Safety Operation Maintenance - Max Engineeringmaxeng.co.kr/pdf/tc3-5_om_rev20oct10.pdf · ·...

TITANTC 3 / TC 5with piston motor

Safety Operation Maintenance

400000 0253 3_29.05.2008

2 400000 0253

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

Part numberTC 3 TC 5400000 1484400000 1485400000 1486400000 1487400000 1488400000 1489400000 1490400000 1491400000 1492 400000 1493400000 1494400000 1495400000 2703

400000 1140400000 1843400000 1844400000 1845400000 1846400000 1847400000 1848400000 1849400000 1850400000 1851400000 1852400000 1853400000 1854

400000 0253 3

Table of Contents

Table of Contents1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 51.2 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . 61.3 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.1 Designated Use . . . . . . . . . . . . . . . . . . . . . 72.2 Identification of Dangers and Notice

Signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.3 Requirements of the User and Owner . . . . 82.4 Work Safety . . . . . . . . . . . . . . . . . . . . . . . . 82.4.1 Safety Instructions Regarding Winch

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 92.4.2 Safety Instructions when Handling

Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.4.3 Safety Notes for the Mechanic

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 92.4.4 Safety Instructions for the Hydraulic

Components . . . . . . . . . . . . . . . . . . . . . . . . 92.4.5 Safety Instructions for the Electric

Components . . . . . . . . . . . . . . . . . . . . . . . 102.4.6 Protection Devices . . . . . . . . . . . . . . . . . . 102.5 Danger Zones and Permitted Access

Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112.5.1 Danger Zones . . . . . . . . . . . . . . . . . . . . . . 112.5.2 Permitted Access Areas . . . . . . . . . . . . . . 11

2.5.3 Possible Dangers During Operation . . . . . 12

3 Product description . . . . . . . . . . . . . . . . 133.1 Component overview of the winch . . . . . . 133.2 Cooperation of the Components . . . . . . . . 133.3 Options and Accessories . . . . . . . . . . . . . 143.3.1 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.3.2 Accessories. . . . . . . . . . . . . . . . . . . . . . . . 14

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . 154.1 Indications of How to Spool on the

Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5 Maintenance, Care and Functional Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5.1 Maintenance work. . . . . . . . . . . . . . . . . . . 17

6 Troubleshooting . . . . . . . . . . . . . . . . . . . 19

7 Technical Data . . . . . . . . . . . . . . . . . . . . . 277.1 Dimensions TC 3 with piston motor . . . . . 277.2 Dimensions TC 5 with piston motor . . . . . 287.3 Technical Data . . . . . . . . . . . . . . . . . . . . . 297.3.1 Performance Data TC 3 . . . . . . . . . . . . . . 297.3.2 Performance Data TC 5 . . . . . . . . . . . . . . 307.3.3 Performance Data TC 5 (only for

400000 1140 Winches) . . . . . . . . . . . . . . . 317.3.4 Using Time, Hydraulic system, Rope . . . . 32

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Table of Contents

7.4 Operating Materials. . . . . . . . . . . . . . . . . . 337.4.1 Operating Materials Specification . . . . . . . 337.4.2 Gear Oil Specifications . . . . . . . . . . . . . . . 347.4.3 Viscosity of Hydraulic Oil . . . . . . . . . . . . . 347.5 Hydraulic Scheme . . . . . . . . . . . . . . . . . . 35

8 Installation . . . . . . . . . . . . . . . . . . . . . . . . 378.1 Mechanical Installation . . . . . . . . . . . . . . . 378.2 Hydraulic Installation. . . . . . . . . . . . . . . . . 388.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . 388.2.2 Explanation . . . . . . . . . . . . . . . . . . . . . . . . 388.2.3 Connections TC 3 / TC 5 . . . . . . . . . . . . . 398.2.4 Separate Leakage Oil Line . . . . . . . . . . . . 398.3 Installation of the rope. . . . . . . . . . . . . . . . 398.4 Inspection after installation . . . . . . . . . . . . 40

9 Service Cards . . . . . . . . . . . . . . . . . . . . . 419.1 General Repair Notes . . . . . . . . . . . . . . . . 419.2 O-Rings and other Seal Rings . . . . . . . . . 419.3 Conducts and other Surfaces . . . . . . . . . . 429.4 Securing of Screw Connections . . . . . . . . 42

Service Card 400000 0342Check, Replenish and Replace ofGear Oil for TITAN Winches . . . . . . . . . . . 43Service Card 400000 0452Cleaning the winch, rope cleaning, rope care. . . . . . . . . . . . . . . . . . . . . . . . . . 45

Service Card 400000 0344Rope change for TITAN Winches . . . . . . . 49Service Card 400000 0418Check rope . . . . . . . . . . . . . . . . . . . . . . . . 51Service Card 400000 0346Maintenances of the Rope End Monitoring Device of TITAN Winches . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Alphabetic Index . . . . . . . . . . . . . . . . . . . 55

400000 0253 5

1 General

1 General1.1 IntroductionThis manual contains important information on thesafety, operation and maintenance of the ROTZLERwinch unit and is especially designed for the operatingand maintenance personnel. Prior to operation,starting operation and maintenance, all instructionsmust be read, understood and observed by theoperating and maintenance personnel. The ROTZLERwinches must be operated, maintained and repairedby trained personnel only.

• Please follow the safety instructions listed inChapter 2 !

• Permanent operational safety is only guaranteed ifthe winch unit is operated in accordance with theinstructions, the maintenance and inspectionintervals are observed, and the specified operatingmaterials are used.

• This manual must always be at hand near the winchunit and accessible to the operating andmaintenance personnel.

• Please note that we cannot be held liable for anydamage and malfunctions resulting from the non-observance of the instructions. Operating errors

and insufficient care can result in operationalfailures and unnecessary repairs.

• In the country of use, the current nationalregulations for winches and traction devices mustbe observed. In Germany, they include, inter alia,the Accident Prevention Regulations (UVV) for»winches, lifting and traction devices« of thecommercial health and safety control boards (BGV-D8), DIN15020, Sheet 2 and ISO 4309.

• ROTZLER GMBH + CO. KG reserve the right tomake technical modifications.

• If, nevertheless, problems arise while operating orservicing the winch unit, please contact our service.

AFTER SALES SERVICES EUROPEPhone: +49 (0) 76 27 / 7 01 - 1 12 Mo. – Fr. 7:00 a.m. – 6:00 p.m. CESTe-mail: [email protected]

AFTER SALES SERVICE NORTH AMERICAPhone: (604) 940-7134; Fax: (604) 940-7135e-mail: [email protected]

6 400000 0253

1 General

1.2 CopyrightROTZLER GMBH + CO. KG is in possession of thecopyright to this manual.

This manual contains texts, procedures, figures anddrawings of a technical nature whose partial orcomplete reproduction, distribution or unauthorizeduse for competitive purposes or communication toothers is strictly prohibited.

Company addressROTZLER GMBH + CO. KG Robert-Bosch-Str. 4 79585 Steinen GermanyPhone: +49 (0) 76 27 / 7 01 - 0 Fax: +49 (0) 76 27 / 7 01 - 166

ROTZLER INC.Unit 122, 7350 - 72 StreetDelta, British ColumbiaCanada V4G 1H9Phone: (604) 940-7134Fax: (604) 940-7135e-mail: [email protected]

1.3 WarrantyGuarantee claims are accepted under the followingconditions:

• The winch unit is used according to its designateduse.

• All instructions in this operating manual have beenobserved.

• Constructive and safety-related modifications haveonly been made by express approval of theROTZLER GMBH + CO. KG.

• Only original ROTZLER spare parts have beenused.

• Maintenance and inspection intervals have beenobserved.

• Repairs have been carried out by skilled personnel.

• The installation of the winch unit has been carriedout in accordance with the instructions.

400000 0253 7

2 Safety

2 SafetyThe TITAN winch has been designed, built and in-spected to ensure safe operation. Notwithstanding, thewinch and its components may present a risk to per-sons and materials when operated incorrectly. Accord-ingly, the operating manual must be read in full, andthe safety instructions must be observed. When usedincorrectly and not according to its designated use, themanufacturer declines any liability and guarantee.

2.1 Designated UseThe ROTZLER TITAN winches belong to the group ofhoisting winches. The designated use is hoisting andlowering of loads as specified for each winch type andunder the attention of the given installation regulationsas 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 equip-ment manufacturer’s recommendations regarding installation, operation and maintenance.

The Technical Data (see chapter 7) must be observed.

No structural modifications or changes may be doneon the unit.

Only original spare parts of the ROTZLER GMBH &CO. KG may be used.

The operator has the duty to observe the instructionsgiven in the operating manual and maintenance man-ual.

2.2 Identification of Dangers and Notice Signs

Danger!

This symbol is found in the manual next toany work in which there is a risk to life andlimb of persons and a risk that the winch unitmay become destroyed. Please, strictlyobserve these notice signs and act withparticular caution in these cases.

Attention!

This symbol is found in the manual next to allnotice signs in which attention is drawn tospecific work sequences to guarantee safeoperation with the winch unit

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2 Safety

Likewise, this symbol is found in those places of themanual in which attention is drawn to specific technicaldata and requirements.

Note!

This symbol identifies useful tips.

2.3 Requirements of the User and Owner• Each person dealing with the operation and main-

tenance of the winch unit must have read and un-derstood the manual.The owner must instruct the operator in accordancewith this manual.The operator must be informed of all the risks asso-ciated in using this equipment.

• The winch unit must be operated and serviced byinstructed personnel only.

• The owner must make sure that the safety instruc-tions and the Accident Prevention Regulations ef-fective 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 re-moved.

• During winch operation, the operator must watchthe movements of the load and the entire dangerzone. In complex situations, viewing by auxiliarypersons or by radio contact must be ensured.

• Persons must not be allowed to stay in the dangerzone (see Chapter 2.5).

• Maintenance and inspection intervals must be ob-served.

• Winch units contain parts that are subject to wear ordesigned for a limited service life. Accordingly,winch units must be subjected to a general over-haul once they have used up their theoretical ser-vice life.The owner must order a general overhaul based onthe determination of the used-up portion of the the-oretical service life or no later than after 10 years ofuse. The general overhaul must be ordered by theowner and carried out by the manufacturer or per-sons authorized by the manufacturer.

• Certain parts of the winch unit must not be surfacetreated or covered in anyway (painted, coveredwith adhesive, etc). These are wire ropes, ropeguiding parts, valve actuators, operating elements,sensors, optical displays, notice signs and ventila-tion on electronic units and operating parts.

400000 0253 9

2 Safety

2.4.1 Safety Instructions Regarding Winch Operation

• Passenger transport is prohibited.

• In which operation, it is strictly prohibited to guidethe wire rope by hand in the winch area and nearthe rope guiding parts (rope pulleys, rollers, ropechannels, etc.) and rope outlets (fairlead, swivelfairlead, top roller, rope trumpet).Deflection pulleys, clevises, chains, ropes, etc,must conform to the applicable regulations (if nec-essary, consult ROTZLER).

2.4.2 Safety Instructions when Handling Ropes

• Only the ropes delivered or approved by ROTZLERmay be used.

• When working with ropes, always wear protectivegloves.

• Rope connections, sleeves, press heads, shortsplices, etc. must not be driven through the drivesystem/rope drive.

• Deflecting the rope over sharp edges, corners, ob-stacles, etc., is prohibited.A rope under burden must not be guided by hand.

• If required, the rope must be cleaned and checkedafter each use for deformation and damage (seeService Card 400000 0350).

• Do not clean the rope with a steam jet blower orhigh-pressure cleaner. For rope care, do not useengine oil, machine oil or grease.

• Damaged ropes must be replaced.

2.4.3 Safety Notes for the Mechanic Installation

• All ROTZLER TITAN winches are designed for aninstallation position in horizontal axis. In case yourequest different installation positions (seechapter 8.1), please contact us.

• The mounting plate on which the winch is fastened,must be sufficiently dimensioned in order to take upthe forces during winch operation.

• The winch must be sufficiently secured during theinstallation until all mounting elements are correctlyattached.

2.4.4 Safety Instructions for the Hydraulic Components

• For the hydraulic components (installation), the na-tional regulations of the country of use must be ob-

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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 tubesmust meet the requirements.

• The hydraulic valves adjusted in-factory by theROTZLER GMBH + CO. KG must not be tamperedwith.

• ROTZLER GMBH + CO. KG cannot be held liablefor incorrect connection of the hydraulic lines.

• The duration of use of the tubes should not exceedsix years, including a storage period of no morethan two years.

2.4.5 Safety Instructions for the Electric Components

• The winch unit must be secured against overcur-rent by means of a fuse.

• The electric signal lines must be connected in accor-dance with the installation instructions.

• When opening electric components, live parts maybecome exposed. Once maintenance work is com-plete, these components must be closed againproperly.

• The electric components are splash-protected, butmust not be operated underwater!

2.4.6 Protection Devices

The following protection devices are installed on thewinch.

• 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 atregular intervals (see chapter 5).

400000 0253 11

2 Safety

2.5 Danger Zones and Permitted Access Areas

The user and other persons required foroperation may only stay in the permittedaccess areas during the operation (loadon the rope).

Further persons, especially children, and animalsmust be kept away from the operation site anddanger zone.

The user is responsible for third parties in the dan-ger zone.

The user and other persons required for operationmust wear the obligatory personal protectiveequipment (e.g. helmet, sturdy footwear, gloves,etc.)

The user must keep the danger zone and espe-cially the rope movements under observation dur-ing the operation (load on the rope).

In blind situations, further observation must be en-sured by additional persons who use radios as anaid if required.

2.5.1 Danger Zones

a) Danger zone during operation

The danger zone is declared as the area under theload 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 opera-tion, the complete rope path, particularly at guide pul-leys/ rollers, must be regarded as being a dangerzone. A hazard of crushing exists there as soon as thewinch is operated. This is explained in detail in the gen-eral safety instructions in Chapter 2.4.

2.5.2 Permitted Access Areas

The permitted access areas during operation (load onthe rope) are located in the drivers cab and within pro-tected facilities on the vehicles as well as on the sidenext to the vehicles. They apply only for the user andfurther persons required for operation.

Absolute safety is also not given in the permitted ac-cess areas, so that the effects of damage can not bediscounted there.

Therefore, check the situation before starting opera-tion and keep your retreat options open.

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2 Safety

Stay alert and keep the rope movements under obser-vation. Move to safety in good time.

2.5.3 Possible Dangers During Operation

Systems placed under load may perform unpredictablyand cause dangerous movements. This also applieswhen removing a load from one system.

Furthermore, for instance, an incorrectly slung ropemay release unexpectedly to cause release of the en-ergy stored in the system under tension, which repre-sents a considerable danger potential to the user,other persons, and animals as well as the hazard ofdamage to property within the range of released partsof the rope, attachment fitting, or the load, or loadpoint.

400000 0253 13

3 Product description

3 Product description3.1 Component overview of the winch 3.2 Cooperation of the Components

Hydraulic oil is pumped to the hydraulic motor (1) re-spectively via the hydraulic system of the hoisting unit.The hydraulic motor changes the given hydraulic en-ergy into mechanical work and drives the planetarygear 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, hydraulicallyreleased brake. For the exact positioning of the load a hoisting clutch isintegrated.

The primary and final base (2a, 2b) which are con-nected by the spacer bar (4) serve for the fixation of thewinch.

If a load has to be lifted, an increased quantity of hy-draulic fluid is supplied to the motor at the pressureconnection ROPE IN. The rope is pulled in, the load islifted. Proportionally to the supplied hydraulic fluid theload is lifted quicker or slower. If the load has to beheld, the supply of hydraulic fluid has to be interrupted.The sprag clutch blocks the brake shaft and preventsthe load from lowering.

Fig. 3.1 Product overview

3

1

2a

4

2b

TITAN standard winch with(1) piston motor(2a) primary base (MS)(2b) final base (GS) (3) standard drum(4) spacer bar

14 400000 0253

3 Product description

If the load has to be lowered, the motor at the pres-sure connection ROPE OUT is supplied with an in-creased quantity of hydraulic fluid. Proportionally to thesupplied hydraulic fluid the load is lowered quicker orslower. The motor is regulating the release pressure in thebrake continuously, so that the lowering of the load iscontrolled. If the load has to be held, the supply of hy-draulic fluid is interrupted and the brake prevents thatthe load from lowering.

3.3 Options and Accessories

3.3.1 Options

The ROTZLER TITAN winches can optionally beequipped with a Measuring Control and DisplaySystem (MCD) (to this subject also see manual791046 5001 for MCD step 1, step 2, step 3 and manual 791046 5002 or 400000 2558 for MCD step 4,step 5).The components of this system are:MCD step 1: rope end controlMCD step 2: rope end control and 1-point-torque

controlMCD step 3: rope end control and 2-point-torque

control

MCD step 4: combined rope end and torque signalsMCD step 5: separate rope end and torque signals

Further options: Equipment of the winch with stainlesssteel screws.

3.3.2 Accessories

• two drum barrels with groovesThrough this also the following technical data willchange:Drum diameterHoisting forceRope length respectively rope storageRope speed

• pressure roller for stabilisation of the stored rope onthe rope drum.

400000 0253 15

4 Operation

4 OperationRegarding the operation you have tofollow the Operating Instructions of thehoisting unit, containing the safetyrecommendations, as well as the safetyinstructions in chapter 2 of these instruc-tions.

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 waterand brushed before they are spooled on.

• In order to achieve a better spooling quality and du-rability the rope always has to be spooled on with aminimum hook load (see chart below).

As a basic rule we recommend 1 - 2 % of the mini-mum breaking strength of the rope as minimumload.

winch type minimum hook loadTC 3 150 – 300 kgTC 5 200 – 400 kg

Tab. 4.1 minimum hook load

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4 Operation

400000 0253 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 andmust be secured against inadvertent star-tup (switch off drives).

Failure to properly maintain and servicethe winch could result in a major mecha-nical failure and allow the load to drop,severe injury or death or causing proper-ty damage.

Maintenance interval Activity Operating materials R / O* ServiceCard

At every use Visual and acoustic observation of the com-plete winch system for abnormal operation and noises

R

After each use Visual control of the rope1 R 400000 0418Visual control of leaks R

Once a week Check-up of the fixing elements RWhen required Cleaning of rope Clear water and

brushR 400000 0452

Rope care recommended rope cleaning agent

R 400000 0452

Change of rope1 New rope R 400000 0344Monthly Visual control of touch roller

(rope end monitoring device)New touch roller R 400000 0346

Tab. 5.1 Maintenance work * R = recommended, O = obligatory

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5 Maintenance, Care and Functional Tests

General Overhaul (obligatory in Germany)

Under normal winch usage the service life is approximately 10 years, after which a overhaul willbe mandatory. Under intensive winch usage the service life is approximately 6 years, and ap-proximately 12 years if it is only used occasionally. A general overhaul increases the service lifeof the winch and reduces the danger of total failure. During a general overhaul the winch under-goes a thorough check, maintenance, and structural components are replaced as required.

After 100 operating hours, latest after 6 months

First change of gear oil

Gear oil2

O 400000 0342

Every 3 months Gear oil control3 R 400000 0342After 1000 operating hours, latest after 1 year

Change of gear oil O 400000 0342

Once a year Check-up of clutch4 OComplete winch system Expert O

1 When the rope must be discarded see Service Card 400000 0418.2 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, thewinch operation has to be finished and the authorised AFTER SALES SERVICES has to be informed

Maintenance interval Activity Operating materials R / O* ServiceCard

Tab. 5.1 Maintenance work (cont.) * R = recommended, O = obligatory

400000 0253 19

6 Troubleshooting

6 TroubleshootingFailure to properly maintain and servicethe winch could result in a major mecha-nical failure and allow the load to drop,severe injury or death or causing proper-ly damage.

The ServiceCards in the reference co-lumn marked with (*) are not part of thismanual. For techincal description (Ser-viceCards) please contact the ROTZLERAfter Sales Service

Symptom Possible Cause Corrective Action Reference

Winch will not hoist/pull rated load.

Inadequate hydraulic system sup-ply pressure.

Install gauges at motor ports to verify hydraulic system supply pressure and correct as required.

Damaged winch motor. Replace or repair winch motor accord-ing to Service Card.

*SC 400000 0350

Winch centerline is distorted due to uneven mounting surface.

Refer to Installation Instructions for proper winch mounting.

chapter 8, page 37

Binding load carrying sheaves. Inspect and repair or lubricate sheaves as required.

Tab. 6.1 Troubleshooting

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6 Troubleshooting

Winch will not turn at rated speed.

Inadequate hydraulic system sup-ply volume.

Use an in-line flow meter at the motor to verify hydraulic system supply volume and correct as required.


*SC 400000 0350



chapter 8, page 37

Binding load carrying sheaves. Inspect and repair or lubricate sheaves as required.


Tab. 6.1 Troubleshooting (cont.)

400000 0253 21

6 Troubleshooting

Winch will not hold the load.

Wire rope is wound onto the cable drum in the wrong direction.

Spool rope according to INSTALLA-TION INSTRUCTIONS. Watch turning direction CC or CW.

chapter 8, page 38

Hydraulic system is trapping pres-sure at external brake release port.

Vent the external brake release port to tank when in neutral.

Hydraulic system control valve is equipped with the wrong spool and traps pressure at the motor lower-ing port when returned to the neu-tral position

Install a control valve with «H» or «Y» position in the neutral position.

Clutch assembly is damaged. Disassemble and inspect the Sprag Clutch, Brake Shaft and Brake Hub according to Service Card. Replace as required.

*SC 400000 0358

Brake Friction or Separator Plates are worn or damaged.

Disassemble and inspect the brake Discs and Brake Separators according to Service Card. Replace as required.

*SC 400000 0358

Hydraulic fluid contamination is causing Brake Piston to bined in Primary Base.

Disassemble and inspect the bore of the Primary Base for contamination or abrasion damage according to Service Card. Repair or replace as required.

*SC 400000 0356



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6 Troubleshooting

Winch will not turn in direc-tion ROPE OUT.

Inadquate hydraulic system supply pressure.

Install gauges at motor ports to verify hydraulic system pressure. Correct as required.

Brake release pressure does not develop due to damaged O-Rings at the Brake Piston or damaged valve.

Dissassemble and inspect Brake Piston O-Rings and valve according to Service Card. Replace as required.

*SC 400000 0358

Brake release pressure is pre-vented due to blocked valve.

Disassemble and inspect valve according to Service Card. Repair as required.

*SC 400000 0358


*SC 400000 0350



chapter 8, page 37



400000 0253 23

6 Troubleshooting

Winch vibrates in direction ROPE OUT.

Inadequate hydraulic system sup-ply volume.

Use an in-line flow meter at the motor port to verify hydraulic system supply volume is greater than the minimum vol-ume specified in PERFORMANCE DATA. Correct as required.

Air in hydraulic fluid Ensure that the hydraulic fluid is clear. If appearance is milky or cloudy, air is being introduced into the hydraulic sys-tem. Diagnose and correct as required.

Cooling oil supply to brake or flushing line is blocked by a plugged brake piston orifice.

Remove Brake Piston and inspect ori-fice according to Service Card. Replace as required.

*SC 400000 0358

Brake discs or separators are damaged or worn

Disassemble and inspect the Brake Discs and Separators according to Ser-vice Card. Replace as required.

*SC 400000 0358

Clutch assembly is damaged. Disassemble and inspect the Sprag Clutch, Brake Shaft and Brake Hub according to Service Card. Replace worn or damaged components.

*SC 400000 0358



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6 Troubleshooting

Winch leaks oil. Hydraulic fluid leaks from between the motor shaft end cover and the primary base due to a damaged O-ring.

Disassemble and inspect the motor shaft end cover O-ring and sealing sur-faces according to Service Card. Replace or repair as required.

*SC 400000 0350

Hydraulic fluid leaks from the motor gear housing due to dam-aged motor housing seals.

Disassemble the motor and inspect the seals and sealing surfaces according to Service Card. Replace or repair as required.

*SC 400000 0350

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 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 400000 0360



400000 0253 25

6 Troubleshooting

* For techincal description (ServiceCards) please contact the ROTZLER After Sales Service.

Winch leaks oil (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.

• 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.

*SC 400000 0358

Gear lubricating oil leaks from between the Primary Base and Cable Drum flange due to a dam-aged primary end Cable Drum Seal or Bearing Holder O-ring.

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 400000 0350



26 400000 0253

6 Troubleshooting

400000 0253 27

7 Technical Data

7 Technical Data7.1 Dimensions TC 3 with piston motor

Fig. 7.1 Dimensions TC 3

O B

C I

K

G

EA D

FM N

J

PQ

A

R

H L

A 488 mm (19.2 in)B 432 mm (17.0 in)C 430 mm (16.9 in)D 316 mm (12.4 in)E 360.7 mm (14.2 in)F 275.3 mm (10.8 in)G 20 mm (0.8 in)H 229 mm (9.0 in)

I 279 mm (11.0 in) without grooved drum sleeve

I1 295 mm (11.6 in) with grooved drum sleeve

J 424 mm 16.7 in)K 218 mm (8.6 in)L 157 mm (6.2 in)M 55 mm (2.2 in)

N 19 mm (0.8 in)O 502.6 mm (19.79 in)P 514.2 mm (20.24 in)Q 587.6 mm (23.13 in)

at MCD 2/3Q1 559,6 mm (22.03 in)

at MCD 4/5R 441.8 mm (17.39 in)

28 400000 0253

7 Technical Data

7.2 Dimensions TC 5 with piston motor

Abb. 7.2 Dimensions TC 5

O B

C I

K

G

EA D

FM N

J

PQ

A

R

H L

A 495 mm (19.5 in)B 510 mm (20 in)C 433 mm (17 in)D 395 mm (15.6 in)E 360.7 mm (14.2 in)F 275.3 mm (10,8 in)G 20 mm (0.8 in)H 309.4 mm (12.18 in)

I 279.4 mm (11.0 in) without grooved drum sleeve

I1 295.4 mm (11.6 in) with grooved drum sleeve

J 423.4 mm (16.6 in)K 218 mm (8.6 in)L 157 mm (6.2 in)M 67 mm (2.6 in)

N 20.3 mm (0.8 in)O 505 mm (19.9 in)P 520 mm (20.5 in)Q 590 mm (23.2 in)

at MCD 2/3Q1 565 mm (22.2 in)

at MCD 4/5R 520 mm (20.5 in)

400000 0253 29

7 Technical Data

7.3 Technical Data7.3.1 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. UnitRope Layer

Rope capacity according to DIN 15020

1. 2. 3. 4. 5.

hoisting force, design according to 1Bm1)

1) gear according to FEM 9.511

[kN][lbs]

41 (39)9200

(8800)

37 (35)8400

(7900)

34 (33)7700

(7420)

32 (30)7100

(6750)

29 (x)6600 (x)

total rope length2)

2) drum core diameter according to DIN 15020

[m][feet]

14 (14)47 (47)

29 (30)97 (99)

46 (47)151 (154)

63 (64)209 (210)

82 (x)271 (x)

rope speed with standard motor (Q = 100 l/min); (= 27 USGPM)

vnom ≥ [m/min][inch/min]

44 (46)144 (151)

48 (50)158 (164)

52 (54)172 (177)

56 (59)185 (194)

60 (x)199 (x)

max. oil volume flow standard motor Qmax < [l/min][USGPM]

10027

min. oil volume flow standard motor Qmin ≥ [l/min][USGPM]

205.28

weight of the winch (approx.) [kg][lbs]

169373

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

30 400000 0253

7 Technical Data

7.3.2 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.


Rope capacity according to DIN 15020

1. 2. 3. 4. 5.



[kN][lbs]

57 (54)13000

(12300)

52 (49)11700

(11100)

47 (45)10600

(10200)

43 (xx)9800(xx)

xx (xx)xx

(xx)

total rope length2)


[m][feet]

17 (17)56 (56)

35 (35)117 (117)

55 (55)184 (184)

77 (xx)256 (xx)

xx (xx)xx (xx)


vnom ≥ [m/min][in/min]

44 (46)144 (152)

49 (51)159 (167)

54 (56)175 (183)

58 (xx)191 (xx)

xx (xx)xx (xx)


12032


113

weight of the winch (approx.) [kg][lbs]

191421

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

400000 0253 31

7 Technical Data

7.3.3 Performance Data TC 5 (only for 400000 1140 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.


Rope capacity according to DIN 150201. 2. 3. 4. 5.



[kN][lbs]

57 (54)12800

(12100)

52 (49)11700

(11200)

48 (46)10800

(10400)

45 (43)10100(9700)

41 (xx)9200(xx)

rope length, rope diameter 14 mm2)

2) rope diameter according to FEM 5.013

[m][feet]

19 (20)63 (66)

21 (21)69 (69)

23 (23)76 (76)

24 (25)79 (82)

26 (xx)85 (xx)

total rope length3)


[m][feet]

19 (20)63 (66)

40 (41)132 (135)

63 (64)207 (210)

97 (89)319 (292)

113 (xx)371 (xx)


vnenn ≥ [m/min][in/min]

44 (46)145 (151)

48 (50)158 (164)

52 (54)171 (178)

56 (59)184 (194)

60 (xx)197 (xx)


12032


113

weight of the winch (approx.) [kg] / [lbs]

191421

noise level dBA 86Tab. 7.3 Technial data TC 5 – figures in brackets are valid with grooved drum option

(X) = layer not available with grooved drum optionMax. oil pressure 320 bar (4700 psi) – return flow pressure10 bar (145 psi) in consideration

32 400000 0253

7 Technical Data

7.3.4 Using Time, Hydraulic system, Rope

After having used up the theoreticalservice life, winch units must besubjected to a general overhaul.

At all times, only special ropes deliveredor approved by ROTZLER must be used!

It is imperative to observe the current standards of thecountry of use. This is true in particular of the allowedload of the rope.

Drive group Abbrev. Unit TC 3 TC 5TC 5

400000 1140using time class of operating time T 3 T3 T3

calculated total operating time [h] 1600 1600 1600theoretical using time [years] 12.8 – 6.4 12.8 – 6.4 12.8 – 6.4average daily operating time [h] 0.5 – 1.0 0.5 – 1.0 0.5 – 1.0load spectrum L 2 L 2 L 2hours of full line pull [h] 400 400 400

hydraulic system1)

max. return flow pressure 2) py max ≤ [bar] ([psi)] 14 (203) 14 (203) 14 (203)max. backpressure 3) px max ≤ [bar] ([psi)] 10 (145) 10 (145) 10 (145)max. leak oil pressure 4) pl max [bar] ([psi)] 2 (29) 1.7 (25) 2 (29)

rope rope diameter dnom [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.

400000 0253 33

7 Technical Data

7.4 Operating Materials

7.4.1 Operating Materials Specification

Application Specification / Type Range of application Ambient temperature range [°C] ([°F)]at

Gear oil1) SAE 80W-90-API-GL5 First filling and oil change -15 to +60 °C

(5 to 140 °F)Lubricating grease

commercially available multi-purpose grease

standard

min. start temper-ature [°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

Central and South European conditions

-20 (-4)-13 (9)

-15 (5) to 75 (167)-7 (19) to 87 (188)

HLP 68 or HLP 100

tropical conditions -5 (23)0 (32)

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 400000 0253

7 Technical Data

7.4.2 Gear Oil Specifications

7.4.3 Viscosity of Hydraulic Oil

The leak oil temperature is always higherthan the circulation temperature. The maximum temperature allowed for a shortperiod is Tmax = 90 °C (194 °F).

As a function of the particular ambienttemperatures, oils from other viscosityclasses must be used to reach the speci-fied viscosity.

Specification SAE 80W-901)

1) First filling SAE 80W; SAE 80W-90 and SAE 90 are alternativeoils, for usage of other oil please contact ROTZLER.

mil. spec. API-GL 5

specific weight at 15 °C (59 °F) 0.90 g/ml

viscosity at 40 °C (104 °F) 92 mm2/s (0.14 in2/s)

viscosity at 100 °C (212 °F) 11 mm2/s (0.02 in2/s)

pour-point -27 °C (-16 °F)

flash point +240 °C (464 °F)

Tab. 7.5 Gear oil specifications

optimal visco-sity range

νopt. = 50 mm2/s (0.08 in2/s) (cSt)

viscosity limits νmax/min = 1000 mm2/s (1.55 in2/s) (cSt) – 10 mm2/s (0.015 in2/s) (cSt)

Tab. 7.6 Viscosity of Hydraulic Oil

400000 0253 35

7 Technical Data

7.5 Hydraulic Scheme

Fig. 7.3 Hydraulic scheme

(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

V1 return oil connection for direction ROPE IN

V2 pressure oil connection for direction ROPE OUT

L1/L2 leakage oil connectionR return line to reservoirP pressure lineL leakage oil line

Position of V1 and V2 depends on direction of rotation (CC or CW).

G HY 0075b

P R

A B

V2 V1

L1

L

L2

1

3

2

5

6

7

8 9

4

36 400000 0253

7 Technical Data

400000 0253 37

8 Installation

8 Installation8.1 Mechanical Installation

Hoisting a load with an improperly installedwinch could result in winch failure and allowthe load to drop and severe injury or death orcausing property damage.

Only mount winch in horizontal axis (H) forpropper lubrication of the internal gear com-ponents.

Bolt winch on mounting plate (2) by means of screws(1) (size, quality and tightening torque see (6)). Themounting plate(2) must be sufficiently dimensioned, inorder to take up the forces at winch operation. The fix-ing surface (A) must be free of rust, dirt, oil and grease.

The flatness tolerance of the surface is 0.5 mm (0.02 inch).

Inspect each of the four winch feet for contact with themounting surface. If one of the feet does not contactthe mounting surface, correct as follows:

• Install the recommended mounting bolts (for re-quired size and grade) on the three mounting feetthat are in contact with the mounting surface. Light-ly tighten until snug.

• Use shim stock to securely fill the gap beneath thefourth mounting foot.

• Install the fourth mounting bolt.

• Fully tighten all four mounting bolts to recommend-ed torque.

0,5

H

V

X

A

GTH 0026

winch type quantity size qual-

ity

tightening torque [Nm]

[(lb-ft)]

meas.[mm][(in)]

TC 3 4 M20 8.8 340(251)

20(0.79)

TC 5 4 M22 8.8 395(291)

20(0.79)

38 400000 0253

8 Installation

Rope Spooling according to the 2° Principle (recommendation)

In order to guarantee a better rope spooling, the dis-tance (measure A) from the middle of the winch (1) upto the first firm pulley (2) has to be chosen in such away, that a deflection angle of α = 1–2° is not ex-ceeded.

The formula we suggest is:

28 x B > A > 14 x B

8.2 Hydraulic Installation8.2.1 General

The connections «V1» and «V2» are located on themotor (2).

The connections «V1» «V2» are connected with thecontrol device of the hydraulic system (control valve).

Here the control valve which has to be used has to bein 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 intothe hydraulic circuit. At the set-up of the hydraulic cir-cuit various components in the winch system require toconsider maximum permissible pressures.

The maximum values for back pressure (pX max), returnflow pressure (pY max) and leakage oil pressure of themotor (pL max) are listed in the table on page 32.

8.2.2 Explanation

Back pressure (px) Pressure measured at motor output line (in back flowline), when control valve is in neutral position.

Return flow pressure (pY)pressure measured at motor port, in the return linewhen control valve is in working position.

Leakage oil pressure (pL)pressure in leakage oil line,measured at the customer side interface.

GDR 3021

B

A

α

α

400000 0253 39

8 Installation

8.2.3 Connections TC 3 / TC 5

Note

CC counter clockwiseCW clockwiseV1 return oil connection for direction ROPE INV2 pressure oil connection for direction ROPE INL1/ L2 leakage oil connectionNA external brake release port

You can find the permissible values for the maximumpressure rates in the table on page 29.

If the return flow pressure exceeds 14 bar, a separateleakage oil line from the motor to the tank has to be in-stalled (see chapter 8.2.4).

8.2.4 Separate Leakage Oil Line

A separate leakage oil line from the motor to the tankhas to be installed.

The leakage oil line must be connected to the upper-most leakage oil port.

8.3 Installation of the ropeIf the rope is not installed when the winch is deliveredplease refer to the ServiceCard 400000 0344 Sec. 2“Pull on new rope“.

Fig. 8.1 Connections

L1

V1 (CW)V2 (CC)

V2 (CW)V1 (CC)

L2

GTH 5058

NA (CW)

NA (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

L2 7/16-20 / BSPP 7/16-20 / BSPP

40 400000 0253

8 Installation

8.4 Inspection after installationIt is dangerous not to follow winch moun-ting instructions and hoisting the loadwith an improperly installed winch!Check winch before start up to proper in-stallation and correct function.

Following the installation a complete check up of the en-tire winch system including all safety functions must bemade. The applicable standards and regulations mustbe followed.

400000 0253 41

9 Service Cards

9 Service Cards9.1 General Repair Notes• The winch has to be stopped, before repair works

are carried out.

• Any remaining hydraulic oil can drain off from thepipes. The oil has to be collected in suitable contai-ners and must be disposed of correctly.Hot oil can cause danger of burning!

• Screws, nuts, O rings and seals have to be re-placed after disassembly. In addition during assem-bly glue, oil and universal grease are necessary foruse.Before assembly it has to be organised that all partsand resources which have to be exchanged will beat disposal.

• Check disassembled parts for damage and functionand replace, if required.

• Clean parts before they are installed. Especially bo-reholes and surfaces have to be cleaned tho-roughly.

An incorrect assembly of the parts (forexample brake discs) can lead to a dan-ger of life during operation (for examplefalling load).

Screws and surfaces which are secured re-spectively sealed with LOCTITE, are markedin the sketches.

CODE:D-01 = LOCTITE 270 (screw locking)D-03 = LOCTITE 601F-02 = Universal greaseF-05 = VaselineO-02 = Gear oil 80

9.2 O-Rings and other Seal Rings• Seal rings and O-rings have to be generally re-

placed. Grease O-rings and seal rings at the outerdiameter.

42 400000 0253

9 Service Cards

9.3 Conducts and other Surfaces• Check conducts/surfaces for damages.

• If rework is not possible, the corresponding part hasto be replaced.

9.4 Securing of Screw Connections• Screws which are secured with LOCTITE are mar-

ked at the corresponding places in the graphics.

• Fixing elements and threaded holes have to beclean 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 tightento the stated torque.

• Remove excess LOCTITE.

• Let connection dry for approx. 24 hours.

• The secured screw connections can be unscrewedwith the usual tool.

• Screws which should be tightened to a specifictorque, must always be replaced during re-assem-bly.

• If there are several screws in a flange, proceed asfollows: Always tighten the opposite screw in turn.

ROTZLER GMBH + CO. KGWinches, Capstans and Winchsystems,P.O. Box 1165 · 79577 Steinen · Germany

Check, Replenish and Replace of Gear Oil for TITAN Winches

Service Card400000 0342 43

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When carrying out a gear oil change, there may be a risk of burning due to hot gear oil!

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 oilTools: Allen key 6 mm / open ended wrench 19 mm / screwdriver

(E/A) Charging or draining screw (6 mm Allen key)(N) Level screw (19 mm open ended wrench or 18 mm

screwdriver)

+0,1 l (0.02 gal US) if winch has No. 400000...xxxSpecifications see chapter Technical Data.

E/A

N

winch type

gear oil quantityoil change complete new filling

TC 1 0.40 l (0.106 gal US) 0.50 l (0.132 gal US)TC 2 0.50* 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 3 2.2 l (0.581 gal US) 2.3 l (0.608 gal US)TC 5 3.20 (0.845 gal US) 3.5 (0.925 gal US)TH 1 0.60 l (0.159 gal US) 0.70 l (0.185 gal US)TH 2 0.65 l (0.172 gal US) 0.80 l (0.211 gal US)TH 3 2.45 l (0.647 gal US) 2.70 l (0.713 gal US)TH 5 3.20 (0.845 gal US) 3.5 (0.925 gal US)

44 Service Card400000 0342


ROTZLER GMBH + CO. KGWinches, Capstans and Winchsystems,P.O. Box 1165 · 79577 Steinen · Germany

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Working steps:1. Preparatory work

Note! In order to perform gear oil replacement, spool off the rope completely or remove the com-plete winch unit from the vehicle, if the mainte-nance points are not accessible.– The winch must stand on flat ground.– To perform a gear oil replacement please con-

tinue with step 3.2. Oil level check:

– Unscrew level screw (N) and check if oil is leak-ing. The gear oil must slightly overflow throughthe opening of the upper level screw (N).

– When there is sufficient gear oil in the winchscrew in level screw (N) again and firmly tightenit.

– If no oil is leaking continue with step 4.3. Gear oil replacement

– Heat gear oil: if necessary, completely pay outand reel in rope once.

– Spool off rope to such an extent, until there is ac-cess to the oil filling screw (E/A).

– Place a suitable oil collecting basin under thedrain screw (A).

– If necessary, use an oil guiding duct.– Unscrew charging / draining screw (E/A).

– Turn drum, until the screw is situated underneaththe drum.

– Drain gear oil into oil collecting basin via oil guid-ing duct.

– Unscrew level screw (N).– Dispose of the used oil according to the instruc-

tions.4. Fill in new gear oil

– Turn drum, until screw (E/A) is situated on top ofthe drum.

– Fill in new gear oil through the opening of thescrew (E/A) until some gear oil slightly overflowthrough the opening of the upper level screw (N).

– Note! These filling amount can be less than indi-cated filling amount, since oil remains in thewinch (see page 43).

– Screw in level screw (N) and charging / drainingscrew (E/A) again and firmly tighten them.

ROTZLER GMBH + CO. KGWinches, Capstans and WinchsystemsP.O. Box 1165 · 79577 SteinenGermany

Cleaning the winch, rope cleaning, rope care


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Material: Clear water; brush

Rope cleaning agent: – for ropes of TREIBMATIC winches use only rope cleaning agent ROTZLER order no.010970 0000

– for ROTZLER TITAN and ROTZLER hoist- and pulling winch ropes use grease and oilin accordance with the standards (see ISO 4309 and DIN 15020 sheet 2).

■ Cleaning the winchIn extreme environmental conditions (i.e. exposure to salt water and/or extinguishing agent with chemical addi-tives) the TREIBMATIC winch, storage drum and accessories must be checked for dirt deposits. They must be removed to ensure safe operation.

Working steps:

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

Upon exposure to salt water and/or extinguishing agent with chemical additives, the device, including rope, stor-age 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”).

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.




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■ Rope cleaningIn 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 pre-servative is necessary for avoiding damage caused by corrosion.

■ Rope careRegular care of the rope increases its service life.

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 15020 sheet 2.

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.

For TREIBMATIC winches:It is mandatory to use the ROTZLER rope protection agent, ROTZLER order no. 010970 0000.Apply the rope preservative only in a thin layer. Risk of reduced friction power between rope and capstan drum!




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Working steps – TREIBMATIC ropes (rope cleaning agent ROTZLER order no. 010970 0000):

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 tem-peratures, 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.




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ROTZLER GMBH + CO. KGWinches, Capstans and WinchsystemsP.O. Box 1165 · 79577 Steinen · Germany

Rope change for TITAN Winches Service Card400000 0344 49

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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 ropeSpool 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 4004

312

420

50 Service Card400000 0344 Rope change for TITAN Winches ROTZLER GMBH + CO. KG

Winches, Capstans and WinchsystemsP.O. Box 1165 · 79577 Steinen · Germany

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2. Pull on new rope

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).

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.

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.

richtig/right falsch/wrong

GTH 4005

2 1 3

GTH 4002

GTH 4003

CW

CC


Check rope Service Card400000 0418 51

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Check rope

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 400000 0452).In Germany, the decisive regulation is ISO 4309 and DIN 15020.

Additional to the standards ISO 4309 and DIN 15020 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 of6 x d, resp.

– 4 wire breakages take place over a length of30 x d for ropes Ø = 7, 8, 10 mm, resp.

– 5 wire breakages take place over a length of30 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)

After each use, the rope must be checked for damage, individual wire breakages, deforma-tion and corrosion according to the national regulations of the country of use. Damaged ropes must be replaced immediately!

52 Service Card400000 0418 Check rope


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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

The rope preservative recommended by ROTZLER is a special oil (see Service Card 400000 0452). This oil is particularly easy to use and deeply penetrates the rope structure owing to its favorable flow properties.


Maintenances of the Rope End Monitoring Device of TITAN


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Maintenances of the Rope End Monitoring Device of TITAN Winches

Tools: Allen key 5 mmAt the tracing device for the rope end monitoring a wearing part (40) is located.

The wearing part must be replaced, before metal (M) (ofclamp or head cap screws) is showing. In order to preventpossible rope damage.

It is recommended to inspect the wearing part at least every 6 months. Under the following conditions it may be necessary to inspect the wear-ing parts at an earlier stage: • intensive use• mainly operation on the top rope layer • rough environmental conditions (sand, dust, etc.)

Changing of the wearing partUnscrew socket head cap screws (80) and remove old wearing part (40) from clamp (10). Fix new wearing part with socket head cap screws (80).

GTH5049-1

M40

GTH 5050

10 4080


Maintenances of the Rope End Monitoring Device of TITAN


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400000 0282 55

Alphabetic Index

2° principle . . . . . . . . . . . . . . . . . . . 38

Aaccessories. . . . . . . . . . . . . . . . . . . 14

Ccare. . . . . . . . . . . . . . . . . . . . . . . . . 17Check rope . . . . . . . . . . . . . . . . . . . 51Cleaning the winch . . . . . . . . . . . . . 45company address . . . . . . . . . . . . . . . 6component overview. . . . . . . . . . . . 13copyright . . . . . . . . . . . . . . . . . . . . . . 6

Ddesignated use . . . . . . . . . . . . . . . . . 7dimensions . . . . . . . . . . . . . . . . 27, 28

Ffunctional tests . . . . . . . . . . . . . . . . 17

Ggear oil . . . . . . . . . . . . . . . . . . . . . . 33

check . . . . . . . . . . . . . . . . . . . . . . 43replace . . . . . . . . . . . . . . . . . . . . . 43replenish . . . . . . . . . . . . . . . . . . . . 43

general overhaul . . . . . . . . . . . . . . . 18

Hhydraulic oil. . . . . . . . . . . . . . . . . . . 33hydraulic scheme . . . . . . . . . . . . . . 35

Iidentification of dangers . . . . . . . . . . 7installation, hydraulic . . . . . . . . . . . 38installation, mechanical. . . . . . . 37, 38

Lleakage oil line . . . . . . . . . . . . . . . . 39lubricating grease . . . . . . . . . . . . . . 33

Mmaintenance . . . . . . . . . . . . . . . . . . 17

Ooperating materials . . . . . . . . . . . . . 33

specification . . . . . . . . . . . . . . . . . 33operation. . . . . . . . . . . . . . . . . . . . . 15options . . . . . . . . . . . . . . . . . . . . . . 14o-rings. . . . . . . . . . . . . . . . . . . . . . . 41

Pperformance data . . . . . . . . . . . 29, 30product description . . . . . . . . . . . . . 13protection devices. . . . . . . . . . . . . . 10

Rrequirements of the user and owner . 8Rope care . . . . . . . . . . . . . . . . . . . . 46rope change . . . . . . . . . . . . . . . . . . 49Rope cleaning. . . . . . . . . . . . . . . . . 46

Ssafety . . . . . . . . . . . . . . . . . . . . . . . . 7screw connections, securing of . . . 42seal rings . . . . . . . . . . . . . . . . . . . . 41Service Card

400000 0342 . . . . . . . . . . . . . . . . 43400000 0344 . . . . . . . . . . . . . . . . 49400000 0418 . . . . . . . . . . . . . . . . 51400000 0452 . . . . . . . . . . . . . . . . 45

Ttechnical data . . . . . . . . . . . . . . 27, 29troubleshooting . . . . . . . . . . . . . . . . 19type plate . . . . . . . . . . . . . . 29, 30, 31

Vviscosity of hydraulic oil . . . . . . . . . 34

Wwarranty . . . . . . . . . . . . . . . . . . . . . . 6work safety . . . . . . . . . . . . . . . . . . . . 8

ROTZLER GMBH + CO. KG Robert-Bosch-Str. 4 79585 SteinenGermanyPhone+49 (0) 76 27 / 7 01 - 0 Fax+49 (0) 76 27 / 7 01 - 166

400000 0253

ROTZLER INC.Unit 122, 7350 - 72 StreetDelta, British ColumbiaCanada V4G 1H9Phone: (604) 940-7134Fax: (604) 940-7135e-mail: [email protected]

400000 0253

Safety Operation Maintenance - Max Engineeringmaxeng.co.kr/pdf/tc3-5_om_rev20oct10.pdf · ·...

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Transcript of Safety Operation Maintenance - Max Engineeringmaxeng.co.kr/pdf/tc3-5_om_rev20oct10.pdf · ·...