MAXWALD A 501U User manual

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INSTRUCTION MANUAL
MAXWALD Skidding Winches
A 501 (U)
A 501 S (U)
A 5000 (U)
A 611 S (U) A 516 S (U)
A 611 S (U)
A 6000 (U)
M 2000
Premium
MAXWALD -since 1771!
For technical information and spare parts orders please contact
any well-stocked specialised dealer or us directly at:
MAXWALD Maschinen GmbH
Irresbergstraße 1
4694 Ohlsdorf
AUSTRIA
Phone: [phone]
Fax: [phone]
[e-mail]
www.maxwald.at

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Dear customer
We are delighted that you have decided on a MAXWALD skidding winch made in Austria.
Please read this instruction manual carefully and heed all of the advice included in these
pages before putting the cable winch into service.
Table of contents
Page
3 Introduction
3/4 Information on intended use –Accident prevention
5 Winch description
Operating instructions (during work)
6 1) Preparation / Attachment / Assembly
7 2) Operation / Control
2a) with pulling rope
8 2b) with pulling rope and hydraulic clutch cylinder / alternative 0
9 2c) with remote cable control / control panel (electro-hydraulic) / alternative IV
10 2d) with radio control ("intermittent brake")
11 Hydraulic cable entry brake / cable discharge
12 Maintenance / Servicing
13 Faults
Spare parts (drawing/list): rope-controlled winch with reduction gear and
spooling device
Spare parts (drawing/list): rope-controlled winch and alternative 0
Spare parts (drawing/list): winch with electro-hydraulic control / alternative IV
Spare parts (drawing/list): cable entry brake / cable discharge
Electrical wiring diagram
Hand-over protocol –Please complete and confirm before returning!
Declaration of conformity

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Introduction
Each operator must have read and understood this instruction manual prior to using the winch for
the first time to ensure that the machine is operated safely according to the instructions.
Please observe the general safety instructions and only use the machine for its intended purpose so
to prevent accidents. ATTENTION! Only for ground traction mode, for example.
The warranty will be forfeited if the operating instructions are ignored or structural modifications
carried out on the machine.
The manufacturer can accept no liability for any kind of consequential damage incurred due to the
fact that the machine has not been operated correctly or not used for its intended purpose.
Furthermore, any claim for damages under the Product Liability Act is also forfeited should involved
or non-involved persons be injured or property damaged as a result of this.
Please refer to our "General terms and conditions of sale and delivery" as well as the latest
"Warranty conditions" which are available on request at any time.
The free forestry winch test book can be downloaded from: www.kwf-online.de/ or www.lsv.de/bw
Accident prevention–published in German by KWF Groß-Umstadt (Federal Republic of
Germany)
Work safely to prevent accidents. Observe the accident prevention regulations.
The winch may only be operated and serviced by a suitable and reliable person who is familiar with
such a job and is over the age of 18.
Check that the cable winch is in perfect working order before use and at least once each work day.
Remedy any defects in a professional manner.
In addition, have the winch checked by an expert before it is put into service for the first time, after
substantial modifications and at least once a year.
Shut down the winch drive before remedying faults and carrying out repair and maintenance work.
Do not simply disengage the winch drive but turn off the skidder's engine.
Do not disable any of the winch's safety devices.
Only use a preformed cable which is strong enough and which complies with the specifications on
the winch's nameplate and in this instruction manual as a means of traction.
Replace any defective cables in due time.
Only use a length of cable which guarantees that the drum's flanges still project beyond the top
cable layer turn by at least 1 ½ times the cable diameter when the cable is fully wound up.
The operator must make sure that nobody is at risk before starting the skidding winch.

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Only operate the winch from a safe location so that the winch operator is not endangered by either
the machine itself, the load, cable or sling gear.
The winch operator must make sure that at least 4 to 5 cable turns remain on the drum under load,
except in the event of danger.
The winch operator must be able to monitor the skidding load from his location at all times; if this is
not the case, make sure that another person can monitor the path of the load and that signals have
been agreed between the observer and operator so that they can stay in contact.
There may be no persons between the winch and load or in the danger angle between the winch,
deflection and load when working with the winch. Please refer to the diagram.
There may be no persons below a trunk attached to the winch during skidding work on slopes, for
example.
Always attach the cable to the tree before starting cutting work so that it can be pulled down
afterwards. The distance between the skidder and the tree to be felled must be at least double the
length of the tree.
Use non-slip chains in snow or ice.
Secure the skidder safely with a sprag or similar device before starting the skidding work.
Choose the cable entry point as low as possible and in the winch pulling direction, i.e. without lateral
deflection.
* If the ostacle is a tree, the winch
operator must watch out for falling
branches or crown parts and keep
a safe distance as necessary.
Safe location for
radio control
Obstacle*)
Danger zone
Lateral cable attachment at right
angles to the pulling direction
Torn-off
deflection pulley
Danger angle
Traction
cable
Deflection
pulley
Tree

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Description of the winch
MAXWALD skidding winch
Drive: via prop shaft / duplex roller chain
Clutch: dry single-disc clutch
Brake: automatic disc brake
(dead-man system, patented by MAXWALD)
Operation / control: a) with rope control
b) with rope control and hydraulic clutch cylinder / alternative 0
c) with remote cable control / (electro-hydraulic) control panel /
alternative IV
d) with radio control ("intermittent brake")
Cable spooling device: for A 516 S and M2000-Premium
Cable entry brake/cable discharge:
OPTION, for winches with alt. IV,
M2000 Premium series
Equipment: OPTION - lower cable entry roller
- lateral hoop guards
- tool box
etc.
Type
A501(U), A501S(U),
A5000(U), A516S(U),
M2000 Premium
A611S, A6000
Permissible load at bottom
layer:
6.5 t
7.0 t
Permissible load at top
layer:
4.5 t
5.0 t
Max. cable capacity:
100 m/10 mm or 80 m/11
mm
160 m/10 mm or 130 m/11
mm
90 m/11 mm
Required cable breaking
strength:
130 kN
140 kN
Rated strength:
1960 N/mm²
1960 N/mm²
Max. drive speed:
540 rpm
540 rpm
Recommended tractor
power:
50 PS
60 PS
For alternative IV / radio
control:
Control pressure:
140 bar
140 bar
Voltage:
12 volt
12 volt
Ideal cable length = max. cable capacity –15 %

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Operating instructions (for work)
1) Preparation / Attachment / Assembly
a. In order to attach the winch, reverse the tractor up to the winch, insert the lower link of the
hydraulic three-point linkage into the winch's towing lugs, connect to the plug-in bolts and
secure with a linchpin or R-clip. Repeat the procedure for the upper link.
b. Lift the hydraulic three-point linkage with the attached winch on the tractor.
Insert the winch's supporting legs in the respective holders and secure in place.
c. Connect the drive shafts of the tractor and winch with an appropriate prop shaft and secure
the prop shaft guard against turning with the chain. Make sure that the prop shaft has the
correct length to avoid blocking at only short distances. (Please refer to the instruction
manual of the prop shaft).
ATTENTION: Do not use a prop shaft with a friction clutch.
d. Lower the hydraulic three-point linkage with the winch to the ground during winching, bring
the lever of the hydraulic control unit in the float position and switch on the standard PTO at
540 rpm.
e. ATTENTION:
Unwind the entire cable (about 4 to 5 turns must remain on the drum) and wind up
again under load before using the cable for the first time and if the cable has been
wound up on the drum under no load. This prevents the cable from jamming or
being damaged.
Repeat this procedure from time to time!
NOTE: - Fitting the cable –please refer to page 12
- For hydraulic clutch cylinder / alternative 0 –please refer to page 19
- For electro-hydraulic control system / alternative IV –
please refer to page 20 and following pages

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2) Operation / Control
2a) Operation by rope
DESCRIPTION:
The winch is controlled by two ropes.
Blue rope: Clutch rope (pull the load)
Orange rope: Brake rope (release the brake)
–linchpin
FUNCTION / OPERATION:
To unwind the cable (open the brake):
pull the orange rope until the brake lever is in a
horizontal position. Hold the orange rope in this
position or clamp in the lever (linchpin)*. The
brake is now open, you can unwind the cable.
To pull the load / to wind up the cable:
Release the orange rope on the brake lever.
The brake lever is in its low position, i.e. the brake is ready for operation. Pull the blue clutch rope
through to its limit position and hold tight.
ATTENTION:
When winching, the clutch rope must be pulled through to the limit stop to achieve the
maximum traction force and to prevent the clutch from slipping.
To release the brake gradually:
IMPORTANT if the cable is under tension.
Pull the orange rope through quickly in one action until the brake lever is in its uppermost position.
The brake opens only briefly, the cable is released and thus prevents the cable drum from running
on (which is not desired).
(RUN-ON BRAKE / the counter wedge can be adjusted with the stop nut no. 27e –see
table 2 –on the brake wedge.)
Sticker (on the winch):
Pull the load
Release the brake gradually
Open the brake
Brake is ready for operation (load can be pulled)

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2b) Operation by rope and hydraulic clutch cylinder / alternative 0
- can also be retrofitted but requires a single-acting
control unit
ASSEMBLY:
1) As described for rope-operated winches
(page 7).
2) Connect the hydraulic hose.
DESCRIPTION:
Please refer to rope operation (page 8).
Apart from using the rope, the clutch can also be
operated via the vehicle's control unit.
FUNCTION / OPERATION:
1) As described for rope-operated winches (page 7)
2) Plus: you can pull the load with the hydraulic cylinder by actuating the control lever.
ATTENTION:
Should the control lever of the single-acting control unit not return into the float position
automatically after releasing, it is absolutely essential that you attach the elastic cord (provided
for this purpose and included in the scope of delivery) to the control lever.
Otherwise the dead-man system is ineffective! –SAFETY!
NOTE:
After disconnecting from the tractor, NEVER plug the hydraulic hose into the clutch lever guard!
Oil residues from the hose or plug may soil the clutch and brake.

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2c) Remote cable control / control panel / alternative IV
(prepared for radio control, electro-hydraulic, own oil supply)
ASSEMBLY:
1) As described for rope-operated cable winches (page 7)
2) Plug the remote control unit into the tractor's socket outlet (7-pole) and switch
the parking light on!
DESCRIPTION:
FUNCTION / OPERATION:
To unwind the cable (open the brake):
Press the left control panel pushbutton (Z) for more than 3 seconds.
The brake is opened hydraulically, remains open and the cable can be unwound as desired.
To pull the load / to wind up the cable:
The clutch is engaged as soon as pushbutton (Y) is pressed. Release the pushbutton to stop the
cable drum. (The brake is activated automatically.)
To release the brake briefly:
Press pushbutton (Z) briefly several times if the brake has to be opened under high tension. This
prevents the drum from running on.
EMERGENCY STOP:
Press to trigger an EMERGENCY STOP.
Turn to the right to reset the pushbutton after an EMERGENCY STOP.
NOTE: Always open the brake by actuating it briefly several times in succession
(intermittent release), particularly if the cable is under tension. Only then
release the brake permanently.
You may hear some recharging noises from the hydraulic system!
Z = Brake (pushbutton):
Press = to open the brake
Press briefly several times = to release the brake briefly / intermittent release
Release = the brake is ready for operation (dead-man system)
y = Clutch (pushbutton): Press to pull the load
X = EMERCENCY STOP / STOP

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2d) Radio control
In principle, you can use any radio-control system but you should bear SAFETY, QUALITY
and SERVICE in mind!
NOTE:
MAX radio-control system from HBC with additional "intermittent release" function.
MAX radio-control system from TELENOT with additional "intermittent release" function.
- Separate documentation!
ASSEMBLY:
Connect the radio receiver to the 7-pole plug on the winch (instead of the remote cable control unit)
and fix in the driver's cabin.
Remote transmitter –winch operator (with belt or strap)
DESCRIPTION:
FUNCTION / OPERATION:
Switch the light on.
a) Switch the radio receiver on.
b) Switch the radio transmitter on.
For further information please refer to the respective radio-control manual.
A lifting spindle drive or electric speed adjustment is required for the Speed +/- function!
MAX radio control system from HBC
* Only MAXWALD winches with a disc brake allow an intermittent release of the brake!
IMPORTANT!!!
NO EXCEPTION - ALWAYS trigger the intermittent brake function before releasing the
brake.
The function must be set correctly for this purpose! Please refer to page 12.
Transmitter
ON:
down:
Release the brake
permanently:
down
Speed -
Speed +
Pull the load:
up
Sender
AUS
Release the brake
intermittently*
Motor Start/Stop
(if selected!)

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Adjusting the HBC intermittent brake
Attention: separate documentation for the Telenot system!
The cable is only tensioned with an optimum adjustment, in other words it is not released in one
single action but intermittently when under tension and thus wound perfectly.
ATTENTION! The cable will form loops or be crushed if this function is not adjusted properly.
The following adjustments can be made:
Length of the interval between opening and closing the brake
a) How long the brake remains open (opening angle)
b) How long the brake remains closed (closing angle)
BASIC ADJUSTMENT = shortest possible interval:
1) Push the intermittent brake lever UP, hold the lever and press SPEED- until the length of the
interval no longer changes.
Opening angle.
2) Push the intermittent brake lever DOWN, hold the lever and press SPEED- until the length of
the interval no longer changes.
Closing angle.
3) The winch now generates a jerking pulse, i.e. the winch discharges the cable in jerks if the
intermittent brake lever is pressed.
The following fine adjustments must be made to ensure that the intermittent brake also
functions perfectly when the cable is under tension:
FINE ADJUSTMENT
4a) Push the intermittent brake lever UP, hold the lever and touch SPEED+ briefly (only once or
twice!). The winch will now discharge the cable intermittently only if under tension.
Repeat the basic adjustment points 1 to 3 and then continue with point 4b) if point 4a) does not
lead to the desired effect.
4b) Push the intermittent brake lever DOWN, hold the lever and touch SPEED- briefly (only once
or twice!). The winch will now discharge the cable intermittently only if under tension.
To check the setting in practice: remove the guard, watch the BRAKE, i.e. the brake disc and brake
wedge, and carry out the adjustments as described above (see the video).
The spring of the run-on brake should be set to the maximum tension for a winch with cable
discharge!
Repeat the basic and fine adjustment points 1 to 4 whenever the settings have become misadjusted.

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Option: hydraulic cable entry brake / cable discharge
(can be retrofitted)
ATTENTION: only use compacted cables with a "smooth" surface!
ASSEMBLY:
Please refer to the retrofitting instructions which have to be ordered separately.
DESCRIPTION:
FUNCTION / OPERATION:
Cable entry brake works automatically with the "Pull load" function.
Cable discharge is activated by the "Release brake permanently" function (approx. 3 s).
Activate cable discharge: press once for approx. 3 s
Stop cable discharge: press once briefly
ADJUSTMENT:
Cable entry brake
Cable discharge
Cable discharge speed
Swivel the cover of the control unit guard up.
Upper throttle:
Loosen the lock nut and
* turn to the left to reduce the speed
* turn to the right to increase the speed
Retighten the lock nut.
+
-
-
+
Cable entry brake
Swivel the cover of the control unit guard up.
Lower throttle:
Loosen the lock nut and
* turn to the left to reduce the brake action
* turn to the right to increase the brake action
Retighten the lock nut.

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3) Maintenance / Servicing
Clean as necessary!
- Lubrication –
Drive chain:
Remove the guard plate at the bottom and spray a small amount of chain lubricant onto the chain.
ATTENTION: Only use a well-adhering chain-lubricant spray!
NOTE: Do not use excessive amounts of lubricant to prevent the clutch disc
and brake linings from being clogged.
Clutch and brake linkage:
Lightly oil all moving parts and connecting bolts only.
Upper swivel pulley:
Lift the swivel pulley completely. Spray lubricant onto the inner and outer tube.
Automatic cable spooling device:
Spray lubricant onto the lubricating nipple on the swivel arm, bearing and bearing surface.
- Adjusting the clutch –
The clutch may only be adjusted by an authorised workshop!
- Changing the cable -
Remove the protective grid from the drum. Insert the end of the cable in the lateral bore of the
cable drum and secure with a cable clamp.
A516S / M2000 model with spooling arm:
Mount the cable along the swivel arm
(see photo).
ATTENTION:
The traction cable must be wound up under load
to ensure that the cable package rests firmly in
the drum and the cable is not jammed between
the individual cable turns.
(See page 6: Before using the winch for the
first time …)
NOTE: Do not wind up more cable than is necessary on the drum!!!

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4) Faults
Potential faults which can be remedied in next to no time.
Fault
Cause
Remedy
Reduction in pulling power
The clutch lining is worn.
The clutch lining is soiled.
Adjust the clutch
(specialised workshop).
Clean the lining.
Replace the clutch.
Reduction in brake power
The brake pads are soiled.
The brake pads are worn.
Clean the brake pads.
Change the brake pads.
Brake does not release.
Alternative IV
The brake wedge chain is
torn.
Power supply.
Replace the chain.
Switch the light on.
Check the power supply.
Winch does not haul in.
Alternative IV
The distance between the
clutch and drum is too
large.
Power supply.
EMERGENCY STOP was
pressed.
Adjust the clutch.
Switch the light on.
Check the power supply.
Deactivate the EMERGENCY
STOP.
Radio control does not
respond.
Power supply of transmitter
Power supply of receiver
Check with the remote
cable control.
Charge the batteries.
Switch the light on.
Check the power supply
(plugs, fuses, etc.)
Contact MAXWALD
Should you need any help with remedying the faults listed in this table or for any other
troubleshooting, please feel free to contact us. Just call us at ++43 (0) 7612/47219-0

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5) Spare parts list / Exploded drawings

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- 19 -

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Spare parts
Teil
Bestell.
-Nr.
Teilbezeichnung
Stück
Tafel
Seilwindenaggregat
2
11508
Stoppmutter
1
1
3
00601
Rahmenbügel mit Nabenhälfte (ab Bj. 84)
1
1
4
11018
3 Kugeln (vor Bj. 1980 = Bolzen)
3
1
5
11040
Kupplungsnabe
1
1
6
01529
Kugellager 6307.2 RS für Seiltrommel (bei Var. IV 4 Stück)
3
1
7
00411
Seiltrommel (80m/10mm, 130m/10mm, 160m/10mm)
1
1
7a
00411
Bremsscheibe (lose, roh)
1
1
8
00412
Korb mit Schrauben (vgl. Trommelgröße)
1
1
9
01529
Kugellager 6307.2 RS (bei A611S/A6000 3 Stück)
2
1
10
01519
Feder - Druckfeder + Distanzhülse
1
1
11
01038
Kettenrad mit Lamelle (auch als Austauschkupplung)
1
1
12
01037
Lamelle - Kupplungsbelag
1
1
14
01035
Distanzring 7mm
1
1
15
00422
Hauptwelle (Vgl. Trommelgröße)
1
1
16
01001
Feder - Zugfeder für Schaltung
1
1
17
00423
Hebel für Schaltung
1
1
18
01027
Rolle für Bedienungsleine
5
19
01045
Zwischenstück für Schaltung
1
1
19a
01025
Bolzen mit Splint
3
1
20
Bedienungsleine blau
1
3
Bremsenteile (Bremskopf u. Nachlaufbremse) -= BRAKE
21
00602
Sperrkette (vor Bj. 1980 = Sperrstange)
1
1
21a
00610
Rohr für Sperrkette
1
1
22
00603
Bremsbügel mit Belag (Nachlaufbremse)
1
1
22a
00603a
Belag für Nachlaufbremse
1
1
23
00604
Feder - Zugfeder für Nachlaufbremse
1
1
24
00605
Lagerung - Bremsaushebung
1
2
25
00606
Kette mit Glied für Bremsaushebung
1
2
26
00607
Bremsschuh mit Lager (vor 1985 = Bremsplatte) +
(Bremsgehäuse)
1
2
26a
00608a
Belag für Bremsschuh (nur in Verbindung mit Belag für Bremskeil,
dh 1 Garnitur m. Nieten!)
1
2
26b
00607a
Druckrolle
1
2
26c
13503
Hülse
1
2
26d
13503a
Welle
1
2
26e
13503b
Anlaufscheibe beschichtet
1
2
26f
13503c
Beilagen
2
2
27
00608
Bremskeil mit Belag
1
2
27a
00608a
Belag für Bremskeil (nur in Verbindung mit Belag für Bremsschuh,
dh 1 Garnitur m. Nieten!)
1
2
27b
1001c
Gegenkeil
2
2
27c
1001d
Gewindestange für Gegenkeil
1
2
27d
1001e
Druckfedern
2
2
27e
1001f
Stopmutter
1
2
28
00609
Zugfeder lang für Bremskeil
1
2
28a
00609a
Zugfeder kurz für Bremskeil
1
2
28b
Federstifte
2
2
29
00610
Bremshebel
1
2
30+33
01027
Rolle für Bedienungsleine
3
34
Bedienungsleine orange
1
2