Operating Manual
Vehicle From WKU 824 10815.en Kässbohrer Geländefahrzeug AG Kässbohrerstraße 11 D-88471 Laupheim
Printed in Germany Copyright ® Not to be reprinted, translated or duplicated either wholly or in part without written permission. Technical details might not necessarily be exactly as described or illustrated in this operating manual. Printed on environmentally compatible paper (bleached without chlorine, recyclable). 400.10815.2.de uiir qimn...... 31 . auxiliary equipment. weights Permissible 17 . Safety instructions S 13 . . Fluids andlubricants 11 . Technical data T Technical customer service Safety symbolsused I C NTRODUCTION ECHNICAL AFETY ONTENTS
INSTRUCTIONS
DATA of front-mounted . . 7 6 Driving tips and information ...... 131 . Driving tipsandinformation 130 . Towing vehicle Entering -driving . 122 Starting thedieselengine O C U Inspections and checks ...... 111 Inspections andchecks 99 . Electrical Tilting thedriver'scab/ Installing auxiliarydriven 35 Cockpit. . HECKS SE PERATION - exiting ...... 124 - exiting load platform . 93 . load platform implements . . 88 . implements
3/151 Operation Checks Use Safety Technical Overview data CONTENTS
AUXILIARY DRIVEN MACHINERY OTHER ON-BOARD DOCUMENTS
Front blade...... 141 – Log book AlpinFlex tiller ...... 144 – Operating manual, diesel engine – Maintenance instructions – Operating manual for Kahlbacher front-mounted tiller blower (optional equipment) – Operating manual for drum winch (optional equipment)
4/151 400.10815.2.de 400.10815.2.de E-mail: [email protected] Fax No.: +49(0)7392/900100 Attn.: Mr.Peter Görlich D-88471 Laupheim Kässbohrerstraße 11 Kässbohrer Geländefahrzeug AG To: Fax: No.: Phone Sender: I To ensurethatyouroperatingmanualisoptimum inall NTRODUCTION IMPORTANT Y OUR
ways. OPINION
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US
IS . Comments: Graphics and photos: Comments: Quality of translation: A CD-ROM would be good! diagrams required More explanatory Provide goodexplanations Mistakes intranslation Correctly translated
5/151 Operation Checks Use Safety Technical Overview data INTRODUCTION TO THE OPERATING MANUAL
This operating manual provides information about: SYMBOLS USED how to handle, maintain and care for your PistenBully.
important instructions concerning correct and economical operation. DANGER!
warnings so that you recognise dangers in good time and Direct and imminent danger threatening life and avoid them. limb unless appropriate precautions are taken.
WARNING!
Make sure that the operating manual is always in the odd- Potentially highly dangerous situation! ments tray in the driver's cab. Danger to life and limb unless appropriate precau- tions are taken.
ABBREVIATIONS USED CAUTION! Dangerous situation! e.g. = for example Could lead to injury unless appropriate precautions MA = tightening torque are taken SP no. = order number for spare part min./max.= minimum / maximum Important notes! Possibility of damage to the machine or its immediate sur- roundings. i This symbol draws attention to practical tips 6/151 400.10815.2.de TECHNICAL CUSTOMER SERVICE AND SPARE PARTS DEPARTMENT
Service worldwide Phone, office Overview Director of Service (GS) Mr. Mayer +49(0)7392/900-101
Technical customer service (TKD)
Head of department TKD Mr. Strähle +49(0)7392/900-103 data Area Manager TKD Mr. Kirsamer +49(0)7392/900-137 Area Manager TKD Mr. Braun +49(0)7392/900-105 Area Manager TKD Mr. Arbogast +49(0)7392/900-118 Area Manager TKD Mr. Bohnet +49(0)7392/900-116 Area Manager TKD Mr. Dehm +49(0)7392/900-117 Fax +49(0)7392/900-100 24-hour service emergency number: Phone. +49 171/7124096
Spare Parts department (ETV) Director, ETV, Mr. Heim +49(0)7392/900-107 Fax +49(0)7392/900-130
Spare parts distribution (ETV) emergency number: Tel. 0171/3732230
Contact at my national office: Technical customer service Name:...... Telephone number:...... Spare parts department Name:...... Telephone number:...... Repair mechanic Name:...... Telephone number:...... Always quote the vehicle number when making enquiries and ordering spare parts.
The deployment of service mechanics is controlled centrally by TKD (Technical Service). Operation Checks Use Safety Technical
400.10815.2.de 7/151 VEHICLE AND ENGINE NUMBERS
Vehicle number Engine number
The vehicle number is stamped on the front of the vehicle, The engine number is stamped on the engine type plate. on the face end of the right hand frame.
This operating manual is for the vehicle Please insert the appropriate entries
WKU......
8/151 400.10815.2.de 400.10815.2.de Kässbohrer Geländefahrzeug AG damage resulting from such use. guarantee. We refuse toaccept liability for consequential of partsotherthangenuineThepartsspare use voids your and install the components using the correctprocedures. – including advice on permissible technical modifications – ther experts service centre.The sion are available from your Kässbohrer Geländefahrzeug AG Genuineandparts approved accessoriesand partsforconver- we refuse to accept liability for them. which anofficialapproval has been– and issued consequently, scrutinised ucts thathavebeen aspects of unable toassessthese vehicles. Despite continuous observation of the market, weare proven tobereliable, safeand suitable forKässbohrer off-road been subjectedprocedure toaspecial test and theyhave been expressly approved for yourtype of vehicle. These parts have Geländefahrzeugconversionandaccessories and partsfor AG We recommend the useof genuine spare parts fromKässbohrer In your own interests, pl U SE
OF
GENUINE ease note the following: the note ease
SPARE e will providein-depth advice by atechnical inspector or for other products – even prod-
PARTS
9/151 Operation Checks Use Safety Technical Overview data NOTES
10/151 400.10815.2.de 400.10815.2.de Dimensions Load area With tiller and pusherblade Length Heightcab tilted with Height Across AlpinFlex tiller steeltracks across across aluminium tracks without tracks Width T ECHNICAL
DATA 2120 x 1920 mm x1920 2120 9010 mm 3250 mm 2830 mm 5500 mm 4206 mm 4206 mm 2500 mm Engine Operating parameters Weight Maximum torque Output, ECE rating Displacement Number of cylinders Type At maximum tiller Production ratewith tracksGround pressurewithsteel Ground pressurewithaluminium tracks Continuously variable speed machinery. driven Payloadloadwithout of area auxiliary machinery driven Permissible gross weight withauxiliary Dead weight withsteel tracks Dead weight withaluminium tracks 1519 Nmat 1500 rpm 8.9 litres / 8900 cc 276 kW (370 hp) Cummins QSL9 126,000 m 0.057 kg/cm 0.052 kg/cm 93,000 m 0 - 23 km/h 11,800 kg 1500 kg 8020 kg 7340 kg 2 2 /h /h 6 2 2
11/151 Operation Checks Use Safety TechnicalTechnical data Overview Overviewdata TECHNICAL DATA
Oil capacity with filter 24 litres Sound power level and vibrations Fuel consumption at least 19 l/h Per EN 15059 Tank capacity 260 litres Exhaust-emissions stand- EUROMOT lllA / EPA TIER 3 Measured at rated engine speed ard and maximum fan speed Sound pressure level at operator's work- 79 dB(A) Brakes place Wear-free (hydrostatic) Radiated sound power level 113,4 dB(A) 2 multi-plate brakes Measured during grooming Electrical (vector sum) 2 Light-current circuit 24 V Vibrations at the steering wheel <2.5 m/s 2 Generator 28 V /140 amperes Vibration at driver's seat <0.5 m/s Batteries 2 x 12 V /135 Ah Cold-start power 900 A
Suggested garage dimensions Length 11,000 mm Width 6000 mm Height 3500 mm
12/151 400.10815.2.de 400.10815.2.de quirements. Note: ducts. ant moval ofheat, formation of deposits, and clogging of cool- to comply withthis requirement means: less efficient re- Free of contaminants (grease, dirt, lime...), because failure Water quality: fuelthe information supplier.from thefuel the temperature characteristics in thearea ofuse and source Selectthe diesel fuel's resistance Diesel fuels atlow temperatures C D F OOLANT LUIDS IESEL If the engine is run on dieselrunIf theenginesulphurawith fuels is content See theCD'Cummins equipment. Service Bulletin No.3379 changes must be halved. 0.5 percent by weight, the scheduled times between oil of morethan Drinking water often sati often water Drinking
FUEL AND
LUBRICANTS 001-10' suppliedwiththe to the cold inaccordancewith tothe sfies the water quality re- volumeof antifreeze in theengineyear.the throughout Maintain acoolant mixture of50%drinking water +50%by with water filterwith water ET-No.8.312.105.021.0 by engineoperatinghours: At least: Antifreeze change interval cent byvolume. 55 to exceed per- of antifreeze the proportion permit Do not Risk ofengine overheating! agent antifreeze correct the Select dues of other fluids and lubricants. Note: coolant: Changing See theCD 'Cummins ment. Service BulletinNo.3666132-04'suppliedwiththeequip- Make sure thatcontainer and funnel arefree of resi- every2years every 2000 hours
13/151 Operation Checks Use Safety TechnicalTechnical data Overview Overviewdata TABLE OF FLUIDS AND LUBRICANTS
Designation Grade Capacity Interval between changes Cummins QSL9 CES 20072 / DHD-1 / ALEA E-5 24 litres At least: once a year API-CH 4 every 500 hours SAE 10W40 See the CD 'Cummins Service Bulletin No. 381 0340-06' supplied with the equipment Fuel tank Diesel fuel 260 litres At least: once a year see the CD 'Cummins drain condensation. Service Bulletin No. 3379 001-10' supplied with the equipment Fuel filter every 800 hours Air filter At least: once a year every 1200 hours Cooling / heating system 50% water + 50% antifreeze agent see the 30 litres At least: every 2years CD 'Cummins every 2000 hours Service Bulletin No. 3666 132-04' supplied exchange water filter with the equipment Transfer box Poly Alpha Oleofin (PAO) 1,8 litres At least: once a year - CLP HC VG 150 / 220 every 800 hours ISO VG 220 (for summer operation) at 100 hours (new vehicle) - API GL4, SAE 75 W 90 (PAO)
14/151 400.10815.2.de 400.10815.2.de T (see customer's workshop information) (see customer's workshop information) Lubricate wheel hubs andradius ABLE Propulsion unit +auxiliarydrivenma- Propulsion Hydrostatic vehicle drive Other lubricationpoints (planetary gears) Electrical system
Designation OF Hydraulic oilfilter Hydraulic Battery terminals Wheel drive Wheel Hydraulics
FLUIDS chinery
AND arms Calcium saponified Calcium saponified grease arms
LUBRICANTS < -30 ISO VG220 (for summer operation) Poly Alpha Oleofin (PAO) Poly AlphaOleofin - API GL4, SAE 75 W 90 (PAO) 0 C -AVIA Syntofluid PE-B 30 (PAO) 30 PE-B Syntofluid -AVIA C Calcium saponified Calcium saponified grease - CLP HC VG 150 / 220 / 150 VG HC CLP - Bosch FT 40V1 grease FT40V1 Bosch KP2K-30, DIN 51502 51502 DIN KP2K-30, KP2K-30, DIN 51502 51502 DIN KP2K-30, ATF Type A Suffix A Suffix ATF TypeA DEXRON ll D / lll F / lll D ll DEXRON HVLP DIN 51524 HVLP DIN e.g. Aviacal 2LD Aviacal e.g. Aviacal 2 LDA 2 Aviacal Grade OKS 250 OKS Capacity 80 ltotal 47 l tank l 47 1.9 litres At least: once a year oncea least: At litres 1.9 Interval betweenchanges new vehicle 100 hours At least: onceayear At every 1200hours every 1200hours every 400 hours every 400 hours every 100 hours at 100 100 hours at
15/151 Operation Checks Use Safety TechnicalTechnical data Overview Overviewdata NOTES
16/151 400.10815.2.de SAFETY INSTRUCTIONS Overview
INTENDED USE ...... 18 data DRIVER...... 18
DANGER ZONE FOR PERSONS. . . . 19 Safety OPERATION ...... 19
MAINTENANCE...... 23
FIRST-AID BOX ...... 25
FIRE EXTINGUISHER ...... 25
WARNING SIGNS ...... 27
ADDITIONAL WEIGHTS ...... 31 Operation Checks Use Safety Technical
400.10815.2.de 17/151 SAFETY INSTRUCTIONS
be familiar with first-aid procedures Correct usage: RIVER D in the event of an accident. Snow groomers may only be operated as Drivers must be specifically ap- if avalanches pose a threat in the specified in the manufacturer's operating pointed to drive snow groomers. area where snow groomers are to be manual. used, in addition to the aforemen- You may appoint people to drive the tioned conditions, drivers must also snow groomers on their own only be instructed about how avalanches when you are certain that they will are started, the consequences of be able to reliably fulfil the tasks as- The PistenBully may be used for them and how to behave when there signed to them. the following purposes only: is a risk of avalanches. - Preparing slopes for downhill In particular, they must satisfy the skiing. following: - Removing snow from paths. be at least 18 years old. - Tracks in countryside (not public be physically and mentally suitable. roads). be trained in how to drive the snow - Preparing trails for Nordic skiing. groomer and have proven their driv- - Transporting people in the special ing ability to the operator. people-carrier cabin (optional extra). be familiar with snow conditions and with the peculiarities of operating equipment in facilities for skiers. If you wish to use the equipment for any be familiar with the area where the other purpose, you must apply for and ob- vehicle is to be used, especially with tain prior written approval from the man- regard to particularly dangerous ufacturer. areas. 18/151 400.10815.2.de 400.10815.2.de D PERSONS S ANGER The driver may only operate and drive Special protection measures mustbe AFETY The driver must issue warningsdriverThe must to enter the is permittedto No-one limit markers. warning signs, closed runs or off- of form the take may measures these the circumstances of eachcase, people in itsvicinity. Depending on might not be immediately visible to terrain is suchthat the machine roundingterrain,the or thenature of does not haveaclearviewof the sur- used in an area where the driver taken ifthesnowgroomerisbeing danger zone. there is no-one in the immediate the snow groomer providedthat draw attention to potential dangers. zone. snow groomer's immediate danger
INSTRUCTIONS ZONE
FOR
E NTERING When parking onaslope,be particu- Complete the daily checks andComplete main-checks thedaily Buckle thesafety belt. onto thetrack. Step Walk right round the vehicle and vehicle. vehicle. the entering when door driver's of the handle onthe grip afirm take Always entering and exiting the driver's cab. Danger ofslippingon thetrackwhen clear of persons and objects. make sure that the danger zone is The door opens suddenly. larly careful when opening the door. tenance tasks. D RIVING The driver maystart and/or move the Do not attempt to adjustthedriver's not attempt Do Drivers must always restrict thevehi- Snow groomers mustbe used and poisoningRisk of fromexhaust Never leave the vehicle unattended seat belt. the driver's seat, after fastening the snow groomer only when seatedin of the angle of theterrain.Drivers vehicle cannotstopped be asaresult not apply tosteep slopes where the within the distance visible. This does cle toaspeedcan stop they atwhich their stability. operated in a manner which ensures spaces. enclosed Never leave the engine running in gases. with the engine running. seat orsteering wheel when driving.
19/151 Operation Checks UseSafety Safety Technical Overview data SAFETY INSTRUCTIONS
may drive on such steep slopes only The assistance of a second person to TOPPING EXITING when certain that they can do so give directions is necessary if visibility S / without putting themselves and oth- is poor. Park in clearly surveyable spots. ers at risk. Avoid crossing slopes at an angle Apply the parking brake only when the because the PistenBully may slip Drivers may drive the snow groomer vehicle is at a standstill. only at a speed at which they main- downhill. Risk of poisoning! tain control at all times. They must When a tracked vehicle is being Do not leave the engine running in an adapt the speed to the snow, terrain driven, the traction is so great that enclosed space. and visibility conditions and to the the vehicle may be driven well be- characteristics of the snow groomer, yond the point at which it should Turbocharger - risk of overheating:! with due allowance for the auxiliary start to tilt; if this happens the vehi- Do not immediately switch off the die- equipment fitted. cle might then suddenly tip over. sel engine after it has been run at full load. Drive for approx. 2 minutes in Make sure that the doors are closed. the part-load range and then switch Check that loads are correctly secured. off.
When driving past people, slow Lower the auxiliary equipment at the down, keep at a safe distance and al- front and back, switch off the tiller, ways bear in mind that the people and turn the driving direction switch may behave unexpectedly. to "neutral".
Always come to a complete stop be- Before exiting the driver's cab! fore reversing the vehicle. - Applying parking brake Make sure that the area behind the - Switch off the engine. machine is clear. - Remove the ignition key. 20/151 400.10815.2.de 400.10815.2.de S Swivel up the steering column and left and column steering up the Swivel AFETY Lock thedriver'scab. ontothetrack! Step vehicle. the exiting when door driver's of the handle onthe grip afirm take Always cab.. thedriver's entering andexiting track when Danger ofslippingonthe armrest completely.
INSTRUCTIONS
Risk of break-through of Risk T ERRAIN Driving on frozen rivers and lakes is Before using the snow groomer, are urgently advised not to do so. urgentlyareto do advised not very dangerous. Consequently, you drivable. check thattheintendedterrain is Avalanches / Rockfalls Avalanches Snowdrifts The driver must be accompanied by a by accompanied be must driver The where thevehicle cannotbeseen co-driver when driving in areas
21/151 Operation Checks UseSafety Safety Technical Overview data SAFETY INSTRUCTIONS
and when the weather is bad, unless When persons travel in the PB people several vehicles are working together carrier cabin, they must sit in their as a team. This does not apply if the seats with their safety belts correctly driver uses a two-way radio to fastened, and hold tight. remain in constant contact with someone at the base who can send The retaining screws of the people out a rescue team should an accident carrier cabin must be checked every 2 1 occur. day to ensure that they are tight. Inclinometer When using snow groomers at night- Do not drive the vehicle with time, handheld searchlights must people on: At the beginning of travel, everyone also be used. - the load area must stand and have a firm grip on - the auxiliary equipment When the winch is in use, the driver the open rear deck railing. - externally mounted machinery. must wear the seat belt at all times. If the inclinometer indicates more Avoid abrupt changes of direction than 300 degrees in the longitudinal and angles of inclination. DRIVING WITH direction 1 or more than 250 degrees in the lateral direction 2, the opera- PASSENGERS Auxiliary equipment, rear tor must refrain from driving any fur- deck railing (optional) ther on the steep terrain for safety Only 1 co-driver may sit in the driver's reasons when carrying passengers. cab. Correct usage The rear deck railing must be secured The co-driver must be seated in the The country-specific regulations must co-driver's seat at all times when the be observe for the transport of peo- at both ends. Both safety chains must vehicle is in motion. ple. be closed and locked. 22/151 400.10815.2.de 400.10815.2.de S AFETY Risk of burns caused bytheexhaust caused Risk ofburns holding points. Close the rear deck railing using When lowering the rear deck railing. form railing. deckrailing,load holdontothe plat- When climbing onto and off the rear load platform! and angles of inclination. muffler. Keepclear. Risk of injury byinjury crushing Risk of action! Danger of slipping on the track and Avoid abrupt changes of direction
INSTRUCTIONS
M Compliance withthe manufacturer's Snow groomers and raised equip- un- work maintenance perform Do not Snow groomers mustbe maintained them from accidentallythem moving. tenance work isstartedto prevent ment mustbe secured before main- dropping. or closed ming from slam- secured toprevent them been have they positionsunless raised dermoveable partstheir in open or by the operator. by trained staff specifically appointed tory. maintenancemanda- instructions is ible in any other way. otherible inany moved orcovered overormade illeg- auxiliary equipment mustnot be re- mation plates onthe PistenBully and Markings, warning signs and infor- AINTENANCE Faults which couldFaults affect safety levels Repair welding isan operation that est Service Support Centre. measures. Please consult yournear- invariably requires extensive safety must be rectified immediately.
23/151 Operation Checks UseSafety Safety Technical Overview data SAFETY INSTRUCTIONS
In the event of damage, defects or ONITORING M changes that endanger operational safety, the driver must immediately Before starting off, the driver must cease operation of the vehicle. check operation of the safety-rele- vant components, e.g.: The supervisor must be notified im- - by testing the brakes. mediately in the event of accidents - by switching on the lights, involving injury to persons or dam- - by checking that the warning age to property or to the vehicle. systems are fully operational. The supervisor must perform random - by checking the controls of the checks in order to ensure that the working machinery. snow groomer is operated in a safe manner. If radios are required to ensure safe operation of the snow groomer, be- fore starting off checks must be per- formed to ensure that the radio is functioning correctly and that there is a radio connection.
The driver must immediately report defects to the supervisor and, on ve- hicle handover, to the replacement driver.
24/151 400.10815.2.de 400.10815.2.de operation. groomers are in a condition suitable for that they can judge whether snow lations ornational equivalents) toensure practice (e.g. DIN publications, VDE regu- generally accepted rules of engineering dent prevention guidelines, directives and national safety atwork legislation,acci- sufficiently familiar with the appropriate trainingand experience. Theyalso are nology as a result of their specialist extensive knowledge about vehicle tech- Skilled specialists arepeople who have an I S NSPECTION AFETY The resultsofthe inspection mustbe The operator must ensure that the formed by a skilled specialist. groomers aresafeandmust be per- ensure thatthesnow must spection afterand maintenance work. This in- ever necessary, at least once a year snow groomers areinspectedwhen- recorded in writing and filed.
INSTRUCTIONS driver's seat. driver's door or stowed beneath the co- The first-aid kitis secured to theco- complete. surethatthefirst-aidkitis Always make F IRST - AID
BOX
ately. Replace used fire extinguishers immedi- date. expiration seat.Note driver's Theextinguisher fire in frontoftheco- is F IRE
EXTINGUISHER
25/151 Operation Checks UseSafety Safety Technical Overview data NOTES
26/151 400.10815.2.de 400.10815.2.de W S AFETY Make sure that warning signs that Strict compliancewith thewarning placed immediately. are damaged or come loose are re- tory. iliaryimplements drivenmanda- is signs on the PistenBully and on aux- ARNING
INSTRUCTIONS
SIGNS while the vehicle is in motion. is in vehicle the while area load the on permitted is No-one Attention: Text: No. 8.762.658.000E cab Location: W ARNING Rear bulkhead of driver's driver's of bulkhead Rear
SIGN transport ofmaterialsandpeople. reardeckrailingisforthe Opened of peopleontheloadplatform. Text: Danger offalling! No transport No. 8.762.750.00E Location: W ARNING Rear deckrailing
SIGN :
27/151 Operation Checks UseSafety Safety Technical Overview data SAFETY INSTRUCTIONS
WARNING SIGN WARNING SIGN WARNING SIGN Location: Driver's cab/parking brake. Location: Fan/engine Location: KFS (tiller blower) No. 8.765.311.058E No. 8.762.634.054E No. 8.762.435.058E Text: Text: Text: Attention: Attention: Apply the parking brake before Switch off the engine of the vehicle The fan ring rotates when the diesel leaving the cockpit. before work on the snow blower engine is running. commences.
28/151 400.10815.2.de 400.10815.2.de complete standstill before touching. toa come parts have all until Wait WARNING! Text: No. 8.762.638.058E Location: W S ARNING AFETY Tiller
SIGN
INSTRUCTIONS the load platform. load the of movement downward to prevent support the lock and engage Always injurybycrushing: Risk of WARNING! Text: No. 8.766.062.000.0 Location: W ARNING Frame
SIGN while parts there may be moving! be may there parts while Do not reach into crushing zone WARNING! Text: No. 8.762.660.000E Location: W ARNING Auxiliary driven machinery
SIGN
29/151 Operation Checks UseSafety Safety Technical Overview data SAFETY INSTRUCTIONS
WARNING SIGN Location: Tiller No. 8.762.271.053C WARNING SIGN SIGN Text: Location: Rear deck railing Location: Driver's cab Attention: No. 8.762.702.000.0 No. 8.762.642.000E Before connecting or disconnecting the hydraulic hoses, diesel engine Text: Rear deck railing open. Text: must be shut down. Make sure that safety catch of Read operating manual and safety locking lever is engaged. instructions before startup and comply with both at all times.
30/151 400.10815.2.de 400.10815.2.de driver's cab and load platform. loweringandLever forraising Text: No. 8.766.017.000 E Location: S S IGN AFETY Frame
INSTRUCTIONS driver's cab and load platform. loweringandLever forraising Text: No. 8.762.689.000 E Location: S IGN Frame to the product. the to applicable laws and standards tives, direc- all with compliance facturer's manu- the indicates symbol CE The Text: No. 8.762.631.000E Location: S YMBOL Console/co-driver's seat
31/151 Operation Checks UseSafety Safety Technical Overview data PERMISSIBLE WEIGHTS OF FRONT-MOUNTED AUXILIARY EQUIPMENT
Attachment at pivot point, main frame (1) - Maximum long-term attachment weight 1650 kg.
Attachment at hook plane, quick-change system (2) - Maximum long-term attachment weight 1315 kg.
Attachment at quick-change system with front blade (3) 1 2 3 4 - Maximum long-term attachment weight 665 kg. - Maximum short-term attachment weight 1100 kg.
Additional weights Attachment to fork (4), length 400 mm When transporting loads, always bear in mind the maximum - Maximum short-term attachment weight 1000 kg. attachment weights at the attachment points. 1 Main frame / 2 Quick-change system / 3 Front blade / Safety instructions 4 ParkBlade fork Note: Attaching excessively heavy machinery or machinery with 1 = Pivot point (main frame, quick-change system) an excessively high moment voids the vehicle manufacturer's warranty and excludes liability on the part of the vehicle manu- 2 = Hook plane, quick-change system facturer. The only exceptions to this rule are those items of auxiliary driven 3 = End face, front blade centre machinery for which the vehicle manufacturer has issued 4 = Fork, length 400 mm (ParkBlade) approval.
32/151 400.10815.2.de 400.10815.2.de weights attachment short-term and long-term for instructions Safety P Operation withthemaximumsh Note requirementsNote regardingtransport positions ofauxiliary equipment. not shift. Check the terrain and make sure it is suitable for driving. vrabilityof thevehicle. turer of the auxiliary equipment auxiliary equipment the turer of See the operating instructions Drive at walking speed only. limit of thetime requiredfor said purpose (short-term). is restricted to the intended purpose and is subject tothe sion. The tiller has to be installed as a counterweight. The load must be adequately secured to ensure that it can- Do not permit theloadto obs toppling.Risk of The high moment of the attach ERMISSIBLE
WEIGHTS truct the driver's field of vi-
ment restricts themanoeu- ort-term attachment weight OF issued by themanufac-
FRONT - MOUNTED
AUXILIARY ParkBlade instructions, Safety blade mustbe pivoted all the way out. Make surethattheweightof loadmustThe besuitable liftingwith theforks. for are prohibited. to theforks Alterations When the forks areextended,th Always retracttheforkswh The transport of persons is prohibited. across both forks. across both Make sure there is no-oneMakezone.is inthedangersure there when extending / retracting the forks. Risk of injury bycrushing:
EQUIPMENT en they are not needed. the load is evenly distributed e sidesectionof the front
33/151 Operation Checks UseSafety Safety Technical Overview data NOTES
34/151 400.10815.2.de OVERVIEW Overview
INSTRUMENT DISPLAYS ...... 39 WARNING SYMBOLS ...... 42
PUSHBUTTONS, STANDARD ...... 44 data PUSHBUTTONS, DRUM WINCH . . . . . 51
USING THE JOYSTICK ...... 53
FUNPARK JOYSTICK ...... 60 Safety Technical STICK OPTIONAL ...... 68 NORDIC-TRAIL TRACKER PLATES (OPTIONAL) ...... 73 Use Use TERMINAL ...... 77
DRIVER'S SEAT ...... 85 Operation Checks
400.10815.2.de 35/151 COCKPIT
3 Knurled knob for driving speed 1 The speed at which the vehicle travels depends on engine rpm, 6 on the setting of the potentiometer, and on drag. You bring the engine to the correct rpm by depressing or easing up the accel- erator pedal, and set the maximum speed by turning the poten- tiometer. 4 Knurled knob for adjusting tiller speed 2 3 4 5 Turn the potentiometer to adjust tiller shaft speed. Tilling speed is increased / reduced to suit the snow conditions. Steering wheel 5 Pushbutton, tiller drive ON / OFF 1 Swivelling rear equipment carrier (see Section entitled "Using the joystick")
2 Direction-of-travel pushbutton When the parking brake is engaged, the tiller drive automatically switches off. Once the parking brake Top section pressed = Forward has been released, the tiller drive remains off. (Indi- Neutral position = Press again cator for tiller flashes). You must operate the push- Bottom section pressed = Reversing (with reversing button again in order to reactivate the tiller. alarm) Note: Engine speed increases when you press the direc- tion-of-travel pushbutton.
36/151 400.10815.2.de 400.10815.2.de answer to the steering. The PistenBully comes to an immediate stop and will not The PistenBullyisagain operation. ready for Restart complete stop. If you hit the STOP button, the PistenBully brakes sharply to a the direction-of-travel switch foot your lift you when abruptly ping, it has only a parking brake. The PistenBully does not stop The PistenBully doesnothave aseparate service brake for stop- 6 STOP button C OCKPIT Immediately theparkingbrake. Immediately apply Hit the STOP switchin the event of sudden danger. = Turn the STOP button andbuttonit up. pull =TurntheSTOP to theneutralposition. off theaccelera tor pedalor set 7 Pushbutton for wipers for Pushbutton 7 7 Move lever Move Heated windshield wipers: tohave Press front wipersexecuteasinglestroke. Bottom sectionpressed=Floatingposition Bottom =TillerNeutral position locked =Centred Top sectionpressed position floating / position Rigid carrierhorizontal equipment Rear switch /rocker Pushbutton 8 in the direction indicatedby inthedirection the arrow. 8
37/151 Operation Checks UseUse Safety Technical Overview data COCKPIT
Applying parking brake Move the lever in the direction indicated by the arrow. i When the parking brake is engaged, the direction-of- 3 travel switch automatically goes to the neutral position. 2 Lock for steering-column 1 2 4 adjustment Height adjustment 3 Warm-air outlets, adjustable 4 Accelerator 1 Parking brake
WARNING! Use the parking brake only to keep the vehicle at a standstill. The PistenBully will brake sharply to a complete stop if the parking brake is applied while the vehicle is in motion.
Always apply the parking brake before you park or exit the vehicle. Buzzer sounds as reminder: Door open, but brake not ap- plied.
38/151 400.10815.2.de 400.10815.2.de 6 Coolant temperature, diesel engine diesel temperature, Coolant 6 5 Outdoor temperature 4 Clock Snow-flap position for tiller 3 Ignition lock 2 1 Tiller-depth indicator Instrument displays C II l 0 OCKPIT Starting Ready for Driving operation / Switching off engine. Inserting andremoving ignitionkey. 8 1 2 3 4 5 6 7 14 24 V socket V 24 14 adjustable steplessly blower, Heater 13 adjustable steplessly control, Temperature 12 Pushbutton: Windscreen heating ON 11 tomaximum heating and Blower 10 Cab heating 8 Revolution counter 7 Diesel fuel 10 11 13 12 14
39/151 Operation Checks UseUse Safety Technical Overview data COCKPIT
Reading out fault messages 8 Switch off the engine.
Ignition ON 8b 8d 8a 8c 8e Rocker switch, engine diagnosis ON Rocker switch Revolution counter Engine diagnosis ON / OFF Top section pressed = OFF Bottom section pressed = Check flashing code 8a Battery charge indicator If the indicator light comes on while the vehicle is on the move: The indicator light for the engine management system - Cease operations flashes red; the flashes represent a three-digit code. - Ascertain the cause of the problem. List of fault codes, see Cummins CD supplied with the equipment. 8b Intake-air preheating Situational help (see the section entitled "Diesel engine"). Fault code 131 is represented by the following sequence of flashes: 8c Indicator for engine management system - 1 flash Lights up to indicate faults in the engine management - brief pause system. - 3 flashes If light is ON, proceed with caution to the nearest work- - short pause shop. Only trained specialists are permitted to carry out re- - 1 flash pair work. - long pause 40/151 400.10815.2.de 400.10815.2.de 8e Engine oil pressure indicator oil pressure Engine 8e Flashes yellow = Minor engine fault 8d Check forotherfaultsorrepeat: C OCKPIT 8 for theengine management system. light ontheindicator see thesection checking For acoustic warning is issued thebuzzer. acoustic warningisissued by level,an If theoilpressuredropstoanimpermissible 8a 8b fault shown. sectionpressed=Readoutlastengine Bottom faults. out otherengine Top sectionpressed=Read check Engine-fault Pushbutton 8c 8d 8e brake – Ascertain the cause. Donotbrake –Ascertain drive the thevehicle. parking the Apply – vehicle Stopthe value: permissible or maximum its minimum reached has parameter operating thatan indicate to sounds (buzzer) warning acoustic The
41/151 Operation Checks UseUse Safety Technical Overview data COCKPIT
Warning light Attention: Driver's cab tilt-locking device not engaged.
Indicator light Tiller relief (Up pressure).
Indicator light Warning symbols Tiller shaft turning
Warning light Attention: Indicator light Brake - indicator for parking brake Release Tiller drive ON pressure has dropped below 120 bar. Indicator light shows for: Indicator light Parking brake applied. Floating position, rear Not used lift / lower (vertical)
Indicator light Floating position, rear (horizontal)
42/151 400.10815.2.de 400.10815.2.de C OCKPIT Intake air preheating ON preheating air Intake Indicator light indicator filter Hydraulic-fluid Warning light Also signalled acoustically by buzzer. maximum Hydraulic-fluid temperature is above Warning light Also signalled acoustically by buzzer. Hydraulic fluid isbelow theminimum level Warning light vehicle. Do notdrivethe Electric heater for windshield ON. windshield for heater Electric Indicator light "Dieselthe sectionentitled engine") (see relief Track Indicator light flashes - Rectify the fault - Rectifythe actuated High-beam headlights ON headlights High-beam Indicator light repeater indicator turn right / Left Indicator light
43/151 Operation Checks UseUse Safety Technical Overview data COCKPIT
Rocker switch Parking lights / driving lights Pressed once = Parking light Pressed again = Low-beam headlights 6 7 Rocker switch Front worklights Overhead console
6 Two-way radio / radio prepared Rocker switch Front worklights 7 Spotlight
Rocker switch Rotating beacon Rocker switch Note: Rear worklights When the circuit is active, the indicator lights up (see arrow). A 2-stage switch has indicators top and bottom Rocker switch (optional equipment) Treeline worklights
44/151 400.10815.2.de 400.10815.2.de 6 Potentiometer Rocker switch/pushbutton C OCKPIT Contactpressure /reliefpressure tiller of 6 Bottom section pressed = Acoustic warning ON reversing for warning Acoustic = Top sectionpressed warning Acoustic 2-stage switch, Rocker Horn ON Pushbutton right. sectionpressedBottom andmove joystickto left / Kahlbacher Offset Rocker switch carrier equipment Front bottomsection pressed= Unlatched and Latching rocker switch sectionpressed=ON Bottom =OFF Top sectionpressed Spotlight ON / OFF Rocker switch sectionpressed=Flashleft Bottom sectionpressed=Flashright Bottom indicators Direction 2-stage Rocker switch, (optional) (optional) front blower to either side. either to frontblower in floating position
45/151 Operation Checks UseUse Safety Technical Overview data COCKPIT
Rocker switch Rocker switch, 2-stage ParkBlade (FunPark) Front wiper Top section pressed = Extend Top section pressed = OFF Bottom section pressed = Retract Bottom section pressed = Intermittent wipe Pressed again = Speed 1 Pushbutton Windscreen heating Intermittent wipe setting Clear thick coating of ice or snow from the screen Press shortly the intermittent, then switch off. by hand before switching on the heater. Wait for the desired intermittent. Switch on intermittent. ON time is limited to approximately 10 minutes with The desired intermittent is stored. the engine running. Press the switch again if a longer ON time is necessary. Rocker switch Power consumption is relatively high, so the drain Side-window heating / exterior-mirror on the battery is correspondingly severe. Switch off heating the screen heater as soon as the screen is demisted or de-iced. Rocker switch Rear window heater
46/151 400.10815.2.de 400.10815.2.de C OCKPIT The desired intermittent is stored. intermittent is The desired Switch on the heating if outdoor temperature isbe- temperature Switch ifoutdoor theheating on Diesel-fuel heating from WKU 100274 WKU from heating Diesel-fuel Rocker switch Intermittent wipesetting Pressed again=Speed1 Bottom section pressed =OFF Top sectionpressed Rear wiper Rocker switch,2-stage Switch offtheheating whenoperationscease. intermittent. Switch on thedesiredintermittent. for Wait thenswitch intermittent, the shortly Press low -10 0
Celsius. = Intermittent wipe = Intermittent off . - Secure the vehicle to prevent itmoving prevent to vehicle the Secure - surface level on a flat, the vehicle - Park brake parking the Apply - Before relieving tracktension: trackstretching stringers. the to prevent tracks the on tension the relieve always of time, period prolonged fora use of out be to is PistenBully If the Coolant level below the minimum level minimum the below level Coolant light,bottom Indicator Check /replaceairfilter monitor Air-filter light,top Indicator Relieve track tension bottomsection pressed= Unlatched and rockerswitch Latching If the indicator light comes on while thevehicle while is on If theindicatorlightcomes - Determine the cause of theproblem. thecauseof - Determine thevehicletoastop. - Bring move: on the
47/151 Operation Checks UseUse Safety Technical Overview data COCKPIT
Rocker switch Pushbutton Engine diagnosis ON / OFF Side finisher / smoother, left See Page 40 Top section pressed and held down = Pivot forward Bottom section pressed and held down = Pivot to Pushbutton rear Engine-fault check Pushbutton See Page 40 Side finisher / smoother, right Top section pressed and held down = Pivot forward Pushbutton Bottom section pressed and held down = Pivot to Adjusting tiller depth rear Top section pressed and held down = Reduce tiller Latching rocker switch (optional) depth Nordic-trail tracking tiller ON / OFF Bottom section pressed = Increase tiller depth Unlatched and bottom section pressed = Tiller ON See instrument display for tiller depth See the section on the Nordic-trail tracking plates.
Pushbutton / rocker switch (optional) Adjusting Nordic tracking tiller depth Top section pressed and held down = Reduce tiller depth Centred = Tiller locked Bottom section pressed = Tiller depth
48/151 400.10815.2.de 400.10815.2.de C OCKPIT reversing. for ofsidefinisher lifting Automatic Rocker switch plates. the Nordic-trail tracking the sectionon See sectionpressedandhelddown=Wide Bottom Centred =Locked held down=Narrow Top sectionpressedand / wide narrow spacing Tracker-plate Pushbutton sectionpressedandhelddown=Wide Bottom Centred =Locked helddown=Narrow Top sectionpressedand wide / narrow spacing Track Pushbutton sectionpressed=Lower Bottom Centred =Locked helddown=Raise Top sectionpressedand Raise/lower tracker plate /rockerswitch Pushbutton (optional) (optional) (optional) tion Bottom sectionpressed =Tiller locked in rigid posi- Top section pressed =Unlock tiller position rigid in Tiller equipment section ondrive See the lift automaticall not does atrear machinery driven Auxiliary bottomsection pressed= Unlatched and Latching rocker switch sectionpressed=Counter-rotating Bottom Top sectionpressed / counter-rotating operation forward Tiller Rocker switch See thesectionon tiller Alpinflex depth flap Bottom sectionpressed= Increase tiller snow- depth tillersnow-flap =Reduce pressed section Top snow-flap Tiller Rocker switch y for reversing = Forwardoperation (FunPark) hydraulics for auxiliaryhydraulics for
49/151 Operation Checks UseUse Safety Technical Overview data COCKPIT
Rocker switch Change the direction of travel only by using the direction- of-travel switch. Drive hydraulics for auxiliary equipment front / rear Top section pressed = Front Bottom section pressed = Rear
Drive hydraulics for auxiliary equipment at front ON + pump for tiller drive ON Restraint! - if the load carried combined with a steep downhill gradient prevent the PistenBully from coming to a standstill. Restraint by means of propulsion-speed potentiometer settings 0 to -3.
WARNING! Reversing with direction-of-travel indicator showing forward! If the PistenBully comes to a complete stop and the driver turns the drive potentiometer to a scale reading from 0 to -3 and presses the accelerator, the PistenBully will start to move backward. The steering is reversed.
50/151 400.10815.2.de 400.10815.2.de Drum winch D RIVE
HYDRAULICS Rocker switch Indicator light comes on to indicate winch ON monitor strand warning, acoustic Reset sectionpressed= Bottom Pushbutton sectionpressed=Pivotleft Bottom Top sectionpressed=Pivotright Swivel winch boom Pushbutton sectionpressed=Payoutcable Bottom Winch OFF Centred = in cable Top sectionpressed=Reel Reel in/pay out winchcable Latching rockerswitch sectionpressed=ReleaseBottom brake Top sectionpressed=Applybrake Turret-gear parking brake - AUXILIARY
DRIVEN
MACHINERY See the operating instructions forthedrumwinch. See theoperating Adjustableby meanspotentiometer. of pressure.section pressed=Apply Bottom = Centred Floating position Top section pressed =Relieve pressure pressure relieve / intosnow tiller Press Pushbutton sectionpressed=Lower Bottom Centred =Locked =Raise Top sectionpressed tiller lower / Raise Pushbutton isswitchedoff. monitor Belt Note: Indicatorlight isON cockpit lock, seat-belt Release Rocker switch
51/151 Operation Checks UseUse Safety Technical Overview data DRIVE HYDRAULICS - AUXILIARY DRIVEN MACHINERY
Preconditions for operation of the drive Tiller forward operation / counter-rotating hydraulics for auxiliary equipment Rocker switch The driver's cab must be fully lowered and locked in posi- Tiller forward operation / counter-rotating tion. Top section pressed = Forward operation The load platform must be fully lowered. Bottom section pressed = Counter-rotating
The rear-mounted tiller must be less than 500 mm clear of On account of the additional draw on engine power it the surface of the snow. would cause, counter-rotating mode is not advisable while climbing slopes. The plug of the auxiliary implement must be in the socket (socket E). Note: Failure to comply with this precaution will mean that the electronically controlled speed reduction function is not available.
The diesel engine must be revving at a speed at least equal to the pullaway speed of 800 rpm.
As a safety precaution, the tiller hydraulics are deactivated when the rear-mounted driven implement is raised to a height of approx. 50 cm.
If there is a leak in the drive hydraulics always switch off the diesel engine and have the fault rectified. 52/151 400.10815.2.de 400.10815.2.de - Reversingis lighton. switched - Ifthein tiller operation, is the tiller isdeactivatedlifted when 1.2 m clearof thesurface of theslope. - Equipment carrierthe lifts auxiliary drivenapprox. machinery - Equipment carrieris centred. - Vertical and horizontal floating position OFF. tion: the direction oftraveltothe switchismoved hydraulic circuits listed below are automatically actuated when When therockerswitch is set to Automatic liftingofrearauxiliarydriven machinery forreversing U more than 0.5 m clear ofthe surface of the slope. SING
lift automaticall Auxiliary driven equipment at rear does not atreardoes equipment driven Auxiliary sectionpressed= Unlatched andbottom switch Latching rocker THE
JOYSTICK y forreversing. "Automatic lifting" "Reverse" the posi-
- If the floating/centred position was selected beforehand, itis tiller- Ifa isinstalled, itrestartswhen itislowered toless than - The equipmentcarrieris Forward" the direction of travel switch ismoved to the hydraulic circuits listed below are automatically actuated when When therockerswitch is setto 0.5 m m above the surface of the slope. 0.5 be selectedaccordingly. automatically reselected. Any other position, if required, must position: automatically lowered. "Automatic lifting" "Neutral / the
53/151 Operation Checks UseUse Safety Technical Overview data USING THE JOYSTICK
Front blade Joystick Pushbutton Position
Raise - lower Floating position A - Lower
B - Raise
Tilt C - Left
D - Right
Roll / A - Forward
B - Back
54/151 400.10815.2.de 400.10815.2.de Wing, right Wing, left Wing, Swivel U SING Front blade
THE
JOYSTICK Joystick Pushbutton D C B A D C - Move wing out. - Move wing in. - Swivel left. - Move wing in. - Move wing out. - Swivel right. Position
55/151 Operation Checks UseUse Safety Technical Overview data USING THE JOYSTICK
Rear equipment carrier Joystick Pushbutton Position
Raise - lower A - Raise Neutral position: Locked B - Lower Note: See versions
Raise - lower Version 1 Version 1 Pushbutton in position C Pushbutton 1 briefly pressed = Raise tiller to full 120 cm Press again = Lower tiller Note: Press before tiller is fully raised = Hold tiller in position
Version 1.1 Pushbutton 1 pressed for longer than 1 second = Raise tiller Release pushbutton = Hold tiller in position Pressed again = Lower tiller.
56/151 400.10815.2.de 400.10815.2.de Floating position Floating U Rear equipmentcarrier SING
THE
JOYSTICK Joystick Pushbutton position Bottom sectionpressed=Floating Neutral position=Tillerlocked =Centred sectionpressed Top position /floating position Rigid Rear equipmentcarrier/horizontal Rocker switch Position
57/151 Operation Checks UseUse Safety Technical Overview data USING THE JOYSTICK
Rear equipment carrier Joystick Pushbutton Position
Floating position 1. Pushbutton in position B
Pushbutton D - pressed = Relieve tiller
2. Centred = Floating position
C - pressed = Press tiller into snow
Adjustable by means of potentio- meter.
58/151 400.10815.2.de 400.10815.2.de Swivel horizontally Side finishers Depth setting U Rear equipmentcarrier SING
THE
optional optional JOYSTICK Joystick Pushbutton Pushbutton Tiller depth shownon terminal tiller =Lower down Bottom sectionpressedandheld Neutral position=Tillerlocked Raise tiller down = sectionpressedandheld Top depth tiller Adjusting Pushbutton Bottom sectionpressed=Pivot to rear =Pivotforward sectionpressed Top Side finishers Pushbutton D C = Swivelleft = Swivel right Position see Steering wheel
59/151 Operation Checks UseUse Safety Technical Overview data USING THE FUNPARK JOYSTICK
Starting tiller when raised
As a safety precaution, the drive hydraulics for auxiliary WARNING! equipment are deactivated when the rear-mounted driven Risk of injury by cutting or crushing action. implement is raised to a height of approx. 50 cm. It is very important to ensure that the The FunPark configuration includes a function that enables danger zone is completely clear. the drive hydraulics for auxiliary equipment to be switched on with the implement raised. Consequently, it is very important to ensure that the danger zone is completely Tiller drive ON clear. The tiller indicator light shows. Diesel engine speed higher than 1100 rpm
Pushbutton pressed The tiller is switched on.
60/151 400.10815.2.de 400.10815.2.de . Roll / Version 1 Version 2 Version Version 1 Roll / position Floating Tilt Raise -lower U SING Front blade
THE F UN P ARK
JOYSTICK FunPark joystick Pushbutton B A D C B A - Back - Left - Raise - - Forward - Lower - Right Position
61/151 Operation Checks UseUse Safety Technical Overview data USING THE FUNPARK JOYSTICK
Front blade FunPark joystick Pushbutton Position
Swivel C - Swivel left.
D - Swivel right.
Wing, left A - Move wing in.
B - Move wing out.
Wing, right C - Move wing in.
D - Move wing out.
62/151 400.10815.2.de 400.10815.2.de ParkBlade U SING Front blade
THE F UN P ARK
JOYSTICK FunPark joystick Pushbutton B A - Retract ParkBlade - - ExtendParkBlade Position
63/151 Operation Checks UseUse Safety Technical Overview data USING THE FUNPARK JOYSTICK
Rear equipment carrier FunPark joystick Pushbutton / Position potentiometer
Raise - lower A - Raise Neutral position: Locked B - Lower Note: See versions
Variante 1 Version 1 Pushbutton in position C Pushbutton 1 briefly pressed = Raise tiller to full 120 cm Press again = Lower tiller Note: Press before tiller is fully raised = Hold tiller in position
Version 1.1 Pushbutton 1 pressed for longer than 1 second = Raise tiller Release pushbutton = Hold tiller in position Pressed again = Lower tiller.
64/151 400.10815.2.de 400.10815.2.de Floating position Floating U Rear equipmentcarrier SING
THE F UN P ARK 2. 1.
JOYSTICK Joystick
Pushbutton eter. Adjustable by means of potentiom- sure. Bottom sectionpressed =Apply pres- Centred =Floatingposition Top section pressed =Relieve pressure Pushbutton in position Position B
65/151 Operation Checks UseUse Safety Technical Overview data USING THE FUNPARK JOYSTICK
Rear equipment carrier FunPark joystick Pushbutton Position
Floating position Rocker switch Rear equipment carrier / horizontal Rigid position / floating position Top section pressed = Centred Neutral position = Tiller locked Bottom section pressed = Floating
Swivel horizontally Pushbutton see Steering wheel
C = Swivel left
D = Swivel right
Switch on tiller Tiller ON/OFF
66/151 400.10815.2.de 400.10815.2.de Power Angle Depth setting U Rear equipmentcarrier SING
THE F UN P ARK
JOYSTICK FunPark joystick Pushbutton B A Pushbutton Tiller depth shownon terminal tiller =Lower down Bottom sectionpressedandheld Neutral position=Tillerlocked Raise tiller down = sectionpressedandheld Top depth tiller Adjusting Pushbutton - Retracttiller - Extendtiller Position
67/151 Operation Checks UseUse Safety Technical Overview data STICK OPTIONAL
Operation, stick
Forward Both sticks pushed forward Note: Controlling driving speed - by using the accelerator - by using stick neutral position and swung out all the way. Reverse Both sticks pulled back
Corner left Push right stick forward
Turn right on the spot Right stick pulled back left stick pushed forward
68/151 400.10815.2.de 400.10815.2.de complete stop. If you hit the STOP button, the PistenBully brakes sharply to a position. pedal or set thedirection-of foot offtheaccelerator you liftyour abruptly when stop not stopping, it has only a parking brake. The PistenBully does The PistenBully does not have a separate service brake for 2 STOP button knob. accelerator pedal,and set the enginedepressingto thecorrectrpm by easing the or up rpm, on the setting of the knob, and on drag. You bring the The speed atwhich thevehicledepends travelson engine Knurled knob for driving speed 1 S TICK Hit the STOP buttonintheeventof sudden danger.
OPTIONAL -travel switchto the neutral maximum speed by turning the 3 2 1 / reduced to suit the snowconditions. Turn the knob toadjust tilling speed. Tilling speed isincreased Knurled knob for adjusting tiller shaft speed 3 Restart = The PistenBully comes to an immediate stop and will not will and stop immediate an to comes PistenBully The e PistenBully brakes sharply to a complete stop! answer to the steering. answer tothe Immediately apply the parking brake. CAUTION! 5 seconds. Press the STOP button and hold it down for
69/151 Operation Checks UseUse Safety Technical Overview data STICK OPTIONAL
Activating manual throttle control Use the accelerator to bring the engine up to the desired 5 diesel-engine speed. Press button 5 and hold it down for at least 3 seconds. 4 The diesel-engine speed remains constant.
WARNING! Driving with manual throttle control! 4 Pushbutton, tiller drive ON - OFF Easing the accelerator will no longer produced a reduction in driving speed and diesel-engine speed! When the parking brake is engaged, the tiller drive auto- Engine rpm will respond only by increasing in matically switches off. When the parking brake is released, response to increased pressure on the accelerator. the tiller drive remains off (indicator for tiller flashes). You must operate the pushbutton again in order to reactivate Reducing diesel-engine speed / driving speed the tiller. Version 1 Move the sticks toward the neutral position. Version 2 Press button for manual throttle control 5 5 Pushbutton for manual throttle control Use manual throttle control for driving at very low speed and high tilling speed in extremely difficult terrain. The diesel-engine speed can be adjusted up to max. 1600 rpm.
70/151 400.10815.2.de 400.10815.2.de Swivel horizontally Swivel position Floating S Rear equipmentcarrier TICK
OPTIONAL Joystick D C A Pushbutton B Pushbutton B Neutral position=Tillerlocked Button position /floating position Rigid Rear equipmentcarrier/horizontal Rocker switch D C pressed =Floating pressed position = Swivelleft = Swivel right A pressed =Centred Position see Steering wheel
71/151 Operation Checks UseUse Safety Technical Overview data NOTES
72/151 400.10815.2.de 400.10815.2.de N ORDIC D B C - TRAIL C B Raise/lower/press into snow into Raise/lower/press Nordic-trail trackerplates B
TRACKER A A A
PLATES Potentiometer Apply pressure D C C B B A B A A A-D - A-D - B A - Right tracker plate,- Righttracker - Left tracker plate, Apply pressure Potentiometer raise /lower raise /lower raise / lower / raise raise / lower / raise Tracker plates, Tracker plates
73/151 Operation Checks UseUse Safety Technical Overview data NORDIC-TRAIL TRACKER PLATES
Variant 1 / 2 2x Nordic-trail tracker plates
C C/D Track spacing
D
C-F Track spacing E C G G/H Distance between tracker plates
F D H
74/151 400.10815.2.de 400.10815.2.de N ORDIC - TRAIL 3 / 4x Nordic-trail trackerplates3 /4xNordic-trail Variant 3/4
TRACKER
PLATES D D C C C/D C/D Track spacing Track spacing
75/151 Operation Checks UseUse Safety Technical Overview data NORDIC-TRAIL TRACKER PLATES
Variant 5 / 6 2x Nordic-trailer tracker plates with 1/ 2 Nordic-trail tracking tillers
C/D Track spacing C G G/H Distance between tracker H D plates
X1 Nordic-trail tiller A Unlatched and bottom section pressed = Tiller ON X1 B A/B Nordic-trail tracking tiller, raise / lower
X1 Nordic-trail tracking tiller X 2 Unlatched and bottom section G pressed = Tiller ON X2 X1 H G/H Distance between tracker plates
76/151 400.10815.2.de 400.10815.2.de Press the Checking settings: Terminal display T ERMINAL Select a function button button Select afunction Start thedieselengine. ESC button tocancel F1 - F5 F1 - . - Stepback1levelat a time to Startpage. - Proceed to next level - Show video-camera image - Tillerspeed - Operating-hours counter - Operatinghours,total - Operating hours today - Steeringsetting - Engine-oil pressure - Coolanttemperature - Engine-oil temperature (ResetF3) - Average diesel fuel consumption (optional) Press F4 to set tozero to Press F4 Press F4 to set tozero to Press F4
77/151 Operation Checks UseUse Safety Technical Overview data TERMINAL
Viewing software version
Command Display 2nd screen Result
Press F5 twice Press F1 Press F1
Setting language / display brightness
Command Display 2nd screen Result
Selecting the language of your choice
Press F5 twice Press F3 Press F1 Press F3 to select the language
Setting display brightness
Use P1 to adjust brightness Press ESC to cancel. 78/151 400.10815.2.de 400.10815.2.de Adjusting to thenearestworkshop. than further itno drive mode, emergency isin vehicle the If - Direction-of-travel switch pedal - Accelerator - Steeringpotentiometer in the event ofa failure of any of the following: mode Activate emergency electronics Emergency mode,propulsion T ERMINAL Drive at low speed only. Variations in load cancausethe inload Variations Drive atlowspeedonly. engine tocutout. engine Press Press Press F4 F5
twice Direction oftravel Propulsion speed Propulsion steering equal inlength. Blue and yellow bars of Driving straight-ahead = Use Use Back offpropulsion-speed po- Use tentiometer tentiometer pulsion speed. want tobrake. steering. F3 F2 F1 P2 P1 reverse neutral forward to increase/reduce pro- toincrease/reduce to adjust toadjust propulsion P2 when you whenyou P1 are are
79/151 Operation Checks UseUse Safety Technical Overview data TERMINAL
Adjusting steering sensitivity Using teach-in mode for calibration
Press F5 twice Switch on the ignition Press F3 Press F5 twice Press F2. Press F3 twice
Calibrating accelerator P1 Increase value: Slight steering movement has pedal increased steering effect. Set P1 to value of 0101
P2 Change value: Press F1 to confirm Correct straight-line drive for- ward. Without operating the acceler- ator, press F5 to confirm. P3 Change value: Correct straight-line drive in Applying uniform pressure, reverse. slowly depress the accelerator pedal to the limit of its travel. Press F5 to continue Keep the accelerator pedal P1 Change value: pressed down and press F5. Track speed for cornering. Press F5 to confirm.
P values for calibration 0101 = accelerator pedal / 0102 = steering potentiometer / 0103 = inch potentiometer 80/151 0204 = Tiller potentiometer 400.10815.2.de 400.10815.2.de T in damage tothevehicle. in damage result that would fault a indicating message message: Repeated Fault Press code: fault Check - Ceaseoperation. - Redwarningsymbol - DisplayshowsSTOP tone Continuous buzzersounds: Warning High-priority fault. ERMINAL Fault-code displays : Press OK . Category ESC Ifyouignorea Display Action
81/151 Operation Checks UseUse Safety Technical Overview data TERMINAL
Category Display Action
Medium-priority fault.
Warning buzzer sounds: 10 sec. ON and 0.5 sec. OFF - Display shows ATTENTION - Yellow warning symbol - Restriction possible
Low-priority fault
Warning buzzer sounds: 0.5 sec. ON and 1.5 sec. OFF - Display shows !W - Green warning symbol - Minor restriction possible
82/151 400.10815.2.de 400.10815.2.de 0 = Serial number, fault code . . . 001 3 2 1 Fault 14 10 7 6 5 4 3 2 1 Subassembly Key tofaultcodes T = Medium-priority fault(yellow) =Medium-priority = monitoring CAN = Display = ESX = Winch control = Tiller control =Vehicle =Engine 3,2,001 ERMINAL =Rear equipment =Auxiliary hydraulics 3,2,001 3,2,001 = Low-priority fault (green) fault =Low-priority fault(red) =High-priority to 1,2,068 Fault 3,2,035 3,2,034 3,2,024 2,2,033 2,2,032 2,2,031 1,2,074 1,2,044 1,2,040 2,1,073 2,1,072 2,1,071 2,1,070 2,1,036 2,1,030 tolerance Tiller potentiometer values, control Tiller speed potentiometer Tiller ON/OFF switch Inch potentiometer, Inch potentiometer ance Steering potentiometer,controltoler- Constant choke Engine Pedal value / engine setpoint Servo output, forward,right Servo output, reverse,right Servo output, reverse,left Servo output, forward, left Forward / reverse button Steering potentiometer Meaning control tolerance
83/151 Operation Checks UseUse Safety Technical Overview data TERMINAL
Fault Meaning 3,2,075 Valve 3rd pump (tiller) 4,2,038 Winch speed-range detection 4,2,069 Winch detection 7,2,043 No engine data available on CAN 1,3,004 No engine data 6,3,022 No data from display 16,3,037 Front-equipment detection
84/151 400.10815.2.de 400.10815.2.de 3Knob Knob 2 Head-restraint cushion 1 D RIVER for adjusting lumbar support. for adjustinglumbar For adjustingsidewings. angleareadjustable. Height and 9 8 ' S
SEAT 7 6 5 4 3 2 1 9 Horizontal fore-and-aft adjustment adjustment fore-and-aft Horizontal 9 control two-stage for Switch 8 Stepless adjustmentof seat depth. 7 Knob 6 3-stop lever 5 Knob 4 By locking rails on both sides. lockingrailsonboth By forseatcushionandbackrest. Heating 8°. through cushion seat ofthe adjustment stepless For position) (no-float 75mmtravel - - 90mmtravel - 150mmtravel floatto limiting For ofbackrestrake. adjustment stepless For
85/151 Operation Checks UseUse Safety Technical Overview data NOTES
86/151 400.10815.2.de 400.10815.2.de O VERVIEW io PLATFORM T O MACHINERY I NSTALLING ILTING PENING
THE
THE ...... 93 .
AUXILIARY ...... 88 . DRIVER
REAR
' DECK S
CAB
DRIVEN
RAILING / LOAD
91 .
87/151 Operation ChecksUse Use Safety Technical data Overview AUXILIARY DRIVEN IMPLEMENTS
4 3 4 2 1 2 1 3
5
5 Installing auxiliary driven implements
Clear all ice and snow off the adapter plate 1 and centring head of the auxiliary driven implement. Tilt adapter plate 3.
Drive the PistenBully up to the equipment. WARNING! Apply the parking brake. Do not permit anyone to enter the zone between the vehicle and the auxiliary driven implement while the Slowly raise carrier plate or blade frame 2. Adapter plate 3 engine is running. engages hooks 4, mating plate 1 seats against the adapter Lower the carrier plate or blade frame. plate and simultaneously centres itself with the two centring wedges on the adapter plate. 88/151 400.10815.2.de 400.10815.2.de longed periods of dozing work. of dozing periods longed pro- before implement auxiliary rear-mounted the Remove A UXILIARY Lower the auxiliary driven implement. Lower theauxiliarydriven nutsand the 10minutesoperation,recheck After approx. Swing eyebolts Switch offtheengine. to just farenough frame Raise thecarrierplateorpusher make make sure theyare correctlytightened. torque 250Nm). position. thecorrect into theauxiliarydrivenequipment jerks willjuggle few sharp the centringwedges seat againsttheadapterplate.If equipment to the enable
DRIVEN 5
inward and tighten the nuts (tightening inward andtightenthenuts(tightening
do not slip theadapterplate,a under
IMPLEMENTS B =Deviceend A = Vehicle end actuated automatically in the coupling process. Check valves that enable or disable flow, as applicable, are and disconnecting hydraulic hoses. The threaded Connecting hydraulics A high-pressure couplings B are for connecting arefor
89/151 Operation ChecksUse Use Safety Technical data Overview AUXILIARY DRIVEN IMPLEMENTS
Connect the electrical plug of the auxiliary driven imple- ment to the socket of the PistenBully and make sure it is correctly engaged. The plug completes the electrical cir- cuit, so that the controller can recognise the auxiliary driven implement.
Function-test the auxiliary driven implement.
WARNING! Before connecting or disconnecting the hoses for aux- iliary driven implement, always: Make sure there is no-one in the danger zone. - Switch off the engine. - Apply the parking brake. Check the driven implement for fluid leaks and, if neces- sary, have the equipment repaired by trained, qualified per- Switch the ignition for the diesel engine ON and actuate sons. the appropriate functions to depressurise the hydraulic lines. Removing the auxiliary driven implement Ignition for diesel engine OFF
When making the connections, always make sure that both Lower the driven implement, with the stands fully extended parts of the couplings are perfectly clean. and secured, onto firm, smooth ground. Connect the leak-off oil line first see illustration, arrow. This will enable excess pressure in the system to escape. Removal is the reverse of the installation procedure.
Connect the hydraulic hoses, making sure that the num- Disconnect the leak-off oil line last. bers match and that the hydraulic couplings are correctly seated. Use suitable tools to tighten the hydraulic cou- Protect the driven implement from the sun if it is to be out plings. of use for a prolonged period of time. 90/151 400.10815.2.de 400.10815.2.de engage. must lever locking the on catch safety The opening. for hold to points for arrows direction See Opening thereardeckrailing R EAR Always comply with the ins Raise the hinged reardeckrailing Raise thehinged Install thetwospringpinstosecurefootbar. safetychains. both Close Push bothlockingleversallthewaydown. gers inthesectionenti
DECK CAUTION! railing of the load platform. load railing ofthe onthe afirmgrip keep railing,always deck steppinguptoordownfrom the rear When platform. load the onthetrackand Danger ofslipping
RAILING tled "Safetyinstructions". tructions for carrying passen- . (option) Closing thedeckrailing Fully lower the rear deck railing. deck rear the lower Fully Press safety catch safety Press lowering thereardeckrailing. when specifiedpoints onlyatthe Remedy: Hold railing reardeck the lowering when crushing: by injury of Risk 1 andopenthelockinglever 1 .
91/151 Operation ChecksUse Use Safety Technical data Overview NOTES
92/151 400.10815.2.de 400.10815.2.de Precondition: T ILTING Always removeAlwaysall looseobjects before tilting thedriver's Park the vehicleonafirmsurf possible. driven implements. cab or load platform. Lower thefront-mounted an Direction of travel switch in neutral position. Switch off the tiller drive. Apply the parking brake.
THE
DRIVER ' S d rear-mounted auxiliary
ace that is ashorizontalace thatis as CAB / LOAD
PLATFORM accident due to doorsslamming closed. this precau comply with Failure to Close the doors. implement. driven auxiliary the and cab driver's or the platform load the between collision of inthe risk result will precaution with this tocomply Failure Make sure there is no-one in the danger zone. Exit thedriver's cab. CAUTION! tion willresultinarisk of
93/151 Operation Checks UseUse Safety Technical data Overview TILTING THE DRIVER'S CAB / LOAD PLATFORM
Tilting the driver's cab PistenBully 400
Move the levers of block ball cock 1 and 2 to the appro- 1 priate positions.
Move adjuster valve 3 to the appropriate position. Press button 4. The driver's cab will tilt. 3 2 You can interrupt this movement by releasing the button. Switch off the diesel engine by pressing STOP button 5. PistenBully 400 W
1
3 2
5 4
94/151 400.10815.2.de 400.10815.2.de Lowering thedriver'scab T i ILTING latching mechanism goes out. The driver's cabwill lower.The warning light for thecab Press button Start the diesel engine bypressing button Move the adjuster valve to the appropriate position. You can interruptYou can this movement byreleasingthe button.
THE 4
. DRIVER ' S
CAB / LOAD 6.
PLATFORM PistenBully 400W PistenBully 400 6 4
95/151 Operation Checks UseUse Safety Technical data Overview TILTING THE DRIVER'S CAB / LOAD PLATFORM
Tilting the load platform
Remove toggle screw 7 from the load platform. Move the lever of the block ball cock to the appropriate position.
Raise the load platform all the way (see Tilting the driver's cab for details).
WARNING!
Risk of injury by crushing: If hydraulic pres- 8 sure is lost the load platform will move downward! Secure support 8 to ensure that the assembly cannot move downward of its own accord. 7
Raise the load platform all the way and release support 8 and swing it down. 8a 8b Engage the support and press it down into the anchorage (see Fig. 8a).
WARNING! The support can be inadvertently knocked out of its anchorage. Lower the load platform until the stud is seated in the guide slot (see Fig. 8b). 96/151 400.10815.2.de 400.10815.2.de Lowering theloadplatform T 8c ILTING Disengageits thesupport from anchoragesecure itin and for details). the holder. Tighten the toggle screw in the load platform. Lower theloadplatform Securewith retaining thesupportring Tilt the load platform all the way up.
THE
DRIVER (see Lowering thedriver's cab ' S
CAB / 8c LOAD .
PLATFORM lowering /tilting Driver's cabandloadplatform,
97/151 Operation Checks UseUse Safety Technical data Overview TILTING THE DRIVER'S CAB / LOAD PLATFORM
9
Using the manual pump for tilting and Driving the vehicle lowering Move the lever of the block ball cock to the appropriate Switch off the diesel engine. position. Prepare the block ball cock / adjuster valve and the sup- port in the same way as for the corresponding operation with the engine-powered hydraulics. Note that the rear hydraulics will not operate if the driver's cab locking mechanism is not engaged or the load platform Fit tubular extension (toolkit) on manual pump 9 and is not fully lowered. The warning symbol for the cab latching operate the pump. mechanism lights up.
98/151 400.10815.2.de OVERVIEW OF ELECTRICS
Overview
LIGHTS ...... 100 data
FUSES...... 103
EMERGENCY ACTUATION, Safety Technical AUXILIARY HYDRAULICS . . . . 105 Use
BATTERY ...... 106 Use
BATTERY MASTER SWITCH . . . 108 Operation Checks
400.10815.2.de 99/151 ELECTRICS
1 7 2 3 4 5 8 10 11 9 6
Lights 14 13 Do not touch the glass of halogen bulbs. (See notes on halogen-xenon bulbs). 12
1 Front searchlight
2 High-beam headlight / parking light H7
3 Low-beam headlight H7 8 Side-mounted flashing indicators
4 Worklight, front (xenon optional) 9 Turn indicators / rear light
5 Treeline light H3 (optional) 10 / 11 Turn indicators / rear light
6 Worklight, rear, H11(xenon optional) 12 Side worklights
7 Rotating beacon 13 / 14 ON/OFF button, engine-compartment lighting 100/151 400.10815.2.de 400.10815.2.de Do not look directly into the bright light. thebright lookdirectlyinto Do not Bright lightcouldinjureeyes. Halogen -Xenon E LECTRICS TreeLine lights Tail lamps WARNING! Working lights 0m2 30m 20m 10 m
Low beamFull SideFinder lights with xenonlights PistenBully 400 with standard lights PistenBully 400 hot. while the lens to useliquid clean Do not lens: the breaking of Risk flickers. light the if immediately off Switch ballast. the in cuitry cir- electronic the to damage in result can light discharge gas- ofthe flickering by indicated problems light Persistent electronicDamage to ballast: minutes beforereentering. forat least20 ventilatetheroom immediately and If axenonbulbbreaksinanenclosedspace,leave togas. hazarddue Health Clean the glass lens ifdirty, but only when the lens is cold. Do not use aggressive or abrasive cleaning agents. Do notuse orabrasivecleaning aggressive WARNING!
101/151 Operation Checks UseUse Safety Technical Overview data ELECTRICS
Safety instructions for changing xenon bulbs Wear protective goggles and protective gloves when changing bulbs. Before changing a bulb, always switch off the headlights and isolate them from the power supply. Danger of flying splinters of glass. The glass body of a xenon bulb is pressurised and can shat- Do not probe into the bulb socket. ter. The electrical connection between headlight and ballast Always hold the bulb by the base. carries a high voltage: do not break this connection. Operate xenon bulbs in closed headlights only. Never operate the ballast without a bulb, as this could cause dangerous arcing at the bulb socket and result in damage.
Allow the bulb to cool down before you commence work. Dispose of the spent xenon bulb as hazardous waste.
Electrical connection
Before connecting, always interrupt the circuit by switching off the battery master switch. Use only the factory-installed wiring harness for electrical connection.
102/151 400.10815.2.de 400.10815.2.de latches the console in the fully raised position. strut console untilthegas-filled lift thecentre Use thegripto underneath thecentreconsole. are The fuses high currents in the electrical system. Fuses are designed to provide protection against excessively Replacing fuses E LECTRICS than the the originals. than replacement fuses witha Never attemptrepair tojumperor insert fusesor short-circuit. and fire cable of Risk higher ampere rating rating ampere higher 13 12 11 10 9 8 7 6 5 4 3 2 1 Fuses (10 A) Front wiper, radio Frontwiper, Searchlight,reversing light (10 A) Drum winch (20 A) Cab heating, right (25 A) Cab heating, left (15 A) rear Worklight, (10 A) Worklight, front (20 A) (20 A) Instrumentlighting, parking light/rear light, (10 A) Dashboardlighting, parking light/rear light, Low-beam headlight, sidefinder right (20 A) Low-beam headlight, sidefinder left (10 A) High-beam headlight, right (10 A) High-beam headlight, left, andtelltale (10 A) (10 A) right left
103/151 Operation Checks UseUse Safety Technical Overview data ELECTRICS
49 H1
14 (10 A) Rear wiper / auxiliary hydraulics, rear 28 (30 A) Rear-window heater 15 (10 A) Steering wheel, reversing alarm 29 (10 A) Reserve 16 (10 A) Front tiller blower, Pipe Magician, reversing 30 (20 A) Rotating beacon, clock, camera interior lighting 17 (10 A) Instruments, telltale lights 31 (10 A) Cold-start system 18 (20 A) Flashing indicators, horn 32-34(10 A) Reserve 35 (10 A) Tracker plates 19 (20 A) Auxiliary hydraulics 36 (10 A) Tracker plate tiller 20 (3 A) PSX electronics 21 (5 A) Engine electronics 48 (40 A) Low-beam headlights, sidefinders on both 22 (20 A) 24/12 V converter, driver's seat sides 23 (30 A) Engine electronics 49 (40 A) Front windscreen heater 24 (10 A) Terminal 25 (3 A) PSX electronics H1 Main fuse 26 (30 A) PSX electronics 27 (30 A) Voltage with engine running, mirror heater, 100 A 2 x main fuse side-window heater 80 A 2 x Engine start 104/151 400.10815.2.de 400.10815.2.de 16 - 24 16 - 15 14 13 12 11 10 9 8 7 6 5 4 2 1 Miniature relays arenot Miniature relay(K) E Flashing Driving indicators / radio SAT Parking lights Windscreen heating lights LECTRICS Reversing light Reversing Cold-start system Rear-window heater Reserve Warning buzzer Intermittent wipe, front Voltage withengine running Intermittent wipe, rear Drum winch interchangeable. gency pushbutton working equipment can be raised / lowered by means of emer- If thecontrol system fails, the Emergency actuationworkhydraulics power supply =fuse FR DO +RE UP +RE =Reserve Switch off the rotary tiller therotary Switch off pressed =raising of the implement carrier 5 pressed
5 = loweringof theimplementcarrier . 6 (20 Ampere) rear hydraulics for the auxiliary 6
105/151 Operation Checks UseUse Safety Technical Overview data ELECTRICS
Topping up battery fluid
WARNING! Take care when handling battery acid Risk of caustic burns: Wear protective goggles and protective gloves.
Remove the screw caps. vehicle battery Top up the fluid in the cells to the max. mark with distilled water. The two 12 V, 135 Ah batteries are mounted on the upper frame. Opening the cover on the carrier frame
The battery must be held in place by the retainer.
WARNING! Risk of explosion of oxyhydrogen gas: Keep all sources of ignition well away from the battery. Do not place metal objects on the battery. 106/151 400.10815.2.de 400.10815.2.de Charging thebattery E LECTRICS Connect the battery to theon-b to thebattery Connect activating the battery masterswitch. thebattery activating battery. objectson top ofthe Do notplacemetal charged is well ventilated. thesureMake roominwhich the battery is tact witheachother. Do not bring the battery clamps into con- sure Make that polarity isnot reversed. posts. battery the to clamps battery the Connect WARNING! oard electrical system by oard electricalsystem battery. substitutetobattery or boost asa forpower packs the the Do not attempt to start theengineusing power boosters or units! control electronic damaging of Risk cable. jumber the disconnecting before heating) seat heating, windscreen (e.g. appliances ongreat Switch packaging! electronic the damaging of Risk adapter the disconnecting when peaks Voltage Jump starting Do not to electricshock. resultinfatalityor due could severe burns procedure A mistakeinthejump-starting connections between the two batteries. betweenthetwo connections Do not ble terminals. WARNING! connect the jump-start leadstothe thejump-start connect betweentheca- makeaconnection
107/151 Operation Checks UseUse Safety Technical Overview data ELECTRICS
Connecting jump leads (see illustration)
1. From + pole clamp PB battery to + pole of donor battery The engine electronics will lose data. Only 75% of (24 V). rated engine power will be available when the 2. From – pole clamp PB battery to – pole of donor battery engine is restarted. (24 V) Before disconnecting the battery from the vehicle's on- Connect the battery to the on-board electrical system by board electrics: activating the battery master switch. - Switch off the ignition. - Wait 30 seconds. Battery master switch - Then operate the battery master switch. Switch off the battery master switch: Situational help If you make a mistake in the procedure: Switch off the
if the electronics are defective. ignition in the correct way and restart the engine. The engine ill operate at full power to help prevent the battery from discharging during a pro- longed storage. The battery master switch provides a means of isolating the battery from the vehicle's on-board electrics.
Voltage peaks: While the engine is running, do not switch off the battery master switch except in an emergency. 108/151 400.10815.2.de 400.10815.2.de Disconnectingbattery fromon-board electrics E Connecting battery to on-board electrics ( The battery isnowisolated from 1b LECTRICS ). Turn battery master switch master battery Turn Switch ontheignition. 30seconds. Wait Operate thebatterymasterswitch. the arrow. arrow. the 1 1 the vehicle's on-b in the direction indicated by inthedirectionindicated oard electrics 1b
109/151 Operation Checks UseUse Safety Technical Overview data NOTES
110/151 400.10815.2.de 400.10815.2.de MAINTENANCE I D NSTRUCTIONS AILY Check security of wheels after Check securityofwheels Perform allcheckswiththeengineoffandvehicle Perform off. starting specifiedchecksbefore the perform Always Make sure that the oil and co Make surethattheoiland TighteningNm. torque300 parked onahorizontalsurface. specification (checkatoildipstick,overflowplug,etc.). distance from rotatingparts. from distance keepatasafe isrunning, theengine When action. bycuttingorcrushing ofinjury Risk WARNING!
CHECKS
FOR
CHECKS olant levelsarealwaysto the first 5 operating hours. first 5operating the
AND
ronmentally compatible manner (comply with local laws). local with (comply manner compatible ronmentally envi- an in substances these of dispose Always water). and tosoil hazardous are (they or lubricants fluids spill not Do poisoning). (riskof orlubricants notinhaleorswallowfluids Do wetclothing). change gloves, withtheskin(wearprotective contact fluidsorlubricantstocomeinto notpermit Do T OPPING clear when the vehicle isbeing refuelled. when of ignition sources allpossible Keep tank. fuel in gas of build-up to due explosion of Risk WARNING! WARNING!
UP
FLUIDS
AND
LUBRICANTS
111/151 OperationChecks Checks Use Safety Technical Overview data DAILY CHECKS
CHECKING COOLANT LEVEL 2
Check the coolant level and top up only when the engine is cold. Slacken bleed screw 2 when topping up the coolant. This will enable the system to fill much more rapidly.
Check the coolant level in the sight glass of the expansion tank. The water level must be between the min. and max. marks. Check the antifreeze of the coolant, (see the section on flu- ids and lubricants). Check that the hoses in the cooling and heating systems are tight and not leaking.
112/151 400.10815.2.de 400.10815.2.de ifications). spec- lubricants and fluids (see oil engine approved Use only C D HECKING AILY Top up the oil with the engine stopped and the PistenBully and the stopped with theengine uptheoil Top Use dipstick the oildipstick. markson min. and max. The oillevelmustbebetweenthe onlevel,horizontalground. standing
CHECKS
5 ENGINE tocheck the engineoillevel.
OIL
LEVEL 5
113/151 OperationChecks Checks Use Safety Technical Overview data DAILY CHECKS
CHECKING HYDRAULIC FLUID LEVEL
Check the hydraulic-fluid level and top up only when warm.
The fluid level must be between the min. and max. marks.
Use only approved hydraulic fluid (see fluids and lubricants specification).
114/151 400.10815.2.de 400.10815.2.de Non-compliance can result in the diesel engine losing power. losing canresultinthedieselengine Non-compliance Air-intake flap set toindu quires replacement. upassoon Air-filter symbol lights of icedamagingtheblades of theturbocharger. particles up and icing air filter the result in can Non-compliance partment Air-intaketo inductaircom- setflap fromengine A D DJUSTING AILY At temperatures above 0 For powdersnoworfinedust
CHECKS
RECIRCULATED ° C ct freshoutside airct from as theairfiltericesuporre- - AIR
INTAKE 2 = Fresh air (cold air) air (cold = Fresh 2 compartment engine from = Airintake 1 load platform/cab. for raising/loweringthe The controlfor adjusting theair-int Adjusting air-intakeflap 1 Turn the lever to the left and push Turn thelevertoleftandpush it inall the way in thedi- Turn thelevertoleftandpullitindirectionindi- Turn the lever to the right to lock. rightto tothe thelever Turn arrow. the cated by lock. to right the to lever the Turn the arrow. indicated by rection 2 ake flap is beside the control
115/151 OperationChecks Checks Use Safety Technical Overview data WEEKLY CHECKS
CHECKING ELECTRICAL SYSTEM VISUAL INSPECTION
Check the lights and flashing indicators and the rotating Visually inspect the tracks and sprockets, check for tire beacon system; repair or replace components as neces- damage. sary. Always comply with the instructions for working on Visually inspect the fasteners of the auxiliary driven imple- the rotating beacon system (high-voltage system). ments (locking pins, bolts, nuts). Replace defective bulbs and fuses. Visually inspect the hydraulic system (drive hydraulics and Check the wipers, horn and back-up alarm. hydraulics for auxiliary driven implement), hydraulic lines, connectors, hoses, hydraulic cylinders for leaks and chaf- ing.
Never operate the PistenBully if the warning lights and rotating PistenBully with diesel particulate filter beacon system are not fully functional. Check the exhaust pipe for soot deposits. Check formation of smoke during operation. Stop operation during the exhaust of black smoke / Inform the service.
116/151 400.10815.2.de 400.10815.2.de isdefective. brake if parking the vehicle the operate Do not rpm. 2000 and brieflyaccele "Forward" to lever propulsion or the switch direction-of-travel Set the C W HECKING Start the engine and apply the parking brake:Indicatorlight applytheparking Start theengineand Check thedrivebelt fan,alternator); on theengine(engine Make sure there is no-one inthedangerzone. Make surethereisno-one Perform allthedailychecks. Perform clustermustgoout The indicatorlightintheinstrument manufacturer). (seethemanualsuppliedbyengine free ofdamage make sure thatbelttensioniscorrectandthe when isreleased. when the parkingbrake comes on. EEKLY The PistenBully must remain motionless.
CHECKS
PARKING rate the engine to approx. rate theengine
BRAKE
117/151 OperationChecks Checks Use Safety Technical Overview data WEEKLY CHECKS
TRACK TENSION TEST DRIVE
Checking track tension Check operation and test all instruments and indicators. Check running gear and engine / transmission unit for ab- - Vehicle parked on horizontal, snow-covered ground. normal noises. - No load on vehicle and auxiliary driven implements Visually inspect for smoke at the exhaust. lowered. Equalise track tension by driving backwards and for- wards. Check the air filter element if the exhaust is smoky.
Track tension is correct when the upper section of the track can be lifted approx. 40 – 50 mm midway along its run.
Check the condition of the track cleats, track lacings, tire guides and backing plates, replace damaged components.
118/151 400.10815.2.de 400.10815.2.de Tightening torques C W PistenBully 400 T HECKING Check the wheel fasteners and check tyrepressures. fastenersandcheck wheel Check the EEKLY YPE
CHECKS
WHEELS 300 Nm T ENSIONING
AXLE 300 Nm 300 D RIVE
AXLE 7.0 bar bar 7.0 A IR
PRESSURE , DRIVE
AXLE
119/151 OperationChecks Checks Use Safety Technical Overview data WEEKLY CHECKS
TRANSFER CASE 1 Tilt the load platform.
Use the dipstick to check the engine oil level. Brass cap 1 w/f 36; measure with oil dipstick set on (screw threads not engaged). The oil level must be between the min. and max. marks on the oil dipstick.
Use only approved oil for transfer cases (see fluids and lubricants specifications).
120/151 400.10815.2.de 400.10815.2.de E E NTERING NTERING Walk right round the vehicle and make sure that danger thevehicleandmakesurethat the round Walk right Take a grip on steering wheel on steering Take agrip Press the door lock. The driver's door opens. Step ontothetrack. grabhandle gripon Always takeafirm Before enteringthecab,complete the dailychecksand Fully raisearmrest grabhandle gripon Always takeafirm door when thevehicle. door when entering tasks. maintenance door. zone isclear ofpersonsandobjects. driver's seat when opening the door. The door opens suddenly. opens door The door. the opening when careful particularly be slope, a on parking When Note: the handle in order to step onto the track. the orderstep onto the handlein to and out of driver's cab. Always take a firm grip on ofslipping Risk – DRIVING 3 . on the track when climbingon thetrackwhen into – 4 and swing yourselfintothe swing and EXITING 1 2 ofthedriver's ofthedriver's Adjust the seat and the steering wheel toanergonomically steering the Adjust theseatand Visual check: Fasten theseatbelt. door. Close the brake applied. brake parking switchin"Neutral"position, Direction-of-travel armrest is not loweredtotally). isnot armrest when ofoperation USA-out chines withsticks,version (ma- armrest ofthe lowering position.Total comfortable
121/151 OperationOperation Checks Use Safety Technical Overview data ENTERING – DRIVING – EXITING
When the intake-air preheating light goes out: STARTING THE DIESEL ENGINE Start the engine
Do not depress the accelerator - Operate the starter until the engine is turning at 700 rpm The use of proprietary starting agents (such as Startpilot, for - Maximum duration of start attempt 30 seconds example) is prohibited on account of the risk of explosion. Engine refuses to start? WARNING! Immediately repeat the start attempt (do not repeat the pre- heating procedure). Duration of start attempt, max. 30 sec- Risk of poisoning from exhaust gases. onds Do not leave the engine running unattended or run- ning in an enclosed space. If it is necessary to repeat the reheating Start procedure procedure:
Ignition ON Ignition OFF Wait 5 - 10 seconds
Ignition ON Depending on the ambient temperature, the intake-air pre- heating light goes out after approx. 2 seconds (no preheat- ing) or within 30 seconds (maximum preheating time).
122/151 400.10815.2.de 400.10815.2.de - Disconnectthebatteryfromon-boardelectrics. - Proceedwithcautiontothenearestworkshop - Ceaseoperation operation: lightforair-intakepreheatinglightsupduring If thewarning toelectronics Damage to approx.engine 3minutesthe afterstarts. The warninglight forair-intake preheatingstay litforup may Situational help E NTERING – DRIVING – EXITING W Air temperature below –20 below Air temperature 0 above Air temperature ARMING - Drive with the engine operating inthepartial- engine operating the Drive with UP The enginecanbe operated at full load as of The enginecanbe operated at full load as of Drivein thepartial- engine operating the with Allow thediesel toidleforapproxi- engine Allow thediesel toidleforapproxi- engine mately 6minutes. mately 3mins. a coolanttemperatureof+80 a coolanttemperatureof+80 load range. load range.
PHASE 0 C to –20 C to 0 C 0 C O O C. C.
123/151 OperationOperation Checks Use Safety Technical Overview data ENTERING – DRIVING – EXITING
INSTRUCTIONS FOR ENGINE BREAK-IN
Up to 40 operating hours
Operate carefully up to max. 3/4 full-load speed After 40 operating hours
Gradually work up to full load
ENGINE SPEED RANGE
On steep gradients
Increase engine speed.
Operating in extremely difficult terrain
Use the potentiometer to reduce driving speed.
The speed of the auxiliary driven machinery remains unchanged.
124/151 400.10815.2.de 400.10815.2.de and adjust the hydraulic ratio inaccordance with load, sothat speed set in response to movements of the accelerator pedal theWhen vehicle ismoving,electronics the engine monitorthe engine speed increases. The PistenBully accelerates steplessly toitsmaximum speed as D E NTERING RIVING Before driving,Beforeno-onethe is in alwayscheckthatthere beacon. on therotating Switch Press the direction-of-travel switch to the position corre- theposition switchto Press thedirection-of-travel Depress the accelerator pedal to increase engine rpm to rpmto engine increase pedalto accelerator the Depress Release parkingbrake. sary ifvisibilityispoor. asecondpersontogivedirectionsisneces- of assistance isclear.The machine sure thattheareabehind Make thevehiclewhenreversing. hind remain undertheobligationtocheckcarefullyareabe- thevehicleis fitted Even though with a back-up alarm, you reverse. positionto switchtothe tion ifyousetthedirec- alarm)sounds signal(back-up audible totravel.An inwhichyouwant tothedirection sponding above drive away speed: The PistenBully drives away. above driveawayspeed:ThePistenBullydrives thevehicleon thetracks. at or or danger zone, in other wordsin the immediate vicinity of – DRIVING – EXITING filter particulate ofthe diesel cleaning Optimal PistenBully withdies its own length. lockis applied steering tothewheel. The PistenBully turns in hydraulics switchto propulsion vehicle changes. engine speed remains constant and only the speed of the i Avoid long periods of idle speed. periodsof Avoid long highservice and Driving withlowdiesel speed engine Observe all instruments whendriving. Observe allinstruments Maintenance ofthedieselparticulatefilter Maintenance loading. When you turn, bear in mind that the left and right mind thattheleftand bear in turn, When you el particulatefilter counter-rotation justbeforefull
125/151 OperationOperation Checks Use Safety Technical Overview data ENTERING – DRIVING – EXITING
Engine oil pressure Switch the ignition OFF and wait for approximately 20 sec.
The warning light for the diesel engine comes on during the Switch the ignition ON and wait for approximately 30 sec. start procedure and if oil pressure drops. Start the engine.
Engine operating temperature Battery charge indicator Gauge showing that temperature is too high? If the battery charge indicator lights up when the engine is Determine the cause, for example: running, the alternator is no longer charging the starter - Gauge in working order batteries. Determine the cause, for example: - Not enough coolant in system - Loose cable connectors - Foreign matter clogging radiator on outside - Generator dirty - Check belt tension - Drive belt slipping or broken - Check visco fan Hydraulic fluid level warning light Fuel supply Occasional flashing on descents is not indicative of a fault. Continually monitor the fuel supply and fill up in good time. This precaution will prevent the fuel supply from failing on a gradient, Telltale light for parking brake which would mean the engine stopping inopportunely. If the indicator lamp lights up, check the parking brake. Diesel tank empty! The fuel system has drawn in air! Situational help Refuel the vehicle (see the section entitled "Exiting") PistenBully slows down on account of lack of propulsive power Switch the ignition ON and wait for approximately 30 sec. The fuel primer pump switches on. Use the potentiometer to reduce the speed of the auxiliary. 126/151 400.10815.2.de 400.10815.2.de motion. whilethevehicleisin if theparkingbrakeisapplied stop complete PistenBullywillbrakesharplytoa The standstill. onlytokeepthevehicleata Use theparkingbrake brake lever in the driver's cab actson the driving wheels. A parkingbrake(spring-loaded brake) operated byaparking- pull-away speed. The PistenBully will come toa stopif engine speed dropsbelow hydraulic ratio causesthe vehicle to slow down. erator pedal;changetheand engine inthe lowers speed You reduceengineeasing speed by thepressure ontheaccel- The hydrostatic drive brakes thevehiclewithout causing wear. B E RAKING NTERING WARNING! - – STOPPING DRIVING – EXITING andthenswitchoff. load range inthepart- 2minutes approx. atfullload.Drivefor been run engineafterithas switchoffthediesel Do notimmediately overheating: Turbocharger -riskof S TOPPING Remove ignition key and lockthecab. ignitionkeyand Remove Switching offengine. Set engineidlespeedtobelow800rpm. andrearauxiliaryimplements, Lower front levelsurface. thevehicleonafirm, Park itisclearlyvisible. Park thevehiclewhere Turn the ignition keytothe theignition Turn ofthetrack. - Relievethetension theparkingbrake. - Apply neutralposition. - Directionoftravelswitch in - Switchoffthetiller.
AFTER
USE 0 position.
127/151 OperationOperation Checks Use Safety Technical Overview data ENTERING – DRIVING – EXITING
EXITING 2
Fully raise the steering-wheel column and the armrest. 3 Be particularly careful when opening the door if the vehicle is parked on a gradient. The door opens suddenly. The procedure for exiting the vehicle is the reverse of the entry procedure.
Then remove as much snow and ice as possible from the WARNING! tracks, sprockets and wheels to prevent them freezing fast, Danger of slipping on the track when in order to avoid damage when the machine is restarted. entering and exiting the driver's cab. Secure raised auxiliary driven implements. Always take a firm grip on the handle in Connect coolant preheating (optional extra). order to step off the track.
WARNING! 110/220 V adapter 3 provides a means of preheating the coolant system with the thermostatically controlled preheater, Risk of explosion due to build-up of gas in fuel tank. or of preheating the hydraulic fluid with a heater available as Keep all possible sources of ignition when an optional extra. clear when the vehicle is being refuelled.
Refuel 2 the PistenBully immediately after operation, in or- der to prevent condensation forming in the tank. 128/151 400.10815.2.de 400.10815.2.de the parking after immediately preheating Undertake starting. cold not improve does starting to prior preheating of 1 -2hours vehicle. E NTERING Use only cables that comply with the applicable regula- applicable the with thatcomply cables only Use tions in the country of of use. inthe country tions – DRIVING – EXITING
129/151 OperationOperation Checks Use Safety Technical Overview data TOWING AWAY / TOWING HITCH
TOWING AWAY / TOWING HITCH
Towing the PistenBully Attachment weights, towing hitch Only trained, qualified persons are permitted to operate the Permissible towed weight emergency release of the parking brake. Max. towed weight 3000 kg. Towing a PistenBully is an operation requiring extensive safety measures. Please consult your nearest Service Sup- port Centre. Risk of collision between trailer and propulsion track. Do not pivot the device carrier.
The towed load must be secured to ensure that it cannot skew beyond the maximum permissible off-centre angle on descents or when inclines are crossed. 130/151 400.10815.2.de 400.10815.2.de iarisation with the driving char iarisation withthe famil- adequate as providing in itself considered be to stances circum- any under isnot and overview asan merely intended i i D RIVING Quantity is not as important as quality and economy.. and asquality Quantity isnotasimportant The section entitled "Driving tips and information" is is information" tipsand "Driving entitled section The
TIPS
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INFORMATION acteristics of the PistenBully.
L OW Variably adjust the downforce of the tiller comb by by comb tiller the of downforce the adjust Variably Variably adjust tiller depth Adjust shaftspeed Adjust tiller Diesel engine rpm much snow asisabsolutelynecessary. snow much controls. observingthe gaugeand using thepushbutton turning thepotentiometer. snow conditions snow lowest down-force setting the Use potentiometer. and joystick the of means torque 1519 Nmat1500rpm.
FUEL Set the depth sothatthetillerremovesonlyas Set thedepth
CONSUMPTION green green zone on rev.counter.Max. to suit snow conditions conditions snow suit to to suit snow conditions conditions suitsnow to that is compatible with that iscompatible
by by
131/151 OperationOperation Checks Use Safety Technical Overview data DRIVING TIPS AND INFORMATION
Over and above these changes, which take place naturally and EDIUM SNOW M cannot be influenced (they are caused by wind pressure, In the atmosphere, snow forms from water droplets at temper- freezing and evaporation producing a loss in volume, whereas atures of at least –4° C. differences in the temperature of the air trapped close to the ground and the external air tend to produce an increase in Ice crystals in widely varying shapes form: volume), it is important to bear the following in mind: Always work so as to cause as little damage as possible to the Hailstones are snow crystals enlarged by the adhesion of ice; snow. The aggressive action of driven implements such as a they are usually spherical or tapered in shape. tiller damages the snow crystals; these damaged crystals have lost their ability to mesh as a loose blanket, tending instead to Hoarfrost or rime forms from water vapour or precipitation ball and form gritty snow (often at entrances to garages, on chilled objects (fences, bushes, surface of snow). approaches to lifts, bottlenecks).
White frost develops when the wind carries chilled droplets of water onto solid objects. Preparing fresh-fallen snow
Fresh-fallen snow initially forms an airy structure of loosely Fresh-fallen/powdery snow consists of crystals that are loosely intermeshed snowflakes. attached to each other and which therefore trap a great deal The original shapes soon disappear, however, and the indi- of air. The process of preparation inevitably expels some of this vidual flakes are no longer recognisable only a few days after air and packs the crystals more tightly together. This gives the falling. surface layer of snow the ability to bear weight.
132/151 400.10815.2.de 400.10815.2.de not powderysnow,can be produced from ice. theirof abilitytocohere.Thisis damages the ice crystals, sothey lose a considerable proportion of gritty snow together. Breaking down the lumpy snow also shapes thesurface andawaterfilm forms toholdthegrains which fillssurfaceof therun;finisherthein thehollows The teeth of the tiller break th vehicle. the rearof the on mounted tiller a with work to is well look run a ski making of freezes and forms lumps - If outdoor temperatures are correspondingly lowthe snow produces a durable surface. with relativelyfresh-fallen snow (snowcrystals)andthis Preparing slopes like this isa pr humps and hollows form and the run becomes bumpy. period oftimeskiers Over a them. beside softerspots the and ice to melt and form a film of water, and this produces sheets of skisThe overofthe crystalsthe surface frictionof some causes Bumpy runs D RIVING
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AND when this happens the only way the only thishappens when break down the topmost layer – the topmost break down
the reasonwhyonlygrittysnow, e lumps down into gritty snow, ocess inwhichold snowismixed INFORMATION
aged, the less will be their ability to cohere. to ability their be less will the aged, dam- crystals the and is turned ice the frequently more The from deepercrystals inthesnow. otherwise in good condition can be broken up and mixed with ice tomake the slope skiable. Sheets oficeon slopes that are Consequently, itisadvisable only toroughen the surface ofthe water -andth it willcoherewith breaking up the ice needs fresh-fallen snowtocohere, orelse thickness or fresh snowfalls. The gritty snow produced by Do not break up an iced slope unless the ice isof adequate Iced slopes/sheetsofice levels. deeper from snow old unused with snow or fresh-fallen with rial mate- this mixing by only be formed can slope ski A durable iswill again cause icetoform.
133/151 OperationOperation Checks Use Safety Technical Overview data DRIVING TIPS AND INFORMATION
Wet snow/slushy snow Extremely slushy snow in spring
The relatively large amounts of moisture and the formation of It is advisable to use the side wings, because the tiller can a film of water on the finisher can produce a relatively hard produce edge walls as it passes through the snow. We also offer surface, which inexperienced skiers in particular find difficult. an extra-wide side wing for more efficiency when used in In order to counteract this effect, Kässbohrer has developed a combination with the rear frame steering – this also means that bolt mechanism for tilting the rear-mounted tiller comb. In the machine can prepare on one side at a time. combination with special finishers, this machine can change If a satisfactory run cannot be prepared in slushy snow, is the uniform surface structure and produce a "powdery-snow" might be advisable to wait two or three hours to allow the effect. temperatures to change. Work on preparing slopes at higher altitudes can proceed in the interim.
Allow the snow to set-up, so that crystals can form.
134/151 400.10815.2.de 400.10815.2.de hand. before- question in area the in was avehicle because merely in operate to safe is it that Each situationmustbeassesse H = Downgrade force of gravity S =Centre driver. the prevailing conditions, and on the skill and ability of the dependenton the wayinwhich thevehicleis used, onload, on there is a risk of the vehicle toppling. The limits are heavily tracks as possible is in contact with the ground, as otherwise the driver toensure that as mu another factorinfluencing climbing ability. Itisimportant for mach of thesnow.The adhesion The climbingabilityof thePistenBullydepends on thelimitof C D LIMBING RIVING
TIPS ABILITY
AND a certain area at any given time time any given area at a certain
INFORMATION ch of the surface area of the area surface ch of the d withcare. Never assume ine's centregravity of is
operationsin difficult terrain. with thevehicleselvesequipment and before undertaking Inexperiencedparticular, drivers, in familiarise should them-
135/151 OperationOperation Checks Use Safety Technical Overview data DRIVING TIPS AND INFORMATION
DRIVING WITH THE PISTENBULLY Driving: on upgrades Always study upgrades and look for the easiest route; do not start at the steepest point. Frequently, it is better to detour to the highest point of a slope via an alternative route and then The basic rule is: Do not use the vehicle until the snow is work from the top down to prepare the first part of the run. deep enough to prevent damage to the underlying vegeta- Whenever possible, negotiate slopes by following the line of tion. fall and by keeping steering movements to a minimum. Do not overrev the engine: use only as much power as is neces- The objective in preparing a ski-slope is to achieve visually sary; note the level of traction. Overrevving will cause the tracks excellent slope quality: to slip, with the result that the vehicle will dig into the snow. If Build up supplies of snow in good time at critical points, so that the tracks start to dig in stop immediately and try a different line. reserves will be available to make up for the snow removed from the slope. Holes and snow heaped up by movement and by manoeuvring must be smoothed out with as little delay as possible. Digging in ruins the ski-slope and destroys the surface If speed is excessive, the tracks will throw snow out sideways beneath the snow. and over the auxiliary mounted implement onto the prepared surface. Turning Regularly remove snow from the load platform. Otherwise, the In order to avoid damaging the surface of the ski-slope, you increase in weight will result in higher fuel consumption. must turn at or beyond the edge of the prepared slope. You Always keep the engine revving in the most economical range should, of course, use areas that are free of vegetation (forestry (indicated by the green zone on the tachometer). plantations and the like) for this purpose. Always keep the front-mounted and rear-mounted auxiliary The drive electronics adjust speed to suit engine rpm. driven implements raised when turning. 136/151 400.10815.2.de 400.10815.2.de frontbladefromfrom diggingtraction.losing inandthetracks the vehicle under control as it tips forward. This will prevent the Reduce speed as you crestrises, in order to ensure that you have that bothtracks are turning. steeringRestrictto aminimum. movementsyour sure Make descent. reduce thespeedof to speed potentiometer is not dragged downhill by the action of the tracks. Use the overrev, the vehicle does notdrif precautionenablewillto ensure that you theengine does not Always maintain a moderate speed on downgrades. This Driving: ondowngrades the trackcleats. rotatingtracks places veryandbeltson therubberstrains high turning in exceptional situations only. Turning with counter- adequate depth.is advisable It methodto employ of this you should manoeuvrewhenonlythisinis thesnow way of the tracks.This causes thevehicledigextent,tosome in to so counter-rotating by length own can turnthevehicleinits You Turning withcounter-rotatingtracks D RIVING
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INFORMATION t outofcontrol,andthesnow
the frontbladetore the tiller shaft's direction of rotation and carefully employing You cancounteract slippage alonglinetheby reversingof fall engine speed in the process. longitudinal axis back onto the line of fall. Briefly increase rotating the tracks if necessary, in order to bring the vehicle's the steering wheel tothe right orleft, as applicable), counter- lineimmediately offall),you must opposite apply lock(turning an angle to left orright (vehicle's longitudinal axis drifts off the If thePistenBully startsslipping ona downgrade and driftsat - there are no skiers in the danger zone. that: are sure you unless downgrade a negotiate not do Invariably, - yourrunout at thebottomof - theadhesion of thesnowisadequate. safe. -stabilise the vehicle. theslopeadequate is and
137/151 OperationOperation Checks Use Safety Technical Overview data DRIVING TIPS AND INFORMATION
Counter-rotating tiller shaft: PREPARING THE SKI-SLOPE A PistenBully with electronic tiller control enables you to set the When preparing a slope, always make sure that the side tiller shaft to rotate either forward (standard direction of rota- finishers overlap onto the prepared surface, in order to ensure tion) or backward. a smooth transition from one pass to the next.
Notes on depth of tiller It can be helpful to have the tiller counter-rotate, for exam- ple as an additional brake in very steep terrain. The tiller has to be set to the correct depth in order to achieve: - A visually attractive ski-slope. - Retain the firmness of the slope's substructure. - Operate within the most economical range. - Apply least load to the PistenBully and the tiller. Effects of incorrectly set tiller depth: - Tiller shaft depth too high: Tiller quality output is negligible. - Slope is not contoured in areas of hard snow. - Tiller shaft depth too low: Insufficient snow processing, so the snow is forced out of the tiller at the side and forms an edge wall. - The snow crystals' ability to cohere and the quality of the slope's substructure are impaired. - More power input necessary – less economical.
138/151 400.10815.2.de 400.10815.2.de Vehicle comes almost to a stop: toa almost comes Vehicle not satisfactory: slope prepared of appearance Visual right: and left on forming walls Edge Summarised countermeasures Errors inoperationandcountermeasures - Tiller shafts stopped –clogged, jammed,frozen. - Tiller shafts are counter-rotating. - Cylinder of carrier plate significantly out of adjustment. - Speed of shaft rotation too high. - Tiller depth too low. - Nosmoothsurface withthefron Vehicle travelling- fast. too Balllocked handle- not inposition(floatingposition). - Speedof rotation toolow. - Tiller depth set too high (adjust height setting). - Side finishers retracted. - Tillershafts not rotating. - Cylinder of carrier plate out of adjustment. - Downforce settingselected - Tiller depth set too low. - Speed of shaft rotation too high. D RIVING
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instead of floatingsetting. INFORMATION t blade (tiller is on ahump). is switched on: is switched tiller the when vehicle in perceptible vibrations Severe - Imbalance means vibration – screws workloose, bearings - Frozen with snow – remove. - Shaft imbalanced, tooth missing – have repairs carried out are damaged – have the imbalance rectified. by specialists.
139/151 OperationOperation Checks Use Safety Technical Overview data NOTES
140/151 400.10815.2.de 400.10815.2.de to leavefront bladethe installed times.at all prevent the vehicle from slipping. Consequently, it is advisable through fresh-fallen snowand it can be used as a brake to snow clear.front The blade isalso very useful forworking uphill preparation.ideal Itis forsmoothing bumpydozing runsand A front blade is essential for modern ski-slope upkeep and plate. rearcarrier raise fully blade), front the with snow pushing when (i.e. work dozing During load. to due wear Material Correct usage: - Making a location line. - Smoothing bumpy ski slopes. - Smoothing heavily worn ski slopes. - Useof the front blade on steep slopes covered with fresh- F fallen snow. RONT
BLADE irregularities. adjust automaticallment to equip- the enable will asthis blade, ofthe front in mounted roller snow leader a have to is configuration ideal The slope. the front blade. This is the mostdependable wayofsmoothing out to adjust the depth ofcut, instead of raising and lowering the othercylindertheto usetheroll side.best this In case,too,itis push the snow forward off the bump and into the hollow on height and the float function switched off, sothat the blade will Approachapproximatelywith thebladelarge at half bumps the snow. angle of attack is too steep the front blade will tend todig into Exercisegreat care when setting theroll cylinder, because ifthe The blade's angle of attack is set bymeans of theroll cylinder. surface, without being pushed downward bythe hydraulics. means that thefront blade applies only its own weight tothe the frontblade inwhatis known asthe"floating" position. This to use methodor wavesThebumps ofsmoothing is best low Smoothing bumpyskislopes y to compensate for surface
141/151 OperationOperation Checks Use Safety Technical Overview data FRONT BLADE
Making a location line Smoothing heavily worn ski slopes
The best way of doing this is to approach the downslope at an One consequence of modern skiing techniques is that the skiers angle from above and, with the pusher blade swivelled to one carry the snow progressively further down the slope, finally side, doze a flat location line in the snow. depositing it toward the bottom of the slope. The objective, therefore, is to restore the snow to as uniform a depth as It is advisable to start with no more than a small amount of possible over the entire length of the slope. This entails pushing snow, picking up more and more snow as you proceed along the snow back up the slope from the bottom. If necessary, the line. This should enable you to complete the full length in winch the PistenBully into position. a single run. Pivot the front blade to an angle at which the snow can slide The snow you push out on the downhill side inevitably widens along it toward the inside. If you are using a 12-way front blade your location line, increasing the margin of safety. you can set the wings to an angle that best suits this method of handling the snow. The front blade can be adjusted in a Use of the front blade on steep slopes number of ways to the position that best suits the terrain. The covered with fresh-fallen snow end result is efficient transportation of the snow to the parts of the slope where it is needed. When you prepare fresh-fallen snow you need the front blade Less experienced drivers in particular should bear in mind that not only to push the snow, but also to distribute the weight and transporting large amounts of snow quickly is not always the way apply pressure to the surface of the snow. You can use the front to achieve the best results. The driver has to assess the terrain blade to help the vehicle climb steep slopes by stopping just and decide whether it would be advisable to push snow downhill, before the PistenBully digs in, and reversing with the front or whether this might result in even more snow being lost. blade lowered. This will smooth out the step. Raise the front A well-prepared slope is free of heaps of snow, does not have blade and drive forward a few meters before repeating the walls along the edges, and is contoured so as to be attractive procedure; this is one way of climbing difficult slopes. to the eye. 142/151 400.10815.2.de 400.10815.2.de Correct usage: ParkBlade ported on theforks. funboxescan betrans- rails andsuch as Funpark obstacles F Make sure there is no-one in the danger zone. inthedanger Make surethereisno-one /retracting theforks. when extending Risk ofinjurybycrushing: RONT The ParkBlade isdesigned forconstructing and maintain- ing funparkscrosses. andboardering WARNING!
BLADE The forks must not be moved /raisedsidewise! be The forksmustnot load! side by caused damage Fork ParkBlade
143/151 OperationOperation Checks Use Safety Technical Overview data ALPINFLEX TILLER
The specially designed tiller shafts and finishers ensure optimum snow distribution, with the result that the finished run has attractive, end-to-end contouring irrespective of the oper- 1 ating conditions.
Side finishers (optional)
Side finisher 1 has hydraulic tilt control, facilitating overlap with the prepared part of the run and helping prevent surface The AlpinFlex tiller has been evolved as an even more versatile irregularities on the slope. and practical snow handler.
It can tilt to angles up to 200, so it adapts to the natural contours of the terrain.
The two-part tiller features separate three-point mounts that enable each section to follow the contours, so the finished pass resembles a naturally formed slope.
The two tiller shafts are driven by a hydraulic motor and are coupled by a synchronising universal shaft, in order to ensure that both shafts operate at the same speed and the same torque.
144/151 400.10815.2.de 400.10815.2.de Cancelling "set torigid"(unlock) Hydraulic actuationfor"settorigid" terrain),Alpinflexthecan set you position.to therigid tiller If you want toproduce a flat (not following the contours of the Setting theAlpinflextillertorigid position A LPIN Press the Set downthe Alpinflex tiller on a firm, level surface. Set down the Alpinflex tiller on afirm,levelsurface. theAlpinflextilleron Set down Press the button until thehydr Press thebuttonuntil tracted. inder is fully extended. isfully inder F Bottom sectionpressed:Bottom Tillerposition inrigid Top section pressed: Tiller unlocked Tiller inrigidposition LEX Tiller, settorigid
TILLER button until the buttonuntilthe hydrauliccyl- aulic cylinder is fully re- isfully cylinder aulic (FunPark) (FunPark) Cancelling the"settorigid"function (standard) Manual actuationfor"settorigid" Pin Pull thepinandsetadjustinglever Insert the retainer to secure the pin. securethe to theretainer Insert Lock pin 1 and adjusting lever andadjusting 1 and install the retainertosecure. andinstallthe 2 in position. inposition. 1 2 1 to position. 2 2
145/151 OperationOperation Checks Use Safety Technical Overview data ALPINFLEX TILLER
Snow-flap adjuster for tiller
The snow-flap adjuster enables you to vary the snow path An attempt to operate the tiller at too high a speed will through the tiller by means of pushbutton controls. divert too much output power from the engine, with the result that the engine will not be able to develop enough power to propel the PistenBully. Snow flap retracted: When descending extremely steep gradients, the tiller With the snow flap set to this position when the vehicle is used shaft can be set to counter-rotate so as to help stabilise on an ice-covered slope, for example, chunks of ice will be the PistenBully. forced to pass the tiller shaft several times and this will help ensure optimum processing.
Snow-flap adjuster for tiller Pressed = Extend / retract snow flap Situational help Snow flaps extended to different settings? Remedy: Press and hold down the button for 1 - 2 minutes. The cylinders are equalised.
When ascending, always set the tiller shaft to forward operation and use a suitable working speed until the ski slope has been prepared to specification. 146/151 400.10815.2.de INDEX
Number Charging the battery ...... 106 Checking coolant level ...... 112 24 V socket ...... 39 Checking electrical system ...... 116 A Checking engine oil level ...... 113 Accelerator ...... 38 Checking hydraulic fluid level ...... 114 Additional weights ...... 32 Checking parking brake ...... 117 Adjusting Nordic tracking tiller depth ...... 48 Checking wheels ...... 119 Adjusting recirculated-air intake ...... 115 Climbing ability ...... 135 Adjusting tiller depth ...... 48, 59, 67 Clock ...... 39 Air temperature ...... 123 Closing the deck railing ...... 91 Air-filter monitor ...... 47 Connecting hydraulics ...... 89 AlpinFlex tiller ...... 144 Connecting jump leads ...... 108 Attachment weights, towing hitch ...... 130 Coolant level below the minimum level ...... 47 Auxiliary driven machinery at rear does not Coolant temperature, diesel engine ...... 39 lift automatically for reversing ...... 49 Counter-rotating tiller shaft ...... 138 B D Battery ...... 108 Daily checks ...... 111 Battery charge indicator ...... 40 Data loss ...... 108 Battery master switch ...... 108 Diagnostics overview ...... 80 Battery-charge indicator ...... 126 Diesel fuel ...... 39 Bumpy runs ...... 133 Diesel tank empty ...... 126 Direction indicators ...... 45 C Direction-of-travel pushbutton ...... 36 Cab heating ...... 17, 39 Downgrade force ...... 135 Cancelling the "set to rigid" function ...... 145 Drive hydraulics for auxiliary equipment front / rear ...... 50 Centre of gravity ...... 135
400.10815.2.de 147/151 INDEX
Driving ...... 125 H On downgrades ...... 137 Halogen-xenon ...... 101 On upgrades ...... 136 Heated windshield wipers ...... 37 Driving with the PistenBully ...... 136 Heater blower, steplessly adjustable ...... 39 Drum winch ...... 51 High-beam headlight / parking light H7 ...... 100 E High-priority fault ...... 81 Edge walls forming ...... 139 Horn ...... 45 Emergency mode, propulsion electronics ...... 79 Hydraulic actuation for "set to rigid" ...... 145 Engine diagnosis ON / OFF ...... 40, 48 Hydraulic fluid level warning light ...... 126 Engine oil pressure ...... 126 I Engine oil pressure indicator ...... 41 Iced slopes/sheets of ice ...... 133 Engine operating temperature ...... 126 If it is necessary to repeat the reheating procedure ...... 122 Engine speed range ...... 124 Ignition lock ...... 39 Engine-fault check ...... 41, 48 Indicator for engine management system ...... 40 Entering – driving – exiting ...... 121 Installing auxiliary driven implements ...... 88 Exiting ...... 128 Instructions for checks and maintenance ...... 111 Extremely slushy snow ...... 134 Instructions for engine break-in ...... 124 F Instrument displays ...... 39 Fault-code displays ...... 80 Intake air preheating ...... 40 Front blade ...... 141 J Front equipment carrier in floating position ...... 45 Jump starting ...... 107 Front spotlight ...... 100 Front wiper ...... 46 K Front worklights ...... 44, 100 Key to fault codes ...... 83 Fuel supply ...... 126 Knurled knob for adjusting tiller shaft speed ...... 36, 69 148/151 Knurled knob for driving speed ...... 36, 69 400.10815.2.de INDEX
L Parking lights ...... 100 Parking lights / driving lights ...... 44 Lights ...... 100 Power Angel ...... 67 Lock for steering-column adjustment ...... 38 Preparing fresh-fallen snow ...... 132 Low fuel consumption ...... 131 Preparing the ski-slope ...... 138 Low-beam headlight H7 ...... 100 Press tiller into snow / relieve pressure ...... 51 Low-priority fault ...... 82 Pushbutton, tiller drive ON / OFF ...... 36 M R Making a location line ...... 142 Manual actuation for "set to rigid" ...... 145 Raise / lower tiller ...... 51 Manual throttle control ...... 70 Raising tracker plates ...... 48, 49 Medium-priority fault ...... 82 Ready for operation / driving ...... 39 Miniature relays ...... 105 Rear deck railing ...... 91 Most economical engine speed range ...... 124 Rear light ...... 100 Multifunction switch ...... 35, 51 Rear window heater ...... 46 Rear worklights ...... 44, 100 N Reel in/pay out winch cable ...... 51 Nordic-trail tracker plates ...... 73 Release seat-belt lock, cockpit ...... 51 Relieve track tension ...... 47 O Removing the auxiliary driven implement ...... 90 Offset front blower to either side...... 45 Replacing fuses ...... 103 Opening the rear deck railing ...... 91 Reset acoustic warning, strand monitor ...... 51 Outdoor temperature ...... 39 Retracting side finishers ...... 48 P Revolution counter ...... 39, 40 Rocker switch / pushbutton ...... 45 ParkBlade ...... 46, 143 Rotary beacon ...... 100 Parking brake ...... 38 Rotating beacon ...... 44, 100 Parking brake indicator ...... 126
400.10815.2.de 149/151 INDEX
S T Setting the Alpinflex tiller to the rigid position ...... 145 Temperature control, steplessly adjustable ...... 39 Side finishers ...... 59, 66, 144 Terminal ...... 73 Side worklights ...... 100 Terminal display ...... 77 Side-mounted flashing indicators ...... 100 Test drive ...... 118 Side-window heating / exterior-mirror heating ...... 46 Tightening torques ...... 119 Smoothing bumpy ski slopes ...... 141 Tiller forward operation / counter-rotating ...... 49, 52 Snow types ...... 132 Tiller in rigid position ...... 49, 145 Snow-flap adjuster for tiller ...... 146 Tiller ON - OFF ...... 70 Snow-flap position for tiller ...... 39 Tiller snow-flap ...... 49 Spotlight ...... 44 Tiller-depth indicator ...... 39 Spotlight ON / OFF ...... 45 Tilting the driver's cab ...... 94 Start procedure ...... 122 Tilting the driver's cab and load platform ...... 97 Starting ...... 39 Tilting the load platform ...... 96 Starting the diesel engine ...... 122 Topping up battery fluid ...... 106 Starting the engine ...... 122 Topping up fluids and lubricants ...... 111 Stick optional ...... 68 Towing hitch ...... 130 STOP button ...... 37, 69 Towing the PistenBully ...... 130 Stopping / exiting ...... 20 Towing vehicle ...... 130 Stopping after use ...... 127 Track tension ...... 118 Swivel winch boom ...... 51 Track width, Nordic trail ...... 49 Swivelling rear equipment carrier ...... 36 Tracker-plate spacing ...... 49
150/151 400.10815.2.de INDEX
Transfer case ...... 120 Treeline light ...... 100 Treeline worklights ...... 44 Turn indicators ...... 100 Turning ...... 136 Turning with counter-rotating tracks ...... 137 Turret-gear parking brake ...... 51 U Using the manual pump for tilting and lowering ...... 98 V Vehicle and engine numbers ...... 8 Vehicle battery ...... 105, 106 Visual inspection ...... 116 Voltage peaks ...... 108 W Warming-up phase ...... 123 Warning symbols ...... 42 Weekly checks ...... 117 Wet snow/slushy snow ...... 134 Windscreen heating ...... 46 Windscreen wiper, front ...... 47
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