Allied Systems W3C 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 2300190W 09/24/2015

09/24/2015
Printed in USA
A Product of Allied Systems Company
Sherwood, Oregon USA
Winch Model W3C
Date Delivered
Serial Number
Date Installed
Special Equipment or Attachments

i
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, and copies of Parts
Manual and Service Manual are 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
How the Winch Operates..........................................1
Nameplate ................................................................2
Wire Rope Selection.................................................3
Approved Oil List & Capacity....................................4
W3C Winch Description............................................5
Optional Equipment..................................................6
Serial Number Codes ...............................................7
Tractor & Skidder Identification Codes...............8
Operation
Operating Procedures ............................................11
Power Operation, Power Forward Only (PFO)........11
Power Forward/Reverse Operation (Optional)........12
FREESPOOL Operation.........................................13
FREESPOOL Drag Adjust ...............................13
Mechanical FREESPOOL Lock .......................14
Checks Before Operation .......................................15
Checks During Operation .......................................15
Troubleshooting Analysis Chart ..............................16
Maintenance
Maintenance Points ................................................19
Maintenance Schedule...........................................20
Control Cable Adjustment, PFO .............................21
Control Cable Adjustment, PFR .............................22
Direction Lever Adjustments...................................25
Operating Techniques, PFO
Tractor or Skidder Operation ..................................27
Operating Techniques, PFR
Tractor or Skidder Operation ..................................31
How To Move A Disabled Vehicle.........................35
Working on A Steep Slope (PFR Only)
Tractor Is Down The Slope ...............................37
Other Equipment Is Down The Slope...............38
Contents
(Continued on next page)

iv
Operational Differences, Optional Equipment
Integral Arch.....................................................41
Fairlead ............................................................41
Drawbar............................................................42
Optional Gear Ratios .......................................42

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:
DANGER
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.
WARNING
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.
CAUTION
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. It is in the
operator’s own interest to be conversant with these
regulations and to comply with them in full. This also
applies to local bylaws and regulations in force on a
particular worksite.
Should the recommendations in this manual deviate from
those in the user’ 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.
WARNING
The winch shall not be used for hoisting.
WARNING
Use hearing protection when operating
winches.

vii
• 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 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,
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.
Safety Summary

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.
• 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.

ix
• 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
• 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 2300191W.
• 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.
Safety Summary

x
• 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
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 not rated for any application involved
in the lifting or moving of personnel.
• Use only the lubricants listed in the Recommended
Oil List. See Page 4.
• 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.
• 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.

xi
Safety Summary
Notes

xii
Notes

1
General
Introduction
This Operating Manual contains basic information
necessary for the operation and maintenance of the W3C
winch.
How the Winch Operates
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 has a hydraulic clutch that is similar to a
hydraulic (powershift) transmission. Each tractor and
skidder has a power take-off (PTO) that is used to connect
the power from the engine to the winch. The SCH (Self
Contained Hydraulics) indicates that the entire hydraulic
system that controls the winch is inside the winch case.
When the PTO is operating, a hydraulic pump in the winch
case takes hydraulic oil from the winch sump and sends it
to the hydraulic control valve. The hydraulic control valve
controls the operation of the winch.
The PTO is connected to the winch’s input shaft. The input
shaft turns the housing of the clutch. When the clutch is
applied, power is transmitted by the gears to the drum. As
the drum rotates, wire rope is pulled into the winch.
The W3C winch has the following operations:
• LINE-IN (For “PFR” Line-in/Line-out)
• BRAKE-ON
• FREESPOOL
• BRAKE-OFF
General

2
Figure 1 - Nameplate
The winch has a gear assembly inside the drum. The
inner gear can slide on splines and is engaged with the
outer gear by a spring. When the control lever is in the
FREESPOOL position the inner gear is disengaged from
the outer gear by a hydraulically actuated piston. Only
the drum rotates when the gear assembly is disengaged.
The W3C winch has a maximum line pull of 41,200 lbs.,
rated at 30,000 lbs.
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.

3
General
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 2 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.
WARNING
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 injury
and damage.
For maximum wire rope strength, there should be at least
three wraps of wire rope on the drum. Painting the last ten
feet red will alert the operator that the wire rope is coming
to the end of its length.
Wire Rope Diameter Drum Capacity
1/2 in. (13 mm)
5/8 in. (16 mm)
3/4 in. (19 mm)
234 ft. (72 m)
227 ft. (69 m)
160 ft. (49 m)
NOTE: Loosely or unevenly spooled line will
reduce capacities.
Figure 2 - Wire Rope Size and Capacities

4
Approved Oil List & Capacity
The type of oil used affects the line control. Use the
following oils in the W3C winch for improved performance:
Figure 3 - Approved Oil List
NOTE: For operation in temperatures below -23°C
(-10° F), use John Deere J20D “LowViscosity Hygard”
or equivalent.
Oil Company Oil Brand
Amoco Oil Company Amoco 1000 Fluid
Exxon Company Hydraul 560
John Deere Hy-Gard Transmission &
Hydraulic Oil
Sun Oil Company Sunfleet TH Universal
Tractor Fluid
The oil capacity for the W3C is 5.5 gallons (20.8 liters).

5
Figure 4 - W3C Towing Winch
1. Frame
2. Cover, Front
3. Cover, LH
4. Cover, Brake
5. Cover, RH
6. Knob, FREESPOOL Drag Adjust
7. Drum
8. Oil Filler/Breather
9. Oil Strainer Cover
10.Oil Drain Plug
11.Oil Level Check Plug
12.Control Lever
General
W3C Winch Description

6
Fairlead Assembly
Figure 5 - W3C Towing Winch, Optional Equipment
Optional Equipment
The W3C winch may be equipped with the following
options:
• fairlead assembly
• alternate gear ratio
• integral arch
• drawbar
• power forward/reverse (PFR)
• mechanical FREESPOOL lock
• extended heavy-duty drawbar
NOTE: Not all optional equipment listed is available
for each model of tractor.
Integral Arch Drawbar