Allied Systems W8L User manual

CUSTOMER
EDITION
P/N 599033W Printed in U.S.A. 5/07/2018
Please check the Allied Systems website
regularly for updates to this manual.
www.alliedsystems.com

Safety Precautions
Read, understand and observe the precautions on the following pages
to prevent injury to personnel and damage to equipment.
Winch serial number _________________________
Date put into service _________________________
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.

i
Safety Summary
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 and 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 serious injury or death.
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.
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.
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.
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’s country, the national regulations should
be followed.
Operation, Inspection, and Maintenance Warnings
WARNING
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
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.
• 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.

ii
»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.
• 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.
• 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!
• 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).
KG
KG
KG
KG
Safety Summary

iii
• 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 599781W.
• 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.
• 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 page 1-11.
• 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.
Safety Summary

iv
Notes
Ordering Parts:
When ordering replacement parts, give the unit serial number,
part number, name of part and quantity required.
For any further information on parts, service or ordering, consult your local winch dealer, or contact Allied Systems Company:
Allied Systems Company
21433 SW Oregon Street
Sherwood, OR 97140
U.S.A.
Phone: [phone]
Fax: [phone]
E-Mail: par[email protected]
Also see our website, www.alliedsystems.com, where the most current copy of this manual is always available.

v
Contents
Contents
Safety Summary .........................................................i
Section 1: General ..................................................1-1
Introduction...............................................................1-1
Description ...............................................................1-1
Unit Identification .................................................1-2
Installation Drawings by Tractor ...........................1-4
Serial Number Codes ..........................................1-5
Nameplate ...........................................................1-5
Warning and Maintenance Decals.......................1-6
Gear Train ................................................................1-7
Operation and Control ..............................................1-8
Power Controls ....................................................1-8
Electronic Controls ..............................................1-8
Description of Operations ....................................1-8
Capacities & Specifications ....................................1-11
Recommended Oil List ......................................1-11
Winch Drum Line Capacities .............................1-11
Winch Oil Capacity ............................................1-11
Winch Weight.....................................................1-11
Torque Specifications.........................................1-12
Hydraulic Specifications.....................................1-13
Section 2: Power/Cable Controls ..........................2-1
Hydraulic System .....................................................2-1
Forward & Reverse Clutches ...............................2-2
Oil Brake Assembly .............................................2-3
Hydraulic Control Valve........................................2-3
Hydraulic Control Relief Valve .............................2-3
Hydraulic Pump ...................................................2-3
Accumulators.......................................................2-5
Accumulator Valve ...............................................2-5
Check Valve .........................................................2-5
Cooling Oil Relief Valve .......................................2-5
Sequence of Operation - BRAKE-ON..................2-6
Sequence of Operation - LINE-IN........................2-7
Sequence of Operation - LINE-OUT INCHING....2-8
Sequence of Operation - LINE-OUT....................2-9
Sequence of Operation - BRAKE-OFF..............2-10
Service ...................................................................2-11
Maintenance Points ...........................................2-11
Maintenance Schedule ......................................2-11
Checks Before Operation...................................2-12
Checks During Operation ..................................2-12
Checks and Adjustments...................................2-12
Control Cable Adjustments................................2-12
FREESPOOL Cable Adjustment .......................2-13
Hydraulic System Pressure Checks ..................2-14
Preparation ........................................................2-14
Pressure Gauges ..............................................2-14
Brake Pressure Check.......................................2-14
Cooling Oil Pressure Check...............................2-14
Accumulator Pressure Check ............................2-16
Forward Clutch Pressure Check and Forward
Modulator Valve Check/Adjustment ...................2-16
Reverse Clutch Pressure Check and Reverse
Modulator Valve Check/Adjustment ...................2-16
Control Valve Spool Travel Check ......................2-17
Hydraulic Systems Pressure Tests Chart ..........2-18
Troubleshooting ......................................................2-19
Troubleshooting Analysis Check Chart ..............2-19
Troubleshooting Analysis Check Chart
for FREESPOOL Option....................................2-22
Section 3: Electronic Controls ..............................3-1
Hydraulic System......................................................3-1
Valve Manifold Assembly......................................3-2
Relief Valve.........................................................3-10
Forward & Reverse Clutches..............................3-10
Oil Brake Assembly.............................................3-10
Hydraulic Pump..................................................3-10
Accumulator Valve..............................................3-10
Check Valve........................................................3-10
Sequence of Operation - BRAKE-ON........3-11/3-15
Sequence of Operation - LINE-IN..............3-12/3-16
Sequence of Operation - LINE-OUT..........3-13/3-17
Sequence of Operation - BRAKE-OFF......3-14/3-18
Electronic Control Module ......................................3-19
LED States For Various Functions.....................3-19
Input / Output Functions ....................................3-20
Electronic Control Program Diagram .................3-20
Service ...................................................................3-21
Maintenance Points ...........................................3-21
Maintenance Schedule ......................................3-21
Checks Before Operation...................................3-22
Checks During Operation ..................................3-22
Control Lever Detent Force Adjustment.............3-22
Hydraulic System Pressure Check ....................3-28
Preparation ........................................................3-26
Pressure Gauges...............................................3-26
Brake Pressure Check.......................................3-26
Cooling Oil Pressure Check...............................3-26
Accumulator Pressure Check ............................3-26
Forward Clutch Pressure Check ........................3-27
Reverse Clutch Pressure Check........................3-27
Hydraulic System Pressure Test Chart ..............3-28
(continued on next page)

vi
Contents (continued)
Contents
Troubleshooting ......................................................3-29
Troubleshooting Analysis Check Chart
for Operators......................................................3-29
Troubleshooting Analysis Check Chart
for Service Personnel ........................................3-31
Troubleshooting Chart
for Electronic Control Module ............................3-35
Interfacing with the Electronic Control Module ..3-36
DVC Controller Goes into Programming Mode
When Powered On.............................................3-36
eControls Utility Instructions ..............................3-37
eControls Schematic .........................................3-45
Section 4: Repairs .................................................4-1
General ....................................................................4-1
Winch Removal ........................................................4-1
Winch Disassembly ..................................................4-1
General Gear Arrangement......................................4-2
PTO Shaft Removal & Disassembly .........................4-4
Oil Brake Removal & Disassembly ...........................4-6
Hydraulic Pump Removal & Disassembly ..............4-10
Pump Disassembly ............................................4-10
Pump Inspection................................................4-11
Pump Gear ........................................................4-11
Pump Front & Backplates ..................................4-11
Pump Body ........................................................4-11
Clutch Shaft Removal & Disassembly ....................4-12
Ratios #1 - #7.....................................................4-14
Ratios # 8 - #10..................................................4-16
Oil Clutch Disassembly...........................................4-20
Brake Shaft Removal..............................................4-22
Intermediate Shaft Removal, Freespool .................4-24
Intermediate Shaft Removal, Non-Freespool .........4-26
Drum Shaft & Drum Removal .................................4-28
Winch Assembly .....................................................4-32
Visual Inspection ...............................................4-32
Drum Shaft & Drum Installation..............................4-34
Intermediate Shaft Installation, Non-Freespool ......4-38
Intermediate Shaft Installation, Freespool..............4-40
Brake Shaft Installation...........................................4-44
Oil Clutch Reassembly ...........................................4-46
Clutch Shaft Reassembly & Installation..................4-50
Rebuilding & Installation of Parts Instructions
for Repair of Reverse Clutch Gear......................4-56
Hydraulic Pump Reassembly & Installation............4-66
Pump Installation ...............................................4-67
Oil Brake Reassembly & Installation.......................4-68
PTO Shaft Reassembly & Installation.....................4-72
Winch Installation ...................................................4-74
Specialized Tools ....................................................4-76

vii
Notes
Notes

viii
Notes
Notes

Section 1
1 - 1
General
Introduction
This service manual is for the W8L winch. The following
information is included in this manual:
Section 1. General includes operational descriptions of
systems and components as an aid for troubleshooting
and repair.
Section 2. Power/Cable Controls focuses on the
system formation, provides a guide for periodic
maintenance, checks and adjustments, and lists
common problems and the possible causes and
corrections for a winch with power/cable controls.
Section 3. Electronic Controls focuses on the system
formation, provides a guide for periodic maintenance,
checks and adjustments, and lists common problems
and the possible causes and corrections for a winch
with electronic controls.
Section 4. Repairs describes the removal, disassembly,
assembly, and installation of the winch.
Description
The W8L winch is a Power Forward (LINE-IN) and Power
Reverse (LINE-OUT) winch used on tractors with a
constant running power takeoff (PTO). The winch utilizes
a Self Contained Hydraulic (SCH) system where all
hydraulic power is produced inside the winch case.
The W8L winch has a BRAKE-OFF function, which
permits the wire rope to be pulled from the drum. A
FREESPOOL function is available as an option on the
W8L winch.
The W8L winch has a rated line pull capacity of 355,480
N (80,000 lbf) when there is one layer of wire rope on
the drum.
DRUM SHAFT RETAINER
CLUTCH SHAFT RETAINER
OIL LEVEL PLUG
BRAKE SHAFT RETAINER
INTERMEDIATE SHAFT RETAINER
FREESPOOL DRAG ADJUST
DRAWBAR PIN
DRAWBAR
FILTER COVER
BRAKE COVER
SERIAL NUMBER
PLATE
Figure 1-1 Model Views

General
1 - 2
In Addition to the serial number plate,
the serial number is stamped on to
the left hand side of the frame. (See
Figure 1-4 on page 1-4.)
Circled numbers in Figure 1-2 indicate
possible gear ratios.
2.
Notes: 1.
Unit Identification
Allied Winch S/N Nameplate Data For Tractor Mountings
A W8L P 3 F 1555 H51
Manufactured By Vehicle Code
Sequence Number
Internal Option
Winch Model
Type Drive
Gear Ratio
A = Allied Systems Company
(no "A" = Hyster Company)
P = Power Controls
E = Electronic Controls
X = Direct Drive (Gear Drive)
See Figure 1-2
W8L = Standard
K8L = Special Design (Contact Factory)
Code = Forward Ratio/Reverse Ratio
1 = 49.8:1/19.9:1
2 = 71.6:1/28.6:1 (95.4/38.1 - K50)
3 = 94.0:1/37.6:1 (125/50 - K50)
4 = 84.0:1/33.6:1 (Non-Current)
5 = 90.1:1/36.0:1 (Non-Current)
6 = 68.8:1/27.5:1 (49.8/19.9 Winch x 1.38 Gearbox)
7 = 47.1:1/31.1:1
8 = 125:1/190:1 (94/143 Winch x 1.33 Gearbox)
9 = 94:1/102:1
10 = 125:1/136:1 (94/102 Winch x 1.33 Gearbox)
11 = 85.4:1/34.1:1 (49.8/19.9 Winch x 1.71 Gearbox)
F = Freespool
N = Non-Freespool
V = Underwind Non-Freespool
Tractor Make Model and Starting Tractor Serial Number Where Applicable
C
O
D
E
A
Fiat-Hitachi/
New Holland
C
Caterpillar
G
Terex
H
Dresser
K
Komatsu
M
MF
N
Zoomlion
48 D68ESS-12

50 D85E/PX-15

51
16B PS
S/N 10301 & UP

D7F *a,
D7G PS Series I

D700A,
82-20B, 82-20

TD20E/G/H PS,
TD20M

D80A-12

D700C,
D700D TEREX

52
16B DD
S/N 10301 & UP

D7F DD, D7G DD *b

D85A-12

53
AB/BD 20 PS,
20B FL20

572 *c,
572G

D85E-18,
D85P-18

Figure 1-2 Tractor Identification and Gear Ratio
(Continued on next page)

Section 1
1 - 3
®
Figure 1-2 Tractor Identification and Gear Ratio (continued)
Tractor Make Model and Starting Tractor Serial Number Where Applicable
C
O
D
E
A
Fiat-Hitachi/
New Holland
C
Caterpillar
G
Terex
H
Dresser
K
Komatsu
M
MF
N
Zoomlion
54
20 DD

983 S/N 38K,
D7R, D7H PS

D85E-21,
D85P-21

55
FD20/FL20,
FP60

D8N *d

D83-1,
D85E-SS-1

56
DX255, FD255,
D255

D8N *e,
D8R

D135A

57 D7R PS

D85E-SS-2 *f
⑪
ZD220

58 D8R

D87E-2

59 D8R SERIES II

D155AX-5

60 572R

70 572R SERIES II

72
D7R SERIES II


74 D8T

83 D7G SERIES II

983
983 Track Loader
S/N 38K

*a Caterpillar D7F S/N 94N5660 & UP
*b Caterpillar D7 DD S/N 91V, 93N, 64V & 45W
*c Caterpillar 572 S/N 40U, 6J
*d Caterpillar prior to D8N S/N 5TJ0001, same as C56 for AW8L-2293 & up; D7H not used
*e Caterpillar D8N S/N 5TJ0001 & UP
*f Komatsu D85E-SS-2 Gear Ratios 1 & 5 are both 90.1:1.

General
1 - 4
Figure 1-3 List of Installation Drawings
W8L INSTALLATION DRAWINGS BY TRACTOR
Winch Serial
Number Description
Installation
Drawing
Part Number
W8LE**C57 W8L CAT D7R 2310568
W8LE**C58 W8L CAT D8R 2310568
W8LE**C59 W8L CAT D8R SERIES II 2310568
W8LE**C60 W8L CAT 572R 2312113
W8LE**C72 W8L CAT D7R SERIES II 2310568
W8LE*NC74 W8L CAT D8T 2313767
W8LP**A55 W8L F/H 308424W
W8LP**A56 W8L F/H FD255 2301867W
W8LP**C51 W8L CAT D7F & D7G SERIES 1 256611W
W8LP**C53 W8L CAT 572G 2313220
W8LP**C54 W8L CAT D7H/R 379453W
W8LP**C56 W8L CAT D8N PS 379453W
W8LP**C57 W8L CAT D7R 379453W
W8LP**C58 W8L CAT D8R 379453W
W8LP**C59 W8L CAT D8R SERIES II 379453W
W8LP**C60 W8L CAT 572R 2305491W
W8LP**C72 W8L CAT D7R SERIES II 379453W
W8LP**C74 W8L CAT D8T 2312690
W8LP**C83 W8L CAT D7G SERIES 2 2310921
W8LP**H51 W8L IH & DRESSER TD20E & G 338843W
W8LP**K48 W8L KOM D68ESS-12 2301259W
W8LP**K50 W8L KOM D85EX-15 2305919W
W8LP**K53 W8L KOM D85-18 304385W
W8LP**K54 W8L KOM D85-21 304385W
W8LP**K55 W8L KOM D83 1308404W
W8LP**K56 W8L KOM D135A 1310760W
W8LP**K57 W8L KOM D85ESS-2 2301259W
W8LP**K58 W8L KOMATSU D87 338843W
W8LP**N57 W8L ZOOMLION ZD220 2315560
W8LP6NU57 W8LP ON SHANTUI SD20-5 2313502
W8LP3NC983 W8LP ON CAT TRACK LOADER 983 S/N 38K 2314363
Power Control (push pull cable)
Electronic Control
This list is for operators to keep track of necessary information of their winch installation drawings by tractors.
If any of the installation drawings listed above is needed, please contact the Service Department of Allied Systems Company.
2.
Notes: 1.

Section 1
1 - 5
Serial Number Codes
The serial number codes are described on pages 1-2 and
1-3 of this manual. The nameplate with the serial number
code is found on the top left hand side of the winch case.
The serial number code is also stamped on the left hand
side of the winch frame.
Nameplate
Each winch is shipped from the factory with a nameplate
as shown in Figure 1-4. The nameplate is stamped with:
• winch model
• winch serial number
• maximum bare drum line pull
• maximum wire rope diameter
DO NOT operate the winch with larger diameter wire rope.
If the nameplate is missing, DO NOT operate the winch
until its capacity is known.
The serial number for the winch is also stamped into the
frame next to the nameplate.
Figure 1-4 Nameplate

General
1 - 6
Figure 1-5 Decal Installaion
Warning and Maintenance Decals
The unit nameplate, a Warning Decal and a Maintenance
Plate are located on the winch as shown in Figure 1-5.
If the nameplate has been damaged, obtain a new one
and install the new nameplate in the location shown in the
figure. If the Warning Decal or Maintenance Plate have
been damaged, install a new one in the location shown.
Decals are used on both sides of the winch frame as
shown. Replace as necessary.

Section 1
1 - 7
Figure 1-7 Gear Train Rotation Torque Transfer (Ratios #1 - #7 only)
Gear Train (Ratios #1 - #7)
The gear train (Figure 1-6) consists of:
1. a PTO shaft assembly
2. a clutch shaft assembly
3. a brake shaft assembly
4. an intermediate shaft assembly; and
5. a drum shaft assembly
Figure 1-6 Gear Train (Ratios #1 - #7 only)
Torque transfer during operation is shown in Figure 1-7.
NOTE: PTO rotation direction is determined by
standing behind tractor and looking forward at the
PTO shaft entering the winch case.
BRAKE-ON (Neutral) LINE-IN (Forward) LINE-OUT (Reverse)

General
1 - 8
Figure 1-8 Typical Winch Power Controls
Operation and Control
Power Controls
The control lever assembly has a power control lever
for winch control (See Figure 1-8). If the winch does
not have the FREESPOOL function, the second control
lever is not used. Both control levers are connected to
the winch through control cables. The power control
lever is connected to the spool in the control valve. The
power control lever is used to select one of the following
operations:
BRAKE-OFF
LINE-OUT
BRAKE-ON
LINE-IN
Electronic Controls
The electronic control assembly has one control lever (See
Figures 1-9 and 1-10). The control lever is connected to
the winch through electrical wiring, an electronic control
module and a solenoid-actuated control valve. This lever
is used to select one of the following operations:
BRAKE-OFF
LINE-OUT
BRAKE-ON
LINE-IN
Description of Operations
BRAKE-OFF is the only detented position on the
handlever (electronic controls) or control lever (power
controls), and the operator must pull the lever to release
it from that position. A spring arrangement on the lever
returns the lever from the LINE-IN and LINE-OUT
positions to the BRAKE-ON position. With the lever in
the BRAKE-OFF position, oil pressure releases the brake
but wire rope cannot be pulled from the winch by hand
because of friction in the clutches, brake and gear train.
The BRAKE-OFF position is used when the operator has
a load attached to the winch wire rope. The operator can
move the tractor forward without moving the load.
LINE-OUT position applies the reverse clutch and
releases the brake. The winch will unwind the wire rope
at a speed controlled by the PTO speed of the tractor and
the weight of the load.
BRAKE-ON is a neutral position. No hydraulic pressure
is applied to the brake or the clutches. Springs apply the
brake so that the winch drum will not rotate.
LINE-IN position applies the forward clutch and releases
the brake. The winch will wind the wire rope at a speed
controlled by the PTO speed of the tractor.
Inching is used for fine control of the load. When the
control lever is slowly moved to a position between
BRAKE-ON and LINE-IN or between BRAKE-ON and
LINE-OUT, inching occurs.
1
2
1. Power Control Lever
2. Freespool Lever (Optional)
READ OPERATING
INSTRUCTIONS
271731W
BRAKE
OFF
BRAKE
ON
LINE
IN
LINE
OUT
NORMAL
OPERATION
FREESPOOL
FREESPOOL
CONTROL
READ OPERATING
INSTRUCTIONS
271731W
BRAKE
OFF
BRAKE
ON
LINE
IN
LINE
OUT
NORMAL
OPERATION
FREESPOOL
FREESPOOL
CONTROL

Section 1
1 - 9
NOTE: Inching rapidly increases the temperatures of
the clutch, the brakes and the oil, and will accelerate
clutch and brake wear.
Inching (LINE-IN).This operation is used to slowly move
a load toward the tractor. As the control lever is moved
gradually towards the LINE-IN position, the control valve
will cause the oil pressure to slowly release the brake and
slowly apply the forward clutch. As the brake is released,
the clutch takes control and begins to move the load.
Inching (LINE-OUT). This operation will release the brake
as the reverse clutch is applied.This permits the weight of
the load, with assistance from the reverse clutch, to unwind
wire rope from the winch drum against the resistance of
the brake.The operator controls the resistance of the brake
by the position of the control lever.
1. Electronic Control Lever
2. LED Bypass Assembly
3. Rocker Switch Assembly
4. Winch Light Decal
5. Winch Light Indicator Decal
6. Control Lever Decal
7. Activation Switch Decal
Figure 1-9 Electronic Controls (Old Type)
Figure 1-10 Electronic Controls (New Type)
1. Electronic Control Lever
2. LED Bypass Assembly
3. Winch Light Decal
4. Rocker Switch Assembly
5. Activation Switch Decal
6. Winch Light Indicator Decal
7. Control Lever Decal

General
1 - 10
The FREESPOOL arrangement allows mechanical
disengagement of the drum gear from the remainder of the
gear train.When the FREESPOOL control lever is shifted,
the dental clutch engages or disengages the drum pinion
and intermediate gear. (See Figure 1-11)
WARNING
When the control lever is moved to the
FREESPOOL position, it will release the
gear train and any load that may be on
the wire rope. An uncontrolled release of
the load may occur. Loss of the load can
result in injury and damage.
The power control lever must be in the BRAKE-ON or
BRAKE-OFF positions to operate the FREESPOOL
control lever. When the FREESPOOL control lever is
moved to the FREESPOOL position, the sliding sleeve
disengages the drum pinion gear from the intermediate
gear. The gear train is disengaged from the drum gear so
that the wire rope can be pulled from the drum by hand.
Only the drum and drum pinion gear rotates when the
wire rope is pulled during FREESPOOL operation. The
resistance to rotation by the drum during FREESPOOL
is controlled by the preload on the bearings for the
intermediate shaft.
If the FREESPOOL control lever cannot be moved to
engage the gear train for power operation, apply the clutch
to move the gear train a small amount.This action will align
the splines in the dental clutch so that the intermediate
gear can be engaged.
Figure 1-11 Freespool