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Operating Manual
A Product of
Sherwood, OR USA
W6G
Towing Winch
for Caterpillar Dozers
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
Applicable to winches with serial numbers:
•
AW6GE6*2057C***
•
AW6GE6*2059C*** and later
P/N 599002W-CAT
Printed in U.S.A.
08/14/2020
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Summary of Contents for Allied Systems W6G
- Page 1 Towing Winch for Caterpillar Dozers 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 Applicable to winches with serial numbers: A Product of •...
- Page 2 Serial Number Winch Model Date Installed Date Delivered Special Equipment or Attachments A Product of Allied Systems Company 08/14/2020 Sherwood, Oregon Printed in U.S.A. U.S.A.
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Page 3: Foreword
Operating Manual, contact your local winch dealer, in good condition. or contact Allied Systems Company: • Read and understand the SAFETY SUMMARY and OPERATING PROCEDURES contained in this Allied Systems Company Operating Manual. - Page 4 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.
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Page 5: Table Of Contents
Nameplate ..............2 Wire Rope Selection ..........3 Maintenance Recommended Oil List & Oil Capacity .....4 Maintenance ............21 W6G Winch Description ...........5 Maintenance Points ..........21 Optional Equipment ..........6 Maintenance Schedule ........22 Serial Number Codes ..........7 Dozer Identifi cation and Gear Ratios ......8... -
Page 6: Contents
Contents (continued) Operating Techniques Dozer or Skidder Operation ........23 How To Move A Disabled Vehicle......26 Working on A Steep Slope ........28 Tractor Is Down The Slope .......28 Other Equipment Is Down The Slope ....29 Operational Differences, Optional Equipment Integral Arch ............31 Fairlead ..............31 Drawbar ..............32 Optional Gear Ratios ..........32... -
Page 7: Safety Summary
Safety Summary Safety Summary General Safety Notices WARNING The following pages contain general safety warnings which supplement specific warnings and cautions T h e “ WA R N I N G ” s y m b o l a p p e a rs appearing elsewhere in this manual. - Page 8 NOTE: All possible safety hazards cannot NOTICE be foreseen so as to be included in this manual. Therefore, you must always This signal word alerts to a situation that be alert to potential hazards that could is not related to personal injury but may endanger personnel and/or damage the cause equipment damage.
- Page 9 Safety Summary » Do not work with a damaged or worn wire rope. Obey the following cautions and warnings before using your winch to » Do not use a winch that needs repairs. avoid equipment damage, personal » If the wire rope and ferrule must be removed from injury or death.
- Page 10 • Do not leave the vehicle when the winch wire rope • Always inspect wire rope, tail chain and other rigging is under tension. components for wear, damage, broken strands or abuse before use. • Do not permit riders on the vehicle or load. •...
- Page 11 • Replace any par ts only with genuine Allied Winch parts. Refer to W6G Parts Manual (P/N • Do not attempt to pull loads in excess of the rated 599003W-CAT).
- Page 12 » Infection and gangrene are possible when • This winch is neither intended, designed, nor rated for any application involved in the lifting or moving hydraulic oil penetrates the skin. See a doctor of personnel. immediately to prevent loss of limb or death. •...
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Page 13: General
This Operating Manual contains basic information Removable covers on the winch case allow access for repairs and adjustments. necessary for the operation and maintenance of the W6G winch. When PTO is rotating, the hydraulic pump shaft is also rotating. Oil from the hydraulic pump is used to cool How the Winch Operates and lubricate the winch components. -
Page 14: Nameplate
• winch serial number to fall uncontrollably. • maximum bare drum line pull The W6G winch has a maximum line pull capacity of • maximum wire rope diameter 266,880 N (60,000 lbf) when there is one layer or less of DO NOT operate the winch with larger diameter wire rope. -
Page 15: Wire Rope Selection
General Wire Rope Selection WARNING Each winch model can have a variety of wire rope sizes Load loss hazard. installed by the user. The maximum wire rope size is shown on the nameplate. See Figure 2 for approved wire rope A loaded wire rope with fewer than sizes and drum capacities. -
Page 16: Recommended Oil List & Oil Capacity
Recommended Oil List and Oil Capacity The type of oil used in Allied winches affects the line control. Use the following oils in the W6G winch: Recommended Oils* - General Conditions Ambient Temperature Range Manufacturer Oil Type °F °C ExxonMobil... -
Page 17: W6G Winch Description
15. Drawbar Pin Access Cover to Hydraulic System 10. Intermediate Shaft Bearing Retainer 16. Clutch Shaft Retainer Plug to Check Oil Level 11. Drum Shaft Bearing Retainer 17. Idler Shaft Retainer Plug to Drain Oil 12. Drawbar Figure 5 - W6G Winch... -
Page 18: Optional Equipment
Optional Equipment (See also Page 31 for details) The W6G winch may be equipped with the following options: • Integral Arch - To raise the load slightly to reduce drag • Heavy Duty Extended Drawbar due to ground contact; • Fairlead Assembly - To protect wire rope and frame NOTE: Not all optional equipment listed is available from damage at odd pull angles;... -
Page 19: Serial Number Codes
1555 C712 Branding Manufactured By Blank = Allied Branded N = Unbranded A = Allied Systems Company Winch Model Vehicle Code W6G = Standard See Figure 7 K6G = Special Design (Contact Factory) Sequence Number Type Drive... -
Page 20: Dozer Identifi Cation And Gear Ratios
Figure 7 - Dozer Identifi cation and Gear Ratios Vehicle Code Caterpillar Model and Serial Number Prefi x, Where Applicable D6R II C712 D6 Build 20A C713 D6 Build 18A, 19A D5 Build 17a C810 D6N Tractor Tier 4i; 4f (s/n prefix PER, PBA, GB6, SGG, NJN, MG5) -
Page 21: Checks Before Operation
Operation, Electronic Controls Operation, Electronic Controls Checks Before Operation Checks During Operation • Check that the wire rope and hook are not worn or • Check the winch indication light: damaged. - Any blinking indicates a problem. • Check that the periodic inspection and maintenance have been done at the recommended operating hours. -
Page 22: Operating Procedures
Operating Procedures This control lever is used to select one of the following operations: The electronic control lever is connected to the winch through electrical wiring, an electronic control module, • BRAKE-OFF and a solenoid actuated control valve. A winch activation •... - Page 23 Operation Consult Service Manual Brake for Error Codes Brake Line Line Free- spool Blade Figure 8 Control Lever...
- Page 24 Winch On LED Off Winch Off LED On Winch Off and Error + Error Code Below, Repeating Detected Oil Filter Bypassing Line‐In Coil Fault Timing Line‐Out Coil Fault 1/4 Second Pulse Brake Release Coil Fault 1/2 Second Pulse 1 Second Pulse Accumulator Coil Fault 3 Second Pulse Cooling Oil Coil Fault...
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Page 25: Operation
Operation, Electronic Controls Operation BRAKE-ON is a neutral position. Neither clutch is applied. The brake is fully applied. LINE-IN position applies the forward clutch and releases the brake. The winch will wind the wire rope at a speed Note: Grey dots controlled by the PTO rpm of the dozer and the weight represent the of the load. -
Page 26: Inching
Inching is used for fi ne control of the winch speed. When BRAKE ON the control lever is slowly moved to a position between Neutral BRAKE-ON and LINE-IN or between BRAKE-ON and LINE OUT LINE IN LINE-OUT, inching occurs. The following paragraphs describe the normal procedures for inching. -
Page 27: Freespool Operation
FREESPOOL Operation (If so equipped) FREESPOOL Drag Adjustment The preload on the bearings of the intermediate shaft WARNING controls the resistance to rotation of the drum during the FREESPOOL operation. The resistance to rotation is Moving the lever into FREESPOOL while correct when the drum can be rotated by hand, but the there is a load on the wire rope will cause drum will not rotate more than one-half revolution freely. - Page 28 CAUTION Setting the preload on the intermediate shaft too tight will cause bearing overload. Setting the preload too loose will allow shaft to not be parallel. Extreme 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 achieved.
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Page 29: Troubleshooting Chart
Operation, Electronic Controls Troubleshooting Chart PROBLEM POSSIBLE CAUSE CORRECTION Operation is rough or irregular. Hydraulic oil is too cold. Put the control lever in the BRAKE-OFF position. Run the engine at 1000 rpm to warm the oil before operating the winch. Low oil level. - Page 30 PROBLEM POSSIBLE CAUSE CORRECTION Brake begins to release before Brake is worn. See the Service Manual for additional clutch is applied. troubleshooting. Winch brake does not apply or Brake is worn. See the Service Manual for additional release correctly. troubleshooting. Low oil pressure.
- Page 31 Operation, Electronic Controls PROBLEM POSSIBLE CAUSE CORRECTION Winch will not operate in any Control module not powered. Check fuse & replace if necessary. function. Control module fault. Consult error codes in Figure 9. Coil open or shorted. Error code on joystick indicates open or shorted circuit.
- Page 32 Operation, Electronic Controls PROBLEM POSSIBLE CAUSE CORRECTION Control lever will not detent in Detent pin, plate, or spring worn or Replace control lever. BRAKE-OFF or FREESPOOL . broken. Winch does not engage and Plugged brake cartridge. Replace cartridge. dozer engine draws down in Faulty brake coil.
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Page 33: Maintenance
Control Valve Plug to Check Oil Level Plug to Che l Level Plug to Drain Oil Plug to Drai Cover for Filter & Strainer Cover for Fi Strainer Fill Plug Fill Plug Breather Breather Figure 13 - W6G Winch Maintenance Points... -
Page 34: Maintenance Schedule
Maintenance Schedule INTERVAL PROCEDURE OR QUANTITY SPECIFICATION 50 hours or weekly. Check oil level at plug (item 2). Add oil as See Figure 3 – Recommended Oil List. necessary through fi ll plug (item 5). Do not operate dozer when checking the oil level. Check Error Codes for oil fi... -
Page 35: Operating Techniques
Operating Techniques Operating Techniques Dozer or Skidder Operation BRAKE-ON LINE-OUT FREESPOOL Step 1. The dozer or skidder is moved to an area where a Step 2. A load (logs) is connected to the wire rope. The load will be connected. The operator turns on the activation operator moves the control lever to the BRAKE-ON switch, and moves the control lever to the LINE-OUT or position. - Page 36 LINE-IN BRAKE-OFF Step 3. The operator can move the control lever to the Step 4. If the dozer or skidder must travel through an LINE-IN position. If the load is less than approximately area with bad traction conditions, the operator can move 75% of the maximum line pull, the operator can begin the control lever to the BRAKE-OFF (DETENT) position.
- Page 37 Operating Techniques LINE-IN BRAKE-OFF FREESPOOL Step 5. When the vehicle is on fi rm ground, the operator Step 6. When the operator wants to disconnect from the can move the control lever to LINE-IN position to pull the load, the vehicle is stopped and the control lever is moved load toward the vehicle.
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Page 38: How To Move A Disabled Vehicle
How to Move a Disabled Vehicle 4. If the vehicle travels faster than the winch winds the wire rope, disengage the transmission until the winch A. A vehicle equipped with a winch can be used to remove wire rope is tightened again. itself from mud or other areas where it cannot move using only the drive wheels or tracks. - Page 39 Operating Techniques B. A dozer or skidder equipped with a winch can be used 1. Fasten the winch wire rope to the tow bar of the other to pull another vehicle from mud or other areas where it vehicle. The wire rope must be in a direction that is cannot move using only the drive wheels or tracks.
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Page 40: Working On A Steep Slope
Working on a Steep Slope dozer, a structure or a tree that has enough strength to hold the dozer on the slope. WARNING A. Moving down the slope: Death or equipment loss hazard. 1. Set the throttle on the dozer for the required engine speed. -
Page 41: Other Equipment Is Down The Slope
Operating Techniques B. Moving up the slope: Other Equipment is Down the Slope (See Figure 18). 1. Set the throttle on the dozer for the required engine In this operation, the dozer and winch are on stable ground speed. and other equipment is working on a steep slope. The winch is used to give additional control to the equipment 2. - Page 42 A. Lowering the equipment on the slope: B. Raising the equipment on the slope: 1. Set the throttle on the dozer for the required engine 1. Set the throttle on the dozer for the required engine speed. Operator experience is required for this speed.
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Page 43: Operational Differences, Optional Equipment
Operational Differences, Optional Equipment Operational Differences, Optional Equipment Integral Arch Fairlead When using an integral arch, the wire rope passes over A fairlead consists of a set of top and bottom horizontal a raised horizontal roller and between a set of smaller rollers and side rollers that the wire rope is fed through. -
Page 44: Drawbar
Drawbar Optional Gear Ratios Do not use the drawbar as an anchor point for a two-part Lower speed ratios allow better operator control of line line from the winch. Loads applied to the drawbar are speed. They may also allow the winch to pull in excess of transmitted to the bolts holding the winch to the dozer. - Page 46 To fi nd a dealer in your area, Call: 503.625.2560, Fax: 503.625.7269, or Email: marketing@alliedsystems.com, or 599002W-CAT 08/14/2020 Printed in U.S.A. Visit our website: www.alliedsystems.com...
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