Thaler KE-SP 3050 Manuel utilisateur

Operation Manual

Cable Pulling Winch

MODEL

KE-SP 3050

Diesel Motor (Yanmar)

Electronic Measuring System (KPR 2000)

Distributor for the United States of America

303-430-7130 800-430-7130 Fax 303-428-7762

[email protected] www.GlobalMachinery.com

705 West 62nd Avenue

Denver, CO 80216

Dear Customer,

We appreciate your purchase or rental of the Jakob Thaler KE-SP 3050 cable pulling winch.

You can expect this machine to function very effectively as we have designed it to operate and perform

with efficiency and to be maintained with ease.

This manual should be kept in the tool box, is an essential part of the equipment, and should always be

readily available.

This manual should also be made available to the following people:

- Machine operators

- Maintenance technicians

- Those who are transporting the machine

We recommend that all people involved in the project, whether in management, operation, or

maintenance, read the manual carefully and completely before the use of the winch. Please contact us for

any clarification and/or additional information you may need.

We recommend that all rules and regulations prescribed by the company and the country where the

winch is being used be observed, in addition to the methods prescribed here for handling, usage and

maintenance of the winch.

Thank you,

Jakob Thaler GmbH Global Machinery

Cable Laying Machinery and Equipment Cable Placing Equipment

Manufacturer USA Distributor

General Safety Instructions

This manual has been prepared to assist you in the operation and

care of your new winch. Please read it thoroughly as the contents

can contribute to more effective operation of your equipment.

The construction of this winch including the mechanical, hydraulic and electrical systems, were all designed

to meet safety standards of European Union No 98/37/EC.

The winch should be operated and handled by qualified personnel only. Qualified operators are those who

have received training from the machine owner’s company or, alternatively, from the manufacturer. Never

permit anyone to operate the winch without proper training.

Operators must be aware of all local, state and federal safety regulations governing the use of this

equipment.

Operators must wear suitable clothing to reduce the possibility of entanglement in the machine’s moving

parts. They should avoid the wearing of any jewellery for the same reason.

Operators must use personal protective gear in accordance with OSHA’s PPE guidelines. (Safety glasses,

gloves, boots, hard hat, etc.)

Operators must carefully follow hazard related instructions contained in this instruction manual or indicated

on the machine.

The work area should be clear of oil or other liquid spills, as well as materials or equipment that may be

considered an obstacle to proper operation.

The operator must avoid the direct inhalation of the equipment’s engine exhaust.

The winch must not be modified without the specific and written consent of the Manufacturer. Factory

provided accessories and spare parts must always be used.

All maintenance and repairs, including electrical, should be performed by trained and authorized personnel

only. Any waste oils, grease or fuel should be disposed of properly in accordance with the local state or

country guidelines.

Note

These units are built according to your order and the latest design changes. Therefore, differences in the descriptions and pictures

of the equipment may occur as they apply to your machine. We reserve the right to make design changes at any time and without

notice.

Safety Instructions

Standard Operation:

Before starting the job:

-Secure the work area (traffic, manhole, etc.).

-Ensure all safety equipment is in place and operating correctly.

-Be sure that the winch has been stabilized properly.

-Before starting the operation, be sure that no one is standing in the operation area.

-Test the operation of all controls according to the instructions in this manual.

Maintenance:

-Only to be performed by trained personnel.

Danger!

-If the safety devices have been removed for maintenance purposes, operate the machine with

utmost care.

-Refer to the maintenance instructions in this manual.

-Safety devices must be immediately re-installed after maintenance has been completed.

Table of Contents

1 Product Information

1.1 Machine Description..................................................................................................................... 1

1.2 Manufacturer................................................................................................................................. 1

1.3 CE-certification............................................................................................................................. 1

1.4 Application According to Design................................................................................................. 1

1.4.1 Use / Operation Range................................................................................................................. 1

1.5 Operator Station........................................................................................................................... 2

1.6 Technical Data............................................................................................................................... 2

1.7 Product Description...................................................................................................................... 3

2 Transport of the Winch

2.1 Securing the Trailer to the Tow Vehicle..................................................................................... 4

2.1.1 Traffic Regulations....................................................................................................................... 4

2.1.2 Connecting the Trailer.................................................................................................................. 4

2.2 Driving with the Winch................................................................................................................. 6

2.2.1 Forward Movement....................................................................................................................... 6

2.3 Disconnecting the Winch............................................................................................................. 7

2.4 Moving the Winch Manually......................................................................................................... 7

2.5 Changing Tires and Adjusting Tire Pressure.............................................................................. 7

3 Operation of the Winch

3.1 Rear Supports.............................................................................................................................. 9

3.2 Boom Control (Hydraulic Boom)............................................................................................... 10

3.3 Description of Control Panel Components............................................................................... 11

4 Maintenance................................................................................................................................ 16

4.1 Scheduled Maintenance............................................................................................................. 17

4.2 Hydraulic System........................................................................................................................ 18

4.2.1 Checking the Hydraulic Oil Level.............................................................................................. 18

4.2.2 Breather in Filler Cap of Hydraulic Oil Tank............................................................................. 18

4.2.3 Changing the Hydraulic Oil........................................................................................................ 18

4.2.4 Filter Change............................................................................................................................... 18

4.2.5 Regular Control Checks............................................................................................................. 18

4.3 Greasing...................................................................................................................................... 19

4.4 Rope Inspection and Replacement........................................................................................... 19

4.5 Drive Chain and Chain Wheels.................................................................................................. 19

4.6 Check Operation Controls for Proper Function....................................................................... 19

4.7 Maintenance of Yanmar Diesel Engine..................................................................................... 19

Maintenance Schedule............................................................................................................... 20

5 Troubleshooting Guide

5.1 Diesel Engine.............................................................................................................................. 21

5.2 Trailer Electric Brake System.................................................................................................... 21

Service and Warranty Conditions………………………………………………………………….… 22

Attachments:

-Operation and Maintenance Manual for Yanmar Engine

-Spare Parts List

-Electric and Hydraulic Schematics

Page 1

1 Product Information

1.1 Machine Description: Cable Pulling Winch

Model: KE-SP 3050

1.2 Manufacturer: Distributor USA:

Jakob Thaler GmbH Global Machinery

Cable Laying Machinery and Equipment 705 West 62nd Ave.

Justus-von-Liebig-Str. 8 a Denver, CO 80216

D-25335 Elmshorn / Germany (303) 430-7130

Tel. +49(0)4121/57999-0 (800) 430-7130

Fax +49(0)4121/5799957 Fax (303) 428-7762

1.3 CE-certification:

This machine has a

sticker, which is fixed on the serial number plate.

1.4 Application According to Design:

This cable-pulling winch should only be used per the operation manual and the following safety

guidelines.

1.4.1 Use / Operation Range:

The Cable Capstan Winch Model KE-SP 3050 is designed to pull in empty duct and cable in a

horizontal direction up to a pulling force of 11000 pounds, 50 kN.

This machine is only to be used for the work it was designed for.

If the unit is used for other applications or working conditions, prior

consultation with the manufacturer is required.

If this caution is not followed, the manufacturer is free from any liability for

damages or losses incurred.

While operating the machine, all warning signs and decals must be obeyed.

The Cable Capstan Winch must not be used:

• For lifting people and/or goods

• In a location where the machine cannot be positioned and anchored properly

• In areas where brush or other materials can be easily set on fire

• In closed/unventilated sites, or those poorly ventilated (tunnel or similar)

• At sites where fuels or explosives are present

• For structure demolition

• For the pulling of elastic elements

• With ropes or joints having a bigger diameter than that specified in this manual

• With over-ridden or broken safety system devices

• For handling trucks or other mobile equipment

Page 2

1.5 Operator Station:

The operator must stand in an area that is free and clear of all moving parts while the unit is in

operation.

1.6 Technical Data:

VIN / Serial Number : ___________________________________

Delivery Date : January 9, 2013

Drive : 3 Cylinder Diesel / Yanmar 3TNV88

Power : 36 HP (27.1 kW)

Max. Pulling Force : 11000 pounds (50 kN)

Max. Pulling Speed : 0-220 fpm, continuously adjustable

Rope Diameter : 0.472 inches (12 mm)

Rope Length : 2500 feet (765 m)

Overall Length (including tongue) : 157-1/2 inches (4000 mm)

Width : 67 inches (1700 mm)

Height : 67-1/2 inches (1710 mm)

Tires : 215/75R 17.5

Electrical : 12 V

Page 3

1.7 Product Description:

This cable capstan winch represents the latest modern technical standard in the area of

hydraulically operated cable pulling winches. It is specifically designed for pulling in and out

communication and power cables of all types.

The winch is designed for pulling horizontally. It is NOT to be used as a means for lifting loads.

The single axle chassis consists of a rubber suspension axle with electric brakes. The hitch is

height adjustable and equipped with a forged 4-bolt mount hitch. A crank jack is fitted to the trailer

tongue. The tire size is 215/75R 17.5. The lighting system is 12 Volt.

Rear adjustable stabilizers control the stability of this winch during the pulling operation. For

transportation the stabilizers may be raised up and be secured with the appropriate pins.

The capstan unit is hydraulically driven. The power pack consists of a 36HP (27.1 kW) water-cooled

diesel engine (corresponding to the EPA norms) and a pressure and flow controlled hydraulic pump.

The steel wire rope of the winch runs directly from the capstan system to the rope drum. The

machine is equipped with an automatic level-wind system with cross groove spindles so that even

layering of the rope onto the rope drum is guaranteed.

Drive and brake operation of the drum is powered hydraulically.

The boom is hydraulically raised and lowered, manually pivoted +/-45° laterally and is secured by

a manually adjusted boom support.

The measurement of the pulling force is controlled and monitored by an electronic measuring

system (KPR 2000) with a record printer mounted at the control panel. The measuring system

has the following functions:

- Indication of pulling force, length and pulling speed

- Adjustable maximum pulling force limit with automatic stopping function of the winch drive

system when the adjusted pulling force is exceeded

- The ability to print out a complete pull report while in the field

The separate card writer is connected to the KPR 2000 system by a serial cable and has a 32 MB

storage card with card adaptor for storing cable pull data.

By pushing a single button at the KPR 2000, each job can be stored on the card as MS-

DOS/Windows compatible data. A name for each pulling job is automatically generated. The data

can be evaluated on a PC or Laptop and shown in tabular form. If the data is required in graphic

form, it can be opened in Excel for analysis.

All operator controls are centrally mounted at the operation panel. The following controls exist:

- Remote control joystick with deadman switch for controlling the pulling direction and speed

-Throttle lever for engine speed

- Key-operated switch for engine start

- Control indicators for diesel engine

- Fuel gauge

- Working hour meter

- Electronic measuring system (KPR 2000)

- Card-writer with adaptor

- Raise/Lower lever for hydraulic boom

- On/Off switch for rotating beacon light

Page 4

2. Transport of the Winch

The winch is mounted on a single axle trailer chassis fitted with an electric brake system and a

height adjustable hitch.

2.1 Securing the Trailer to the Tow Vehicle:

2.1.1 Traffic Regulations:

Based on local state and country laws, select the appropriate vehicle for the transportation of the

winch.

2.1.2 Connecting the Trailer:

Note that unless the winch is secured against movement, no person is

allowed to stand between the pulling vehicle and the winch.

The hitch of the trailer must be adjusted to the hitch height of the pulling vehicle.

Proper selection and condition of the hitch type and size are essential to

safely towing your winch. A loss of coupling may result in death or serious

injury.

•Be sure the hitch load rating is equal to or greater than the load rating

of the coupler.

•Be sure the hitch size matches the coupler size.

•Observe the hitch for wear, corrosion and cracks before connecting.

Replace worn, corroded or cracked hitch components before

coupling the winch to the tow vehicle.

Be sure the hitch components are tight before coupling the winch to the tow

vehicle.

Height adjustment of the hitch

Hitch height should be adjusted only when the winch is not connected to the

towing vehicle.

Secure the winch against movement!

The hitch can be adjusted in the range of

2.165 inches (55 mm) steps.

Bolts (M16) have to be tightened by a

torque wrench to 155 ft. pounds (210Nm)

Page 5

Coupling

- Prepare the winch for transport

- Secure the trailer from moving by the use of wheel chocks

- Release and open the tow vehicle’s hitch coupling

- Backup the tow vehicle until the coupling is aligned

- Lock coupling around eye on trailer

An improperly coupled winch can result in death or serious injury.

Do not move the winch until:

•The coupler is secured and locked to hitch;

•The safety chains are secured to the tow vehicle;

•The supporting jack is fully retracted; and

•The wheel chocks are stored and secured.

Do not tow the winch on the road until:

•Tires and wheels are checked;

•The winch brakes are checked;

•The breakaway switch is connected to the tow vehicle; and

•The winch lights are connected and checked.

If your winch comes loose from the hitch for any reason, safety chains have been provided, so

that control of the winch can still be maintained.

Improper rigging of the safety chain system can result in loss of control of

the winch and tow vehicle, leading to death or serious injury, if the winch

becomes uncoupled from the tow vehicle.

•Fasten the safety chains to the frame of the tow vehicle. Do not fasten the

safety chains to any part of the hitch, unless the hitch has holes or loops

specifically designed for that purpose.

•Cross the safety chains underneath the hitch and coupler with enough

slack to permit turning while transporting, and to hold the tongue up,

should the winch come loose.

- Completely crank the jack upward until it engages, then fasten it with the safety pin.

The jack is only intended to provide support. Do not manoeuvre the winch if

the jack is lowered. This can cause injury and even death. Make sure that the

front jack is fully raised and secured.

- Secure the wheel chocks.

- Plug in the electrical connecting cable to the pulling vehicle. Use an adapter plug if necessary.

- Examine the lights of the winch for proper functioning.

Before each time this trailer is towed:

-Check the lighting system.

-Check tire conditions (tire pressure, damage).

-Check to be sure the winch is correctly coupled and the jack is fully raised and secured.

-Check the operation of the electric brake system

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