customer's workshop - pistenbully · pdf filecalcium saponified grease kp 2 k-30 din...

EN

Customer's workshopInformation

Capstan winch, 4 metric tonsFROM 52085

– Symbols used in this manual . . . . . . . . . . . . . . . 2

– Abbreviations used in this manual . . . . . . . . . . . 2

– Warning signs affixed to the equipment . . . . . . . 3

– Fluids and lubricants . . . . . . . . . . . . . . . . . . . . . 5

– Winch cable designation . . . . . . . . . . . . . . . . . . 6

– Winch cable notes . . . . . . . . . . . . . . . . . . . . . . . 6

– Cable twist . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

– Strands broken by twist . . . . . . . . . . . . . . . . . . . 9

– Fatigue breakages . . . . . . . . . . . . . . . . . . . . . . . 9

This maintenance manual provides information about:

how to maintain and care for your capstan winch.

warnings so that you recognize dangers in good time and avoid them.

WARNING!Failure to comply with working and operating instructions with this symbol may result in danger to life and limb.

CAUTION!Failure to comply with working and operating instructions with this symbol may result in damage to machines or property.

Important information and recommendations

Handling information

Table 1: OVERVIEW

1 SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . 3

TECHNICAL DATA

02 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . 4

WINCH CABLE

CHECKING WINCH CABLE

SYMBOLS USED

CONTENTS / SAFETY REGULATIONS

2

– Adjusting brake plate. . . . . . . . . . . . . . . . . . . . 11

– Checking winch brake . . . . . . . . . . . . . . . . . . . 13

– Greasing guide roller . . . . . . . . . . . . . . . . . . . . 13

– Checking guide rollers . . . . . . . . . . . . . . . . . . . 13

Table 1: MAINTENANCE

04 REPLACING WINCH CABLE . . . . . . . . . . . . . . . . . . 10

03 CABLE GUIDE ARM . . . . . . . . . . . . . . . . . . . . . . 10

03 CHECKING GROOVED PULLEY . . . . . . . . . . . . . . . . 11

03 WINCH GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . 12

03 DRUM PLANETARY GEAR . . . . . . . . . . . . . . . . . . . 12

03 WINCH BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

03 GUIDE ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . 13

03 TURRET GEAR / DRIVE . . . . . . . . . . . . . . . . . . . . . 15

03 ADJUSTING CABLE-WINDER MONITOR. . . . . . . . . . 14

03 CHECKING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . 15

03 WINCH GEAR LUBRICATION . . . . . . . . . . . . . . . . . 16

03 TIGHTENING TORQUES, BOLTS . . . . . . . . . . . . . . . 17

03 MAINTENANCE WORK . . . . . . . . . . . . . . . . . . . . . 21

Strict compliance with the warning signs affixed to the cap-stan winch is mandatory.

Warning signs must be replaced immediately if lost or dam-aged.

Warning sign:

Location: Winch frameSP No. 8.762.638.058E

WARNING!Rotating components can crush fingers and hands. Keep well clear of components until they have come to a com-plete standstill.

Warning sign:

Location: Winch frameSP No. 8.762.651.000E

WARNING!Danger: Slackening of threaded fasteners. Strict compliance with the tightening torques as stated on the winch mounting is essential.

Table 1: WARNING SIGNS AFFIXED TO THE EQUIPMENT

WARNING SIGNS

52085.2.en

The persons who perform maintenance and repair work must be suitably qualified and commissioned to perform the work in question by the company.

Compliance with the manufacturer's maintenance instruc-tions is mandatory.

Rules for all maintenance and repair work: - Switch off the engine - Apply the parking brake - Remove the ignition key - Close the driver's cab - Interrupt the power-supply circuit (battery master switch)

Note that, after the engine has been switched off, parts re-main hot and pipes, hoses and tanks contain fluids that are still hot.

SAFETY INSTRUCTIONS

2

2

1

1

1

3

4

PistenBully 300 W Polar Speed DimensionsWith capstan winch . . . . . . . . . . . . . . 0 - 19 km/h Height with PistenBully . . . . . . . . . . . . 3,300 mm

Capstan winch in operation speed

0 - 17 km/h

With winch boom lowered . . . . . . . . . 2,910 mm

Fuel consumption at least 22 l/h Winching drum system

Weight Type 40 TL 60 AH 1050/11 . . . . . . . . . Plumettaz

capstan winch 1,700 kg Winch pump

Without cable 1,000 kg Type A4 VG90 . . . . . . . . . . . . . . . . . . Hydromatik

PistenBully 300 W Speed DimensionsWith capstan winch . . . . . . . . . . . . . . 0 - 19 km/h Height with PistenBully . . . . . . . . . . . . 3,300 mm


0 - 17 km/h




capstan winch 1,700 kg Winch pump


PistenBully 600 W DimensionsWith capstan winch . . . . . . . . . . . . . . 0 - 19 km/h Height with PistenBully . . . . . . . . . . . . 3,280 mm


0 - 17 km/h




Capstan winch 1,700 kg Winch pump


TECHNICAL DATA

)P H

)5

P H ion

IN.0

, D

Fully synthetic gear oilBasis: Polyalphaolefin (PAO)Classification: DIN 51517 T3 CLP HC Viscosity class: ISO VG 220

Fully synthetic gear oilBasis: Polyalphaolefin (PAO)Classification: API GL 5 / MIL-L-2105 B/CViscosity class: SAE 75W140

ISO VG 220SP No. 0.941.202.000 . . . . . . . . 20 l

Cable guide roller, turret gear

Calcium saponified greaseSpecification: Aviacal 2 LD, KP2K-20 DIN 51502Ideal for all lubrication points, because water-resistant.Spezialfett Mat.-Nr. 0.946.047.0001kg Dose.

Crown gear

Spray greaseSpecification: Aluplex RHS, OGPF 0 S-20, DIN 51502

SP No. 0.946.143.000 ......................500 ml spray

GEAR OIL FOR WINCH DRIVE

LUBE GREASE

Capacity Interval between changes

C

B/C

10 litres at 100 hoursAt least: once a year

every 1500 hours100 operating hours after W4 main-

tenance

C

)

0.5 litre

0.9 litreturret-gear

drive

at 100 hoursAt least: once a year

every 600 hoursevery 3000 hours

100 operating hours after W4 main-tenance

0.08 litre At least: once a yearevery 3000 hours

5150200

Cable guide roller: dailyTurret gear: every 100 hours

IN 51502 every 100 hoursActive winche very 50 hours

5
52085.2.en
Poly Alpha Oleofin (PAO)Classification: DIN 51517 T3 CLP HCViscosity index: ISO VG 150 ISO VG 220 (summer operation)

Poly Alpha Oleofin (PAO)Classification: API - GL 4 Viscosity class: SAE 75 W 90Viskositätsklasse: SAE 75 W 90Compatible with non-ferrous metals without limited slip additives.

ISO VG 150SP No. 0.941.204.020 . . . . . . . . 20 lSP No. 0.941.204.060 . . . . . . . . 50 lSP No. 0.941.204.200 . . . . . . . 200 l

ISO VG 220Et.-Nr. 0.941.202.000.

Select SAE class engine oil in accordance with the outside temperature (refer to diagram).

Engine oil MB sheet 228.5

Viscosity class:5W40

DRUM PLANETARY GEAR / TURRET-GEAR DRIVE

WINCH BRAKE

Designation Grade

Gear oil

Fully synthetic gear oil Base: Poly Alpha Oleofin (PAO

Classification: DIN 51517 T3 CLViscosity class: ISO VG 220

Fully synthetic gear oilBase: Poly Alpha Oleofin (PAO

Classification: API GL 5/ MIL-L-210Viscosity class:SAE 75W140

Windlass gearand

turret-gear drive

Poly Alpha Oleofin (PAO)Classification: DIN 51517 T3 CL

Viscosity index: ISO VG 150ISO VG 220 (for summer operat

Poly Alpha Oleofin (PAO)Classification: API - GL 4

Viscosity class: SAE 75 W 90

Winch brake Engine oil MB sheet 228.5Viscosity class: 5W40

Grease Cable guide roller / turret

gear

Calcium saponified grease KP 2 K-30 DAVIACAL 2 LD - 1kg - 0.946.047

Crown gear Specification: Aluplex RHS, OGPF 0 S-20

FLUIDS AND LUBRICANTS

Use only winch cable from Kässbohrer Geländefahrzeug AG.

Winch-cable designation:SP No. 8.461.126.391 dia. 11 mm – 105 kN minimum breaking load.Cable length 1050 metres.

Usable cable length 1000 metres. The rest of the winch cable is marked red.

Always comply with applicable national safety regulations for cable monitoring

Load hook

The winch cable is fitted with a load hook with safety lock. In order to help prevent the cable from unravelling, the load hook is attached to the cable without a swivel.

Cable clamps

3 cable clamps (Sk) are installed spaced at 150 mm (see drawing). The specified tightening torque is 25 Nm.2 cable clamps (Sk) are installed spaced at 80 mm (see drawing). The specified tightening torque is 30 Nm.

Pockets

Cause:Tendency of the strands to bunch up on account of intensive use on short stretches of slope.

Remedy:Fully unreel the cable when work ends. Leave the hook attached. Reel the cable back onto the drum with less tension.

Snags

Cause:Incorrect unreeling of the winch cable. The damage to the cable's structure drasti-

cally diminishes the breaking force. The cable has to be short-ened or replaced.

WINCH-CABLE DESIGNATION

WINCH CABLE NOTES

WINCH CABLE

6

Cable chafing

Do not permit the winch cable to chafe against or be deflected by hard, sharp-edged obstructions (stones, ice, steel, etc.).

Corrosion

Do not treat the winch cable with or allow it to come into contact with acids, sulphur, saline vapor or other aggressive substances.

Anchor point

The mount for the load hook must be of non-swivel design. The anchor point must be rated for at least 150 kN.

Anchor cable

The anchor cable (belay) is between the anchor point and the load hook of the winch cable.Use either a double cable or a twist-free cable. This will prevent the winch cable from splaying.

Storage

Protect the winch cable against bright sunlight, rain, dust and snow. If possible, store the winch cable in a closed room.

Cleaning/handling winch cable

Do not attempt to steam-clean the winch cable with a high-pressure water-jet cleaner.Do not treat the winch cable with grease-dissolving products.

300

80

Check for the first time approximately 5 operating hours after the cable is replaced.

Secure the winch cable to the anchor point.

Unreel the cable to its full length and relieve the tension on the cable.

Switch off the engine Apply the parking brake

– Loop does not twist = neutral winch cable.

Check with a small screwdriver: (see illustration)

– Light pressure suffices to insert the tip of the screwdriver blade between two strands.

– When the screwdriver blade is pulled out, the strands return to their original position.

– The winch cable is free of twist and in good condition.

CHECKING CABLE TWIST

NEUTRAL WINCH CABLE

1

22


52085.2.en

Take a grip of the winch cable with each hand close to the winch boom and bring your hands together (see Figure 1).

– The loop you form will mach one of the following variants (see Figures 2 - 4).

7

le

8

– Loop twists counter-clockwise = winch cable twisted loose.

Check with a small screwdriver:

No pressure needed to insert the blade of the screwdriver between two strands.

When the screwdriver blade is pulled out, the strands still protrude out of position.

– Situational help: Unreel the winch cable to approx. 20 m from the anchor point.

– Disengage the winch cable from the anchor point and turn it approximately 10-15 times counter-clockwise.

– Secure the winch cable to the anchor point.

– Unreel the cable to its full length and relieve the tension on the cable..

– Loop twists clockwise = winch cable twisted tight. The winch cable feels stiff.

Check with a small screwdriver: Light pressure does not suffice to insert the blade of the screwdriver between two strands.

– Situational help: Unreel the winch cable to approx. 20 m from the anchor point.

– Disengage the winch cable from the anchor point and turn it approximately 10-15 times clockwise.

– Secure the winch cable to the anchor point.

– Unreel the cable to its full length and relieve the tension on the cable..

TabWINCH CABLE TWISTED LOOSE

WINCH CABLE TWISTED TIGHT

23

4


2:

Recheck cable twist; repeat the procedure as often as nec-essary until the winch cable is neutral.

Recheck winch-cable twist; repeat the procedure as often as necessary until the winch cable is neutral.

Recognition by visual inspection

Loose cable strands (Figure 1).

– The winch cable is over-twisted.

Loose outer strands (Figure 2).

– The winch cable is twisted open.

Fatigue breakages (Figure 3) are the result of cyclic bending forces working on the cable as it is reeled over the capstan.

The influencing factors are: - Pulling force acting on cable - Length of cable used

The winch cable is due for replacement if:

– 5 wires are broken over a length of 66 mm.

– 10 wires are broken over a length of 110 mm.

– A strand is broken.

– Strands protrude.

– The cable corkscrews out of shape.

– The cable is kinked or pinched out of shape.

– A snag is visible.

The cable's useful life depends on dynamic strain and on the number of times it is reeled in and out over the capstan.

Situational help

A wire is broken on the winch cable:

Slightly raise the broken ends and bend them back and forth with a screwdriver until they break off at the root of the strand.

Make sure that there are no projecting wires. Do not cut off broken wires.

DAMAGE DUE TO TWIST

FATIGUE BREAKAGES


52085.2.en

Contact Customer Service if you have queries.

9

All work must be undertaken by specially trained workshop personnel .

Adjusting cable guide arm

Stop the winch drive when the winch cable is 5 mm clear of the storage drum wall.

Switch off the diesel engine of the PistenBully.

Adjust stop screw 9.

Cable guide arm 8 must be seated against stop screw 9.

Check with the winch in operation; re-adjust if necessary.

REPLACING WINCH CABLE

Winch in operation: set rocker switch 1 to "OFF".

CHECKING CABLE GUIDE ARM

#

Rotating components can crush fingers and hands. Keep well clear of component until it has come to a complete standstill.

10

Checking cable guide rollers on cable guide arm

Both guide rollers: - Must move freely - Must be free of wear.

The maximum permissible depth is 15 mm.

Make sure that there are no signs of wear on the side fric-tion face.

1Kässbohrer AG, LaupheimBest.Nr. El0300029 v. 8.4.2004Windenseil X rechtsPW tracPA04- 23466


Adjusting brake plate

The friction face of rail A must be clean and free of dirt.

Using adjuster screws 2, adjust the brake plate on the cable guide arm 1 until clearance X is 0.5 - 0.8 mm.

Brake plate and rail A must be parallel.

Measuring depth of groove

Depth of groove, new . . . . . 8.5 mmWear limit . . . . . . . . . . . . . . 9.5 mm

Always replace grooved pulleys 8 as a pair.

CHECKING GROOVED PULLEY

MAINTENANCE

52085.2.en

8

2

X

A

2

1

11

Oil level indicator:

Oil level indicator 1

Oil drain plug 2

Oil filler plug 3

Gear oil - grade

See fluids and lubricants

Oil level indicator

Oil filler plug 1

Oil level indicator 2

Oil drain plug 3

Gear oil - grade

- See fluids and lubricants

WINCH GEARBOX

DRUM PLANET GEAR

MAINTENANCE

12

1

23

1

3

2

Oil filler plug 2

Oil check plug 4

Initial-fill oil

See fluids and lubricants

Slacken the cover of the multi-plate brake so that the oil can be changed.

Checking winch brake

Prerequisite: The brake must be applied.

Remove threaded plug 3 and use a depth gauge to measure the clearance.

Clearance:

When new . . . . . . . . . . . . . 15.5 mmWear limit . . . . . . . . . . . . . 18.5 mm

Greasing guide roller

Grease nipple 1 and shaft 2 with special grease.

Approved special grease:

Calcium saponified greaseSpecification: Aviacal 2 LD, KP2K-20 DIN 51502

CAUTION!Special greases are not compatible with each other. When changing to another special grease, grease entire guide roller.

Checking guide rollers

CAUTION!Always check the guide rollers when installing a new winch cable. Failure to comply with this precaution can result in dam-age to the winch cable.

Check that both guide rollers move freely and are not worn.

The maximum permissible depth is 18 mm.

WINCH BRAKE

GUIDE ROLLER

MAINTENANCE

52085.2.en

2

3 4

21

13

WARNING!Rotating components can crush fingers and hands. Keep well clear of component until it has come to a complete standstill.

Adjusting end-of-cable alarm

Unreel the cable until 1.5 full winds are left on the drum.

The difference between the two guide rollers must be equal to the thickness of the cable.

The buzzer sounds and warning light 6 comes on.

The monitor can be adjusted by turning stop screw 4 until switching contact 3 clears.

Adjusting cable-winder monitor

Adjust with the winch cable wound onto the drum. The difference between the two guide rollers must be equal to the thickness of the cable.

Raise the higher guide roller and slip a twist drill or stud measuring 11 mm in diameter into position. The buzzer must sound and warning light 6 must come on.


Raise cable monitor 7 and slip a 1.5 mm feeler gauge into position. The buzzer sounds and warning light 7 lights up.


Check the bottom cable sensors in the same sequence.

ADJUSTING CABLE-WINDER MONITOR

CHECKING ALARM FOR CABLE MONITOR, RFD

MAINTENANCE

14

116

4

3

2

11

7

9

8

7

Do not use a high-pressure cleaner to clean the turret gear.

Clean the turret gear.

When applying lubricant, turn the turret gear.

Types of greaseSee fluids and lubricants

Oil change, turret-gear drive

Change the oil only when it is warm.

Swivel winch boom to the rear.

Remove the left winch cover (rubber mat).

Remove the dirt-trap cover.

Tilt the load platform and open the oil drain plug.

Note that the load platform must be tilted in order for all the oil to drain out of the system.

Lower the load platform.

Pour in oil until the level reaches max. (approx. 0.9 litre).

Use a funnel and a length of hose to pour the oil into the sys-tem

Spray crown gear with spray grease

Disconnect and jumper the wire leading to the fan's temper-ature sensor.

The fan must switch ON

TURRET GEAR / DRIVE

CHECKING FAN

MAINTENANCE

52085.2.en
15

16

Small amounts of grease may escape from a gearbox when it is new and after lubrication. This does not mean that there is a problem with the seals.

Lubrication must be carried out using the hand grease press from the onboard toolkit. Compressed-air grease presses must not be used.

Lubricate both lubrication points with special grease (Avia-cal) until the grease starts to escape slightly.

Run the gears for a few minutes.

Lubricate both lubrication points for a second time.

To avoid frequent lubrication, the grease nipples can be replaced by screw plugs. The grease nipples must then be refitted when servicing is carried out. Screw plug:....................KGF no.: 0.100.909.001.0.

WINCH GEAR LUBRICATION

MAINTENANCE

1 Main frame ......................................500 Nm

2 Winch gear ......................................200 Nm

3 Winch-cable monitor ......................... 24 Nm

4 Guide arm, relay roller ....................... 48 Nm

5 Guide arm, screw .............................200 Nm

6 Guide arm, screw ............................... 85 Nm

7 Turret gear........................................120 Nm

8 Turret-gear drive ...............................150 Nm

TIGHTENING TORQUES, BOLTS

77

8

MAINTENANCE

52085.2.en

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2

3

4

5

6

17

ic
Interval Maintenance Service Lubrication Serv
Operating hours

100

200

300

400

500

600

700

800

900

1000

1100

1200

1300

1400

1500

1600

1700

1800

1900

2000

2100

CONFIRMATION OF WORK DONE

18

e Confirmation of work performed after number of op-erating hours

Reading: operating-hours counter

DateSignature

ic
Operating hours

2100

2200

2300

2400

2500

2600

2700

2800

2900

3000

3100

3200

3300

3400

3500

3600

3700

3800

3900

4000

4100


52085.2.en



DateSignature

19

ic
Operating hours

4200

4300

4400

4500

4600

4700

4800

4900

5000

5100

5200

5300

5400

5500

5600

5700

5800

5900

6000

6100

6200


20



DateSignature

21

. . .

. . .

. . .

. . .

. . .

at 1

00 h

ours

100

hour

s af

ter 3

000

hour

s' in

terv

al

ever

y 10

0 ho

urs

Ever

y 80

0 op

erat

ing

hour

s

once

a y

ear

Ever

y 30

00 o

pera

ting

hour

s

Repl

ace

cabl

e

Done

by

the

cust

omer

Done

by

"Käs

sboh

rer S

ervi

ce D

epar

tmen

t"

WA W1

W2

W3

W4

ing

nitor.

d the

52085.2.en

PistenBully capstan winch 4 metric tons

Vehicle No.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating hours: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Name of the customer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Name of "Kässbohrer": . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Date: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE WORK

Visual inspection of all winch components.

Check security of bolts by applying torque wrench. - See Tightening torques, screws

Check hydraulic pressure setting of storage drum drive.

Check hydraulic pressure setting of storage drum drive.

Check release pressure and operation of the turret gear holdbrake.

Check settings of hydraulic system.

Thoroughly check drive capstan winch - replace central shaft with bearing.

Replace mounting bolts of winch gearbox.

Check operation of pulling force mooring regulator.

Unreel the cable as far as the red mark. - Check for damage and deformation. - Reel in the cable, using low pulling force.

Check threaded fasteners of cable clamps.

Check the cable guide wind arm and stop screws for wear.

Check clearance of the brake plate on the cable guide arm.

Check operation of the contact switch of the cable-winder mo

Check operation of safety circuits.

Check cable guide mechanism. - Bearings, cable rollers

Check RFD cable monitor for wear and check operation. - Clean switches if necessary

Replace the bearings of the cable rollers in the winch boom ancable guide rollers.

Check the drive pulleys for wear.

Check the multi-plate brake for wear.

MAINTENANCE WORK

at 1

00 h

ours

100

hour

s af

ter 3

000

hour

s' in

terv

al

ever

y 10

0 ho

urs

Ever

y 80

0 op

erat

ing

hour

s

once

a y

ear

Ever

y 30

00 o

pera

ting

hour

s

Repl

ace

cabl

e

Done

by

the

cust

omer

Done

by

"Käs

sboh

rer S

ervi

ce D

epar

tmen

t"

WA W1

W2

W3

W4

SA S1 S2 S3 S4

MAINTENANCE WORK

Check rotary valve hydraulic / electric

Check/clean breather of winch gearbox.

Check hydraulic hoses for wear / chafing.

Check the pins of the winch boom mount.

Check for cracks and check general condition: - winch mount frame - winch frame - winch boom

Clean cable rollers and drive pulleys.

LUBRICATION WORK

Lubricate the cable guide roller.

Check and lubricate the turret gear.

Spray crown gear with spray grease - Active winche very 50 hours

Change the oil in the turret-gear drive.

Lubricate the turret-gear adjuster.

Check the gear oil in the winch gearbox.

Change the gear oil in the winch gearbox.

Check the oil level in the drum planetary gear

Change the oil in the drum planetary gear.

Check the oil level in the winch brake.

Change the oil in the winch brake.

Replace the filter in the Mooring regulator.

Lubricate the cable guide roller.

MAINTENANCE WORK

22

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