Allied Systems W6F 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 599031W 01/05/2017

01/05/2017
Printed in U.S.A.
A Product of Allied Systems Company
Sherwood, Oregon
U.S.A.
Winch Model W6F
Date Delivered
Serial Number
Date Installed
Special Equipment or Attachments

Foreword
The safe and efficient operation of a winch requires skill
and alertness on the part of the operator. To develop the
skills required, the operator must:
• Receive training in the proper operation of the winch
and the machine on which it is mounted.
• Understand the capabilities and limitations of the winch
and the machine on which it is mounted.
• Become familiar with the winch and the machine on
which it is mounted and see that they are maintained
in good condition.
• Read and understand the SAFETY SUMMARY
and OPERATING PROCEDURES contained in this
Operating Manual.
In addition, a qualified person experienced in the operation
of the winch must guide a new operator through several
load handling applications before the new operator
attempts to operate the equipment alone. It is the
employer’s responsibility to make sure that the operator
can see, hear, and has the physical and mental ability to
operate the equipment safely.
This Operating Manual contains basic information
necessary for the operation and maintenance of a winch.
Optional equipment is sometimes installed that can
change the characteristics described in this manual.
Make sure the necessary instructions are available and
understood before operating the winch.
Some of the components described in this Operating
Manual will NOT be installed on your winch. If you have
questions about any item on your winch or described in
this Operating Manual, contact your local winch dealer,
or contact Allied Systems Company:
Allied Systems Company
21433 SW Oregon Street
Sherwood, OR 97140
U.S.A.
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
Also visit our website, www.alliedsystems.com, where
the most current copy of this manual is always available.
Foreword
i

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

iii
Contents
Foreword ..................................................................i
Contents................................................................. iii
Safety Summary .....................................................v
General
Introduction...............................................................1
How The Winch Operates.........................................1
W6F Winch Description ............................................2
Nameplate ................................................................4
Wire Rope Selection.................................................5
Recommended Oil List & Oil Capacity .....................6
Optional Equipment..................................................7
Unit Identification......................................................8
Tractor Identification & Gear Ratio Codes..........9
Operation
Checks Before Operation .......................................13
Checks During Operation .......................................13
Operating Procedures ............................................14
Power Operation.....................................................16
FREESPOOL Operation.........................................18
FREESPOOL Adjustment ......................................18
Troubleshooting Analysis Chart..............................20
Maintenance
Maintenance Points..........................................29
Maintenance Schedule ....................................30
Control Cable Adjustment.......................................32
Operating Techniques
Tractor or Skidder Operation ..................................35
How To Move A Disabled Vehicle............................38
Working on A Steep Slope .....................................40
Tractor Is Down The Slope ...............................40
Other Equipment Is Down The Slope...............41
Operational Differences, Optional Equipment
Integral Arch ...........................................................43
Fairlead...................................................................43
Optional Gear Ratios..............................................43
FREESPOOL..........................................................44
Extended Heavy Duty Drawbar ..............................44
Contents

iv
Intentionally Blank

v
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/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.

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
Safety Summary
• Inspect the winch before each use:
»Make sure that the controls and instruments
operate correctly.
»Report the need for repairs immediately.
»Do not work with a damaged or worn wire rope.
»Do not use a winch that needs repairs.
»If the wire rope and ferrule must be removed
from the drum, make sure that 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.

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
Safety Summary
• 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 W6F Parts Manual (P/N 599750W).
• 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.

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
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 6.
• 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
Notes
Notes

xii
Notes

1
General
Introduction
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 hydraulic clutches that are similar to a
hydraulic (powershift) transmission. Most tractors and
skidders have a PTO (Power Take-Off) that is used to
connect the power from the engine to the winch. The
SCH (Self Contained Hydraulics) on the winch label
indicates that the hydraulic system for control of the winch
is inside of 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. Removable covers on the winch case allow
access for repairs and adjustments. The design of the
winch cases permits a variation in the arrangement of
PTO assemblies to fit the different tractors and skidders
that use these winches.
The PTO is connected to the pinion assembly in the winch.
When the pinion rotates, a spur gear turns the hydraulic
pump and the pinion turns the ring gear (bevel gear). The
bevel gear is connected to an oil clutch for the LINE-IN
(power forward) operation and another oil clutch for the
LINE-OUT (power reverse) direction.
The power through the winch to the wire rope drum is
controlled by a LINE-IN and a LINE-OUT clutch. When
the LINE-IN clutch is applied, the drum rotates to pull the
wire rope into the winch. When the LINE-OUT clutch is
applied, the drum rotates to unwind the wire rope from the
winch at the speed controlled by the PTO rpm.
General

2
When the control lever is in the BRAKE-ON position, an
oil brake is automatically applied by a spring to hold the
drum in its position. If the control lever is moved to apply
one of the clutches, the brake is released by the same oil
pressure that applies the clutch. In the event that hydraulic
power is lost, the brake remains applied and the winch
will not turn.
W6F Winch Description
The W6F is a power forward (LINE-IN) and power reverse
(LINE-OUT) winch used on tractors with a unidirectional
PTO.
On most of the available gear ratios, the LINE-IN function
has a greater gear reduction to provide more power for the
line pull. The LINE-OUT function has less gear reduction
so the cable can be unwound from the drum at a faster
rate.
The W6F winch can be equipped with an optional
FREESPOOL function. FREESPOOL disengages the
winch drum from the winch drive gears, which allows a
person to pull the wire rope from the drum by hand.
The W6F winch has a rated line pull capacity of 266,880
N (60,000 lbf) when there is one layer or less of wire rope
on the drum.
Loads applied to the drawbar are transmitted to the bolts
holding the winch to the tractor. The standard integral
drawbars are designed to handle pulls of 66% of winch
rated capacity.

3
General
13 83
2
6
5
77
4, 9
12
11
1
10
14 15
1. Drum
2. Access Cover for Filter
3. Access Cover to Hydraulic Valve
4. Access Cover to Hydraulic System
5. Plug to Check Oil Level
6. Plug to Drain Oil
7. Tie Rod
8. Fill Plug
9. Cover for Oil Brake
10. Intermediate Shaft Bearing Retainer
& Freespool Adjuster *
11. Drum Shaft Bearing Retainer
12. Drawbar
13. Breather
14. Serial Number Stamped (New)
15. Serial Number Stamped (Old)
* NOTE: Exterior freespool adjust mechanism available
as standard only on AW6F-4062 and above.
Older winches may be fitted with the exterior
adjustment mechanism as well.
Figure 1 - W6F Towing Winch

4
Figure 2 - Nameplate
Nameplate
Each winch is shipped from the factory with a nameplate
as shown in Figure 2. 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.

5
Wire Rope Selection
Each winch model can have a variety of wire rope sizes
installed by the user.The maximum wire rope size is shown
on the nameplate. 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.
Figure 3 - Drum Line Approximate Capacities
Wire Rope
Diameter
Capacity for
10 in (254 mm)
Drum Diameter
Capacity for
7 in (178 mm)
Drum Diameter
3/4 in (19 mm) 399 ft (121 m) 425 ft (129 m)
7/8 in (22 mm) 287 ft (87 m) 305 ft (93 m)
1.0 in (25 mm)* 223 ft (68 m) 237 ft (72 m)
Notes:
1. Loosely or unevenly spooled line will change capacities.
2. Use flexible wire rope with independent wire rope center.
3. Ferule size: ø2.0 inches, 2 1/4 inches long.
* If your winch is equipped with the optional arch, the largest wire
rope diameter approved for use is 7/8 inch.
General
WARNING
The wire rope may disengage from the
ferrule pocket if there is a load on the wire
rope with fewer than 3 complete wraps on
the drum.This will cause a loss of load and
possible injury.When spooling cable from
the drum, it is very difficult for the operator
to know when nearing the end of the wire
rope. It is recommended that the last 5
wraps of wire be painted a contrasting
color to alert the operator that the end of
the usable wire rope has been reached.

6
Recommended Oil List and Oil Capacity
The type of oil used in Allied winches affects the line
control. Use the following oils in the W6F winch:
Figure 4 - Recommended Oil List
°F °C
ExxonMobil Mobil Fluid 424 (Factory fill) -13 to 105 -25 to 43
John Deere Hy-Gard™ -13 to 122 -25 to 50
Chevron 1000 THF -13 to 105 -25 to 43
Caterpillar Multipurpose Tractor Oil (MTO) -13 to 104 -25 to 40
Case Hy-Tran Ultra -20 to 122 -30 to 50
°F °C
ExxonMobil Mobil Fluid LT -40 to 86 -40 to 30
John Deere Low Viscosity Hy-Gard -40 to 86 -40 to 30
Chevron THF W -40 to 86 -40 to 30
* Note: Use of non-recommended oils may void warranty.
Recommended Oils* - General Conditions
Ambient Temperature Range
Recommended Oils* - Low Temperature Conditions
Ambient Temperature Range
Manufacturer Oil Type
Manufacturer Oil Type
Winch Model Oil Capacity
W6FP - Standard 16.5 Gal (62.5L)
W6FP - with Dropbox 17 Gal (64.5L)
Figure 4.1 - Oil Capacity