Allied Systems W6G, Operating Manual

Page 1: ...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...

Page 2: ...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...

Page 3: ...onsibility 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 operat...

Page 4: ...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 i...

Page 5: ...ing 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 Adjustmen...

Page 6: ...g 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...

Page 7: ...e 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 fol...

Page 8: ...ith 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 i...

Page 9: ...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 Inspect...

Page 10: ...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...

Page 11: ...r 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 spoo...

Page 12: ...enever 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...

Page 13: ...xi Safety Summary Notes...

Page 14: ...xii Notes...

Page 15: ...d 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 su...

Page 16: ...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 sli...

Page 17: ...amped 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...

Page 18: ...ope 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 few...

Page 19: ...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...

Page 20: ...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 Adjust...

Page 21: ...ay be equipped with the following options integral arch fairlead assembly alternate gear ratio heavy duty extended drawbar electronic controls NOTE Not all optional equipment listed is available for e...

Page 22: ...Option Winch Model Type Drive Gear Ratio 1 45 0 1 2 56 0 1 6 103 0 1 8 83 0 1 15 153 0 1 A Made by Allied Systems Company P Power Controls E Electronic Controls See Figure 6 F Freespool N Non Freespoo...

Page 23: ...o Tractor Make Model and Starting Tractor Serial Number Where Applicable C O D E A Fiat Hitachi New Holland C Caterpillar E John Deere H Dresser Dressta K Komatsu R Case 39 Quadtrac 40 1650L 41 750B W...

Page 24: ...terpillar E John Deere H Dresser Dressta K Komatsu R Case 44 750B W CAB TD15E PS 45 750C I II TD15E DD 46 850C I II TD15H TIER I PS D65E 12 D65EX 12 15 D65EX 15E0 D65WX 15E0 47 D6N TD15H TIER II TD15M...

Page 25: ...ctor Make Model and Starting Tractor Serial Number Where Applicable C O D E A Fiat Hitachi New Holland C Caterpillar E John Deere H Dresser Dressta K Komatsu R Case 48 FD14E DX FD175 195 480 D6H PS 48...

Page 26: ...nued on next page Tractor Make Model and Starting Tractor Serial Number Where Applicable C O D E A Fiat Hitachi New Holland C Caterpillar E John Deere H Dresser Dressta K Komatsu R Case 50 D6R PS 71 D...

Page 27: ...Prior to the following serial numbers tractor code C47 was used for D6N D6N CBJ00400 ALH00735 CCK00500 ALR00635 AKM01235 ALY01335 Tractors C78 with pilot operated hydraulics After the above serial nu...

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Page 29: ...aintenance Schedule for the W6G winch on page 46 Check lever adjustment Checks During Operation Check FREESPOOL drag adjustment if equipped TheTroubleshooting Chart at the end of this section can be u...

Page 30: ...he brake or the clutches Springs apply the brake so that the winch drum will not rotate The BRAKE OFF position has a detent and is a neutral position for the clutches Hydraulic pressure is applied to...

Page 31: ...l Option 1 Power Control Lever 2 Freespool Lever WARNING Moving the control lever with the engine OFF and the keyswitch ON may result in accumulator discharge and brake release which will cause loss o...

Page 32: ...18 Figure 7 2 W6G Winch Operator Controls_Dual Axis...

Page 33: ...ch will unwind the wire rope at a speed controlled by the PTO speed of the tractor and the weight of the load BRAKE OFF position is a detent position The clutches are released and the oil pressure has...

Page 34: ...on is used to slowly move a load toward the tractor The control valve will cause the oil pressure to slowly release the brake and slowly apply the LINE IN clutch As the brake is released the clutch ta...

Page 35: ...e following test 1 Engage the winch with the tractor track drive in neutral 2 While the winch drum is turning engage the track drive in High gear and step on the brake until the tractor stops moving t...

Page 36: ...NE IN Inching Operation Decelerate the tractor engine rpm to idle Move the winch control lever until the load is moving at the speed required Whenever possible move the lever completely into the full...

Page 37: ...f the FREESPOOL control lever cannot be moved to engage the gear train for power operation apply a clutch to move the gear train a small amount This action will align the splines in the sliding sleeve...

Page 38: ...e care must be used when adjusting FREESPOOL drag Determine the correct preload by starting with the preload too loose and gradually increase the preload until the correct resistance to rotation is ac...

Page 39: ...Make sure the ends of the cables are fastened correctly Hydraulic oil becomes too hot Winch is operated in the BRAKE OFF position for long periods Use the BRAKE OFF position less When the BRAKE OFF po...

Page 40: ...nual for additional troubleshooting checks and adjustments Control valve or control cable needs adjustment Low oil pressure Clutch does not apply correctly at low PTO rpm Accumulator not charged Check...

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Page 43: ...system fault Light slow blink 3 second on and 3 second off means controls not active Note The winch oil should be warm approximately 80 F prior to operating the winch Checks During Operation Check th...

Page 44: ...E ON position The operator must pull the control lever from the BRAKE OFF or FREESPOOL position The BRAKE ON position is a neutral position No hydraulic pressure is applied to the brake or the clutche...

Page 45: ...CATOR LIGHT CONTROL LEVER ON OFF NOTE THE FILTER LED IS USED TO SIGNAL A SHORTED OR OPEN VALVE COIL CIRCUIT THIS LED WILL ALSO ILLUMINATE MOMENTARILY AS A SELF TEST ON STARTUP WARNING Moving the contr...

Page 46: ...WINCH INDICATOR LIGHT ACTIVATION SWITCH DECAL ACTIVATION SWITCH WINCH INDICATOR LIGHT DECAL BRAKE ON LINE OUT FREESPOOL OPTIONAL BRAKE OFF LINE IN ON OFF WARNING Moving the control lever with the eng...

Page 47: ...he winch will unwind the wire rope at a speed controlled by the PTO rpm of the tractor and the weight of the load BRAKE OFF is a detent position Oil pressure has released the brake but the wire rope c...

Page 48: ...h overheating Inching for more than a few seconds should be followed by several minutes of cooling recovery Operate the PTO at least 1000 RPM to provide adequate cooling flow Inching LINE IN This oper...

Page 49: ...clutch is engaged the speed that the drum unwinds is controlled by the rpm of the tractor PTO Determining Tractor PTO Type Allied PTO winches are designed to allow a smooth line speed transition when...

Page 50: ...NE IN Inching Operation Decelerate the tractor engine rpm to idle Move the winch control lever until the load is moving at the speed required Whenever possible move the lever completely into the full...

Page 51: ...control lever from FREESPOOL to LINE IN with a moving load attached to the wire rope FREESPOOL Drag Adjustment The preload on the bearings of the intermediate shaft controls the resistance to rotatio...

Page 52: ...sting FREESPOOL drag Determine the correct preload by starting with the preload too loose and gradually increase the preload until the correct resistance to rotation is achieved Increase the preload b...

Page 53: ...nch is operated in the BRAKE OFF position for long periods Use the BRAKE OFF position less When the BRAKE OFF position is used the hydraulic oil flows continuously through the relief valve See the Ser...

Page 54: ...filter bypass Monitor LED condition If LED remains illuminated after normal operating temperature has been reached change oil and filter Electrical short circuit Check appropriate section of wiring ha...

Page 55: ...for additional troubleshooting checks and adjustments Winch will not operate in any function Continued on next page Control lever off center at startup Return control lever to neutral position and att...

Page 56: ...t Control lever will not detent in BRAKE OFF or FREESPOOL Detent pin plate or spring worn or broken Replace appropriate parts Note See procedure for control lever disassembly and reassembly in Service...

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Page 59: ...ating time Maintenance on the hour meter of the tractor to find the maintenance time for the winch Figure 13 W6G Winch Maintenance Points Maintenance 1 Access Cover for Control Valve 2 Plug to Check O...

Page 60: ...OL control lever Use SAE 30 on the linkage as needed Check that the control wire rope and control housing are fastened correctly 500 hours or every 3 months Clean the oil suction screen and magnets Us...

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Page 63: ...t the wire rope can be pulled from the winch drum Step 2 A load logs is connected to the wire rope The operator moves the control level to the BRAKE ON position and the FREESPOOL control lever to the...

Page 64: ...d the vehicle as it travels If the load is nearly the capacity of the line pull the operator must move the load close to the vehicle before beginning to travel Step 4 If the tractor or skidder must tr...

Page 65: ...the load toward the vehicle Step 6 When the operator wants to disconnect from the load the vehicle is stopped and the control levers are moved to the BRAKE OFF DETENT or FREESPOOL positions to loosen...

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Page 67: ...NE OUT or the FREESPOOL position so that the wire rope can be pulled from the winch drum Step 2 A load logs is connected to the wire rope The operator moves the control lever to the BRAKE ON position...

Page 68: ...arly the capacity of the line pull the operator must move the load close to the vehicle before beginning to travel Step 4 If the tractor or skidder must travel through an area with bad traction condit...

Page 69: ...o pull the load toward the vehicle Step 6 When the operator wants to disconnect from the load the vehicle is stopped and the control lever is moved to the BRAKE OFF or FREESPOOL positions to loosen th...

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Page 71: ...ks or drive wheels Operator experience is required because the winch can use most of the engine power in some vehicles 3 Put the control lever in the LINE IN position to tighten the winch wire rope Wh...

Page 72: ...that the chain will not injure people or damage the vehicle An operator must be on the disabled vehicle to operate the steering and brakes when it is towed 1 Fasten the winch wire rope to the tow bar...

Page 73: ...e rope while working on a steep slope can cause death or injury and loss of equipment Tractor is Down the Slope See Figure 20 Sometimes a tractor must work on a steep slope and can use a winch to give...

Page 74: ...as necessary and use minimal inching to prevent additional heat and wear Do not permit the winch wire rope to loosen and pass under the drive wheels or tracks of the tractor Other Equipment is Down t...

Page 75: ...prevent additional heat and wear B Raising the equipment on the slope 1 Set the throttle on the tractor for the required engine speed Operator experience is required for this operation so that the loa...

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Page 77: ...tractor can handle stably especially on side slopes Line pulls through the arch also exert higher loads on the fasteners holding the winch to the tractor For this reason the wire rope diameter is lim...

Page 78: ...onal heavy duty and extended drawbars are available which increase the capacity of the drawbar and or move the pin farther back so it is not under the winch drum Optional Gear Ratios Lower speed ratio...

Page 79: ...65 Notes Notes...

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Page 82: ...To find a dealer in your area Call 503 625 2560 Fax 503 625 7269 or Email marketing alliedsystems com or Visit our website www alliedsystems com 599002W 11 05 2015 Printed in U S A...