Allied W12E User manual

CUSTOMER
EDITION
P/N 599034W Printed in U.S.A. 11/21/2016
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

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 599782W.
• 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 for details.
• 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
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
Safety Summary ......................................................... i
Section 1: General ..................................................1-1
Introduction...............................................................1-1
Description ...............................................................1-1
Unit Identification ...............................................1-2
Installation Drawings ..........................................1-4
Serial Number Codes.........................................1-5
Nameplate .........................................................1-5
Warning and Maintenance Decals .....................1-5
Gear Train ................................................................1-6
Operation and Control ..............................................1-8
Capacities & Specifications ....................................1-11
Recommended Oil List.....................................1-11
Winch Oil Capacity...........................................1-11
Hydraulic Specifications...................................1-11
Bolt Torque Specifications................................1-12
Section 2: Power/Cable Controls ..........................2-1
Hydraulic System .....................................................2-1
Forward & Reverse Clutches .............................2-2
Oil Brake ............................................................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 ......................................2-6
- BRAKE-ON ......................................................2-6
- LINE-IN ............................................................2-7
- LINE-OUT ........................................................2-8
- LINE-OUT INCHING........................................2-9
- 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
Hydraulic System Pressure Checks.................2-13
Preparation ......................................................2-13
Pressure Gauges ............................................2-13
Brake Pressure Check .....................................2-13
Cooling Oil Pressure Check.............................2-15
Accumulator Pressure Check...........................2-15
Forward Clutch Pressure Check and Forward
Modulator Valve Check ....................................2-15
Reverse Clutch Pressure Check and Reverse
Modulator Valve Check ....................................2-16
Control Valve Spool Travel Check ....................2-16
Hydraulic Systems Pressure Tests Chart.........2-17
Troubleshooting ......................................................2-18
Troubleshooting Analysis Check Chart
for Power Controls ...........................................2-18
Section 3: Electronic Controls ..............................3-1
Hydraulic System......................................................3-1
Valve Manifold Assembly
& Hydraulic Schematic.......................................3-2
Relief Valve ......................................................3-10
Forward & Reverse Clutches ...........................3-10
Oil Brake ..........................................................3-10
Accumulator Valve ...........................................3-10
Check Valve .....................................................3-10
Sequence of Operation (for Old Manifold)........3-11
- BRAKE-ON ...................................................3-11
- LINE-IN .........................................................3-12
- LINE-OUT .....................................................3-13
- BRAKE OFF .................................................3-14
Sequence of Operation (for New Manifold) ......3-15
- BRAKE-ON ...................................................3-15
- LINE-IN .........................................................3-16
- LINE-OUT .....................................................3-17
- BRAKE OFF .................................................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
DVC10 Electronic Schematic ...........................3-21
Service ...................................................................3-25
Maintenance Points..........................................3-25
Maintenance Schedule ....................................3-25
Checks Before Operation.................................3-26
Checks During Operation.................................3-26
Control Lever Lubrication & Adjustment...........3-26
Control Lever Detent Pin Lubrication ...............3-26
Adjusting Joystick Detent Force.......................3-26
Types of Electronic Controls Levers.................3-27
Hydraulic System Pressure Check...................3-28
Preparation ...................................................3-28
Pressure Gauges..........................................3-28
Brake Pressure Check ..................................3-28
Cooling Oil Pressure Check..........................3-28
Accumulator Pressure Check .......................3-28
Forward Clutch Pressure Check ...................3-29
Reverse Clutch Pressure Check...................3-29
Hydraulic Pressure Test Ports.......................3-30
Hydraulic System Pressure Test Chart .........3-32
Contents
(continued on next page)

vi
Contents (continued)
Troubleshooting ......................................................3-33
Troubleshooting Analysis Check Chart
for Operators ....................................................3-33
Troubleshooting Analysis Check Chart
for Service Personnel.......................................3-35
Troubleshooting Chart
for Electronic Control Module...........................3-38
Interfacing with the Electronic Control Modul...3-39
DVC Controller Goes into Programming Mode
When Powered On...........................................3-39
Re-Commissioning DVC Master Modules........3-40
Section 4: Repairs .................................................4-1
General ....................................................................4-1
Winch Removal ..................................................4-1
Winch Disassembly............................................4-1
Ratios #1, #3, #4 and #6 ..........................................4-2
Gear Arrangement .............................................4-2
PTO Shaft Removal & Disassembly...................4-3
Oil Brake Removal & Disassembly.....................4-5
Hydraulic Pump Removal & Disassembly..........4-8
Pump Disassembly ......................................4-8
General Inspection.......................................4-9
Pump Gear...................................................4-9
Pump Front and Backplates.........................4-9
Pump Body ..................................................4-9
Clutch Shaft Removal & Disassembly..............4-10
Oil Clutch Disassembly ....................................4-13
Intermediate Shaft Removal.............................4-17
Brake Shaft Removal .......................................4-19
Drum Shaft & Drum Removal...........................4-21
Winch Assembly...............................................4-24
Visual Inspection..............................................4-24
Drum Shaft & Drum Installation .......................4-26
Intermediate Shaft Installation .........................4-30
Brake Shaft Installation ....................................4-32
Oil Clutch Reassembly.....................................4-34
Clutch Shaft Reassembly & Installation ...........4-39
Hydraulic Pump Reassembly & Installation .....4-45
Hydraulic Pump Reassembly.....................4-45
Pump Installation .......................................4-46
Oil Brake Reassembly & Installation ................4-47
PTO Shaft Reassembly & Installation ..............4-50
Ratio #7 ..................................................................4-53
Clutch Shaft Location.......................................4-53
PTO Shaft Removal & Disassembly.................4-54
Oil Brake Removal & Disassembly...................4-54
Intermediate Shaft Removal.............................4-54
Brake Shaft Removal .......................................4-55
Clutch Shaft Removal & Disassembly..............4-56
Drum & Drum Shaft Removal...........................4-57
Drum & Drum Shaft Installation .......................4-57
Clutch Shaft Reassembly & Installation ...........4-58
Brake Shaft Installation ....................................4-61
Intermediate Shaft Reinstallation .....................4-62
Hydraulic Pump Assembly Installation .............4-63
Winch Installation ...................................................4-65
Special Tools...........................................................4-66

Section 1
1 - 1
General
Introduction
This service manual is for the W12E 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 W12E 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 for winch controls is produced inside
the winch case. The design of the winch case permits
different arrangements of PTO gear assemblies to fit
different tractors that use these winches. (See Section 4
for the PTO gear assemblies.)
The W12E winch has a BRAKE-OFF function, which
permits the wire rope to be pulled from the drum.
The W12E winch has a rated line pull capacity of 533,760
N (120,000 lbf) when there is one layer or less of wire
rope on the drum.
Figure 1-1 Model Views (Equal Speed Shown)
BRAKE COVER
FILTER COVER
DRAWBAR
DRAWBAR
DRUM SHAFT RETAINER
INTERMEDIATE SHAFT RETAINER
BRAKE SHAFT RETAINER
OIL LEVEL PLUG

General
1 - 2
Unit Identification
Allied Winch S/N Nameplate Data For Tractor Mountings
A W12E P 1 N 1555 C17 Z
Manufactured By
Sequence Number
Internal Options
Winch Model
Drive Type
Gear Ratio
1 = 46.10:1 (Not Available)
3 = 60.40:1 Forward/20.5 Reverse
4 = 83.60:1 Forward/28.4 Reverse
6 = 148.8:1 Forward (83.60:1 with 1.78:1 Dropbox)/50.5 Reverse
7 = 148:1 Forward/Reverse
8 = 83.6:1 Forward/Reverse
A = Made by Allied Systems Company
(Without "A" indicates made by Hyster)
P = Power Control
E = Electronic Control
Vehicle Code
See Figure 1
N = Non-Freespool
S = HD Frame, Non-Freespool
In addition to the serial number plate,
the serial number is stamped on the
top left-hand side of the frame.
Circled numbers in Figure 1 indicate
possible gear ratios.
2.
Notes: 1.
Figure 1 - Tractor or Skidder Identification and Gear Ratio (Continued on next page)
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/
Dressta
K
Komatsu
59 D8R Series II

60 D275A-2

61 21C 
FD30 
D8K PS

82-30, 82-30B,
D750A

TD25C PS

D155A-1 & 2

62
FD40B, FP120,
31

D9 PS, D9H, 594H

D800

63 41-B

583
Serial No. 78V 61A

583H/K

TD25E PS
Serial No. 1001
& Up

64 FD30B/C, D350

594H
Serial No. 96V 62H

TD25G/H/M

D375A-1

65 FD40

D8L, D9N,
D9R (Clutch Br.
Steer)
, *
TD40B/C

W12E = Standard
K12E = Specialized
With Upgraded
eControl Kit
See Figure 2 if a letter or
letters is stamped.
(Without letter(s) indicates that your
winch has the original eControl kit)