Allied Systems H12E User manual

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 599047W 03/03/2014

03/03/2014
Printed in USA
A Product of Allied Systems Company
Sherwood, Oregon USA
Winch Model H12E
Date Delivered
Serial Number
Date Installed
Special Equipment or Attachments

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.
• 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
attempts 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 basic information
necessary for the operation and maintenance of a winch.
Optional 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: [phone]
Fax: [phone]
E-Mail: [email protected]
Also visit our website, www.alliedsystems.com, where
the most current copy of this manual is always available.
Foreword
i

ii
Note: For repairs and overhaul, contact your
Allied winch dealer. If you maintain your own
equipment, a service manual is available for
your specific winch.
Note: This publication may be translated to
different languages for sole purpose of easy
reference in non-English speaking locations.
Should there be differences in interpretations
to the text, please refer to the English language
edition published by Allied Systems Company
as the controlling document.

iii
Contents
Foreword .................................................................... i
Contents....................................................................iii
Safety Summary ....................................................... v
General
Introduction................................................................. 1
Operating Principles of Winch .................................... 1
Nameplate .................................................................. 4
Wire Rope Selection................................................... 5
H12E Winch Descriptions........................................... 6
Oil Selection ............................................................... 7
Recommended Oil List ............................................... 7
Oil Capacity ............................................................... 7
Serial Number Codes ................................................. 8
Optional Equipment .................................................. 10
Operation
Checks Before Operation ......................................... 11
Checks During Operation ......................................... 11
Operating Procedures .............................................. 12
Maintenance
Maintenance............................................................. 17
Maintenance Points .................................................. 18
Maintenance Schedule ............................................. 19
Maintenance Decal................................................... 20
Winch Troubleshooting Chart ................................... 21
Operating Techniques
Tractor Operation...................................................... 23
How To Move A Disabled Vehicle.............................. 26
Working on A Steep Slope ....................................... 28
Tractor Is Down The Slope ................................. 28
Other Equipment Is Down The Slope................. 29
Contents

iv
Intentionally Blank

v
Safety Summary
General Safety Notices
The following pages contain general safety warnings
which supplement specific warnings and cautions
appearing elsewhere in this manual. All electrical and
hydraulic equipment is dangerous. You must thoroughly
review and understand the Safety Summary before
attempting to operate, troubleshoot or service this winch.
The following symbols/terms are used to emphasize safety
precautions and notices in this manual:
The “DANGER” symbol indicates a hazardous
situation which, if not avoided, will result in
death or serious injury. Carefully read the
message that follows to prevent serious injury
or death.
The “WARNING” symbol appears wherever
incorrect operating procedures or practices
could cause serious injury or death. Carefully
read the message that follows to prevent
serious injury or death.
The “CAUTION” symbol appears where a
hazardous situation which, if not avoided,
could result in minor to moderate injury and
equipment damage.
Safety Summary

vi
NOTICE
This signal word alerts to a situation that is
not related to personal injury but may cause
equipment damage.
NOTE: …
The term “NOTE” highlights operating
procedures or practices that may improve
equipment reliability and/or personnel
performance.
Safety Regulations
Each country has its own safety legislation. The operator
should be aware of these regulations and comply
with them in full. This also applies to local bylaws and
regulations in force on a particular worksite.
Should the recommendations in this manual deviate from
those in the user’ country, the national regulations should
be followed.
NOTE: All possible safety hazards cannot
be foreseen so as to be included in this
manual. Therefore, you must always be alert
to potential hazards that could endanger
personnel and/or damage the equipment.
The winch shall not be used for hoisting.
Use hearing protection when operating
winches.

vii
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
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 suddenly move from the drum like a
compressed spring when the ferrule is released
and cause an injury.
• Stay in the operator’s seat when operating the
winch.
• Do not stand on the vehicle when operating the
winch.
• Avoid winch operation near people or other
machines.
Operation, Inspection, and Maintenance Warnings
Obey the following cautions and
warnings before using your winch to
avoid equipment damage, personal
injury or death.
• Do not operate the winch unless your 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,
inspection, 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.

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.
• Do not use the drawbar as an anchor point for a
multipoint (over pulley) 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%.

ix
Safety Summary
• Always inspect wire rope, tail chain and other rigging
components for wear, damage, broken strands or
abuse before use.
• Never use wire rope, tail chain 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,
overloaded, misused, damaged, improperly
maintained or abused.Wire rope or tail chain failure
may cause serious injury or death!
KG
KG
KG
KG
• 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).
• Make sure ground personnel are in plain view of the
operator, and at a distance of at least 1½ 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 Manual.

x
• 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.
• Align the tractor with the load to prevent side loading
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.
• 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 Page 7.
• 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.

xi
Safety Summary
• Be aware of the hazards of pressurized hydraulics:
»Wear personal protective equipment, such as
gloves and safety glasses, whenever servicing
or checking a hydraulic system.
»Assume that all hydraulic hoses and components
are pressurized. Relieve all hydraulic pressure
before disconnecting any hydraulic line.
»Never try to stop or check for a hydraulic leak
with any part of your body; use a piece of
cardboard to check for hydraulic leaks.
»Small hydraulic hose leaks are extremely
dangerous, 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.

xii
Notes
Notes

1
General
Introduction
This Operating Manual contains basic information
necessary for the operation and maintenance of the winch.
Operating Principles of Winch
A winch is normally installed on a skidder or tractor to:
• increase the pulling power of the skidder or tractor.
• reach into an area where a skidder or tractor cannot go.
• 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. Motor torque is transmitted through a holding brake,
a double-reduction planetary speed reducer, a brake-off
clutch, and two 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. There are two types of internal operation option
codes: Internal Operation Option Code B and Code D.
Note: See Figures 1 and 2 on page 2, and check serial
number for both Option Codes on page 8.
General

2
• Internal Option Code B
Operation of the winch is controlled by a control lever,
and a BRAKE-OFF switch at the tractor’s control station.
• Internal Option Code D
Operation of the winch is controlled by a control lever,
a BRAKE-OFF switch and a HI-SPEED switch at the
tractor’s control station.
Figure 1 - Control Levers & Switch
(Option Code B)
Figure 2 - Control Levers & Switch
(Option Code D)

3
The tractor must be running, and the tractor work
equipment lever must be in the unlocked position. 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.
BRAKE-OFF is controlled by a switch located on the
operator console and directs hydraulic pressure to release
the brake-off clutch.
BRAKE-OFF is used when there is a load attached to the
winch wire rope and the operator wants to move the tractor
away from the load with wire rope spooling off the drum in
a controlled manner.
General
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.
BRAKE-OFF should not be used to lower a
suspended load or a load that can slide down
a slope.
Winches with option Code D have a HI-SPEED switch to
override automatic motor displacement control.

4
Nameplate
Each winch is shipped from the factory with a nameplate
as shown in Figure 3.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.
The serial number of your winch is stamped both into
the nameplate and into the frame, as shown in Figure 6.
Figure 3 - Nameplate

5
Wire Rope Selection
Each winch model can have a variety of wire rope sizes
installed by the user.The maximum wire rope size is shown
on the nameplate. See Figure 4 for approved wire rope
sizes and drum capacities. When a larger diameter wire
rope is used, the length of wire rope installed on the drum
will be shorter. In some situations, the winch can create a
tension in the wire rope that is greater than the strength
of the wire rope.The user must be careful to select a wire
rope that has enough strength and length for the job.
The wire rope may disengage from the ferrule
pocket if there is a load on the wire with fewer
than 3 complete wraps on the drum. This will
cause a loss of load and possible injury.When
spooling wire rope from the drum, it is very
difficult for the operator to know when nearing
the end of the wire rope. It is recommended
that the last 5 wraps of wire be painted a
contrasting color to alert the operator that the
end of the usable wire rope has been reached.
Figure 4 - Drum Line Capacities
Figure 5 - Ferrule Size and Type
Ferrule Size & Type
Junior Ferrule 2 3/8” Long x 2 1/4” Dia.
During operation of the winch, the operator
must know or estimate the line pull and make
sure that the line pull is within the capacity of
the winch and the specifications of the wire
rope installed on the drum. A broken wire rope
under high tension can return suddenly in the
direction of the winch and cause equipment
damage, injury or death.
Wire Rope
Diameter
Length (2/3 Drum
Capacity )
Length (Full Drum
Capacity )
25 mm (1 in) 57 m (188 ft.) 87 m (286 ft.)
28 mm (1 1/8 in) 46 m (150 ft.) 70 m (229 ft.)
32 mm (1 1/4 in) 36 m (119 ft.) 55 m (182 ft.)
Note: loosely or unevenly spooled wire rope will change capacities.
Use flexible wire rope with independent wire rope center.
General

6
H12E Winch Descriptions
Figure 6 - H12E Towing Winch
9
12
1
5
10
6
8
7
4
3
2
6
10 15
13
2
13
12
11
2
8. Drum Shaft
9. Drawbar
10. Breather
11. Maintenance & Warning Decals
12. Serial Number Stamp
13. Nameplate
1. Drum
2. Access Cover for Motor and Hydraulics
3. Plug to Drain Oil
4. Plug to Check Oil Level
5. Tie Bar
6. Fill Plug
7. Bearing Retainer for Intermediate Shaft