with HI TEMP SHUT OFF OVERRIDE switch have a temperature shut off for protection of tractor and winch Manual override of high temperature shut off will cause damage of tractor and winch Operation Winches equipped with a HI TEMP SHUT OFF OVER RIDE have a sensor in the winch to sense the oil tem perature of the high pressure working lines Once the oil reaches a set point the sensor automatically activates a switch which energizes a solenoid valve to shut off the tractor pilot supply to the control lever and the red light in the indicator panel will illuminate All functions of the winch will be stopped other than FREESPOOL Tractor controls and operation are not affected Selecting and holding down the HI TEMP SHUT OFF OVERRIDE will resume all operation of the winch Releasing the switch allows it to go back to the winch disabled position LINE OUT DECAL T CONTROLLI HI TEMP SHUT OFF OVERRIDE SWITCH RED LINE IN DECAL DECAL aes SWITCH YELLOW Figure 14 HSC and H6G RESCUE Winch Operator Controls Allied Systems z Allied Troubleshooting Chart PROBLEM POSSIBLE CAUSE CO
30. ntegral Arch Fairlead Figure 9 Optional Equipment H6G Shown 12 Allied Systems Intentionally Blank General 13 Allied Serial Number Codes The nameplate with the serial number code is found on the left front corner of the winch case A serial number indicates the following information H5C 4H 1 E 1501 C80 Winch Model o Vehicle Code H5C was previously known as WH5C See Figure 10 The W designation has been dropped for simplicity Sequence Number Hydraulic Operation Type Internal Options H High Performance dE External Pump PFR FS amp Overwind E Hydraulic or Hydrostatic with 2 Speed amp BRAKE OFF External Pump PFR FS amp Underwind U T Rescue Tractor Direction Spool Single Speed Notes 1 In Addition to the serial number plate the serialnumberis stamped on the top left hand side of the Gear Ratio Code frame 2 Circled numbers in Figure 10 indi 1 45 1 i 9 2 48 1 cate possible gear ratios Ge Allied Systems Tractor Make Model and Starting Tractor Serial Number Where Applicable General A A C E H K R D New Holland Caterpillar John Deere Dressta Komatsu Case E amp Fiat D51 22 37 OG 39 700J 48 750J D6K 80 DO 391 PL61 Figure 10 Tractor or Skidder Identification Codes and Available Gear Ratios for HSC Winch 15 Allied WINCH H6G H 1 B 1501 C81
31. or checking a hydraulic system Assume that all hydraulic hoses and compo nents are pressurized Relieve all hydraulic pressure before disconnecting any hydraulic line Never try to stop or check for a hydraulic leak e with any part of your body use a piece of card yP board to check for hydraulic leaks Small hydraulic hose leaks are extremely dan gerous and can inject hydraulic oil under the skin even through gloves Infection and gangrene are possible when hydraulic oil penetrates the skin See a doctor immediately to prevent loss of limb or death Allied Systems S WINCH xii Notes General General Introduction This Operating Manual contains basic information neces sary for the operation and maintenance of the H5C and H6G winches How Winches Operate 1 Operating Principles of Winches for Caterpillar D6N C81 PL61 C391 John Deere 750J 850J E47 750J E48 and Komatsu D61 15EX K47 Tractors A winch is normally installed on a skidder or tractor to e increase the pulling power of the skidder or tractor e reach into an area where a skidder or tractor cannot go e make lift functions available when special attachments are installed The winch is powered by an internal hydraulic motor connected to the tractor hydraulic system Oil flow and pressure are converted to rotational energy by the winch motor On the H6G torque is transmitted through a holding brake a planetary speed
32. ractor is Down the Slope See Figure 21 Sometimes a tractor must work on a steep slope and can use a winch to give assistance when moving on the slope a Allied Systems Fasten the winch wire rope to the drawbar of another trac tor 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 for the required engine speed 2 Put the tractor in FORWARD At the same time move the winch control lever to a position between BRAKE ON and LINE OUT inching to control the speed of the tractor down the slope Figure 21 Working on a Steep Slope B Moving up the slope 1 Set the throttle on the tractor for the required engine speed Put the control lever in LINE IN position to tighten the winch wire rope When the winch wire rope is tight put the tractor transmission in the FIRST speed range and REVERSE and engage the tracks or drive wheels At the same time move the control lever on the winch to LINE IN Use the steering on the tractor to keep the travel of the tractor in line with the winch wire rope Engage LINE IN as necessary Do not permit the winch wire rope to loosen and pass under the drive wheels or tracks of the tractor Operating Techniques Other Equipment is Down the Slope See Figure 22 In this operation the tractor and winch are on stable ground and other equipment is working on a steep slope
33. tems Allied 1 Access Cover for Motor and Winch Hydraulics 5 Fill Plug 2 Plug to Check Oil Level 6 Breather 3 Plug to Drain Oil Figure 17 H6G Winch Maintenance Points Se Allied Systerns Maintenance Schedule Maintenance INTERVAL PROCEDURE OR QUANTITY SPECIFICATION 50 hours or weekly Check oil level at plug item 2 Add oil as necessary through fill plug item 5 See Figure 15 on page 21 and Figure 16 on page 22 Do not operate winch when checking the oil level See Oil Selection and Oil Capacity for details Clean the breather item 6 Remove debris around breather Clean the breather with solvent if necessary Lubricate the rollers on the integral arch or the fairlead assembly if the winch is equipped with either of these options Use multi purpose grease with 2 4 molybdenum disulfide 2000 hours or every 12 months Change the gear oil Drain oil from plug item 3 Add 16 liters 17 quarts through fill plug item 5 for H5C and 8 liters 8 5 quarts for H6G Check the oil level at oil level check plug item 2 See Oil Selection and Oil Capacity for details Figure 18 Maintenance Schedule 29 WINCH 30 Intentionally Blank Operating Techniques Operating Techniques ractor or Skidder Operation
34. the BRAKE ON position the brake is automatically applied When the BRAKE OFF switch is selected the brake off clutch is disengaged allowing the tractor to move away from a towed load BRAKE OFF is controlled by the rocker switch with a red indicator A safety lock prevents the switch from accidentally being turned on To operate the switch slide the locking tab first then push the rocker switch The BRAKE OFF position is used when there s a load on the winch wire rope It allows the operator to slowly move the tractor away from the load while spooling wire rope off the drum in a controlled manner In BRAKE OFF hydraulic pressure is applied to release the brake off clutch As wire rope is pulled from the winch the turning drum back drives the winch gear train to the brake off clutch The winch motor brake and planetary reducer remain stationary Mechanical drag through the gear train and viscous drag in the brake off clutch keep the wire rope from bird nesting as it is spooled off the drum FREESPOOL is controlled by the rocker switch with the yellow indicator A safety lock prevents the switch from be ing accidentally turned on To operate the switch slide the locking tab then push the rocker switch FREESPOOL me chanically disengages the winch drum from the drive train so wire rope can be pulled from the winch by hand When the FREESPOOL switch is turned on the yellow indicator will light as well as the red indicator on th
35. uck eg tteacettve eege A iii Winch Troubleshooting Chart n se 26 Safety Summary cece eee e teeter eteeeeeeeeee v Maintenance Elle 27 General Maintenance Points 27 lat sie e Le 1 Maintenance Schedule sseeeeeeeeeeeeereeee 28 How Winches Operaie 1 Nameplate ossiani deg eaten 5 Operating Techniques Cable Selection 0 eeccececceeeeeeeeeeseeeeeeeeeeeaeeeteaeeens 6 Tractor or Skidder Operation seese 31 Oil Selection A Capacity ceccceeeeeeeeeteeeeeeteeees 8 How To Move A Disabled Vebcle 34 HSC A H6G Winch Description 10 Working on A Steep Slope ssssieeseeseseeseseesseereeeene 36 Optional Eouipment est ege Ee 12 Tractor Is Down The Slope sseeeeseeseeeeeeeee 36 Serial Number Codes 14 Other Equipment Is Down The Slope 37 Operation Operational Differences Optional Equipment Checks Before Operation ccccceeeeteeeeeteeeees 19 Integral Ath mossa uavencia geed 39 Checks During Operation 19 ell EE 39 Operating Procedures AA 20 Ree A0 FREESPOOL Operation 23 Optional Gear Ratios ccccceeceeeeeeeeeeeeeteeeeeeaes 40 FREESPOOL Drag Adiusiment 23 WINCH Intentionally Blank Safety Summary Safety Summary General Safety Notices A WARNING The following pages contain general safety warnings which supplement specific warnings and cautions appear The WARNING symbol appears wherever ing elsewhere in this manual All electrical and hydraulic incorrect operatin
36. winch can use most of the engine power in some vehicles Put the control lever in the LINE IN position to tighten the winch wire rope When the winch wire rope is tight use the power from the engine to the winch Ensure the wire rope and tow chain have the capacity to do the job If the disabled vehicle does not have a tow pin or other equipment for towing carefully fasten the tow chain around the axle of the disabled vehicle Make sure the tow chain is fastened so that the chain will not injure people or damage the vehicle An operator must be on the disabled vehicle to operate the steering and brakes when it is towed Figure 20 Moving a Disabled Vehicle Step B 35 Allied to pull the vehicle from the bad area If the disabled vehicle moves under its own power keep the towing wire rope tight so that the wire rope does not pass under the drive wheels or tracks of the vehicle being towed Working on a Steep Slope A WARNING The winch and the tractor must be in good condition for the following procedures Make sure that the required maintenance has been done on the tractor and winch Use only a wire rope that is in good condition Make sure the wire rope and winch have enough capacity for the load Make sure the anchor for the wire rope has enough capacity for the load A failure of the tractor winch or wire rope while working on a steep slope can cause death or injury and loss of equipment T
37. winch is ready to operate when the filter indicator light is not illuminated The control lever and electrical switches are used to select the following operations General BRAKE ON LINE IN LINE OUT HI SPEED BRAKE OFF FREESPOOL The operator must reset the switches to deactivate the FREESPOOL and BRAKE OFF functions The tractor mounted lever controls LINE IN LINE OUT HI SPEED and BRAKE ON functions When the lever is in the neutral or spring centered position the winch is in BRAKE ON mode In the BRAKE ON position no oil is directed to the motor and the spring applied holding brake prevents drum movement unless BRAKE OFF or FREESPOOL are selected When the operator selects the LINE IN or LINE OUT posi tion charge pressure is metered to the pump swash plate piston motor swash plate piston and to the winch brake release circuit The operator chooses winch direction at the control lever and oil flow from the main pump is supplied to the motor LINE IN and LINE OUT speed is proportional to lever movement By moving the control lever to full stroke HI SPEED is activated Charge pressure actuates the motor Allied swash plate to reduce motor displacement and increase motor rpm If pressure in the main circuit exceeds a fac tory set level the motor will automatically increase motor displacement to prevent motor stall Motor stall will occur when the load exceeds winch capacity When the control lever is returned to
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