ROTZLER TITAN TI 5, Installation Manual

Page 1: ...4000021245 Rev A 10 10 2019 Hoisting winch TITAN TI 5 INSTALLATION IMPERIAL DATA...

Page 2: ...neral installation manual must be stored in close proximity to the winch and be available to trained personnel at any time Before starting any work installation manual must be read in full and underst...

Page 3: ...on of dangers and notice 19 7 Work safety 20 7 1 Safety instructions regarding winch installation 20 7 2 Safety instructions when handling ropes 20 7 3 Safety instructions for hydraulic installation 2...

Page 4: ...from non observance of ROTZLER installation and maintenance instructions ROTZLER HOLDING GmbH Co KG reserves the right to make technical modifications If problems arise while installing or servicing t...

Page 5: ...s ROTZLER HOLDING GmbH Co KG Robert Bosch Strasse 4 79585 Steinen Germany Phone 49 7627 701 0 Fax 49 7627 701 166 www rotzler com 1 3 Warranty Warranty claims are only accepted under the following con...

Page 6: ...winch which consists of primary base 2 final base 3 and spacer bars 5 The frame also supports the drum 4 The drum contains the planetary gears which connect the motor drive shaft to the drum The winch...

Page 7: ...2 Basic winch 4000021245 7 2 3 Basic winch dimensions 0 80 0 04 14 20 19 88 max 11 00 0 02 17 05 max 12 18 0 08 13 84 0 01 0 03 15 75 max A 0 80 0 04 Fig 3 Dimensions of basic winch inch...

Page 8: ...GPM 12 15 3 sound pressure dB 91 91 91 weight approx lb 410 411 430 dimension A max inch 22 52 23 03 20 28 Data per rope layer 1st 2nd 3rd 4th max hoisting force lbf 12300 11100 10100 9300 max rope s...

Page 9: ...plate 1 Screws 2 Fixing plate A Fixing surface H Horizontal axis V Vertical axis Mounting fasteners Qty Size Quality Tightening torque Measure X standard fasteners 4 7 8 UNC Grade 5 328 lbf ft 0 8 in...

Page 10: ...t option BR Break relief port NA L1 V1 V2 V2 V1 L2 BR Fig 6 Hydraulic connections of piston motor V1 V2 Return Pressure oil connection in hoisting di rection L1 L2 Case drain connection NA Emergency b...

Page 11: ...BR winch hydraulic brake hydraulically released hydraulic motor counter balance valve control valve pressure relief valve hydraulic pump return filter return line to reservoir pressure line case drai...

Page 12: ...voltage 33 V DC max permanent current 10 A core I core II core III Fig 8 Rope end sensor connection Regarding the assembly it has to be secured that through an interruption of the power supply betwee...

Page 13: ...pprox 11 9 Tab 4 Data with pressure roller Pressure roller The pressure roller supports proper spooling of the rope on the drum It is mechanically fastened to the winch frame Its position is always on...

Page 14: ...M049 weight pressure roller incl rope end control lb approx 11 9 Tab 5 Data with pressure roller and rope end control Rope end control The rope end control is mechanically attached to pressure roller...

Page 15: ...cy brake release interface The emergency brake release valve is integrated in the hy draulic motor housing Connection ports BSPP thread NA G 1 4 Tab 6 Hydraulic connection port sizes with external bra...

Page 16: ...onal hydraulic motor counter balance valve control valve pressure relief valve hydraulic pump return filter auxiliary hydraulic system shuttle valve optional if emergency brake re lease is used contro...

Page 17: ...ed for each winch model and meet the highest safety standard for marine loading and service cranes Rope interface ROTZLER ropes are connected to the winch by a rope lock Adding a rope end switch to th...

Page 18: ...107 M 107 ccm gear motor P 049 M 49 ccm piston motor 0 Rotation direction and general layout For position of rotation direction general layout see details on the right Motor layout For position of mot...

Page 19: ...e in potentially explosive areas Conversions and modifications to winches are not ap proved Only original ROTZLER spare parts are to be used for repairs 6 2 Identification of dangers and notice DANGER...

Page 20: ...tructions when handling ropes DANGER Risk of injuries Wrong handling of loaded wire ropes can cause breakage of the rope causing dangerous situa tions If the rope is attached and not tensioned it is m...

Page 21: ...ions for hydraulic instal lation DANGER Risk of injuries The hydraulic motor of the winch can be hot dur ing and after operation Always make sure the motor cooled down be fore working on the winch CAU...

Page 22: ...peratures vibration and sharp objects Gloves must fit properly and be the right kind for the job Gloves can protect hands from Knives sharp edges splinters Chemicals Excessive vibration Hot objects El...

Page 23: ...the winch hoisting force is limited to Fmax 1 2 x Frated This must be done using a mechanical pressure relief valve Additionally the ROTZLER MCD can be used to im plement an additional overload protec...

Page 24: ...uddenly and the rope end may lash out uncontrollably This may cause severe injury Hold the wire rope well while loosening the transport protection Depending on the net weight and size place the winch...

Page 25: ...mperature Range 40 to 63 C depend ing on the hydraulic oil used the usage temperature is limited additionally Max relative air humidity 95 not condensing 8 2 Mechanical installation DANGER Risk of inj...

Page 26: ...ch type Quantity Size Imperial Grade Tightening torque lb ft Meas X in TI 5 4 7 8 UNC grade 5 A4 80 328 439 0 80 Tab 9 Size grade and tightening torque 8 2 2 Mounting the winch rope spooling Rope spoo...

Page 27: ...ssure of the mo tor pL max are listed in the technical data Fill the motor of the winch via the case drain connection with min 0 13 gal US of hydraulic oil prior to initial opera tion WARNING Risk of...

Page 28: ...e figure show the standard posi tions If the motor is turned the connec tions turn accordingly Legend CC Rotation direction counterclockwise CW Rotation direction clockwise V1 Return oil connection fo...

Page 29: ...case drain line has to be connected on the topmost case drain port to assure proper lubrication of the motor at any time If the orientation of the case drain connection at the winch changes during op...

Page 30: ...isk of injuries Hoisting a load with an improperly installed winch can result in winch failure and or dropping of the load causing severe injury or death Check winch for correct installation and funct...

Page 31: ...and dispose of according to environmental standards The winch must be disposed of according to the regula tions applicable in the relevant country The winch may be sent to ROTZLER for disposal De liv...

Page 32: ...ding to technical data considering max allowed pressure and max return flow pressure DANGER Risk of injuries Danger due to dropping load The load can drop uncontrollably if the volume flow of the auxi...

Page 33: ...lic motor counter balance valve control valve pressure relief valve hydraulic pump return filter auxiliary hydraulic system shuttle valve optional if emergency brake re lease is used control valve for...

Page 34: ...e end in direction clock wise 2 Proceed the test by running the winch rope OUT for 10 sec 3 The test is passed if the drum does not turn at maxi mum applied pressure pmax to technical data 4 After com...

Page 35: ...ley 1 scans the rope structure S during winch operation The installed control switch 3 is a break contact which is closed as long as rope end is not reached The contact opens when rope end is reached...

Page 36: ...ntrol must only be per formed without load on the winch Assembly and mode of operation rope end control The scanning pulley 1 scans the rope structure S during winch operation If the scanning pulley l...

Page 37: ...llowing safety instructions have to be observed During maintenance and servicing work the device must be disconnected from any voltage sources Opening the electronic box may ex pose live parts Termina...

Page 38: ...ty Operating materials See Chapter At every use Visual and acoustic check of the complete winch sys tem for abnormal operation and noises Daily Visual check of the rope Refer to chapter rope check Vis...

Page 39: ...oil Gear oil Refer to chapter checking and changing of gear oil Every 3 months Gear oil check Refer to chapter checking and changing of gear oil Every 300 operating hours no longer than 2 years Change...

Page 40: ...is may cause premature wear due to corrosion When used in extreme environmental conditions i e exposure to salt water extreme dust or mud the rope must be cleaned on regular base to avoid premature we...

Page 41: ...on and dis card of wire ropes is ISO 4309 The relevant technical data of the standard ROTZLER TITAN ropes can be found in chapter ropes within this manual Customer specific rope are defined within the...

Page 42: ...mooth rope end through rope inlet 3 e Lay rope in rope wedge 2 as shown and insert both in rope pocket 1 in direction of arrow Spool on rope DANGER Risk of injuries Ensure that the rope with rope wedg...

Page 43: ...80 API GL 5 Alternative gear oils are SAE 80W 90 SAE 75W or SAE 90 Different gear oils must not be mixed Working steps 1 Preparatory work If necessary warm up the gear oil to min 10 C To do so fully p...

Page 44: ...opening of screw E A un til oil comes out of level screw opening Close screw N and E A 10 2 6 Check of holding brake If the winch is equipped with the option brake test valve go to chapter brake test...

Page 45: ...equired A general overhaul must be performed before reaching the calculated overall runtime stated in this installation manual but latest 10 years after commissioning Otherwise the system must be take...

Page 46: ...em Winch cannot hold the load Rope is wound onto the rope drum in the wrong rotation direction Wind rope onto winch in accord ance with assembly instruction Observe rotation direction CC or CW Wrong c...

Page 47: ...d nozzle Replace if re quired Brake cannot be released due to contamination in the nozzle Disassemble nozzle Clean nozzle or re place if required Damaged winch motor Replace winch motor Winch vibrates...

Page 48: ...s with hydraulic oil if the brake shaft seal is damaged If this occurs disassemble the brake and re place the brake shaft seal Replace the rope drum seals if they are leaking also Inspect both areas b...

Page 49: ...11 Troubleshooting 4000021245 49 Revision Index Version Date of change Changes Rev A 10 10 2019 10 10 2019 Port value modified on page 10 and 29...

Page 50: ...ght 5 D Disassembly disposal 33 E environmental 33 H Hydraulic 29 I Inspection after installation 32 38 M Maintenance procedure 42 Mounting winch 27 P Principle 2 28 Protective devices 25 R Rope care...

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Page 52: ...134 www rotzler com ROTZLER HOLDING GmbH Co KG ROTZLER Deutschland GmbH Co KG Robert Bosch Strasse 4 79585 Steinen GERMANY Tel 49 7627 701 0 www rotzler com ROTZLER India Pvt Ltd Plot no 4 5th Main 3r...