Allied Systems W6G 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 599002W 11/05/2015

11/05/2015
Printed in U.S.A.
A Product of Allied Systems Company
Sherwood, Oregon
U.S.A.
Winch Model W6G
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 USA
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
Also visit our website, http://www.alliedsystems.com/pubs/
pubs.htm, where the most current copy of this manual,
and copies of Parts Manual and Service Manual are
always available.
Foreword
i

ii
Note: For repairs and overhaul, contact your Allied
winch dealer. If you maintain your own equipment, a
service manual is available from our website 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
Contents
Foreword .................................................................... i
Contents....................................................................iii
Safety Summary ....................................................... v
General
Introduction................................................................. 1
How The Winch Operates........................................... 1
Nameplate .................................................................. 3
Wire Rope Selection................................................... 4
Oil Capacity & Recommended Oil List ....................... 5
W6G Winch Description ............................................. 6
Optional Equipment .................................................... 7
Serial Number Codes ................................................. 8
Tractor & Skidder Identification Codes ....................... 9
Operation, Power Controls
Checks Before Operation ......................................... 15
Checks During Operation ......................................... 15
Operating Procedures .............................................. 16
Power Operation....................................................... 19
Determining Tractor PTO Type.................................. 21
Engine Direct Driven PTOs....................................... 21
Torque Converter Driven PTOs ................................ 22
FREESPOOL Operation........................................... 23
FREESPOOL Drag Adjustment................................ 23
Troubleshooting Chart .............................................. 25
Operation, Electronic Controls
Checks Before Operation ......................................... 29
Checks During Operation ......................................... 29
Operating Procedures .............................................. 30
Power Operation....................................................... 33
Determining Tractor PTO Type.................................. 35
Engine Direct Driven PTOs....................................... 35
Torque Converter Driven PTOs ................................ 36
FREESPOOL Operation........................................... 37
FREESPOOL Drag Adjustment................................ 37
Troubleshooting Chart .............................................. 39
(Continued on next page)

iv
Maintenance
Maintenance Points .................................................. 45
Maintenance Schedule ............................................. 46
Operating Techniques, Power Controls
Tractor or Skidder Operation .................................... 49
Operating Techniques, Electronic Controls
Tractor or Skidder Operation .................................... 53
Operating Techniques, General
How To Move A Disabled Vehicle.............................. 57
Working on A Steep Slope ....................................... 59
Tractor Is Down The Slope ....................................... 59
Other Equipment Is Down The Slope ....................... 60
Operational Differences, Optional Equipment
Integral Arch ............................................................. 63
Fairlead..................................................................... 63
Drawbar .................................................................... 64
Optional Gear Ratios................................................ 64
Contents

v
Safety Summary
General Safety Notices
The following pages contain general safety warnings
which supplement specific warnings and cautions
appearing elsewhere in this manual. All electrical and
hydraulic equipment is dangerous. You must thoroughly
review and understand the Safety Summary before
attempting to operate, troubleshoot or service this winch.
The following symbols/terms are used to emphasize safety
precautions and notices in this manual:
DANGER
The “DANGER” symbol indicates a
hazardous situation which, if not avoided,
will result in death or serious injury.
Carefully read the message that follows
to prevent serious injury or death.
WARNING
The “WARNING” symbol appears
wherever incorrect operating procedures
or practices could cause serious injury
or death. Carefully read the message that
follows to prevent serious injury or death.
CAUTION
The “CAUTION” symbol appears where a
hazardous situation which, if not avoided,
could result in minor to moderate injury
and equipment damage.
Safety Summary

vi
NOTICE
The “NOTICE” symbol 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’s country, the national regulations should
be followed.
NOTE: All possible safety hazards cannot
be foreseen so as to be included in this
manual. Therefore, you must always
be alert to potential hazards that could
endanger personnel and/or damage the
equipment.
WARNING
The winch shall not be used for hoisting.
WARNING
Use hearing protection when operating
winches.

vii
• Inspect the winch before each use:
»Make sure that the controls and instruments operate
correctly.
»Report the need for repairs immediately.
»Do not work with a damaged or worn wire rope.
»Do not use a winch that needs repairs.
»If the wire rope and ferrule must be removed from the
drum, make sure the end of the wire rope and ferrule
are controlled when the ferrule is released. The end
of the wire rope can suddenly move from the drum
like a compressed spring when the ferrule is released
and cause an injury.
• Stay in the operator’s seat when operating the winch.
• Do not stand on the vehicle when operating the winch.
• Avoid winch operation near people or other machines.
• 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.
Operation, Inspection, and Maintenance Warnings
Obey the following cautions and
warnings before using your winch to
avoid equipment damage, personal
injury or death.
• Do not operate the winch unless you are authorized
and trained to do so.
• Do not operate the winch unless the vehicle is equipped
with a screen to protect the operator if the wire rope
breaks.
• Read, understand, and follow the operating, inspection,
and maintenance instructions in this Operating Manual.
• Do not use the control levers for hand holds when
entering or leaving the vehicle.
• Do not permit other people near the control area when
you inspect or repair a machine.
• Never inspect, repair, or perform maintenance on a
machine that is in motion.
Safety SummarySafety Summary

viii
• 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.
KG
KG

ix
• Stay clear of wire rope entry areas (fairlead or arch
rollers, winch drum etc).
• Make sure ground personnel are in plain view of the
operator, and at a distance of at least 1½ times the
working length of the wire rope.
• Make sure that any hand signals used by ground
personnel are clearly defined and understood by
everyone involved.
• Do not attempt to “jerk” or “shock” a load free. Doing so
can cause loads in excess of the rated capacity of the
wire rope, winch, or mounting hardware.
• Replace any parts only with genuine Allied Winch parts.
Refer to Parts Manual, 599003W.
• 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 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 not rated for any application involved in
the lifting or moving of personnel.
Safety Summary

x
• Use only the lubricants listed in the Recommended Oil
List. See Page 5.
• Do not weld on any part of the winch. Contact Allied
Systems if weld repairs are needed.
• The hydraulic system must be kept clean and free of
contamination at all times.
• Be aware of the hazards of pressurized hydraulics:
»Wear personal protective equipment, such as gloves
and safety glasses, whenever servicing or checking
a hydraulic system.
»Assume that all hydraulic hoses and components are
pressurized. Relieve all hydraulic pressure before
disconnecting any hydraulic line.
»Never try to stop or check for a hydraulic leak with any
part of your body; use a piece of cardboard to check
for hydraulic leaks.
»Small hydraulic hose leaks are extremely dangerous,
and can inject hydraulic oil under the skin, even
through gloves.
»Infection and gangrene are possible when hydraulic
oil penetrates the skin. See a doctor immediately to
prevent loss of limb or death.

xi
Safety Summary
Notes

xii
Notes

1
Introduction
This Operating Manual contains basic information
necessary for the operation and maintenance of the W6G
winch.
How the Winch Operates
A winch is normally installed on a skidder or tractor:
• to increase the pulling power of the skidder or tractor.
• to reach into an area where a skidder or tractor cannot
go.
• to lift a load partially off the ground when special
attachments are installed.
WARNING
Do not use the winch as a hoist. See Safety
Summary.
The winch has hydraulic clutches that are similar to a
hydraulic (powershift) transmission. Most tractors and
skidders have a Power Take-Off (PTO) that is used to
connect the power from the engine to the winch.The SCH
(Self Contained Hydraulics) indicates that the 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 input assembly in the winch.
When the input assembly rotates, a spur gear turns the
hydraulic pump and the pinion, which 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.
General
General

2
The power through the winch to the drum for the wire
rope 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 permit the wire rope
to be pulled from the winch at the speed controlled by the
PTO rpm.
When the control lever is in the BRAKE-ON position, the
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.
The winch has an intermediate gear assembly that
provides a gear reduction and increases the available
torque at the winch drum. For winches equipped with
the FREESPOOL option, a sliding sleeve with splines
engages the drum pinion gear and the intermediate gear.
When the control lever is in the FREESPOOL position,
the sliding sleeve disengages the drum pinion gear from
the intermediate gear. The gear train is disengaged from
the clutch and brake shaft so that the wire rope can be
pulled from the drum by hand. Only the drum and drum
pinion gear rotate when the wire rope is pulled from the
drum during a FREESPOOL operation.
CAUTION
Shifting to FREESPOOL with a suspended
load on the wire rope will cause the load
to fall uncontrollably.
The W6G winch has a maximum line pull capacity of
266,880 N (60,000 lbf) when there is one layer or less of
wire rope on the drum.

3
Figure 1 - Nameplate
Nameplate
Each winch is shipped from the factory with a nameplate
as shown in Figure 1. 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.
General

4
Figure 2 - Drum Line Capacities
Wire Rope Selection
Each winch model can have a variety of wire rope sizes
installed by the user.The maximum wire rope size is shown
on the nameplate. See Figure 2 for approved wire rope
sizes and drum capacities. When a larger diameter wire
rope is used, the length of wire rope installed on the drum
will be shorter. In some situations, the winch can create a
tension in the wire rope that is greater than the strength
of the wire rope.The user must be careful to select a wire
rope that has enough strength and length for the job.
WARNING
During operation of the winch, the
operator must know or estimate the line
pull and make sure that the line pull is
within the capacity of the winch and the
specifications of the wire rope installed
on the drum. A broken wire rope under
high tension can return suddenly in the
direction of the winch and cause injury
and damage.
WARNING
The wire rope may disengage from the
ferrule pocket if there is a load on the
wire with fewer than 3 complete wraps on
the drum. This will cause a loss of load
and possible injury. When spooling wire
rope 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 has been
reached.
Wire Rope
Diameter
Full Drum
Capacity
2/3
Capacity
3/4 in (19 mm) 376 ft (114 m) 251 ft (76 m)
7/8 in (22 mm) 271 ft (82 m) 180 ft (54 m)
1.0 in (25 mm)* 210 ft (64 m) 140 ft (42 m)
Notes:
1. Loosely or unevenly spooled line will change capacities.
2. Use flexible wire rope with independent wire rope center.
3. Ferule size: 2.0 in dia, 2 1/4 in long.
* If your winch is equipped with the optional arch, the largest wire
rope diameter approved for use is 7/8 inch.

5
Oil Capacity & Recommended Oil List
The oil capacity for W6G winch is 19.5 gallons (73.8 liters).
The type of oil used in Allied winches affects the line
control. Use the following oils in the W6G winch:
Figure 3 - Recommended Oil List
Manufacturer Oil Type °F °C °F °C
Caterpillar Multipurpose Tractor Oil (MTO) -13 to 104 -25 to 40 -13 to 104 -25 to 40
John Deere Hy-Gard™ -13 to 122 -25 to 50 -13 to 176 -25 to 80
ExxonMobil Mobil Fluid 424 (Factory fill) -13 to 122 -25 to 50 -13 to 176 -25 to 80
Chevron 1000 THF -13 to 122 -25 to 50 -13 to 176 -25 to 80
Manufacturer Oil Type °F °C °F °C
John Deere Low Viscosity Hy-Gard -40 to 86 -40 to 30 -40 to 150 -40 to 66
ExxonMobil Mobil Fluid LT -40 to 86 -40 to 30 -40 to 150 -40 to 66
Chevron THF W -40 to 86 -40 to 30 -40 to 150 -40 to 66
* Note: Use of a non-recommended oil may void warranty.
Recommended Oils* - All Applications
(Applications such as equipment rescue, logging, cable plow,
(Note: ExxonMobil and John Deere Oils are recommended for Inching Applications)
Ambient Temperature Range Oil Temperature Range
Recommended Oils* - Low Tem
p
erature A
pp
lications
Ambient Temperature Range Oil Temperature Range
and inching applications such as pipe setting, yo-yo, line sagging, etc.)
General

6
Figure 4 - W6G Towing Winch
1. Drum
2. Access Cover for Filter and Strainer
3. Access Cover to Hydraulic Valve
4. Plug to Check Oil Level
5. Plug to Drain Oil
6. Tie Rod
7. Fill Plug
8. Cover for Oil Brake
9. Bearing Retainer for Intermediate Shaft
& FREESPOOL Drag Adjuster
10.Right Side Drum Shaft
11.Breather
W6G Winch Description