TITAN TC 3 / TC 5 with piston motor

Transcription

1 TITAN TC 3 / TC 5 with piston motor Safety Operation Maintenance _

2 This manual is valid for the following ROTZLER part numbers. The number can be found on the type plate. Part number TC 3 TC

3 Table of Contents Table of Contents 1 General Introduction Copyright Warranty Safety Designated Use Identification of Dangers and Notice Signs Requirements of the User and Owner Work Safety Safety Instructions Regarding Winch Operation Safety Instructions when Handling Ropes Safety Notes for the Mechanic Installation Safety Instructions for the Hydraulic Components Safety Instructions for the Electric Components Protection Devices Danger Zones and Permitted Access Areas Danger Zones Permitted Access Areas Possible Dangers During Operation Product description Component overview of the winch Cooperation of the Components Options and Accessories Options Accessories Operation Indications of How to Spool on the Rope Maintenance, Care and Functional Tests Maintenance work Troubleshooting Technical Data Dimensions TC 3 with piston motor Dimensions TC 5 with piston motor Technical Data Performance Data TC Performance Data TC Performance Data TC 5 (only for Winches) Using Time, Hydraulic system, Rope

4 Table of Contents 7.4 Operating Materials Operating Materials Specification Gear Oil Specifications Viscosity of Hydraulic Oil Hydraulic Scheme Installation Mechanical Installation Hydraulic Installation General Explanation Connections TC 3 / TC Separate Leakage Oil Line Installation of the rope Inspection after installation Service Card Rope change for TITAN Winches Service Card Check rope Service Card Maintenances of the Rope End Monitoring Device of TITAN Winches Alphabetic Index Service Cards General Repair Notes O-Rings and other Seal Rings Conducts and other Surfaces Securing of Screw Connections Service Card Check, Replenish and Replace of Gear Oil for TITAN Winches Service Card Cleaning the winch, rope cleaning, rope care

5 1 General 1 General 1.1 Introduction This manual contains important information on the safety, operation and maintenance of the ROTZLER winch unit and is especially designed for the operating and maintenance personnel. Prior to operation, starting operation and maintenance, all instructions must be read, understood and observed by the operating and maintenance personnel. The ROTZLER winches must be operated, maintained and repaired by trained personnel only. Please follow the safety instructions listed in Chapter 2! Permanent operational safety is only guaranteed if the winch unit is operated in accordance with the instructions, the maintenance and inspection intervals are observed, and the specified operating materials are used. This manual must always be at hand near the winch unit and accessible to the operating and maintenance personnel. Please note that we cannot be held liable for any damage and malfunctions resulting from the nonobservance of the instructions. Operating errors and insufficient care can result in operational failures and unnecessary repairs. In the country of use, the current national regulations for winches and traction devices must be observed. In Germany, they include, inter alia, the Accident Prevention Regulations (UVV) for»winches, lifting and traction devices«of the commercial health and safety control boards (BGV- D8), DIN15020, Sheet 2 and ISO ROTZLER GMBH + CO. KG reserve the right to make technical modifications. If, nevertheless, problems arise while operating or servicing the winch unit, please contact our service. AFTER SALES SERVICES EUROPE Phone: +49 (0) / Mo. Fr. 7:00 a.m. 6:00 p.m. CEST after-sales@rotzler.de AFTER SALES SERVICE NORTH AMERICA Phone: (604) ; Fax: (604) rotzlercanada@rotzler.de

6 1 General 1.2 Copyright ROTZLER GMBH + CO. KG is in possession of the copyright to this manual. This manual contains texts, procedures, figures and drawings of a technical nature whose partial or complete reproduction, distribution or unauthorized use for competitive purposes or communication to others is strictly prohibited. Company address ROTZLER GMBH + CO. KG Robert-Bosch-Str Steinen Germany Phone: +49 (0) / Fax: +49 (0) / ROTZLER INC. Unit 122, Street Delta, British Columbia Canada V4G 1H9 Phone: (604) Fax: (604) rotzlercanada@rotzler.de 1.3 Warranty Guarantee claims are accepted under the following conditions: The winch unit is used according to its designated use. All instructions in this operating manual have been observed. Constructive and safety-related modifications have only been made by express approval of the ROTZLER GMBH + CO. KG. Only original ROTZLER spare parts have been used. Maintenance and inspection intervals have been observed. Repairs have been carried out by skilled personnel. The installation of the winch unit has been carried out in accordance with the instructions

7 2 Safety 2 Safety The TITAN winch has been designed, built and inspected to ensure safe operation. Notwithstanding, the winch and its components may present a risk to persons and materials when operated incorrectly. Accordingly, the operating manual must be read in full, and the safety instructions must be observed. When used incorrectly and not according to its designated use, the manufacturer declines any liability and guarantee. 2.1 Designated Use The ROTZLER TITAN winches belong to the group of hoisting winches. The designated use is hoisting and lowering of loads as specified for each winch type and under the attention of the given installation regulations as well as following the safety notes. Any other use is prohibited. Passenger transport with a.m. winches is prohibited. The use as determined also includes the related equipment manufacturer s recommendations regarding installation, operation and maintenance. The Technical Data (see chapter 7) must be observed. No structural modifications or changes may be done on the unit. Only original spare parts of the ROTZLER GMBH & CO. KG may be used. The operator has the duty to observe the instructions given in the operating manual and maintenance manual. 2.2 Identification of Dangers and Notice Signs Danger! This symbol is found in the manual next to any work in which there is a risk to life and limb of persons and a risk that the winch unit may become destroyed. Please, strictly observe these notice signs and act with particular caution in these cases. Attention! This symbol is found in the manual next to all notice signs in which attention is drawn to specific work sequences to guarantee safe operation with the winch unit

8 2 Safety Likewise, this symbol is found in those places of the manual in which attention is drawn to specific technical data and requirements. Note! This symbol identifies useful tips. 2.3 Requirements of the User and Owner Each person dealing with the operation and maintenance of the winch unit must have read and understood the manual. The owner must instruct the operator in accordance with this manual. The operator must be informed of all the risks associated in using this equipment. The winch unit must be operated and serviced by instructed personnel only. The owner must make sure that the safety instructions and the Accident Prevention Regulations effective in the country of use are observed. 2.4 Work Safety Notice signs attached to the winch unit and to the accessories must be observed and must not be removed. During winch operation, the operator must watch the movements of the load and the entire danger zone. In complex situations, viewing by auxiliary persons or by radio contact must be ensured. Persons must not be allowed to stay in the danger zone (see Chapter 2.5). Maintenance and inspection intervals must be observed. Winch units contain parts that are subject to wear or designed for a limited service life. Accordingly, winch units must be subjected to a general overhaul once they have used up their theoretical service life. The owner must order a general overhaul based on the determination of the used-up portion of the theoretical service life or no later than after 10 years of use. The general overhaul must be ordered by the owner and carried out by the manufacturer or persons authorized by the manufacturer. Certain parts of the winch unit must not be surface treated or covered in anyway (painted, covered with adhesive, etc). These are wire ropes, rope guiding parts, valve actuators, operating elements, sensors, optical displays, notice signs and ventilation on electronic units and operating parts

9 2 Safety Safety Instructions Regarding Winch Operation Passenger transport is prohibited. In which operation, it is strictly prohibited to guide the wire rope by hand in the winch area and near the rope guiding parts (rope pulleys, rollers, rope channels, etc.) and rope outlets (fairlead, swivel fairlead, top roller, rope trumpet). Deflection pulleys, clevises, chains, ropes, etc, must conform to the applicable regulations (if necessary, consult ROTZLER) Safety Instructions when Handling Ropes Only the ropes delivered or approved by ROTZLER may be used. When working with ropes, always wear protective gloves. Rope connections, sleeves, press heads, short splices, etc. must not be driven through the drive system/rope drive. Deflecting the rope over sharp edges, corners, obstacles, etc., is prohibited. A rope under burden must not be guided by hand. If required, the rope must be cleaned and checked after each use for deformation and damage (see Service Card ). Do not clean the rope with a steam jet blower or high-pressure cleaner. For rope care, do not use engine oil, machine oil or grease. Damaged ropes must be replaced Safety Notes for the Mechanic Installation All ROTZLER TITAN winches are designed for an installation position in horizontal axis. In case you request different installation positions (see chapter 8.1), please contact us. The mounting plate on which the winch is fastened, must be sufficiently dimensioned in order to take up the forces during winch operation. The winch must be sufficiently secured during the installation until all mounting elements are correctly attached Safety Instructions for the Hydraulic Components For the hydraulic components (installation), the national regulations of the country of use must be ob

10 2 Safety served. In Germany, the decisive regulation is DIN/ EN 982. Only approved hydraulic tubes may be used. Length, diameter and grade of the hydraulic tubes must meet the requirements. The hydraulic valves adjusted in-factory by the ROTZLER GMBH + CO. KG must not be tampered with. ROTZLER GMBH + CO. KG cannot be held liable for incorrect connection of the hydraulic lines. The duration of use of the tubes should not exceed six years, including a storage period of no more than two years Safety Instructions for the Electric Components The winch unit must be secured against overcurrent by means of a fuse. The electric signal lines must be connected in accordance with the installation instructions. When opening electric components, live parts may become exposed. Once maintenance work is complete, these components must be closed again properly. The electric components are splash-protected, but must not be operated underwater! Protection Devices The following protection devices are installed on the winch. clutch system rope end monitoring device (option) safeguard against overload (option) Protection devices must not be removed, modified or bridged. Protection devices must be checked at regular intervals (see chapter 5)

11 2 Safety 2.5 Danger Zones and Permitted Access Areas The user and other persons required for operation may only stay in the permitted access areas during the operation (load on the rope). Further persons, especially children, and animals must be kept away from the operation site and danger zone. The user is responsible for third parties in the danger zone. The user and other persons required for operation must wear the obligatory personal protective equipment (e.g. helmet, sturdy footwear, gloves, etc.) The user must keep the danger zone and especially the rope movements under observation during the operation (load on the rope). In blind situations, further observation must be ensured by additional persons who use radios as an aid if required Danger Zones a) Danger zone during operation The danger zone is declared as the area under the load in close to ropes that are under tension. b) Danger zone of rope outlet and direction of rope on the vehicle In addition to the general danger zone during operation, the complete rope path, particularly at guide pulleys/ rollers, must be regarded as being a danger zone. A hazard of crushing exists there as soon as the winch is operated. This is explained in detail in the general safety instructions in Chapter Permitted Access Areas The permitted access areas during operation (load on the rope) are located in the drivers cab and within protected facilities on the vehicles as well as on the side next to the vehicles. They apply only for the user and further persons required for operation. Absolute safety is also not given in the permitted access areas, so that the effects of damage can not be discounted there. Therefore, check the situation before starting operation and keep your retreat options open

12 2 Safety Stay alert and keep the rope movements under observation. Move to safety in good time Possible Dangers During Operation Systems placed under load may perform unpredictably and cause dangerous movements. This also applies when removing a load from one system. Furthermore, for instance, an incorrectly slung rope may release unexpectedly to cause release of the energy stored in the system under tension, which represents a considerable danger potential to the user, other persons, and animals as well as the hazard of damage to property within the range of released parts of the rope, attachment fitting, or the load, or load point

13 3 Product description 3 Product description 3.1 Component overview of the winch 3.2 Cooperation of the Components 3 1 Hydraulic oil is pumped to the hydraulic motor (1) respectively via the hydraulic system of the hoisting unit. The hydraulic motor changes the given hydraulic energy into mechanical work and drives the planetary gear of the winch, which is located inside the drum (3) via a drive shaft. The drum serves to take up the rope. The winch is equipped with an automatic, hydraulically released brake. For the exact positioning of the load a hoisting clutch is integrated. The primary and final base (2a, 2b) which are connected by the spacer bar (4) serve for the fixation of the winch. 2b 4 2a TITAN standard winch with (1) piston motor (2a) primary base (MS) (2b) final base (GS) (3) standard drum (4) spacer bar If a load has to be lifted, an increased quantity of hydraulic fluid is supplied to the motor at the pressure connection ROPE IN. The rope is pulled in, the load is lifted. Proportionally to the supplied hydraulic fluid the load is lifted quicker or slower. If the load has to be held, the supply of hydraulic fluid has to be interrupted. The sprag clutch blocks the brake shaft and prevents the load from lowering. Fig. 3.1 Product overview

14 3 Product description If the load has to be lowered, the motor at the pressure connection ROPE OUT is supplied with an increased quantity of hydraulic fluid. Proportionally to the supplied hydraulic fluid the load is lowered quicker or slower. The motor is regulating the release pressure in the brake continuously, so that the lowering of the load is controlled. If the load has to be held, the supply of hydraulic fluid is interrupted and the brake prevents that the load from lowering. 3.3 Options and Accessories Options The ROTZLER TITAN winches can optionally be equipped with a Measuring Control and Display System (MCD) (to this subject also see manual for MCD step 1, step 2, step 3 and manual or for MCD step 4, step 5). The components of this system are: MCD step 1: rope end control MCD step 2: rope end control and 1-point-torque control MCD step 3: rope end control and 2-point-torque control MCD step 4: combined rope end and torque signals MCD step 5: separate rope end and torque signals Further options: Equipment of the winch with stainless steel screws Accessories two drum barrels with grooves Through this also the following technical data will change: Drum diameter Hoisting force Rope length respectively rope storage Rope speed pressure roller for stabilisation of the stored rope on the rope drum

15 4 Operation 4 Operation Regarding the operation you have to follow the Operating Instructions of the hoisting unit, containing the safety recommendations, as well as the safety instructions in chapter 2 of these instructions. As a basic rule we recommend 1-2 % of the minimum breaking strength of the rope as minimum load. 4.1 Indications of How to Spool on the Rope The following points have to be noted in order to increase the durability of the rope: Very dirty ropes have to be cleaned with clear water and brushed before they are spooled on. In order to achieve a better spooling quality and durability the rope always has to be spooled on with a minimum hook load (see chart below). winch type TC 3 TC 5 minimum hook load kg kg Tab. 4.1 minimum hook load

16 4 Operation

17 5 Maintenance, Care and Functional Tests 5 Maintenance, Care and Functional Tests 5.1 Maintenance work When maintenance work is performed, the winch must not be operating and must be secured against inadvertent startup (switch off drives). Failure to properly maintain and service the winch could result in a major mechanical failure and allow the load to drop, severe injury or death or causing property damage. Maintenance interval At every use Activity Operating materials R / O* ServiceCard Visual and acoustic observation of the complete winch system for abnormal operation and noises After each use Visual control of the rope 1 R Visual control of leaks R Once a week Check-up of the fixing elements R When required Cleaning of rope Clear water and R brush Rope care recommended rope R cleaning agent Change of rope 1 New rope R Monthly Visual control of touch roller (rope end monitoring device) New touch roller R R Tab. 5.1 Maintenance work * R = recommended, O = obligatory

18 5 Maintenance, Care and Functional Tests Maintenance interval After 100 operating hours, latest after 6 months Activity Operating materials R / O* ServiceCard First change of gear oil O Gear oil 2 Every 3 months Gear oil control 3 R After 1000 operating hours, latest after 1year Change of gear oil O Once a year Check-up of clutch 4 O Complete winch system Expert O Tab. 5.1 Maintenance work (cont.) * R = recommended, O = obligatory 1 When the rope must be discarded see Service Card First filling SAE 80W; SAE 80W-90 and SAE 90 are alternative oils, for usage of other oil please contact ROTZLER. 3 You have to find out the reason which leads to a loss of oil and repair has to be done by experts. 4 At the regular check-up of the crane a test load has to be lifted near to the ground and the energy supply of the hoisting winch has to be switched off (switch off drive motor). Checking time approx. 5 minutes. The load must not sink in this condition. Should the load sink, the winch operation has to be finished and the authorised AFTER SALES SERVICES has to be informed General Overhaul (obligatory in Germany) Under normal winch usage the service life is approximately 10 years, after which a overhaul will be mandatory. Under intensive winch usage the service life is approximately 6 years, and approximately 12 years if it is only used occasionally. A general overhaul increases the service life of the winch and reduces the danger of total failure. During a general overhaul the winch undergoes a thorough check, maintenance, and structural components are replaced as required

19 6 Troubleshooting 6 Troubleshooting Failure to properly maintain and service the winch could result in a major mechanical failure and allow the load to drop, severe injury or death or causing properly damage. The ServiceCards in the reference column marked with (*) are not part of this manual. For techincal description (ServiceCards) please contact the ROTZLER After Sales Service Symptom Possible Cause Corrective Action Reference Winch will not hoist/pull rated load. Tab. 6.1 Troubleshooting Inadequate hydraulic system supply pressure. Damaged winch motor. Winch centerline is distorted due to uneven mounting surface. Binding load carrying sheaves. Install gauges at motor ports to verify hydraulic system supply pressure and correct as required. Replace or repair winch motor according to Service Card. Refer to Installation Instructions for proper winch mounting. Inspect and repair or lubricate sheaves as required. * SC chapter 8, page

20 6 Troubleshooting Symptom Possible Cause Corrective Action Reference Winch will not turn at rated speed. Tab. 6.1 Troubleshooting (cont.) Inadequate hydraulic system supply volume. Damaged winch motor. Winch centerline is distorted due to uneven mounting surface. Binding load carrying sheaves. Use an in-line flow meter at the motor to verify hydraulic system supply volume and correct as required. Replace or repair winch motor according to Service Card. Refer to Installation Instructions for proper winch mounting. Inspect and repair or lubricate sheaves as required. * SC chapter 8, page

21 6 Troubleshooting Symptom Possible Cause Corrective Action Reference Winch will not hold the load. Tab. 6.1 Troubleshooting (cont.) Wire rope is wound onto the cable drum in the wrong direction. Hydraulic system is trapping pressure at external brake release port. Hydraulic system control valve is equipped with the wrong spool and traps pressure at the motor lowering port when returned to the neutral position Clutch assembly is damaged. Brake Friction or Separator Plates are worn or damaged. Hydraulic fluid contamination is causing Brake Piston to bined in Primary Base. Spool rope according to INSTALLA- TION INSTRUCTIONS. Watch turning direction CC or CW. Vent the external brake release port to tank when in neutral. Install a control valve with «H» or «Y» position in the neutral position. Disassemble and inspect the Sprag Clutch, Brake Shaft and Brake Hub according to Service Card. Replace as required. Disassemble and inspect the brake Discs and Brake Separators according to Service Card. Replace as required. Disassemble and inspect the bore of the Primary Base for contamination or abrasion damage according to Service Card. Repair or replace as required. chapter 8, page 38 * SC * SC * SC

22 6 Troubleshooting Symptom Possible Cause Corrective Action Reference Winch will not turn in direction ROPE OUT. Tab. 6.1 Troubleshooting (cont.) Inadquate hydraulic system supply pressure. Brake release pressure does not develop due to damaged O-Rings at the Brake Piston or damaged valve. Brake release pressure is prevented due to blocked valve. Damaged winch motor. Winch centerline is distorted due to uneven mounting surface. Install gauges at motor ports to verify hydraulic system pressure. Correct as required. Dissassemble and inspect Brake Piston O-Rings and valve according to Service Card. Replace as required. Disassemble and inspect valve according to Service Card. Repair as required. Replace or repair winch motor according to Service Card. Refer to Installation Instructions for proper winch mounting. * SC * SC * SC chapter 8, page

23 6 Troubleshooting Symptom Possible Cause Corrective Action Reference Winch vibrates in direction ROPE OUT. Tab. 6.1 Troubleshooting (cont.) Inadequate hydraulic system supply volume. Air in hydraulic fluid Cooling oil supply to brake or flushing line is blocked by a plugged brake piston orifice. Brake discs or separators are damaged or worn Clutch assembly is damaged. Use an in-line flow meter at the motor port to verify hydraulic system supply volume is greater than the minimum volume specified in PERFORMANCE DATA. Correct as required. Ensure that the hydraulic fluid is clear. If appearance is milky or cloudy, air is being introduced into the hydraulic system. Diagnose and correct as required. Remove Brake Piston and inspect orifice according to Service Card. Replace as required. Disassemble and inspect the Brake Discs and Separators according to Service Card. Replace as required. Disassemble and inspect the Sprag Clutch, Brake Shaft and Brake Hub according to Service Card. Replace worn or damaged components. * SC * SC * SC

24 6 Troubleshooting Symptom Possible Cause Corrective Action Reference Winch leaks oil. Tab. 6.1 Troubleshooting (cont.) Hydraulic fluid leaks from between the motor shaft end cover and the primary base due to a damaged O- ring. Hydraulic fluid leaks from the motor gear housing due to damaged motor housing seals. Gear lubricating oil leaks from between the Final Base and Cable Drum flange due to a damaged final end Cable Drum Seal. Disassemble and inspect the motor shaft end cover O-ring and sealing surfaces according to Service Card. Replace or repair as required. Disassemble the motor and inspect the seals and sealing surfaces according to Service Card. Replace or repair as required. Disassemble and inspect the final end Cable Drum Seal according to Service Card. Ensure that the sealing surface of the Seal Sleeve is smooth and that the Seal Sleeve connection to the Final Base is intact. Replace seal and repair sealing surface or connection as required. * SC * SC * SC

25 6 Troubleshooting Symptom Possible Cause Corrective Action Reference Winch leaks oil (cont.). Tab. 6.1 Troubleshooting (cont.) Gear lubricating oil leaks from the Final Base Relief Valve due to one of the following faults: Relief Valve is damaged or blocked open. The Brake Shaft Seal is leaking hydraulic fluid into the Cable Drum and relieving through the Relief Valve. Inspect both areas between the Cable Drum flanges and Bases for oil leakage resulting from damaged Cable Drum Seals. Gear lubricating oil leaks from between the Primary Base and Cable Drum flange due to a damaged primary end Cable Drum Seal or Bearing Holder O-ring. * For techincal description (ServiceCards) please contact the ROTZLER After Sales Service. Remove and inspect Relief Valve. Clear any contamination or replace Valve as required. The Cable Drum cavity fills with hydraulic system fluid if the Brake Shaft Seal has failed. If this occurs, disassemble and inspect the Brake Shaft Seal according to Service Card. Replace as required. If damaged, replace Cable Drum Seals also. Disassemble and inspect the primary end Cable Drum Seal and Bearing Holder O-ring according to Service Card. Inspect the corresponding sealing surfaces. Ensure that the Seal Sleeve connection to the Primary Base. * SC * SC

26 6 Troubleshooting

27 G 7 Technical Data 7 Technical Data 7.1 Dimensions TC 3 with piston motor Q P O A H R B L K I C J Fig. 7.1 Dimensions TC 3 A B C D E F G H 488 mm (19.2 in) 432 mm (17.0 in) 430 mm (16.9 in) 316 mm (12.4 in) mm (14.2 in) mm (10.8 in) 20 mm (0.8 in) 229 mm (9.0 in) E A M I I 1 J K L M N 279 mm (11.0 in) without grooved drum sleeve 295 mm (11.6 in) with grooved drum sleeve 424 mm 16.7 in) 218 mm (8.6 in) 157 mm (6.2 in) 55 mm (2.2 in) F D N O P Q Q 1 R 19 mm (0.8 in) mm (19.79 in) mm (20.24 in) mm (23.13 in) at MCD 2/3 559,6 mm (22.03 in) at MCD 4/ mm (17.39 in)

28 G 7 Technical Data 7.2 Dimensions TC 5 with piston motor Q P O A H R B L K I C J Abb. 7.2 Dimensions TC 5 A B C D E F G H 495 mm (19.5 in) 510 mm (20 in) 433 mm (17 in) 395 mm (15.6 in) mm (14.2 in) mm (10,8 in) 20 mm (0.8 in) mm (12.18 in) E A M I I 1 J K L M mm (11.0 in) without grooved drum sleeve mm (11.6 in) with grooved drum sleeve mm (16.6 in) 218 mm (8.6 in) 157 mm (6.2 in) 67 mm (2.6 in) N F D N O P Q Q 1 R 20.3 mm (0.8 in) 505 mm (19.9 in) 520 mm (20.5 in) 590 mm (23.2 in) at MCD 2/3 565 mm (22.2 in) at MCD 4/5 520 mm (20.5 in)

29 7 Technical Data 7.3 Technical Data Performance Data TC 3 The technical data can be seen from the data sheet of the winch and the type plate on the winch. These characteristic data are necessary for operating and identifying the winch. Designation Abbrev. Unit Rope Layer Rope capacity according to DIN (30) 7100 (6750) hoisting force, design according to 1Bm 1) [kn] [lbs] 41 (39) 9200 (8800) 37 (35) 8400 (7900) 34 (33) 7700 (7420) total rope length 2) [m] 14 (14) 29 (30) 46 (47) [feet] 47 (47) 97 (99) 151 (154) rope speed with standard motor v nom [m/min] 44 (46) 48 (50) 52 (54) (Q = 100 l/min); (= 27 USGPM) [inch/min] 144 (151) 158 (164) 172 (177) max. oil volume flow standard motor Q max < [l/min] 100 [USGPM] 27 min. oil volume flow standard motor Q min [l/min] 20 [USGPM] 5.28 weight of the winch (approx.) [kg] 169 [lbs] 373 noise level dba 91 Tab. 7.1 Technial data TC 3 figures in brackets are valid with grooved drum option (X) = layer not available with grooved drum option Max. oil pressure 270 bar (4000 psi) return flow pressure10 bar (145 psi) in consideration 1) gear according to FEM ) drum core diameter according to DIN (64) 209 (210) 56 (59) 185 (194) 29 (x) 6600 (x) 82 (x) 271 (x) 60 (x) 199 (x)

30 7 Technical Data Performance Data TC 5 The technical data can be seen from the data sheet of the winch and the type plate on the winch. These characteristic data are necessary for operating and identifying the winch. Designation Abbrev. Unit Rope Layer Rope capacity according to DIN hoisting force, design according to 1Bm 1) total rope length 2) rope speed with standard motor (Q = 120 l/min); (= 32 USGPM) max. oil volume flow standard motor min. oil volume flow standard motor weight of the winch (approx.) v nom Q max < Q min noise level dba 86 Tab. 7.2 Technial data TC 5 figures in brackets are valid with grooved drum option (X) = layer not available with grooved drum option Max. oil pressure 320 bar (4700 psi) return flow pressure10 bar (145 psi) in consideration 1) gear according to FEM ) drum core diameter according to DIN [kn] [lbs] [m] [feet] [m/min] [in/min] [l/min] [USGPM] [l/min] [USGPM] [kg] [lbs] 57 (54) (12300) 17 (17) 56 (56) 44 (46) 144 (152) 52 (49) (11100) 35 (35) 117 (117) 49 (51) 159 (167) 47 (45) (10200) 55 (55) 184 (184) 54 (56) 175 (183) (xx) 9800 (xx) 77 (xx) 256 (xx) 58 (xx) 191 (xx) xx (xx) xx (xx) xx (xx) xx (xx) xx (xx) xx (xx)

31 7 Technical Data Performance Data TC 5 (only for Winches) The technical data can be seen from the data sheet of the winch and the type plate on the winch. These characteristic data are necessary for operating and identifying the winch. Designation Abbrev. Unit Rope Layer Rope capacity according to DIN (43) (9700) hoisting force, design according to 1Bm 1) [kn] [lbs] 57 (54) (12100) 52 (49) (11200) 48 (46) (10400) rope length, rope diameter 14 mm 2) [m] 19 (20) 21 (21) 23 (23) [feet] 63 (66) 69 (69) 76 (76) total rope length 3) [m] 19 (20) 40 (41) 63 (64) [feet] 63 (66) 132 (135) 207 (210) rope speed with standard motor v nenn [m/min] 44 (46) 48 (50) 52 (54) (Q = 120 l/min); (= 32 USGPM) [in/min] 145 (151) 158 (164) 171 (178) max. oil volume flow standard motor Q max < [l/min] 120 [USGPM] 32 min. oil volume flow standard motor Q min [l/min] 11 [USGPM] 3 weight of the winch (approx.) [kg] / 191 [lbs] 421 noise level dba 86 Tab. 7.3 Technial data TC 5 figures in brackets are valid with grooved drum option (X) = layer not available with grooved drum option Max. oil pressure 320 bar (4700 psi) return flow pressure10 bar (145 psi) in consideration 1) gear according to FEM ) rope diameter according to FEM ) drum core diameter according to DIN (25) 79 (82) 97 (89) 319 (292) 56 (59) 184 (194) 41 (xx) 9200 (xx) 26 (xx) 85 (xx) 113 (xx) 371 (xx) 60 (xx) 197 (xx)

32 7 Technical Data Using Time, Hydraulic system, Rope TC 5 Drive group Abbrev. Unit TC 3 TC using time class of operating time T 3 T3 T3 calculated total operating time [h] theoretical using time [years] average daily operating time [h] load spectrum L 2 L 2 L 2 hours of full line pull [h] hydraulic max. return flow pressure 2) p y max [bar] ([psi)] 14 (203) 14 (203) 14 (203) system 1) max. backpressure 3) p x max [bar] ([psi)] 10 (145) 10 (145) 10 (145) max. leak oil pressure 4) p l max [bar] ([psi)] 2 (29) 1.7 (25) 2 (29) rope rope diameter d nom [mm] ([in)] 14 (0.55) 16 (0.63) 14 (0.55) 1) Data are based on a hydraulic viscosity of 39 cst and an ambient temperature of 23 C (73 F). 2) p ymax is the maximum permissible return pressure in the system and applies at the interface provided by the customer. 3) p xmax is the maximum permissible back pressure in the system (control valve in neutral position = winch stationary). 4) p lmax is the maximum permissible oil leak pressure at the interface provided by the customer. After having used up the theoretical service life, winch units must be subjected to a general overhaul. At all times, only special ropes delivered or approved by ROTZLER must be used! It is imperative to observe the current standards of the country of use. This is true in particular of the allowed load of the rope

33 7 Technical Data 7.4 Operating Materials Operating Materials Specification Application Specification / Type Range of application Ambient temperature range [ C] ([ F)]at Gear oil 1) SAE 80W-90-API-GL5 First filling and oil change standard -15 to +60 C (5 to 140 F) Lubricating grease commercially available multi-purpose grease min. start temperature [ C] ([ F]) (1600 cst) Usage temperature range / Max. oil temperature [ C] ([ F]) (1000 cst) (10 cst) Hydraulic oil HLP 22 Nordic conditons -30 (-22) -25 (-13) to 63 (145) HLP 32 or HLP 46 HLP 68 or HLP 100 Central and South European conditions -20 (-4) -13 (9) tropical conditions -5 (23) 0 (32) -15 (5) to 75 (167) -7 (19) to 87 (188) 0 (32) to 90* (194*) 7 (45) to 90* (194*) Tab. 7.4 Operating materials specification * max. leakage oil temperature 1) First filling SAE 80W; SAE 80W-90 and SAE 90 are alternative oils, for usage of other oil please contact ROTZLER

34 7 Technical Data Gear Oil Specifications Specification SAE 80W-90 1) mil. spec. API-GL 5 specific weight at 15 C (59 F) 0.90 g/ml viscosity at 40 C (104 F) 92 mm 2 /s (0.14 in 2 /s) viscosity at 100 C (212 F) 11 mm 2 /s (0.02 in 2 /s) pour-point -27 C (-16 F) flash point +240 C (464 F) As a function of the particular ambient temperatures, oils from other viscosity classes must be used to reach the specified viscosity. Tab. 7.5 Gear oil specifications 1) First filling SAE 80W; SAE 80W-90 and SAE 90 are alternative oils, for usage of other oil please contact ROTZLER Viscosity of Hydraulic Oil optimal viscosity range viscosity limits ν opt. = 50 mm 2 /s (0.08 in 2 /s) (cst) ν max/min = 1000 mm 2 /s (1.55 in 2 /s) (cst) 10 mm 2 /s (0.015 in 2 /s) (cst) Tab. 7.6 Viscosity of Hydraulic Oil The leak oil temperature is always higher than the circulation temperature. The maximum temperature allowed for a short period is T max = 90 C (194 F)

35 7 Technical Data 7.5 Hydraulic Scheme L2 L (1) winch (2) hydraulic brake (3) throttle valve (closed, if counterbalance valve is available) (4) hydraulic motor (5) brake valve (option) (6) control valve* (7) relief valve* (8) hydraulic pump* (9) return filter* * not supplied by ROTZLER V2 5 A B 6 V1 7 V1 return oil connection for direction ROPE IN V2 pressure oil connection for direction ROPE OUT L1/L2 leakage oil connection R return line to reservoir P pressure line L leakage oil line Position of V1 and V2 depends on direction of rotation (CC or CW). Fig. 7.3 Hydraulic scheme L 8 9 P R G HY 0075b

36 7 Technical Data

37 8 Installation 8 Installation 8.1 Mechanical Installation A Hoisting a load with an improperly installed winch could result in winch failure and allow the load to drop and severe injury or death or causing property damage. Only mount winch in horizontal axis (H) for propper lubrication of the internal gear components. 0,5 H V X GTH 0026 Bolt winch on mounting plate (2) by means of screws (1) (size, quality and tightening torque see (6)). The mounting plate(2) must be sufficiently dimensioned, in order to take up the forces at winch operation. The fixing surface (A) must be free of rust, dirt, oil and grease. The flatness tolerance of the surface is 0.5 mm (0.02 inch). winch type quantity size quality Inspect each of the four winch feet for contact with the mounting surface. If one of the feet does not contact the mounting surface, correct as follows: Install the recommended mounting bolts (for required size and grade) on the three mounting feet that are in contact with the mounting surface. Lightly tighten until snug. Use shim stock to securely fill the gap beneath the fourth mounting foot. Install the fourth mounting bolt. tightening torque [Nm] [(lb-ft)] TC 3 4 M (251) TC 5 4 M (291) meas. [mm] [(in)] 20 (0.79) 20 (0.79) Fully tighten all four mounting bolts to recommended torque

38 8 Installation Rope Spooling according to the 2 Principle (recommendation) In order to guarantee a better rope spooling, the distance (measure A) from the middle of the winch (1) up to the first firm pulley (2) has to be chosen in such a way, that a deflection angle of α = 1 2 is not exceeded. The formula we suggest is: 28 x B > A > 14 x B 8.2 Hydraulic Installation General A The connections «V1» and «V2» are located on the motor (2). The connections «V1» «V2» are connected with the control device of the hydraulic system (control valve). α α B GDR 3021 Here the control valve which has to be used has to be in neutral position in a «H» respectively «Y» position. In addition a pressure relief valve as well as a line filter (filter fineness max. 10 μm) has to be integrated into the hydraulic circuit. At the set-up of the hydraulic circuit various components in the winch system require to consider maximum permissible pressures. The maximum values for back pressure (p X max ), return flow pressure (p Y max ) and leakage oil pressure of the motor (p L max ) are listed in the table on page Explanation Back pressure (p x ) Pressure measured at motor output line (in back flow line), when control valve is in neutral position. Return flow pressure (p Y ) pressure measured at motor port, in the return line when control valve is in working position. Leakage oil pressure (p L ) pressure in leakage oil line, measured at the customer side interface

39 8 Installation Connections TC 3 / TC 5 NA (CW) L1 V1 (CW) V2 (CC) TC 3 TC 5 V1 G1/2 / BSPP G1/2 / BSPP V2 G1/2 / BSPP G1/2 / BSPP L1 7/16-20 / BSPP 7/16-20 / BSPP Fig. 8.1 Connections Note NA (CC) V2 (CW) V1 (CC) L2 GTH 5058 CC counter clockwise CW clockwise V1 return oil connection for direction ROPE IN V2 pressure oil connection for direction ROPE IN L1/ L2 leakage oil connection NA external brake release port L2 7/16-20 / BSPP 7/16-20 / BSPP You can find the permissible values for the maximum pressure rates in the table on page 29. If the return flow pressure exceeds 14 bar, a separate leakage oil line from the motor to the tank has to be installed (see chapter 8.2.4) Separate Leakage Oil Line A separate leakage oil line from the motor to the tank has to be installed. The leakage oil line must be connected to the uppermost leakage oil port. 8.3 Installation of the rope If the rope is not installed when the winch is delivered please refer to the ServiceCard Sec. 2 Pull on new rope

40 8 Installation 8.4 Inspection after installation It is dangerous not to follow winch mounting instructions and hoisting the load with an improperly installed winch! Check winch before start up to proper installation and correct function. Following the installation a complete check up of the entire winch system including all safety functions must be made. The applicable standards and regulations must be followed

41 9 Service Cards 9 Service Cards 9.1 General Repair Notes The winch has to be stopped, before repair works are carried out. Any remaining hydraulic oil can drain off from the pipes. The oil has to be collected in suitable containers and must be disposed of correctly. Hot oil can cause danger of burning! Screws, nuts, O rings and seals have to be replaced after disassembly. In addition during assembly glue, oil and universal grease are necessary for use. Before assembly it has to be organised that all parts and resources which have to be exchanged will be at disposal. Check disassembled parts for damage and function and replace, if required. Clean parts before they are installed. Especially boreholes and surfaces have to be cleaned thoroughly. An incorrect assembly of the parts (for example brake discs) can lead to a danger of life during operation (for example falling load). Screws and surfaces which are secured respectively sealed with LOCTITE, are marked in the sketches. CODE: D-01 = LOCTITE 270 (screw locking) D-03 = LOCTITE 601 F-02 = Universal grease F-05 = Vaseline O-02 = Gear oil O-Rings and other Seal Rings Seal rings and O-rings have to be generally replaced. Grease O-rings and seal rings at the outer diameter

42 9 Service Cards 9.3 Conducts and other Surfaces Check conducts/surfaces for damages. If rework is not possible, the corresponding part has to be replaced. 9.4 Securing of Screw Connections Screws which are secured with LOCTITE are marked at the corresponding places in the graphics. Fixing elements and threaded holes have to be clean and dry. If possible, apply LOCTITE in a width of approx. 3 mm on screw thread and threaded holes. First screw in the screws manually and then tighten to the stated torque. Remove excess LOCTITE. Let connection dry for approx. 24 hours. The secured screw connections can be unscrewed with the usual tool. Screws which should be tightened to a specific torque, must always be replaced during re-assembly. If there are several screws in a flange, proceed as follows: Always tighten the opposite screw in turn

43 Check, Replenish and Replace of Gear Oil for TITAN Winches When carrying out a gear oil change, there may be a risk of burning due to hot gear oil! all rights reserved by ROTZLER The procedure of the gear oil control and replacement of the gear oil is the same for all three winches and to perform in horizontal position. Material: specified gear oil see chapter Technical Data, collecting basin for the used oil Tools: Allen key 6 mm / open ended wrench 19 mm / screwdriver E/A N ROTZLER GMBH + CO. KG Winches, Capstans and Winchsystems, P.O. Box Steinen Germany (E/A) (N) Charging or draining screw (6 mm Allen key) Level screw (19 mm open ended wrench or 18 mm screwdriver) winch gear oil quantity type oil change complete new filling TC l (0.106 gal US) 0.50 l (0.132 gal US) TC * l (0.132* gal US) 0.60* l (0.159* gal US) TC 2L 1.10* l (0.290* gal US) 1.25* l (0.330* gal US) TC l (0.581 gal US) 2.3 l (0.608 gal US) TC (0.845 gal US) 3.5 (0.925 gal US) TH l (0.159 gal US) 0.70 l (0.185 gal US) TH l (0.172 gal US) 0.80 l (0.211 gal US) TH l (0.647 gal US) 2.70 l (0.713 gal US) TH (0.845 gal US) 3.5 (0.925 gal US) +0,1 l (0.02 gal US) if winch has No xxx Specifications see chapter Technical Data. Check, Replenish and Replace of Gear Oil for TITAN Winches Service Card

44 all rights reserved by ROTZLER Working steps: 1. Preparatory work Note! In order to perform gear oil replacement, spool off the rope completely or remove the complete winch unit from the vehicle, if the maintenance points are not accessible. The winch must stand on flat ground. To perform a gear oil replacement please continue with step Oil level check: Unscrew level screw (N) and check if oil is leaking. The gear oil must slightly overflow through the opening of the upper level screw (N). When there is sufficient gear oil in the winch screw in level screw (N) again and firmly tighten it. If no oil is leaking continue with step Gear oil replacement Heat gear oil: if necessary, completely pay out and reel in rope once. Spool off rope to such an extent, until there is access to the oil filling screw (E/A). Place a suitable oil collecting basin under the drain screw (A). If necessary, use an oil guiding duct. Unscrew charging / draining screw (E/A). 44 Service Card Check, Replenish and Replace of Gear Oil for TITAN Winches Turn drum, until the screw is situated underneath the drum. Drain gear oil into oil collecting basin via oil guiding duct. Unscrew level screw (N). Dispose of the used oil according to the instructions. 4. Fill in new gear oil Turn drum, until screw (E/A) is situated on top of the drum. Fill in new gear oil through the opening of the screw (E/A) until some gear oil slightly overflow through the opening of the upper level screw (N). Note! These filling amount can be less than indicated filling amount, since oil remains in the winch (see page 43). Screw in level screw (N) and charging / draining screw (E/A) again and firmly tighten them. ROTZLER GMBH + CO. KG Winches, Capstans and Winchsystems, P.O. Box Steinen Germany

45 Cleaning the winch, rope cleaning, rope care Material: Clear water; brush Rope cleaning agent: for ropes of TREIBMATIC winches use only rope cleaning agent ROTZLER order no for ROTZLER TITAN and ROTZLER hoist- and pulling winch ropes use grease and oil in accordance with the standards (see ISO 4309 and DIN sheet 2). Cleaning the winch In extreme environmental conditions (i.e. exposure to salt water and/or extinguishing agent with chemical additives) the TREIBMATIC winch, storage drum and accessories must be checked for dirt deposits. They must be removed to ensure safe operation. Working steps: Do not clean the rope with a steam jet blower or high-pressure cleaner. Saltwater and extinguishing agent with chemical additives may damage the rope guides through deposits and the resulting consequences. This may also result in early wear of the winch and the rope caused by corrosion. If required, use clear water and a brush to clean the winch. The storage drum and the rope guidance between winch and storage drum of the TREIBMATIC winch must be cleaned and rinsed with water. Upon exposure to saltwater and/or extinguishing agent with chemical additives all rights reserved by ROTZLER Upon exposure to salt water and/or extinguishing agent with chemical additives, the device, including rope, storage drum (TREIBMATIC winch) and all accessories, must be cleaned with freshwater. After cleaning, the rope must be treated with a rope preservative (see Rope cleaning ). ROTZLER GMBH + CO. KG Winches, Capstans and Winchsystems P.O. Box Steinen Germany Cleaning the winch, rope cleaning, rope care Service Card

46 Rope cleaning In case of dirt, the rope must be cleaned with clear water and a brush. As far as possible, allow the rope to dry. In order to increase the service life of the rope, we recommend to apply a rope preservative (see above). Upon exposure to salt water and/or extinguishing agent with chemical additives, the application of a rope preservative is necessary for avoiding damage caused by corrosion. For the cleaning and care of pulling winch ropes from it is useful to pay out the rope until the red mark at the rope end is visible. Attach the rope at a fix point and apply a pre-tension to lift the rope from the ground. all rights reserved by ROTZLER Rope care Regular care of the rope increases its service life. 46 For TREIBMATIC winches: It is mandatory to use the ROTZLER rope protection agent, ROTZLER order no Apply the rope preservative only in a thin layer. Risk of reduced friction power between rope and capstan drum! On TREIBMATIC winches this rope cleaning agent does not impair the friction power between the rope and the capstan drum if applied properly. Moreover, it is easy to use and deeply penetrates the rope structure owing to its favourable flow properties. The rope preservative may only be applied to clean and dry ropes. For ropes of the ROTZLER TITAN and ROTZLER hoist- and pulling winches grease and oil has to be selected according to the usage and operating conditions in conjunction with ISO 4309 and DIN sheet 2. Service Card Cleaning the winch, rope cleaning, rope care ROTZLER GMBH + CO. KG Winches, Capstans and Winchsystems P.O. Box Steinen Germany

47 Working steps TREIBMATIC ropes (rope cleaning agent ROTZLER order no ): 1. Relubrication of the rope may only be carried out in dry weather. 2. The application instructions on the container of the rope preservative must be observed. 3. Apply rope preservative at room temperature (at least 15 C) in a thin layer. At an ambient temperature of 25 C, the treated rope is ready-to-use after about 2 hours. At lower outside temperatures, the drying time is up to one day. 4. Relubricate ropes, before the previously applied rope preservative loses its softness or even becomes dried out. 5. Ropes used only by seasons must be treated with preservative after each shutdown and prior to each starting operation. Working steps ropes of the ROTZLER TITAN and ROTZLER hoist- and pulling winches: 1. Relubrication of the rope may only be carried out in dry weather. 2. The application instructions on the container of the rope preservative must be observed. 3. Apply sufficing of the the rope protection agent with a brush or a rag to provide a good penetration. 4. Relubricate ropes, before the previously applied rope preservative loses its softness or even becomes dried out. 5. Ropes used only by seasons must be treated with preservative after each shutdown and prior to each starting operation. all rights reserved by ROTZLER ROTZLER GMBH + CO. KG Winches, Capstans and Winchsystems P.O. Box Steinen Germany Cleaning the winch, rope cleaning, rope care Service Card

48 all rights reserved by ROTZLER 48 Service Card Cleaning the winch, rope cleaning, rope care ROTZLER GMBH + CO. KG Winches, Capstans and Winchsystems P.O. Box Steinen Germany

49 Rope change for TITAN Winches Danger from improperly installed rope! Incorrect installation of the rope may allow the load drop down and severe injury or death or causing property damage. When handling ropes, you must wear protective gloves! Material: Gloves, new rope, screwdriver Working steps: 1. Discard old rope Spool off old rope without load, until the last three safety windings are reached. Stop winch. Turn rope drum until you have access to the cast- in pocket (1). Detach rope wedge (420) in direction of arrow. Pull old rope inlet (3) and discard it. GTH all rights reserved by ROTZLER ROTZLER GMBH + CO. KG Winches, Capstans and Winchsystems P.O. Box Steinen Germany Rope change for TITAN Winches Service Card

50 2. Pull on new rope richtig/right falsch/wrong a. Prepare rope. b. Guide the new rope to the rope outlet of the TITAN. When built into a vehicle, make sure that the rope is laid correctly in the vehicle frame (rope guides) GTH 4005 c. Guide smooth rope end through rope inlet (3). Insert rope in rope wedge (2) as shown and insert both in cast-on pocket (1) in direction of arrow. Spool on rope. Pay attention, that the rope with rope wedge are perfectly clamped in the rope pocket. CW GTH 4003 Depending on the direction of rotation of the winch (clockwise «CW» or counter clockwise «CC») it has to be noted, from which side the rope is directed into the rope inlet. CC all rights reserved by ROTZLER 50 Service Card GTH 4002 Rope change for TITAN Winches ROTZLER GMBH + CO. KG Winches, Capstans and Winchsystems P.O. Box Steinen Germany

51 Check rope After each use, the rope must be checked for damage, individual wire breakages, deformation and corrosion according to the national regulations of the country of use. Damaged ropes must be replaced immediately! all rights reserved by ROTZLER Ropes are subject to very high stress and do not have ultimate compressive strength. For the safety of the winch unit and of the operating personnel, it is important that the rope is carefully checked. If the rope is used again following a check, it should be cleaned and treated with the recommended rope preservative (see Service Card ). In Germany, the decisive regulation is ISO 4309 and DIN Additional to the standards ISO 4309 and DIN the following guidelines are valid. The time of discard of the ropes is reached, when: ropes of ROTZLER TITAN winches and ROTZLER HK and LK winches: 2 wire breakages take place over a length of 6 x d, resp. 4 wire breakages take place over a length of 30 x d for ropes Ø = 7, 8, 10 mm, resp. ROTZLER GMBH + CO. KG Winches, Capstans and Winchsystems P.O. Box Steinen Germany 5 wire breakages take place over a length of 30 x d for ropes Ø = 12, 14, 16 mm. ROTZLER TREIBMATIC ropes: 10 wire breakages take place over a length of 20 x d. ropes of ROTZLER HZ winches: 11 wire breakages take place over a length of 30 x d for ropes Ø = 6, 12, 13, 14, 16 mm, resp. 13 wire breakages take place over a length of 30 x d for ropes Ø = 18, 24, 26, 30 mm. all ropes: the rope diameter is reduced by 10% compared with the nominal size. a strand is broken or breakage is imminent the rope is pinched a high degree of rust deposit is detected the rope was exposed to strong heat (tarnish, strands discolored) Check rope Service Card

52 When handling ropes, you must wear protective gloves! Pull out rope full for a check and check for damage. Below are listed some of the most important rope deformations, which require the rope to be replaced. Reduction of rope nominal diameter by more than 10% Corkscrew-type deformation Kinked rope Contractioned rope Flattening rope Loop formation of wires on the rope Knots on the rope Splicing on the rope Basket formation on the rope Loose wires in the rope Individual wire breakages all rights reserved by ROTZLER The rope preservative recommended by ROTZLER is a special oil (see Service Card ). This oil is particularly easy to use and deeply penetrates the rope structure owing to its favorable flow properties. 52 Service Card Check rope ROTZLER GMBH + CO. KG Winches, Capstans and Winchsystems P.O. Box Steinen Germany