PistenBully 600 Polar Snow Groomer Operating Manual
Below you will find brief information for Snow Groomer 600 Polar. This document provides instructions for operating, maintaining, and caring for your PistenBully snow groomer. It includes vital information for correct and efficient operation and warnings to help you identify and avoid potential dangers. This manual is essential for safe and effective use of your snow groomer.
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Operating Manual
PistenBully 600
600 Polar
From WKU 5 826 MA A L 011021
EN
K
ÄSSBOHRER
G
ELÄNDEFAHRZEUG
AG
Kässbohrerstraße 11
D-88471 Laupheim
P
RINTED IN
G
ERMANY
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).
CONTENTS
I
NTRODUCTION
S
AFETY SYMBOLS USED
T
ECHNICAL CUSTOMER SERVICE
. . . . . . . .
T
ECHNICAL DATA
T
ECHNICAL DATA
. . . . . . . . . . . . . . 10
F
LUIDS AND LUBRICANTS
S
AFETY INSTRUCTIONS
S
AFETY INSTRUCTIONS
A
TTACHMENT WEIGHTS
U
SE
C
OCKPIT
. . . . . . . . . . . . . . . . . . . . 34
I
NSTALLING AUXILIARY EQUIPMENT
. . .
R
EAR DECK RAILING
T
ILTING THE DRIVER
'
S CAB
/
LOAD
PLATFORM
. . . . . . . . . . . . . . . . 103
E
LECTRICAL
. . . . . . . . . . . . . . . . . . . . . . .
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CONTENTS
C
HECKS
C
HECKS
. . . . . . . . . . . . . . . . . . . 119
O
PERATION
S
TARTING THE DIESEL ENGINE
E
NTERING
-
DRIVING
-
EXITING
T
OWING VEHICLE
D
RIVING TIPS AND INFORMATION
. . .
O
THER ON
-
BOARD DOCUMENTS
– Log book
– Operating manual, diesel engine
– Maintenance instructions
– Operating manual for Kahlbacher front-mounted tiller blower (optional equipment)
– Operating manual for drum winch (optional equipment)
A
UXILIARY EQUIPMENT
F
RONT BLADE
. . . . . . . . . . . . . . . 149
A
LPIN
F
LEX TILLER
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I
NTRODUCTION
Y
OUR OPINION IS
IMPORTANT TO US
.
Quality of translation:
Correctly translated
To ensure that your operating manual is optimum in all ways.
Sender:
Mistakes in translation
Comments:
Phone No.:
Fax:
Graphics and photos:
Provide good explanations
More explanatory diagrams required
To:
Kässbohrer Geländefahrzeug AG
Kässbohrerstraße 11
D-88471 Laupheim
Attn.: Mr. Peter Görlich
Fax No.: +49(0)7392/900100
E-mail: [email protected]
600.11021.4.de
Comments:
A CD-ROM would be good!
5/162
I
NTRODUCTION TO THE
O
PERATING
M
ANUAL
This operating manual provides information about:
how to handle, maintain and care for your PistenBully.
important instructions concerning correct and economical operation.
warnings so that you recognise dangers in good time and avoid them.
Make sure that the operating manual is always in the oddments tray in the driver's cab.
A
BBREVIATIONS USED
e.g.
= for example
MA = tightening torque
SP no. = order number for spare part min./max.= minimum / maximum
Sec.
= Section
S
YMBOLS USED
DANGER!
Direct and imminent danger threatening life and limb unless appropriate precautions are taken.
WARNING!
Potentially highly dangerous situation!
Danger to life and limb unless appropriate precautions are taken.
CAUTION!
Dangerous situation!
Could lead to injury unless appropriate precautions are taken
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Important notes!
Possibility of damage to the machine or its immediate surroundings.
i
This symbol draws attention to practical tips
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T
ECHNICAL CUSTOMER SERVICE AND SPARE PARTS DEPARTMENT
Service worldwide
Director of Service (GS) Mr. Mayer
Phone, office
+49(0)7392/900-101
Technical customer service (TKD)
Head of department TKD
Area Manager TKD
Area Manager TKD
Area Manager TKD
Area Manager TKD
Area Manager TKD
Mr. Strähle
Mr. Kirsamer
Mr. Braun
Mr. Arbogast
Mr. Bohnet
Mr. Dehm
+49(0)7392/900-103
+49(0)7392/900-137
+49(0)7392/900-105
+49(0)7392/900-118
+49(0)7392/900-116
+49(0)7392/900-117
Fax +49(0)7392/900-100
24 hour emergency service number: Phone +49 171/7124096
Spare Parts department (ETV)
Director, ETV, Mr. Heim +49(0)7392/900-107
Spare parts distribution (ETV) emergency number: Phone +49 171/3732230
Fax +49(0)7392/900-130
Contact at my national office:
Technical customer service
Spare parts department
Repair mechanic
Name:.............................................. ...............
Telephone number:...............................
Name:......................................... ........
Telephone number:.........................
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).
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V
EHICLE AND ENGINE NUMBERS
The vehicle number is stamped on the front of the vehicle, on the face end of the right hand frame.
This operating manual is for the vehicle
Please insert the appropriate entries
WKU...................................................
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The engine number is stamped on the engine type plate.
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U
SE OF GENUINE SPARE PARTS
In your own interests, please note the following:
We recommend the use of genuine spare parts from Kässbohrer Geländefahrzeug AG and parts for conversion and accessories expressly approved for your type of vehicle. These parts have been subjected to a special test procedure and they have been proven to be reliable, safe and suitable for
Kässbohrer off-road vehicles. Despite continuous observation of the market, we are unable to assess these aspects of other products – even products that have been scrutinised by a technical inspector or for which an official approval has been issued – and consequently, we refuse to accept liability for them.
Genuine parts and approved accessories and parts for conversion are available from your Kässbohrer Geländefahrzeug AG service centre. The experts there will provide in-depth advice
– including advice on permissible technical modifications – and install the components using the correct procedures.
The use of parts other than genuine spare parts voids your guarantee. We refuse to accept liability for consequential damage resulting from such use.
Kässbohrer Geländefahrzeug AG
600.11021.4.de
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T
ECHNICAL DATA
Dimensions
:
Width:
without tracks ..................................... 2500 mm across aluminium tracks ...................... 4206 mm across steel tracks ............................... 4206 mm across AlpinFlex tiller........................... 5500 mm
Engine:
Type .............................. Mercedes Benz OM 460 LA
Number of cylinders.............................
6
Displacement ......................................
Output, ECE rating .................295 kW
600 Polar......................... ECE 360 kW
Height .........................................
Height with cab tilted
2,880 mm
3,360 mm
Max. torque .............. 1900 Nm / 1300
600 Polar...................2200 Nm / 1300
Length
With tiller and front blade.................... 9,130 mm
Oil capacity with filter..........................
Fuel consumption from ........................
Load area ........................................... 2250 x 1920 mm Tank capacity ......................................
Exhaust-emissions standard .................
12,820 cc
(400 ECE-HP)
(490 ECE-HP) rpm rpm
42 l
20 l/h
220 l
EUROMOT III
Weight:
Dead weight with aluminium tracks ..... 8,045 kg
Dead weight with steel tracks .............. 8,685 kg
Permissible total weight including auxiliary equipment ....................................
12,500 kg
Payload of load area without auxiliary equipment.
1500 kg
Brakes:
Wear-free (hydrostatic)
2 multi-plate brakes
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T
ECHNICAL DATA
Electrical:
Light-current circuit .............................
Generator ..........................................
Batteries.............................................
Cold-start power.................................
.
Operating parameters:
Continuously variable speed ................
Spec. ground pressure with aluminium tracks .................................................
Spec. ground pressure with steel tracks
Production rate with tiller ....................
Garage:
Suggested garage dimensions
Length................................................
Width .................................................
Height ................................................
24 volts
28V / 140A
2 x 12V / 135 Ah
600 A
0 - 23 km/h
0.051 kg/cm 2
0.053 kg/cm 2
96,000 m 2
/h
11,000 mm
6000 mm
3500 mm
Sound power level and vibrations
Per EN 15059
Measured at rated engine speed and maximum fan speed
Sound pressure level at operator's workplace
Radiated sound power level
79 dB(A)
114 dB(A)
Measured during grooming
(vector sum)
Vibrations at the steering wheel
Vibration at driver's seat
<2.5 m/s
<0.5 m/s
2
2
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T
ABLE OF FLUIDS AND LUBRICANTS
Designation
Mercedes Benz engine
OM 460 LA
MB sheet: www.bevo.mercedes-benz.com
Grade
MB sheet 228.5 / SAE 10W40 / 5W40
MB sheet 228.51 / + Diesel particulate filter
MB sheet 228.3
MB sheet 228.31 / + Diesel particulate filter
Capacity Interval between changes
39.6 litres at least: every year every 600 hours at least: every year every 400 hours.
Fuel tank
Fuel filter
Air filter
Cooling / heating system
50% drinking water + 50% antifreeze (MB sheet 325.0)
Transfer box
Wheel drive
(planetary gears)
If an engine oil of a different grade is used for topping up, the maintenance interval is the interval for the lower-grade oil.
Diesel fuel to
MB sheet 131.0, 132.1, 132.3, 137.0/137.1
Poly Alpha Oleofin (PAO)
- CLP HC VG 150 / 220
ISO VG 220 (for summer operation)
- API GL4, SAE 75 W 90 (PAO)
Poly Alpha Oleofin (PAO)
ISO VG see rating plate
220 litres
36 litres
2.4 litres see rating plate at least: every year drain condensation.
every 800 hours at least: every year every 1200 hours at least: every 3 years every 3600 hours at least: every year every 800 hours at 100 hours (new vehicle) at least: every year every 600 hours at 100 hours (new vehicle)
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T
ABLE OF FLUIDS AND LUBRICANTS
Designation
Hydraulics
Propulsion unit + auxiliary driven machinery see section on hydraulic fluid
Hydraulic oil filter
Grade
HVLP DIN 51524
DEXRON ll D / lll F
ATF Type A suffix A
< -30
0
C -AVIA Synthofluid PE-B 30 (PAO)
Hydrostatic vehicle drive
see section on greases
Lubricate wheel hubs and swinging arms
Greasing
Other lubrication points see section on greases
Radius-arm seal
OKS 250
Calcium-saponified grease
KP2K-30, DIN 51502 e.g. Aviacal 2 LD
Calcium-saponified grease
KP2K-30, DIN 51502 e.g. Aviacal 2 LD
Syntogrease 1
KPE 1K-40, DIN 51502 DIN 51825
Tillers, spiral-bevel coupling Avialith 2 F
OKS 400 / Molykote BR 2
Electrical system
Battery terminals
Bosch FT 40V1 grease
Generator with Stauffer grease cup Bosch FT 1V34 grease
Servo adjustment device for Moog valves
Insulating oil
DIN 57370 / VDE 0370
Capacity Interval between changes
47 l tank
100 l total at least: every year every 1200 hours at 100 hours every 1200 hours every 400 hours every 100 hours at least: after 3 years every 3600 hours every 1200 hours every 1200 hours
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N
OTES
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AFETY INSTRUCTIONS
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I
NTENDED USE
D
RIVER
. . . . . . . . . . . . . . . . 16
D
ANGER ZONE FOR PERSONS
O
PERATION
M
AINTENANCE
F
IRST
-
AID KIT
F
IRE EXTINGUISHER
W
ARNING SIGNS
A
TTACHMENT WEIGHTS
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S
AFETY INSTRUCTIONS
Intended use:
Snow groomers may be operated only as specified in the manufacturer's operating manual.
The PistenBully may be used for the following purposes only:
Preparing slopes for downhill skiing.
Removing snow from paths.
Removing snow from parking areas in non-public terrain.
Vehicular-access routes off-road
Preparing trails for Nordic skiing.
Transporting people in the special people-carrier cabin (optional extra).
If you wish to use the vehicle for any other purpose, you must apply for written approval from the manufacturer.
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D
RIVER
Drivers must be specifically appointed to drive snow groomers.
You may appoint people to drive the snow groomers on their own only when you are certain that they will be able to reliably fulfil the tasks assigned to them.
In particular, they must satisfy the following:
be at least 18 years old or of the minimum legal age required by national law.
be physically and mentally suitable.
be trained in how to drive the snow groomer and have proven their driving ability to the operator.
be familiar with snow conditions and with the peculiarities of operating equipment in facilities for skiers.
be familiar with the area where the vehicle is to be used, especially with regard to particularly dangerous areas.
be familiar with first-aid procedures in the event of an accident.
if avalanches pose a threat in the area where snow groomers are to be used, in addition to the aforementioned conditions, drivers must also be instructed about how avalanches are started, the consequences of them and how to behave when there is a risk of avalanches.
In order to help ensure safe operation, operators must wear appropriate footwear with non-slip soles.
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S
AFETY INSTRUCTIONS
D
ANGER
PERSONS
ZONE FOR
No-one is permitted to enter the snow groomer's immediate danger zone.
The driver may only operate and drive the snow groomer provided that there is no-one in the immediate danger zone.
The driver must issue warnings to draw attention to potential dangers.
Special protection measures must be taken if the snow groomer is being used in an area where the driver does not have a clear view of the surrounding terrain, or the nature of the terrain is such that the machine might not be immediately visible to people in its vicinity. Depending on the circumstances of each case, these measures may take the form of warning signs, closed runs or offlimit markers.
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E
NTERING
Complete the daily checks and maintenance tasks.
Walk right round the vehicle and make sure that the danger zone is clear of persons and objects.
Step on to the track.
Danger of slipping on the track when entering and exiting the driver's cab.
Always take a firm grip on the handle of the driver's door when entering the vehicle.
When parking on a slope, be particularly careful when opening the door.
The door opens suddenly.
Fasten the seat belt.
In order to enter or exit a people-carrier cabin, extend and secure the access ladder.
D
RIVING
Do not leave the vehicle unattended with the diesel engine running.
Risk of poisoning from exhaust gases.
Never leave the engine running in enclosed spaces.
The use of proprietary starting agents (such as Startpilot, for example) is prohibited on account of the risk of explosion.
The driver may start and/or move the snow groomer only when seated in the driver's seat, after fastening the seat belt .
Do not attempt to adjust the driver's seat or steering wheel when driving.
Snow groomers must be used and operated in a manner which ensures their stability.
Drivers may drive the snow groomer only at a speed at which they main-
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S
AFETY INSTRUCTIONS
tain control at all times. They must adapt the speed to the snow, terrain and visibility conditions and to the characteristics of the snow groomer, with due allowance for the auxiliary equipment fitted.
Drivers must always restrict the vehicle to a speed at which they can stop within the distance visible. This does not apply to steep slopes where the vehicle cannot be stopped as a result of the angle of the terrain. Drivers may drive on such steep slopes only when certain that they can do so without putting themselves and others at risk.
Close the doors.
Failure to comply with this precaution will result in a risk of accident due to doors slamming closed.
Switch on the rotating beacon
When driving past people, slow down, keep at a safe distance and
18/162 always bear in mind that the people may behave unexpectedly.
Always come to a complete stop before reversing the vehicle.
Make sure that the area behind the machine is clear.
The assistance of a second person to give directions is necessary if visibility is poor.
Avoid crossing slopes at an angle because the PistenBully may slip downhill.
When a tracked vehicle is being driven, the traction is so great that the vehicle may be driven well beyond the point at which it should start to tilt; if this happens the vehicle might then suddenly tip over.
Risk of interference with the electronics
Do not place an active two-way radio device on the console on the terminal.
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.
Driving with restraint:
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.
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AFETY INSTRUCTIONS
S
TOPPING
/
EXITING
Park the vehicle where it is clearly visible.
Do not apply the parking brake until the vehicle has come to a complete stop.
Turbocharger - risk of overheating:
Do not immediately switch off the diesel engine after it has been run at full load. Drive for approx. 2 minutes in the part-load range and then switch off.
Risk of poisoning from exhaust gases.
Do not leave the engine running unattended or running in an enclosed space.
Lower the front and rear auxiliary driven implements, switch off the tiller, set the direction of travel switch to "neutral".
Before exiting the driver's cab
Apply the parking brake
Switch off the engine
Remove the ignition key from the lock.
Fully raise the steering-wheel column and the left armrest.
Step on to the track.
Danger of slipping on the track when entering and exiting the driver's cab.
Always take a firm grip on the grab handle at the driver's door when exiting the vehicle.
Lock the driver's cab.
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S
AFETY INSTRUCTIONS
T
ERRAIN
Before using the snow groomer, check that the intended terrain is drivable.
Never attempt right-angle crossover across a public road without first obtaining the permission of the appropriate authority.
Angled or staggered crossover across public roads is permissible when in accordance with an approved routing plan.
Risk of break-through
Driving on frozen rivers and lakes is very dangerous. Consequently, you are urgently advised not to do so.
Snowdrifts
Avalanches
Rockfalls
The driver must be accompanied by a co-driver when driving in areas where the vehicle cannot be seen and when the weather is bad, unless several vehicles are working together as a team. This does not apply if the driver uses a two-way radio to remain in constant contact with someone at the base who can send out a rescue team should an accident occur.
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AFETY INSTRUCTIONS
When using snow groomers at nighttime, handheld searchlights must also be used.
D
RIVING
GERS
WITH PASSEN
Only 1 co-driver may sit in the driver's cab.
From WKU 010800 onward a child's seat is installed. The child's seat can be occupied by only 1 person and is designed for an occupant of a maximum height of 150 cm.
The co-driver must be seated in the co-driver's seat at all times when the vehicle is in motion.
When persons travel in the people carrier cabin (optional extra), they must sit in their seats with their safety belts correctly fastened, and hold tight. See also the operating manual for the people-carrier cabin.
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-
Do not drive the vehicle with people on:
- the load area
- the auxiliary equipment
- externally mounted machinery.
Auxiliary equipment, rear deck railing (optional)
Correct usage
The opened rear deck railing is developed for the safe transport of materials and people.
The country-specific regulations must be observe for the transport of people.
At the beginning of travel, everyone must stand and have a firm grip on the open rear deck railing.
If the inclinometer indicates more than 30
0 degrees in the longitudinal direction 1 or more than 25
0 degrees in the lateral direction 2, the operator must refrain from driving any further on the steep terrain for safety reasons when carrying passengers.
2 1
Inclinometer
The rear deck railing must be secured at both ends. Both safety chains must be closed and locked.
Risk of burns caused by the exhaust muffler. Keep clear.
Avoid abrupt changes of direction and angles of inclination.
Danger of slipping on the track and load platform!
When climbing onto and off the rear deck railing, hold onto the load platform railing.
Risk of injury by crushing action!
When lowering the rear deck railing.
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S
AFETY INSTRUCTIONS
M
Close the rear deck railing using holding points.
AINTENANCE
Snow groomers must be maintained by trained staff specifically appointed by the operator.
Do not perform maintenance work under moveable parts in their open or raised positions unless they have been secured to prevent them from slamming closed or dropping.
Snow groomers and raised equipment must be secured before maintenance work is started to prevent them from accidentally moving.
Markings, warning signs and information plates on the PistenBully and auxiliary equipment must not be removed or covered over or made illegible in any other way.
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Compliance with the manufacturer's maintenance instructions is mandatory.
Faults which could affect safety levels must be rectified immediately.
Repair welding is an operation that invariably requires extensive safety measures. Please consult your nearest Support Centre.
Risk of cable fire and short-circuit.
Never attempt to jumper or repair fuses or insert replacement fuses with a higher ampere rating than the originals.
Do not permit fluids or lubricants to come into contact with the skin
(wear protective gloves, change wetted clothing).
Do not inhale or swallow fluids or lubricants (risk of poisoning).
Topping up coolant level.
Risk of scalding
The coolant system is pressurised.
Remedy: Wear protective gloves
Tilting the load platform.
Risk of injury by crushing:
If hydraulic pressure is lost the load platform will move downward.
Secure the support to ensure that the assembly cannot move downward of its own accord.
Halogen/xenon light
Bright light can injury the eyes. Do not look directly into the bright light.
Health hazard due to gas.
If a xenon bulb breaks in an enclosed space, leave immediately and ventilate the room for at least
20 minutes before re-entering.
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AFETY INSTRUCTIONS
Battery
Risk of explosion of oxyhydrogen gas
Keep all sources of ignition well away from the battery.
Do not place metal objects on the battery.
Take care when handling battery acid: risk of caustic burns.
Wear protective goggles and protective gloves.
Connect the battery clamps to the battery posts. Make sure that polarity is not reversed.
Do not make a connection between the cable clamps.
Make sure the room in which the battery is charged is well ventilated.
A mistake in the jump-starting procedure could result in fatality or severe burns due to electric shock.
Do not make a connection between the cable clamps.
Do not connect the jump-start leads to the connections between the two batteries.
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M
ONITORING
Before starting off, the driver must check operation of the safety-relevant components, e.g.:
by testing the brakes.
by switching on the lights.
by function-testing the warning systems.
by checking the controls of the working machinery.
Do not permit fluids or lubricants to come into contact with the skin
(wear protective gloves, change wetted clothing).
Do not inhale or swallow fluids or lubricants (risk of poisoning).
Risk of explosion due to build-up of gas in fuel tank.
Keep all possible sources of ignition well clear when the vehicle is being refuelled.
Risk of injury by cutting or crushing action.
At all moving parts.
When the engine is running, keep well clear of rotating parts.
If radios are required to ensure safe operation of the snow groomer, before starting off checks must be performed 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 vehicle handover, to the replacement driver.
In the event of damage, defects or changes that endanger operational safety, the driver must immediately cease operation of the vehicle.
The supervisor must be notified immediately in the event of accidents involving injury to persons or damage to property or to the vehicle.
The supervisor must perform random checks in order to ensure that the snow groomer is operated in a safe manner.
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AFETY INSTRUCTIONS
I
NSPECTION
The operator must ensure that the snow groomers are inspected whenever necessary, at least once a year and after maintenance work. This inspection must ensure that the snow groomers are safe and must be performed by a skilled specialist.
Skilled specialists are people who have an extensive knowledge about vehicle technology as a result of their specialist training and experience. They are also sufficiently familiar with the appropriate national safety at work legislation, accident prevention guidelines, directives and generally accepted rules of engineering practice (e.g. DIN publications, VDE regulations or national equivalents) to ensure that they can judge whether snow groomers are in a condition suitable for operation.
The results of the inspection must be recorded in writing and filed.
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.
F
IRST
-
AID BOX
F
IRE EXTINGUISHER
The first-aid kit is secured to the codriver's door or stowed beneath the codriver's seat.
Always make sure that the first-aid kit is complete.
The fire extinguisher is stowed beside the driver's seat.
Note expiration date.
Replace used fire extinguishers immediately.
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AFETY INSTRUCTIONS
W
ARNING SIGNS
W
ARNING SIGN
Strict compliance with the warning signs on the PistenBully and on auxiliary driven implements is mandatory.
Make sure that warning signs that are damaged or come loose are replaced immediately.
Location: Driver's cab/parking
brake.
No. 8.765.311.058E
Text:
Attention:
Apply the parking brake before leaving the cockpit.
W
ARNING SIGN
Location: Diesel engine
No. 8.312.085.064
Text:
WARNING!
Do not use start-assist fluids or ether to start the diesel engine
(risk of explosion).
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AFETY INSTRUCTIONS
W
ARNING SIGN
S
IGN
S
IGN
Location: Fan/engine
No. 8.762.634.054E
Location: Driver's cab
No. 8.762.642.000E
Text:
Attention:
The fan ring rotates when the diesel engine is running.
Text:
Read operating manual and safety instructions before startup and comply with both at all times.
Location: Rear bulkhead, driver's
cab
Text:
Child's seat for one occupant up to maximum size of 150 cm.
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AFETY INSTRUCTIONS
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Sign (No. 8.766.017.000 E)
Text:
Figure representing sound power level.
Sign (No. 8.766.017.000 E)
Text:
Lever for raising and lowering driver's cab and load platform.
Warning sign (No. 814.76.00.111.05E)
Text:
Risk of burns caused by the exhaust muffler.
Keep clear of hot surfaces.
Sign (No. 8.762.658.000 E)
Text:
Risk of falling.
No-one is permitted to ride on the load platform.
Sign (No. 8.762.750.000 E)
Text
:
Danger of falling! No transport of people on the load platform. Opened rear deck railing is for the transport of materials and people.
Warning sign
Text:
Rear deck railing open.
Make sure that safety catch of locking lever is engaged.
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AFETY INSTRUCTIONS
Warning signs, front blade
Warning sign
(No. 8.762.271.053C)
Text:
Attention:
Before connecting or disconnecting the hydraulic hoses, it is essential to shut down the diesel engine.
Warning sign
Text:
High-grade, fine-grained structural steel.
Always ensure that welding and straightening work is carried out in strict compliance with the workshop information.
Warning sign (No. 8.762.660.000 E)
Text:
WARNING!
Do not reach into crushing zone while parts there may be moving.
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AFETY INSTRUCTIONS
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Warning signs, tiller
Warning sign (No. 8.762.660.000 E)
Text:
WARNING!
Wait until all parts have come to a complete standstill before touching.
Warning sign
(No. 8.762.271.053C)
Text:
Attention:
Before connecting or disconnecting the hydraulic hoses, it is essential to shut down the diesel engine.
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S
AFETY INSTRUCTIONS
1
2
3
4
Attachment weights
When transporting loads, always bear in mind the maximum attachment weights at the attachment points.
1 = Pivot point (main frame, quick-change system)
2 = Hook plane, quick-change system
3 = End face, front blade centre
Attachment at pivot point, main frame (1)
Maximum long-term attachment weight 1650 kg.
Attachment at hook plane quickchange system (2)
Maximum long-term attachment weight 1315 kg.
4 = Fork, length 400 mm (Park-
Blade)
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S
AFETY INSTRUCTIONS
Attachment at quick-change system with front blade (3)
Maximum long-term attachment weight
665 kg.
Maximum short-term attachment weight 1100 kg.
Attachment to fork (4), length 400 mm
Maximum short-term attachment weight 1000 kg.
Note: The attachment of excessively heavy weights and machinery with excessively high attachment moments voids the vehicle manufacturer's warranty and excludes liability on the part of the vehicle manufacturer.
The only exceptions to this rule are those items of auxiliary driven machinery for which the vehicle manufacturer has issued approval.
Safety instructions for long-term and short-term attachment weights
Operation with the maximum shortterm attachment weight is re-
600.11021.4.de
stricted to the intended purpose and is subject to the limit of the time required for said purpose
(short-term).
Drive at suitably low speed only.
The high moment of the attachment restricts the manoeuvrability of the vehicle.
Risk of toppling.
Check the terrain and make sure it is suitable for driving.
The load must not unduly obscure the driver's field of vision.
The load must be adequately secured to ensure that it cannot shift.
The tiller has to be installed as a counterweight.
Note requirements regarding transport positions of auxiliary equipment.
See the operating instructions issued by the manufacturer of the auxiliary equipment
Safety instructions, ParkBlade
Risk of injury by crushing: when extending / retracting the forks.
Make sure there is no-one in the danger zone.
The transport of persons is prohibited.
Always retract the forks when they are not needed.
When the forks are extended, the side section of the front blade must be pivoted all the way out.
Alterations to the forks are prohibited.
Do not use the forks for pushing or lifting work that involves applying lateral load.
The load must be suitable for lifting with the forks.
Make sure that the weight of the load is evenly distributed across both forks.
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N
OTES
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O
VERVIEW
600.11021.4.de
C
OCKPIT DISPLAY PANEL
I
NSTRUMENT DISPLAYS
M
ULTIFUNCTION JOYSTICK
S
TICK OPTIONAL
T
ERMINAL
C
ONTROL
C
ENTRE
T
ERMINAL
. . . . . . . . . . . . . . 72
C
AB HEATING
R
EMOTE CONTROL
,
OPEN DOOR
D
RIVER
'
S SEAT
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C
OCKPIT
4
2
3
2
1
Multifunction switch
1 Horn
Press button
2 Turn indicators
Self-cancelling: Pus the control stalk past the point of resistance until it engages.
3 High beams and low beams
High beams
= Push stalk to right until it locks in position.
Low beams
= Push stalk to right again until it locks in position.
4 Wipers
Turn control stalk sleeve:
Stage II = Fast wipe
Stage I = Normal speed
Stage 0 = Off
Intermittent-wipe setting: see the section on Touchscreen -
Overview of settings.
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OCKPIT
7
6
8
6 Pushbutton for wipers
Press to have front wipers execute a single stroke.
Intermittent-wipe setting:
- Switch on the front windscreen wipers.
Indicator for intermittent wipe flashes
(see arrow).
- Press pushbutton
6
.
The time between wipes increases.
(see "Touchscreen")
Press again: time between wipes decreases.
To save the intermittent-wipe setting:
- Hold down pushbutton
6
for more than
2 seconds.
(See "General setting" in customer's workshop information).
7 Heated windscreen wipers
8 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. Warning buzzer sounds: Brake not applied and door open!
Applying parking brake:
Only when the PistenBully is at a complete standstill
Move the lever in the direction indicated by the arrow.
i
When the parking brake is engaged, the direction-oftravel switch automatically goes to the neutral position.
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9
10
11
9 Lock for steering-column adjustment
Height adjustment
10 Lock for steering-column adjustment
Fore-and-aft adjustment
11 Accelerator
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OCKPIT
Instrument panel (panel)
Note: Pushbuttons
When the circuit is active, the indicator on the left lights up
(see arrow).
2-stage switch left and right indicators light up.
Pressed again = Switch off
Parking lights / driving lights
Pressed once = Parking light
Pressed again = Low-beam headlights
High-beam headlights
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Spotlight
Rotating beacon
Front worklights
Pressed once = Xenon lights
Pressed again = Xenon lights / side finders
See the section on xenon lights
Foglights
(see the section on xenon lights)
Rear worklights
Pressed again = Twin lights
Flashing turn indicators, left
Hazard warning flashers
Flashing turn indicators, right
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OCKPIT
Pushbutton
Outside-mirror adjuster
Release seat-belt lock, cockpit
If the indicator lights up, the belt monitor is OFF!
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Windscreen heating
Clear thick coating of ice or snow from the screen by hand before switching on the windscreen heater.
See
customer's workshop information
Side-window heater and outside-mirror heater
Rear window heater
Power consumption is relatively high, so the drain on the battery is correspondingly severe. Switch off the screen heater as soon as the screen is demisted or de-iced.
Windscreen wipers, front
Intermittent wipe / speed 1 / speed 2
Intermittent-wipe setting: see the section on the
pushbutton for single-stroke wiping)
Press to have front wipers execute a single stroke.
Windscreen wipers, rear
Intermittent wipe / speed 1
. Intermittent-wipe setting: see the section on the steering wheel
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C
OCKPIT
Acoustic warning
Horn
Tension tracks
Relieve track
tension
Tiller forward operation / counter-rotating
Indicator right ON = Forward operation
Indicator left ON = Counter-rotating
Drive hydraulics for auxiliary driven machinery front / rear
Indicator right ON = Rear
Indicator left ON = Front
Floating position, front equipment carrier
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Extra acoustic warning
(optional equipment)
Before relieving the tension on the tracks, park the vehicle on level ground and secure it so that it cannot roll away.
Apply the parking brake.
If the PistenBully is to be out of use for a prolonged period of time, always relieve the tension on the tracks to prevent stretching the track stringers.
Fuel preheating
(Optional equipment)
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C
OCKPIT
ParkBlade
(
FunPark)
Pushbutton pressed = Extend
see the section on the front blade and safety instructions for fount-mounted weights
ParkBlade
(
FunPark)
Pushbutton pressed = Retract
Restraint
Activate restraint:
- for slow downhill grooming.
- 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.
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Change the direction of travel only by using the direction-of-travel switch.
One-touch lights control ON
Save light-switch settings:
- Press pushbutton
- Use the pushbuttons to switch on the lights of your choice.
- Press pushbutton again (setting is saved).
The next time the diesel engine is restarted, all the lights activated when the setting was saved come on again as soon as the pushbutton is pressed.
Nordic-trail tracker plates
Function toggle:
- Press pushbutton
- green indicator lights up
-
tracker-plate adjustment active
.
- Press pushbutton again
- indicator goes out
-
lift/lower tracker plates is active
- see the section on the Nordic-trail tracker plates for more information
Active winch
ON / OFF
See the operating instructions for the drum winch.
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OCKPIT
Warning symbols
Left / right turn indicator repeater
Indicator for hazard warning flashers ON
Intake air preheating ON
Battery charge indicator
If the indicator light comes on while the vehicle is on the move:
- Cease operations
- Ascertain the cause of the problem.
Situational help!
The indicator light comes on when the engine is idling.
Use the accelerator pedal to increase engine speed briefly. The indicator light goes out and the battery is being charged.
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Driver's cab tilt-locking device not engaged.
Air-filter monitor
Check / replace air filter
Coolant below the minimum level
If the indicator light comes on while the vehicle is on the move:
- Cease operations
- Ascertain the cause of the problem.
Hydraulic fluid is below the minimum level
- Cease operations
- Ascertain the cause of the problem.
High-beam headlights ON
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OCKPIT
Pushbutton, drum winch
Note: Pushbuttons
When the circuit is active, the indicator on the left lights up
(see arrow).
Turret-gear parking brake
Pressed = Apply brake
Indicator lights up
Warning buzzer sounds intermittently if winch is in operation.
Pressed again = Release brake
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Unreel winch cable / winch operation
Top section pressed and held down for at least 2 sec. = Unreel winch cable.
Pressed again = Neutral position
Bottom section pressed = Winch operation ON
Pressed again = Neutral position
Swivel winch boom
Top section pressed and held down = Swivel right
Bottom section pressed and held down = Swivel left
Reset acoustic warning, strand monitor
Active winch
See the operating instructions for the drum winch.
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OCKPIT
Warning symbols drum winch
Slewing-gear holding brake applied
Winch-boom warning indicator
- Winch boom not locked
Cable-winder warning indicator
- Maximum usable cable length reached
- Fault in winch-cable winding onto drum.
Winch-cable strand monitor
- Winch cable defective
- Cease operation
- Ascertain the cause of the problem.
The winch-cable strand monitor is not a substitute for visual inspection of the winch cable.
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Electronic pulling-force control is OFF
Manual pulling-force control by potentiometer for winch pulling force is ON.
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Tiller pushbutton
see the section on the AlpinFlex tiller
Tiller emergency mode / automatic operation
Switch on emergency tiller control for:
- Attaching / removing tiller
- Raising tiller
- Automatic tiller control fault message
Activating emergency tiller control
Use the joystick and shuttle to operate the tiller.
See the section on the terminal
Risk of tiller colliding with winch arm. In emergency mode, upward movement of tiller is not restricted.
Note that the depth of the tiller is shown on the display even in emergency mode.
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Tiller-boost function
Increased tiller speed max.1600 rpm
See terminal touch fields
Snow-flap position for tiller
Top section pressed = Reduce tiller snow-flap depth
Bottom section pressed = Increase tiller snowflap depth
Auxiliary driven machinery at rear lifts automatically for reversing
(see the section entitled "Rear-mounted auxiliary driven machinery")
Tiller in rigid position
(FunPark only)
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OCKPIT
Extend / retract side finishers
Pushbutton, left = Left finisher
Top section pressed and held down =
Retract
Bottom section pressed and held down = Extend
Pushbutton, right = Right finisher
Indicators also light up if finishers are controlled by joystick.
Raise / lower tracker plates
Pushbutton, left = Left tracker plate
Top section pressed = Raise
Bottom section pressed = Lower
Pushbutton, right = Right tracker plate
Adjusting tiller depth
Top section pressed and held down = Raise tiller
Bottom section pressed and held down = Lower tiller
Tiller depth shown on terminal
Diesel engine ON / OFF
Ignition key in the 'ready for operation' position.
START = Start the diesel engine
600.11021.4.de
Off = Diesel engine OFF
1
2
3
4
1 Ignition lock
0
Insert or remove ignition key / shut down engine
l
Ready for operation / ignition ON
To start the engine: Press the START button
2 Revolution counter / operating hours
Display: Oil pressure, turbocharger pressure, oil temperature, battery voltage, engine load
3 Coolant temperature, diesel engine
4 Diesel fuel gauge
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C
OCKPIT
6
W
5
Steering wheel
5 STOP button
The PistenBully does not have a separate service brake for stopping, it has only a parking brake. The PistenBully does not stop abruptly when you lift your foot off the accelerator pedal or set the direction-of-travel switch to the neutral position.
If you hit the STOP button, the PistenBully brakes sharply to a complete stop.
Hit the STOP switch in the event of sudden danger.
The PistenBully comes to an immediate stop and will not answer to the steering.
Immediately apply the parking brake.
Set the direction switch to the neutral position.
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Resuming operation after a stop
Press STOP button
5
and hold it down for at least 5 seconds.
The PistenBully is again ready for operation.
If you switch the diesel engine OFF it is not necessary to press the STOP button again to restart.
6 Display
- Parking brake applied
- Winch ON / OFF
- Alarm indicators: Cable-winder monitor, cable length, strand monitor
- Track tension relieved
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OCKPIT
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Press to have rear wipers execute a single stroke.
Intermittent-wipe setting:
- Switch on the rear windscreen wipers.
Intermittent-wipe indicator light flashes.
- Press pushbutton
W
see illustration
The time between wipes increases.
(see "Touchscreen")
.
Press again: time between wipes decreases.
To save the intermittent-wipe setting:
- Hold down pushbutton
W
for more than 2 seconds.
Tiller ON - OFF
When the parking brake is engaged, the tiller drive automatically switches off. When the parking brake is released, the tiller drive remains off (indicator for tiller flashes). You must operate the pushbutton again in order to reactivate the tiller.
6
8
9
7
10
11
12
6 Keep rear equipment carrier horizontal.
7 Swivel rear equipment carrier horizontally to the right.
8 Swivel rear equipment carrier horizontally to the left.
9 Rear equipment carrier horizontal, in floating position
.
10 Direction-of-travel pushbutton
Top section pressed = Forward
Neutral position = Press again
Bottom section pressed = Reversing (with reversing alarm)
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Engine speed increases when you press the direction-oftravel pushbutton.
Use the accelerator pedal to increase engine speed / driving speed.
The PistenBully moves off.
11 Knurled knob for driving speed
The speed at which the vehicle travels depends on engine rpm, on the setting of the potentiometer, and on drag. You bring the engine to the correct rpm by depressing or easing up the accelerator pedal, and set the maximum speed by turning the potentiometer.
See the section on the button for the restraint function for additional information
12 Knurled knob for adjusting tiller shaft speed
Turn the potentiometer to adjust tiller shaft speed. Tilling speed is increased / reduced to suit the snow conditions.
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M
ULTIFUNCTION JOYSTICK
.
Front blade
Raise - lower
Joystick
Tilt
Dip / version 1
+
Pushbutton
Floating position
Position
A
- Lower
B
- Raise
C
- Left
D
- Right
A
- Forward
B
- Back
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M
ULTIFUNCTION JOYSTICK
Front blade
Swivel
Pushbutton
+
Joystick
Wing, left
+
Wing, right
+
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Position
C
- Swivel left.
D
- Swivel right.
A
- Move wing in.
B
- Move wing out.
C
- Move wing in.
D
- Move wing out.
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M
ULTIFUNCTION JOYSTICK
Rear equipment carrier
Raise - lower
Floating position
Depth setting
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Joystick Pushbutton / potentiometer Position
A
- Raise
B
- Lower
Press = Fully lower.
Press again = Hold
1.
2.
Standard and winch
Just with sideflaps on the tiller
1.
Press
2.
Turn clockwise = Relieve
Centred (latched position) =
Floating position
Turn counter-clockwise =
Press against snow
A
Top section pressed = Raise tiller
B
Bottom section pressed =
Lower tiller
Note:
Tiller depth shown on touchscreen
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M
ULTIFUNCTION JOYSTICK
Rear equipment carrier
Floating position
Joystick Pushbutton Position
Swivel horizontally
C
- Swivel left
D
- Swivel right
Side finishers
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C
E
D
E - Briefly pressed =
Rigid position
E
- Briefly pressed again =
Centred
E
- Pressed and held down =
Equipment carrier centred as long as button is held down.
Left finisher A
Press = Fully extend.
Press again =
Fully retract.
Right finisher B
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F
UN
P
ARK
FunPark equipment carrier Joystick
Power Angle
+
Pushbutton
Roll
Switch on tiller
+
Position
A
- Retract tiller
B
- Extend tiller
Touchscreen shows:
Emergency tiller control
Note:
Switch to automatic when finished.
A
- Roll forward
B
- Roll back
Touch control for tiller
ON
Press and hold down = ON
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N
ORDIC
-
TRAIL TRACKER PLATES
(
OPTIONAL
)
Nordic-trail tracker plates
Raise/lower/press into snow
A
- Right tracker plate, raise / lower
B
- Left tracker plate, raise / lower
B
A
B
A
C
B
A
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C
B
A D
B
B
A
C
A
C
D
All tracker plates
E
F
Press into snow
C
A-C -
Tracker plates raise / lower
E
- Raise all tracker plates
F -
Lower all tracker plates
A-D -
Tracker plates, raise / lower
+/-
Contact pressure for tracker plates, value 0 - 100 %.
see reading shown on terminal
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N
ORDIC
-
TRAIL TRACKER PLATES
(
OPTIONAL
)
Variant 1 / 2
2x Nordic-trail tracker plates
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E
F C
D
D
C
Function toggle, press
- Indicator lights up
C/D
Track spacing
H
G
Function toggle, press
- Indicator lights up
C-F
Track spacing
G-H
Distance between tracker plates
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N
ORDIC
-
TRAIL TRACKER PLATES
(
OPTIONAL
)
Variant 3 / 4
3 / 4x Nordic-trail tracker plates
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D
C
Function toggle, press
- Indicator lights up
C/D
Track spacing
D
C
Function toggle, press
- Indicator lights up
C/D
Track spacing
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N
ORDIC
-
TRAIL TRACKER PLATES
(
OPTIONAL
)
Variant 5
2x Nordic-trailer tracker plates with
1 Nordic-trail tracking tiller
H
G
X1
X nordic-trail tracking plate tiller
(Use terminal to select)
Nordic-trail tracking plate tiller switched off.
Nordic-trail tracking plate tiller is switched off when Nordic-trail tracking plate is raised.
Nordic-trail tracking plate tiller is switched off when tiller is raised.
Function toggle,
- Indicator lights up
C/D
Track spacing
D
C
G-H
Distance between tracker plates
Function toggle,
- Indicator OFF
X1
Nordic-trail tracking tiller, raise / lower
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N
ORDIC
-
TRAIL TRACKER PLATES
(
OPTIONAL
)
Variant 6
2x Nordic-trailer tracker plates with
2 Nordic-trail tracking tillers
H
G
X nordic-trail tracking plate tiller
(Use terminal to select)
Nordic-trail tracking plate tiller switched off.
X2
Nordic-trail tracking tiller is switched off when
Nordic-trail tracking plate is raised.
Nordic-trail tracking plate tiller is switched off when tiller is raised.
X1
Function toggle,
- Indicator lights up
G-H
Distance between tracker plates
Function toggle,
- Indicator OFF
X1/2
Nordic-trail tracking tiller,
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P
IPE
M
AGICIAN
(
OPTIONAL
)
Pipe Magician
Cylinder 1
Multifunction joystick Pushbutton
+
Cylinder 2
+
Cylinder 3
+
600.11021.4.de
Position
A
- Extend cylinder
B
- Retract cylinder
A
- Extend cylinder
B
- Retract cylinder
C
- Retract cylinder
D
- Extend cylinder
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P
IPE
M
AGICIAN
(
OPTIONAL
)
Pipe Magician
Pusher frame
Multifunction joystick Pushbutton
+
Position
C
- Retract cylinder
D
- Extend cylinder
See the operating manual for the Pipe Magician.
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S
TICK
(O
PTIONAL
)
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S
TICK
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
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S
TICK
2
Hit the STOP button in the event of sudden danger.
CAUTION!
The PistenBully brakes sharply to a complete stop!
3
1
1 Knurled knob for driving speed
The speed at which the vehicle travels depends on engine rpm, on the setting of the knob, and on drag. You bring the engine to the correct rpm by depressing or easing up the accelerator pedal, and set the maximum speed by turning the knob.
2 STOP button
The PistenBully does not have a separate service brake for stopping, it has only a parking brake. The PistenBully does not stop abruptly when you lift your foot off the accelerator pedal or set the direction-of-travel switch to the neutral position.
If you hit the STOP button, the PistenBully brakes sharply to a complete stop.
600.11021.4.de
The PistenBully comes to an immediate stop and will not answer to the steering.
Immediately apply the parking brake.
Restart = Press the STOP button and hold it down for
5 seconds.
3 Knurled knob for adjusting tiller shaft speed
Turn the knob to adjust tilling speed. Tilling speed is increased
/ reduced to suit the snow conditions.
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S
TICK
4 Pushbutton, tiller drive ON - OFF
5
4
When the parking brake is engaged, the tiller drive automatically switches off. When the parking brake is released, the tiller drive remains off (indicator for tiller flashes). You must operate the pushbutton again in order to reactivate the tiller.
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.
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Activating manual throttle control
Use the accelerator to bring the engine up to the desired diesel-engine speed.
Press button 5 and hold it down for at least 3 seconds.
The diesel-engine speed remains constant.
WARNING!
Driving with manual throttle control!
Easing the accelerator will no longer produced a reduction in driving speed and diesel-engine speed!
Engine rpm will respond only by increasing in response to increased pressure on the accelerator.
Reducing diesel-engine speed / driving speed
Version 1
Move the sticks toward the neutral position.
Version 2
Press button for manual throttle control 5
600.11021.4.de
S
TICK
Front blade
Raise - lower
Joystick
Tilt
Dip / version 1
+
Pushbutton
Floating position
Position
A - Lower
B - Raise
C - Left
D - Right
A - Forward
B - Back
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S
TICK
Front blade
Swivel
Wing, left
Wing, right
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Joystick
+
Pushbutton
+
+
Position
C - Swivel left.
D - Swivel right.
A - Move wing in.
B - Move wing out.
C - Move wing in.
D - Move wing out.
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S
TICK
Rear equipment carrier
Raise - lower
Floating position
Depth setting
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Joystick Pushbutton / potentiometer Position
A - Raise
B - Lower
Press = Fully lower.
Press again = Hold
1.
2.
1. Press
2. Turn clockwise = Relieve
Centred (latched position) =
Floating position
Turn counter-clockwise =
Press against snow
Standard and winch
Only press closed in case a tiller with side finisher.
A Top section pressed = Raise tiller
B Bottom section pressed =
Lower tiller
Note:
Tiller depth shown on touchscreen
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S
TICK
Rear equipment carrier
Floating position
Multifunction joystick
Swivel horizontally
D
C
Pushbutton
Note:
Function only with a tiller without side finisher lift /
lower
(USA version).
Position
Long press =
Centring
Short press =
Rigid position
Press again=
Floating position
C -Pivot tiller to left
D - Pivot tiller to right
Swivel horizontally
Note:
Function only with a tiller with side finisher lift / lower.
C -Pivot tiller to left
D - Pivot tiller to right
C
D
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S
TICK
Rear equipment carrier
Side finishers
Joystick Pushbutton Position
Left finisher A
Press = Fully extend.
Press again =
Fully retract.
Right finisher B
Active winch
ON / OFF
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S
TICK
/F
UN
P
ARK
(O
PTIONAL
)
FunPark equipment carrier Joystick
Power Angle
+
Pushbutton
Roll
Switch on tiller
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+
Position
A - Retract tiller
B - Extend tiller
Touchscreen shows:
Emergency tiller control
Note: Switch to automatic when finished.
A - Roll forward
B - Roll back
Touch control for tiller ON
Press and hold down
= ON
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T
ERMINAL
C
ONTROL
C
ENTRE
The TCC Terminal Control Centre is an operating unit for the touchscreen in the cockpit. The TCC provides a convenient way of operating the touchscreen while seated. Direct input via the touchscreen itself is not affected, so the two modes can be used in parallel.
Shuttle
Change current setting.
Turn clockwise: Increase value
Turn counter-clockwise: Reduce value.
Change from one selection field to another
- in the active window.
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Confirm a preselection
Preselection is for the shuttle, the menu selector and the program navigator.
- Abort a function / input.
- Go up to the next menu level.
Pushbutton for Home and Favourites page.
Press again to toggle between Home and Favourites page.
Menu selector
Selects the menu in the active program.
Program navigator (not used at this time)
Function software selection:
- Vehicle
- Navigation
- Operational-data logging
- Service
- Manuals
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T
ERMINAL
Start page / Overview
Note: Use only a commercially available glass cleaner to clean the terminal.
Touch-sensitive fields:
Touching activates function selection
Vehicle data . . . . . . . . . . . . . . . . . . . . 77
Tiller page . . . . . . . . . . . . . . . . . . . . . . 78
Camera page . . . . . . . . . . . . . . . . . . . . 80
SnowSat,
option seperate operatin manual
72/162
Go to first page
Confirm a function
Step back one level
Go to last page
Not used
Factory default
Touch-sensitive field: Touching the field will step through the levels "Persons 1 to 3" and "KGF".
Always check that the setting is correct before pulling away from rest.
Person 1 to 3
Custom settings for joystick and panel functions.
Only Kässbohrer Service has authority to enter the code.
600.11021.4.de
T
ERMINAL
Bar graph
Engine oil pressure
Snow-flap adjustment, tiller
See the section entitled "Multiflex tiller"
Tiller contact pressure
Note:
Red surround indicates that function is "Lower rear equipment carrier".
Tiller depth
Tiller speed
Adjusting slope contour
Contact pressure, tracker plates
Use shuttle to adjust
Tiller Surface control switch
i
The tiller switch only appears in the terminal when a Alpin-
Flex Tiller or a MultiFlex Tiller is attached.
M = Manual mode, via potis and buttons
KGF = Not adjustable default values, this mode should be alright for approx. 80% of the snow conditions.
M 1 = Adjustable values
M 2 = Adjustable values
M 3 = Adjustable values
The values for M1, M2 and M3 are adjustable on the tiller screen,
see page 12.
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T
ERMINAL
Start page / indicators
Parking brake applied
Also:
Braking-air check, parking brake
Release pressure has dropped below 120 bar
Parking brake not applied
Front snow blower mounted
Magician mounted
Direction of travel neutral
Direction of travel forward
Direction of travel reverse
74/162
Alpinflex installed
Tiller 2000 mounted
Multiflex tiller mounted
Drum winch ON
Active Drum winsch ON
Tiller at standstill
Tiller ON
Tiller running
600.11021.4.de
T
ERMINAL
Rear equipment carrier rigid
Lower rear equipment carrier
Raise rear equipment carrier
Flap, right lifted
Flap, left lowerd
Both flaps lifted
Rear equipment carrier horizontal in position
rigid
centred
right
left
Floating position
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T
ERMINAL
Emergency tiller control
Tiller control, automatic
Intake air preheating ON
See the section on the diesel engine
Air-filter monitor
Check the air filter and replace if necessary.
Air filter
Air intake, fresh air (cold air)
Air filter
Air intake, engine compartment (warm air)
High-priority fault.
Cease operation.
See the section on the terminal fault codes
Medium-priority fault.
See the section on the terminal fault codes
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Coolant below the minimum level
Cease operation.- Rectify cause.
Top up coolant to specified level
See the section on checks
WARNING!
Risk of scalding:
The coolant system is pressurised.
Remedy: Wear protective gloves.
Superstructure lock closed
Superstructure lock open
Filter in hydraulic-fluid tank clogged.
If the warning light comes on at operating temperature:
- Cease operation.
- Change the filter.
Temperature of hydraulic fluid too high.
Speed reading
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T
ERMINAL
Vehicle data
600.11021.4.de
Daily operating hours
Total operating hours
Driving hours
Tiller operating hours
Winch operating hours
Diesel-engine operating hours
Diesel engine over-revved.
Steering sensitivity
Use shuttle to adjust the setting
Diesel consumption
Extended options
Code required for access to enablement level, access restricted to trained workshop personnel.
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T
ERMINAL
Tiller page
78/162
Tiller speed
Tiller depth
Tiller contact pressure
Adjusting slope contour
(not available for
Parallel equipment carrier)
Use shuttle to adjust
Slope contour
0 = Cap
30 = Follow
60 = Retain unchanged
100 = Heighten
Tilting tiller in raised position
Advantages:
- Better view toward the rear
- Tiller's centre of gravity is closer to the vehicle.
- Useful for bulldozing work
Adjusting:
Raise the carrier
Use shuttle to adjust the tiller setting
Snow-flap adjustment, tiller
See the section entitled "AlpinFlex tiller"
600.11021.4.de
T
ERMINAL
Touch-sensitive fields
Touch to activate function selection
Lift out tiller
Advantages:
When the control is set to lift out tiller, the finisher is the last element to lose contact with the snow when the tiller is lifted. The slope contour tails off smoothly (no wall of snow left behind).
Tiller rigid
Tiller and finishers are lifted at the same time.
Swing damping ON
Swing caused by driving over broken terrain is damped at the equipment carrier.
Swing damping is ON when the engine is restarted.
Automatically retract side finishers.
No automatic retraction.
600.11021.4.de
Nordic-trail tracking plate tiller switched off.
Nordic-trail tracking plate tiller is switched off when Nordic-trail tracking plate is raised.
Nordic-trail tracking tiller is switched off when tiller is raised.
Boost function ON
Tiller speed max. 1600 rpm
Boost function OFF
Tiller speed max. 1300 rpm
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T
ERMINAL
Rear Camera
Optional extra
Camera view for reversing switched off by means of touchscreen
(see arrow).
Touch symbol
see arrow
Camera view for reversing switched on by means of touchscreen.
Even though the vehicle is fitted with this system, you remain under the obligation to check carefully the area behind the vehicle when reversing.
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T
ERMINAL
Tiller adjustments
(not available for Parallel equipment carrier)
M1, M2 and M3 are adjustable for:
The different conditions (new snow-, wet-snow or hard conditions)
For different drivers
Suggested values for different conditions:
Snow type
KGF
M1
Fresh-fallen
snow
M2
Wet snow
M3
Compacted
snow
Tiller speed
700
700
600
900
Tiller depth
50
50
60
70
100
0
Snow flap
100*
100*
Contact pressure Tiller control
750 60
500 60
100*
50
750
1000
Tiller flap 100 = Flap completly open
60
60
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T
ERMINAL
Fault-code displays
Category
Medium-priority fault.
Warning buzzer sounds:
10 sec. ON and 0.5 sec. OFF
- Display shows ATTENTION
- Yellow warning symbol
- Restriction possible
Check fault code:
Press OK.
To acknowledge a fault: Press the ESC key
Repeated message: If you ignore a message indicating a fault that would result in damage to the vehicle.
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Display Action
600.11021.4.de
T
ERMINAL
Category
Low-priority fault
Warning buzzer sounds:
0.5 sec. ON and 1.5 sec. OFF
- Display shows !W
- Green warning symbol
- Minor restriction possible
Category
High-priority fault.
Warning buzzer sounds:
Continuous tone
- Display shows STOP
- Red warning symbol
- Cease operation.
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T
ERMINAL
Key to fault codes
3,2,001
Subassembly
1 = Engine
2 = Vehicle control
3 = Tiller
4 = Winch control
6 = Display
7 = CAN monitoring
10 = Working hydraulics
14 = Rear equipment
3,2,001
Fault
1 = High-priority fault (red)
2 = Medium-priority fault (yellow)
3 = Low-priority fault (green)
3,2,001
001 = Serial number, fault code
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10,1,015
10,1,016
10,1,017
10,1,018
10,1,019
10,1,020
1,2,040
1,2,044 to 1,2,068
Fault
2,1,030
2,1,036
2,1,070
2,1,071
2,1,072
2,1,073
6,1,021
Meaning
Steering potentiometer
Forward / reverse button
Servo output, forward, left
Servo output, reverse, left
Servo output, reverse, right
Servo output, forward, right
Buffer fault PSX
Valve, tiller depth
Valve regulator, tiller depth
Valve current regulator PV9
Valve A, tiller depth
Valve B, tiller depth
No valve data
Pedal value / engine setpoint
Engine
600.11021.4.de
T
ERMINAL
3,2,006
3,2,007
3,2,024
3,2,034
3,2,035
3,2,075
600.11021.4.de
Fault
1,2,074
2,2,031
2,2,032
2,2,033
3,2,001
3,2,002
3,2,005
Meaning
Constant choke
Steering potentiometer, control tolerance
Inch potentiometer
Inch potentiometer, control tolerance
Length measuring system, lifting cylinder
Length measuring system, tiller-depth cylinder
Tiller-depth sensor for lifting defective
Tiller-depth sensor for lowering defective
Tiller-depth sensor defective
Tiller ON/OFF switch
Tiller speed potentiometer
Tiller potentiometer values, control tolerance
Valve 3rd pump (tiller)
4,2,038
4,2,069
Winch speed-range detection
Winch detection
Fault
7,2,043
10,2,013
1,3,004
3,3,003
3,3,008
6,3,022
10,3,012
10,3,014
10,3,023
14,3,041
14,3,042
16,3,037
Meaning
No engine data available on CAN
Proportional control, tiller depth
No engine data
Tiller-depth indicator defective
Button for automatic/manual control of tiller defective
No data from display
Proportional control valve PV9
Proportional control, tiller depth
Switch, tiller joystick
Signal, Multiflex tiller
Signal, enable tiller
Front-equipment detection
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T
ERMINAL
Emergency mode, drive electronics
If the drive electronics fail the following functions are no longer active:
- Steering potentiometer
- Accelerator pedal
- Direction-of-travel switch
Fault-code displays
To acknowledge a fault: Press the ESC key.
If the vehicle is in emergency mode, drive it no further than to the nearest workshop.
Reduced driving speed if steering potentiometer / accelerator pedal develops a fault.
The hazard warning lights are in operation if the vehicle is in emergency mode.
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Emergency mode, vehicle steering
A
E
B
Use outside-mirror controls to adjust
Steering:
A = Steer left
B = Steer right
E = Neutral position
Emergency mode, driving speed
C
D E
Use outside-mirror controls to adjust
Speed:
C = Increase
D = Reduce
E = Neutral / engine idle speed
Emergency mode, direction of travel
Direction of travel forward
Neutral position
Direction of travel reverse
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C
AB HEATING
Manually adjusting blower output
Start the diesel engine.
Press button.
Blower setting:
OFF - AUTO - 1 - 2 - 3 - 4 - 5 - 6 - 7
Use the pushbuttons to select.
Selecting temperature readout in
0
C /
0
F
Ignition ON.
Press the button to confirm.
Press the button to select 0 C / 0 F.
Simultaneously press both buttons.
The setting for temperature readout is saved.
600.11021.4.de
Simultaneously press both buttons.
Display: CODE
CODE = Press the button three times.
Press the button until the display shows 16
Inside-temperature readout
Press the button until the LED is OFF.
Outside-temperature readout
Press the button until the LED is ON.
Reading is displayed automatically when the engine starts.
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C
AB HEATING
Blower and heating to maximum
Press button.
"dEF" appears in the display.
Adjusting automatic heater and blower control
Start the diesel engine.
Adjusting the target interior temperature
= 23
Press button.
The target interior temperature appears in the display. (interior temperature with blower - AUTO).
A 23
= 23
Situational help
The display shows the blower's discharge temperature.
Briefly press both buttons.
The target interior temperature appears in the display.
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Entering target interior temperature
Increase
Decrease
AUTO
Set the blower to AUTO.
Automatic heater and blower control is active.
If the target interior temperature you select is lower than the outdoor temperature the fan will generally run at maximum speed, because there is no air-conditioning system installed.
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R
EMOTE CONTROL
Remote control, open/close doors
Precondition for use
Manually unlock both doors.
The remote control is ready for use.
Closing the central locking system
Press the button once
The turn indicators flash once and the interior lighting comes on as confirmation.
Opening the central locking system
Press the button again.
The turn indicators flash twice and the interior lighting comes on as confirmation.
The doors re-lock if a door is not opened within approximately 60 seconds.
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D
RIVER
'
S SEAT
1
2
3
4
5
6
7
Functional description:
1 Head-restraint cushion
Height and angle are adjustable.
2 Knob
For adjusting the side wings for optimum lateral support.
90/162
3 Knob
For stepless adjustment of backrest rake.
4 3-stop lever
For limiting float to
- 150 mm travel
- 90 mm travel
- 75 mm travel (no-float position)
5 Knob
For stepless adjustment of the seat cushion through 8°.
6 Stepless height adjustment
7 Horizontal fore-and-aft adjustment
By locking rails on both sides.
9 Knob for adjusting side wings
For adjusting the side wings for optimum lateral support.
10 Stepless adjustment of seat depth
From 495 to 570 mm by knob.
11 Strap
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D
RIVER
'
S SEAT
12 Lumbar support
With height adjustment, electrically operated.
13 Rocker switch for curvature
14 Rocker switch for curvature
15 Switch for two-stage control
Heating for seat cushion and backrest
16 Indicator lights for heating
Yellow = 1st stage
Red = 2nd stage
17 Armrest holder
Armrest, left, heated
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17
12
11
10 9
16 15 14 13
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D
RIVER
'
S SEAT
Use
Turn knob (5) clockwise or counter-clockwise to adjust the angle of the seat cushion steplessly through 8°.
i
The angle of seat tilt is correct when the pedals can be operated without the seat applying excessive pressure to the underside of the thighs.
Lumbar support with electrically operated adjustment for curvature and height (12).
Use rocker switch (13) to adjust curvature.
Use rocker switch (14) to adjust height.
Heating for
seat cushion and backrest
Use switch (15) to select either of the two heating stages.
Both indicator lights ON = Heater at full power
Only one indicator light ON = Heater at reduced power.
Armrest
, left, heated, with holder (17)
The angle of tilt of the armrest can be adjusted by means of a knurled screw on the underside.
The armrest holder can be moved 30 mm forward or to the rear.
When the vehicle is laid up for the summer, set the seat to the no-float position to take the strain off the spring. The side wings of the seat are adjustable by mechanical elements. Consequently, do not sit on the wings.
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D
RIVER
'
S SEAT
1 2
Adjusting armrest
1 Fore-and-aft adjustment
2 Rake-angle adjustment
1 2
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OTES
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600.11021.4.de
O
VERVIEW
io
A
TTACHING TILLER
A
TTACHING FRONT BLADE
C
ONNECTING HYDRAULICS
D
RIVE FOR
AUXILIARY EQUIPMENT
O
PENING THE REAR DECK
RAILING
T
ILTING THE DRIVER
'
S CAB
/
LOAD PLATFORM
95/162
A
UXILIARY DRIVEN IMPLEMENTS
2
4
1
1
4
2
3
6
3
6
I
NSTALLING AUXILIARY DRIVEN
IMPLEMENTS
Clear all ice and snow off the adapter plate 1 and centring head of the auxiliary driven implement.
WARNING!
Do not permit anyone to enter the zone between the vehicle and the auxiliary driven implement while the engine is running.
Lower carrier plate or blade frame 2.
96/162
Tilt adapter plate 3.
Drive the PistenBully up to the equipment.
Apply the parking brake.
Slowly raise the carrier plate or pusher frame 2. Adapter plate 3 engages hooks 4, mating plate
1
seats itself against the adapter plate and simultaneously centres itself with the two centring wedges on the adapter plate.
i
Raise the carrier plate or pusher frame just far enough to enable the equipment to seat against the adapter plate. If the centring wedges do not slip under the adapter plate, a few sharp jerks will juggle the auxiliary driven equipment into the correct position.
600.11021.4.de
A
UXILIARY DRIVEN IMPLEMENTS
Switch off engine
Swing eyebolts 6 inward and tighten the nuts (tightening torque 250 Nm).
After approx. 10 minutes operation, recheck the nuts and make sure they are correctly tightened.
i
Remove the rear-mounted auxiliary implement before prolonged periods of dozing work.
600.11021.4.de
A
B
Connecting hydraulics
The threaded high-pressure couplings are for connecting and disconnecting hydraulic hoses.
Check valves that enable or disable flow, as applicable, are actuated automatically in the coupling process.
A = Vehicle end
B = Device end
97/162
A
UXILIARY DRIVEN IMPLEMENTS
Before connecting or disconnecting the hoses for auxiliary driven implement, always:
- Switch off the engine.
- Apply the parking brake.
Switch the ignition for the diesel engine ON and actuate the appropriate functions to depressurise the hydraulic lines.
Ignition for diesel engine OFF
When making the connections, always make sure that both parts of the couplings are perfectly clean.
Connect the leak-off oil line first
see illustration, arrow.
This will enable excess pressure in the system to escape.
98/162
Connect the hydraulic hoses, making sure that the numbers match and that the hydraulic couplings are correctly seated. Use suitable tools to tighten the hydraulic couplings.
Connect the electrical plug of the auxiliary driven implement to the socket of the PistenBully and make sure it is correctly engaged. The plug completes the electrical circuit, so that the controller can recognise the auxiliary driven implement.
Function-test the auxiliary driven implement.
WARNING!
Make sure there is no-one in the danger zone!
Check the driven implement for fluid leaks and, if necessary, have the equipment repaired by trained, qualified persons.
Removing the auxiliary driven implement
Lower the driven implement, with the stands fully extended and secured, onto firm, smooth ground.
Removal is the reverse of the installation procedure.
600.11021.4.de
A
UXILIARY DRIVEN IMPLEMENTS
Disconnect the leak-off oil line last.
Protect the driven implement from the sun if it is to be out of use for a prolonged period of time.
O
PERATION OF AUXILIARY DRIVEN
IMPLEMENT
Precondition for operation of the drive hydraulics
The driver's cab must be fully lowered and locked in position.
The load platform must be fully lowered.
The rear-mounted tiller must be less than 500 mm clear of the surface of the snow.
The plug of the auxiliary implement must be in the socket (socket E). 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.
600.11021.4.de
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.
Tiller - forward operation / counter-rotating
Tiller forward operation / counter-rotating
Indicator right ON = Forward operation
Indicator left ON = Counter-rotating
i
On account of the additional draw on engine power it would cause, counter-rotating mode is not advisable while climbing slopes.
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A
UXILIARY DRIVEN IMPLEMENTS
Automatic lifting of auxiliary driven machinery for reversing
Activate automatic lift.
When the rocker switch is set to "Automatic lifting" the hydraulic circuits listed below are automatically actuated when the direction of travel switch is moved to the "Reverse" position:
- Vertical and horizontal floating position OFF.
- Equipment carrier is centred.
- Equipment carrier lifts the auxiliary driven machinery approx. 1.2 m clear of the surface of the slope.
- If the tiller is in operation, the tiller is deactivated when lifted more than 0.5 m clear of the surface of the slope.
- Reversing light is switched on.
If the direction of travel is "forward", the following hydraulic circuits are activated at the same time:
- The equipment carrier is automatically lowered.
- If the floating position was selected beforehand, it is automatically reselected.
- If a tiller is installed, it restarts when it is lowered to less than 0.5 m above the surface of the slope.
- The equipment carrier remains locked in the centred position.
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R
EAR DECK RAILING
O
PENING THE REAR DECK RAILING
CAUTION!
Danger of slipping on the track and on the load platform.
When stepping up to or down from the rear deck railing, always keep a firm grip on the railing of the load platform.
Raise the hinged rear deck railing
.
i
For designated holding points for raising the railing, see
(Fig. 1).
Push both locking levers all the way up
(Figure 2).
The safety catch on the locking lever must engage.
Close both safety chains
(Figure 3).
Always comply with the instructions for carrying passengers in the section entitled "Safety instructions".
1
2
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3
101/162
R
EAR DECK RAILING
C
LOSING THE DECK RAILING
Press the safety catch and open the locking lever
(Figure 5)
.
CAUTION!
Risk of injury by crushing:
when lowering the rear deck railing.
Take a firm grip at the designated points
(see
Figure 1)
and swing the deck railing into position.
Fully lower the rear deck railing.
44
5
102/162
600.11021.4.de
T
ILTING THE DRIVER
'
S CAB
/
LOAD PLATFORM
Precondition:
Always remove all loose objects before tilting the driver's cab or load platform.
Park the vehicle on a firm surface that is as horizontal as possible.
Apply the parking brake.
Switch off the tiller drive.
Exiting the driver#s cab
CAUTION!
Close the doors.
Failure to comply with this precaution will result in a risk of accident due to doors slamming closed.
Direction of travel switch in neutral position.
Lower the front-mounted and rear-mounted auxiliary driven implements.
WARNING!
Make sure there is no-one in the danger zone.
Failure to comply with this precaution will result in the risk of collision between the load platform or the driver's cab and the auxiliary driven implement.
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T
ILTING THE DRIVER
'
S CAB
/
LOAD PLATFORM
104/162
Tilting the driver's cab
Move the levers of block ball cock 1 and 2 to the appropriate positions.
Move adjuster valve 3 to the appropriate position.
Press button 4.
The driver's cab will tilt.
You can interrupt this movement by releasing the button.
Switch off the diesel engine by pressing STOP button 5.
600.11021.4.de
T
ILTING THE DRIVER
'
S CAB
/
LOAD PLATFORM
Lowering the driver's cab
Move adjuster valve 3 to the appropriate position.
Start the diesel engine by pressing button 5.
Press button 4.
The driver's cab will lower. The warning light for the cab latching mechanism goes out.
You can interrupt this movement by releasing the button.
600.11021.4.de
Tilting the load platform
Move the lever of block ball cock 1 to the appropriate position.
The rest of the procedure is as described in the section on tilting the driver's cab.
Release and pivot down support 7 on the piston rod.
WARNING!
Risk of injury by crushing:
If hydraulic pressure is lost the load platform will move downward! Secure the support to ensure that the platform cannot move downward of its own accord.
Lowering the load platform
Pivot support 7 up until it latches in position in the spring clip.
The rest of the procedure is as described in the section on lowering the driver's cab.
105/162
T
ILTING THE DRIVER
'
S CAB
/
LOAD PLATFORM
Tilting the driver's cab / load platform
Move the lever of block ball cock 1 to the appropriate position.
The rest of the procedure is as described in the section on tilting the driver's cab.
Release and pivot down support 7 on the piston rod.
WARNING!
Risk of injury by crushing:
If hydraulic pressure is lost the load platform will move downward!
Secure the support to ensure that the platform cannot move downward of its own accord.
Lowering driver's cab / load platform
Pivot support 7 up until it latches in position in the spring clip.
The rest of the procedure is as described in the section on lowering the driver's cab.
i
Note that the rear hydraulics will not operate if the driver's cab locking mechanism is not engaged or the load platform is not fully lowered.
The warning symbol for the cab latching mechanism lights up.
106/162
600.11021.4.de
T
ILTING THE DRIVER
'
S CAB
/
LOAD PLATFORM
Driving the vehicle
Move the levers of block ball cock 1 and 2 to the appropriate positions.
Using the manual pump for tilting and lowering
Switch off the diesel engine.
Prepare the block ball cock / adjuster valve and the support in the same way as for the corresponding operation with the engine-powered hydraulics.
Fit tubular extension (toolkit) on manual pump 7 and operate the pump.
CAUTION!
Risk of crushing by the rear-deck railing frame
Keep well clear when lowering the load platform / rear-deck railing.
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N
OTES
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600.11021.4.de
O
VERVIEW
E
LECTRICS
LIGHTS
. . . . . . . . . . . . . . 110
F
USES
. . . . . . . . . . . . . . . . 113
B
ATTERY
. . . . . . . . . . . . . . 114
B
ATTERY MASTER SWITCH
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L
IGHTS
7
1
2
3
4
5
6
8
9
10
11
Lights
Do not touch the glass of halogen bulbs.
(See notes on halogen-xenon bulbs)
.
1 Rotary beacon
2 Front searchlight
3 High-beam headlight / parking light H7
(xenon optional)
4 Low-beam headlight H7
(xenon optional)
110/162
5 Xenon worklight
6 Turn indicator
7 Worklight, front
(xenon optional)
8 Worklight, rear
(xenon optional)
9 Worklight, side
(xenon optional)
10 Turn indicator
11 Rear light
600.11021.4.de
L
IGHTS
Halogen - xenon
WARNING!
Bright light could injure eyes.
Do not look directly into the bright light.
WARNING!
Health hazard due to gas.
If a xenon bulb breaks in an enclosed space, leave immediately and ventilate the room for at least 20 minutes before re-entering.
Damage to electronic ballast:
Persistent light problems indicated by flickering of the gasdischarge light can result in damage to the electronic circuitry in the ballast.
Switch off immediately if the light flickers.
600.11021.4.de
Risk of breaking the lens:
Do not use liquid to clean the lens while hot.
Clean the glass lens if dirty, but only when the lens is cold.
Do not use aggressive or abrasive cleaning agents.
Safety instructions for changing xenon bulbs
Before changing a bulb, always switch off the headlights and isolate them from the power supply.
Do not probe into the bulb socket.
The electrical connection between headlight and ballast carries a high voltage: do not break this connection.
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.
111/162
L
IGHTS
Wear protective goggles and protective gloves when changing bulbs.
Danger of flying splinters of glass.
The glass body of a xenon bulb is pressurised and can shatter.
Always hold the bulb by the base.
Operate xenon bulbs in closed headlights only.
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.
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F
USES
1
2
3 5
7
4 6
8
9
Replacing fuses
Fuses are designed to provide protection against excessively high currents in the electrical system.
The fuses are behind the co-driver's seat.
Remove the screws and lift off the cover.
WARNING!
Risk of cable fire and short-circuit.
Never attempt to jumper or repair fuses or insert replacement fuses with a higher ampere rating than the originals.
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1 Winch control (25 A)
2 Hydraulics 1 (30 A)
3 Hydraulics 2 (30 A)
4 Hydraulics 3 (30 A)
5 Valves (30 A)
6 ECU 1 (30 A)
7 ECU 2 (30 A)
8 ECU 3 (30 A)
9 Starter relay
If a fuse blows the corresponding LED lights up
(see arrow)
.
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B
ATTERY
Vehicle battery
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.
The two 12 V, 135 Ah batteries are mounted on the upper frame.
Checking electrolyte levels
Tilt the driver's cab.
The battery must be held in place by the retainer.
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.
Top up the fluid in the cells to the max. mark with distilled water.
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B
ATTERY
Charging the battery
1
2
1b
Jump starting
WARNING!
A mistake in the jump-starting procedure could result in fatality or severe burns due to electric shock.
Do not make a connection between the cable terminals.
Do not connect the jump-start leads to the connections between the two batteries.
WARNING!
Connect the battery clamps to the battery posts.
Make sure that polarity is not reversed.
Do not bring the battery clamps into contact with each other.
Make sure the room in which the battery is charged is well ventilated.
Do not place metal objects on top of the battery.
Connect the battery to the on-board electrical system by activating the battery master switch.
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Valtage peaks during disconnecting the external current cables. Risk of damaging electronic control units!
Before disconnecting the jumper cables of the vehicle, switch on other electric loads (e.g. window heater / seat heater.
Risk of damaging electronic control units!
Do not attempt to start the engine using power boosters or power packs to boost the battery or as a substitute for the battery.
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B
ATTERY MASTER SWITCH
Connecting jump leads
(see illustration)
1. From + pole clamp 1 to + pole of donor battery (24 V).
2. From – pole clamp 2 to – pole of donor battery (24 V)
Connect the battery to the on-board electrical system by activating the battery master switch.
Battery master switch
Switch off the battery master switch:
if the electronics are defective.
to help prevent the battery from discharging during a prolonged 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.
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Data loss in the digital propulsion and tiller-control electronics.
Before disconnecting the battery from the vehicle's onboard electrics:
- Switch off the ignition.
- Wait 30 seconds.
- Then operate the battery master switch.
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B
ATTERY MASTER SWITCH
1
1b
Disconnecting battery from on-board electrics
Turn battery master switch 1 in the direction indicated by the arrow.
The battery is now isolated from the vehicle's on-board electrics (1b).
Connecting battery to on-board electrics
Operate the battery master switch.
Wait 30 seconds.
Switch on the ignition.
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OTES
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D
AILY CHECKS
I
NSTRUCTIONS FOR CHECKS AND
MAINTENANCE
WARNING!
Risk of injury by cutting or crushing action.
At all moving parts.
When the engine is running, keep well clear of rotating parts.
Always perform the specified checks before starting off.
Perform all checks with the engine off and the vehicle parked on a horizontal surface.
Make sure that the oil and coolant levels are always to specification (check at oil dipstick, overflow plug, etc.).
New vehicle:
Check security of wheels after the first 5 operating hours. Tightening torque 300 Nm.
T
OPPING UP FLUIDS AND LUBRICANTS
WARNING!
Do not permit fluids or lubricants to come into contact with the skin (wear protective gloves, change wet clothing).
Do not inhale or swallow fluids or lubricants (risk of poisoning).
WARNING!
Risk of explosion due to build-up of gas in fuel tank.
Keep all possible sources of ignition when clear when the vehicle is being refuelled.
Do not spill fluids or lubricants (they are hazardous to soil and water). Always dispose of these substances in an environmentally compatible manner (comply with local laws).
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D
AILY CHECKS
C
HECKING COOLANT LEVEL
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 fluids and lubricants).
Check that the hoses in the cooling and heating systems are tight and not leaking.
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2
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D
AILY CHECKS
C
HECKING ENGINE OIL LEVEL
Use the dipstick to check the engine oil level.
Top up the oil with the engine stopped and the Pisten-
Bully standing on level, horizontal ground.
The oil level must be between the min. and max. marks on the oil dipstick.
Use only approved engine oil (see fluids and lubricants specifications).
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D
AILY CHECKS
C
HECKING 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).
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D
AILY CHECKS
C
HECKING ELECTRICAL SYSTEM
Check the lights and flashing indicators and the rotating beacon system; repair or replace components as necessary. Always comply with the instructions for working on the rotating beacon system (high-voltage system).
Replace defective bulbs and fuses.
Check the wipers, horn and back-up alarm.
Never operate the PistenBully if the warning lights and rotating beacon system are not fully functional..
V
ISUAL INSPECTION
Visually inspect the tracks and sprockets, check for tyre damage.
Visually inspect the fasteners of the auxiliary driven implements (locking pins, bolts, nuts).
Visually inspect the hydraulic system (drive hydraulics and hydraulics for auxiliary driven implement), hydraulic lines, connectors, hoses, hydraulic cylinders for leaks and chafing.
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D
AILY CHECKS
C
HECKING PARKING BRAKE
Make sure there is no-one in the danger zone.
Start the engine – Apply the parking brake: Indicator light comes on.
Set the direction-of-travel switch or the propulsion lever to "Forward" and briefly accelerate the engine to approx. 2000 rpm.
The PistenBully must remain motionless.
Do not operate the vehicle if the parking brake is defective.
The indicator light in the instrument cluster must go out when the parking brake is released.
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W
EEKLY CHECKS
W
EEKLY CHECKS
Perform all the daily checks.
Check the drive belt on the engine (engine fan, alternator); make sure that belt tension is correct and that the belt is free of damage (see the manual supplied by the engine manufacturer).
C
HECKING FUEL PREFILTER
Replace the filter element if it is very dirty or damaged.
Screw open filter housing , remove the filter element and clean it in clean diesel fuel, using a soft brush.
Check the sealing ring for the filter housing; replace if necessary.
Slip the filter element into the filter housing and reinstall the housing. Tightening torque 10 Nm.
Dispose of used filters and fuel residues in accordance with the locally applicable environmental-protection and safety regulations.
Make sure that the sealing ring is correctly seated.
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W
EEKLY CHECKS
T
RACK TENSION
Checking track tension:
- Vehicle parked on horizontal, snow-covered ground.
- No load on vehicle and auxiliary driven implements lowered.
- After equalising track tension by driving backwards and forwards.
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 stringers, track lacings, tyre guides and backing plates, replace damaged components.
T
EST DRIVE
Check operation and test all instruments and indicators.
Check running gear and engine / transmission unit for abnormal noises.
Visually inspect for smoke at the exhaust.
Check the air filter element if the exhaust is smoky.
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W
EEKLY CHECKS
C
HECKING WHEELS
Check the wheel fasteners and check tyre pressures.
Tightening torques
T
YPE
PistenBully 600
T
ENSIONING AXLE
D
RIVE AXLE
300 Nm 300 Nm
A
IR PRESSURE
,
DRIVE AXLE
7.0 bar
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W
EEKLY CHECKS
T
RANSFER CASE
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).
1
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E
NTERING
–
DRIVING
–
EXITING
E
NTERING
Before entering the cab, complete the daily checks and maintenance tasks.
Walk right round the vehicle and make sure that the danger zone is clear of persons and objects.
Always take a firm grip on grab handle door when entering the vehicle.
1
of the driver's
Step onto the track.
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CAUTION!
Danger of slipping on the track when entering and exiting the driver's cab.
Always take a firm grip on the handle in order to step onto the track.
In order to help ensure safe operation, operators must wear appropriate footwear with non-slip soles.
Press the door lock. The driver's door opens.
CAUTION!
When parking on a slope, be particularly careful when opening the door. The door opens suddenly.
Always take a firm grip on grab handle
2
of the driver's door.
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E
NTERING
–
DRIVING
–
EXITING
Fully raise armrest 3.
Take a grip on steering wheel
4
and swing yourself into the driver's seat
Close the door.
Adjust the seat and the steering wheel to an ergonomically comfortable position.Total lowering of the armrest (machines with sticks, version USA- out of operation when armrest is not lowered totally).
Fasten the seat belt.
Visual check:
Direction-of-travel switch in "Neutral" position, parking brake applied.
S
TARTING THE DIESEL ENGINE
WARNING!
The use of proprietary starting agents (such as Startpilot, for example) is prohibited on account of the risk of explosion.
WARNING!
Risk of poisoning from exhaust gases.
Do not leave the engine running unattended or running in an enclosed space.
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E
NTERING
–
DRIVING
–
EXITING
Start procedure
Ignition ON
Depending on the ambient temperature, the intake-air preheating light goes out after approx. 2 seconds (no preheating) or within 30 seconds (maximum preheating time).
When the intake-air preheating light goes out:
Start the engine
Do not depress the accelerator
- Operate the starter until the engine is turning at
700 rpm
- Maximum duration of start attempt 30 seconds
Engine refuses to start?
Immediately repeat the start attempt (do not repeat the preheating procedure). Duration of start attempt, max. 30 seconds
If it is necessary to repeat the reheating procedure:
Ignition OFF
Wait 5 - 10 seconds
Ignition ON
Situational help
The warning light for air-intake preheating may stay lit for up to approx. 3 minutes after the engine starts.
Damage to electronics
If the warning light for intake-air preheating comes on during operation:
- Cease operations
- Proceed to the nearest workshop
- Switch off the battery master switch.
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E
NTERING
–
DRIVING
–
EXITING
W
ARMING
-
UP PHASE
I
NSTRUCTIONS FOR ENGINE BREAK
-
IN
Air temperature above 0
0
C to –20
0
C
Allow the diesel engine to idle for approximately 3 minutes.
Pull away with the engine operating in the partial-load range.
The engine can be operated at full load as of a coolant temperature of + 80
O
C.
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
E
NGINE SPEED RANGE
Air temperature below –20
0
C
Allow the diesel engine to idle for approximately 6 minutes.
Pull away with the engine operating in the partial-load range.
The engine can be operated at full load as of a coolant temperature of + 80
O
C.
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.
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E
NTERING
–
DRIVING
–
EXITING
D
RIVING
Switch on the rotating beacon.
WARNING!
Before driving away, always check that there is noone in the danger zone, in other words in the immediate vicinity of the vehicle or at or on the tracks.
Press the direction-of-travel switch to the position corresponding to the direction in which you want to travel. An audible signal (back-up alarm) sounds if you set the direction switch to the position to reverse.
Even though the vehicle is fitted with a back-up alarm, you remain under the obligation to check carefully the area behind the vehicle when reversing.
Make sure that the area behind the machine is clear.
The assistance of a second person to give directions is necessary if visibility is poor.
Release parking brake.
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Use the accelerator to increase engine speed beyond pullaway rpm: The PistenBully begins to move.
The PistenBully accelerates steplessly to its maximum speed as engine speed increases.
When the vehicle is moving, the electronics monitor the engine speed set in response to movements of the accelerator pedal and adjust the hydraulic ratio in accordance with load, so that engine speed remains constant and only the speed of the vehicle changes.
i
When you turn, bear in mind that the left and right propulsion hydraulics switch to counter-rotation just before full lock is applied to the steering wheel. The PistenBully turns in its own length.
Observe all instruments when driving.
If the engine comes to a stop for whatever reason, immediately apply the parking brake.
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E
NTERING
–
DRIVING
–
EXITING
Engine oil pressure
The warning light for the diesel engine comes on during the start procedure and if oil pressure drops.
Engine operating temperature
If the reading is too high, determine the cause, for example:
- Gauge in correct working order.
- Not enough coolant in system.
- Outside of radiator dirty.
- Check V-belt tension .
- Check visco fan.
Fuel supply
Continually monitor the fuel supply and fill up in good time. This precaution will prevent the fuel supply from failing on a gradient, which would mean the engine stopping inopportunely.
Battery charge indicator
If the battery charge indicator lights up when the engine is running, the alternator is no longer charging the starter batteries. Ascertain the cause of the problem, e.g.:
- Loose wiring connections
- Alternator dirty
- Belt slipping or broken
Hydraulic fluid level warning light
Occasional flashing on descents is not indicative of a fault.
Telltale light for parking brake
If the indicator lamp lights up, check the parking brake.
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i
PistenBully slows down on account of lack of propulsive power
Switch the tiller to forward rotation.
Use the potentiometer to reduce the speed of the auxiliary.
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E
NTERING
–
DRIVING
–
EXITING
B
RAKING
-
STOPPING
S
TOPPING AFTER USE
The hydrostatic drive brakes the vehicle without causing wear.
You reduce engine speed by easing the pressure on the accelerator pedal; engine speed lowers and the change in the hydraulic ratio causes the vehicle to slow down.
The PistenBully will come to a stop if engine speed drops below pull-away speed.
A parking brake (spring-loaded brake) operated by a parkingbrake lever in the driver's cab acts on the sprockets.
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.
In the event of sudden danger, hit the STOP switch.
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Park the vehicle where it is clearly visible.
Park the vehicle on a firm, level surface.
Lower front and rear auxiliary implements,
- Switch off the tiller.
- Direction of travel switch in neutral position.
- Apply the parking brake.
- Relieve the tension of the track.
Set engine idle speed to below 800 rpm.
Turbocharger - risk of overheating:
Do not immediately switch off the diesel engine after it has been run at full load. Drive for approx. 2 minutes in the part-load range and then switch off.
Switching off engine.
Turn the ignition key to the
0
position. .
Remove ignition key and lock the cab.
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E
NTERING
–
DRIVING
–
EXITING
E
XITING
/
REFUELLING
2
3
Fully raise the steering-wheel column and the armrest.
The procedure for exiting the vehicle is the reverse of the entry procedure.
CAUTION!
Danger of slipping on the track when entering and exiting the driver's cab.
Always take a firm grip on the handle in order to step off the track.
Refuel
2
the PistenBully immediately after operation, in order to prevent condensation forming in the tank.
WARNING!
Risk of explosion of due to formation of gas.
Keep all possible sources of ignition when clear when the vehicle is being refuelled with diesel fuel.
Then remove as much snow and ice as possible from the tracks, sprockets and wheels to prevent them freezing fast, in order to avoid damage when the machine is restarted.
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Connect coolant preheating (optional extra).
1 10 /220 V adapter 3 provides a means of preheating the coolant system with the thermostatically controlled preheater, or of preheating the hydraulic fluid with a heater available as an optional extra.
i
1 - 2 hours of preheating prior to starting does not improve cold starting.
Undertake preheating immediately after parking the vehicle.
Use only cables that comply with the applicable regulations in the country of use.
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T
OWING AWAY
/
TOWING HITCH
T
OWING AWAY
/
TOWING HITCH
Towing the PistenBully
Only trained, qualified persons are permitted to operate the emergency release of the parking brake.
Towing a PistenBully is an operation requiring extensive safety measures. Please consult your nearest Service Support Centre.
Attachment weights, towing hitch
Permissible towed weight
Max. towed weight 3000 kg.
Max. off-centre angle for descents 16 0 to left or right.
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.
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OTES
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D
RIVING TIPS AND INFORMATION i
The section entitled "Driving tips and information" is intended merely as an overview and is not under any circumstances to be considered in itself as providing adequate familiarisation with the driving characteristics of the PistenBully.
i
Quantity is not as important as quality and economy.
L
OW FUEL CONSUMPTION
Diesel engine rpm green zone on rev. counter. Max. torque 2000 Nm at 1200 rpm.
Adjust tiller shaft speed to suit snow conditions by
turning the potentiometer.
Steplessly adjust tiller depth to suit snow conditions
by observing the gauge and using the pushbutton
controls. Set the depth so that the tiller removes only as much snow as is absolutely necessary.
Variably adjust the downforce of the tiller comb by means of the joystick and potentiometer. Use
the lowest down-force setting that is compatible with snow conditions
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D
RIVING TIPS AND INFORMATION
M
EDIUM SNOW
In the atmosphere, snow forms from water droplets at temperatures of at least -4 °C.
Over and above these changes, which take place naturally and cannot be influenced (they are caused by wind pressure, freezing and evaporation producing a loss in volume, whereas differences in the temperature of the air trapped close to the ground and the external air tend to produce an increase in volume), it is important to bear the following in mind:
Ice crystals in widely varying shapes form:
Hailstones are snow crystals enlarged by the adhesion of ice; they are usually spherical or tapered in shape.
Hoarfrost or rime forms from water vapour or precipitation on chilled objects (fences, bushes, surface of snow).
White frost develops when the wind carries chilled droplets of water onto solid objects.
Always work so as to cause as little damage as possible to the snow. The aggressive action of driven implements such as a tiller damages the snow crystals; these damaged crystals have lost their ability to mesh as a loose blanket, tending instead to ball and form gritty snow (often at entrances to garages, approaches to lifts, bottlenecks).
Fresh-fallen snow initially forms an airy structure of loosely intermeshed snowflakes.
The original shapes soon disappear, however, and the individual flakes are no longer recognisable only a few days after falling.
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RIVING TIPS AND INFORMATION
Preparing fresh-fallen snow
Fresh-fallen/powdery snow consists of crystals that are loosely attached to each other and which therefore trap a great deal of air. The process of preparation inevitably expels some of this air and packs the crystals more tightly together. This gives the surface layer of snow the ability to bear weight.
Bumpy runs
The friction of skis over the surface causes some of the crystals to melt and form a film of water, and this produces sheets of ice and the softer spots beside them.
Over a period of time skiers break down the topmost layer – humps and hollows form and the run becomes bumpy.
Preparing slopes like this is a process in which old snow is mixed with relatively fresh-fallen snow (snow crystals) and this produces a durable surface.
shapes the surface and a water film forms to hold the grains of gritty snow together. Breaking down the lumpy snow also damages the ice crystals, so they lose a considerable proportion of their ability to cohere. This is the reason why only gritty snow, not powdery snow, can be produced from ice.
i
A durable ski slope can be formed only by mixing this material with fresh-fallen snow or with unused old snow from deeper levels.
Iced slopes/sheets of ice
Do not break up an iced slope unless the ice is of adequate thickness or fresh snow falls. The gritty snow produced by breaking up the ice needs fresh-fallen snow to cohere, or else it will cohere with water - and this will again cause ice to form. Consequently, it is advisable only to roughen the surface of the ice to make the slope skiable. Sheets of ice on slopes that are otherwise in good condition can be broken up and mixed with crystals from deeper in the snow.
If outdoor temperatures are correspondingly low the snow freezes and forms lumps - when this happens the only way
of making a ski run look well is to work with a tiller mounted on the rear of the vehicle.
The teeth of the tiller break the lumps down into gritty snow, which fills the hollows in the surface of the run; the finisher
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i
The more frequently the ice is turned and the crystals damaged, the less will be their ability to cohere.
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D
RIVING TIPS AND INFORMATION
Wet snow/slushy snow
The relatively large amounts of moisture and the formation of a film of water on the finisher can produce a relatively hard surface, which inexperienced skiers in particular find difficult.
In order to counteract this effect, Kässbohrer has developed a bolt mechanism for tilting the rear-mounted tiller comb. In combination with special finishers, this machine can change the uniform surface structure and produce a "powdery-snow" effect.
Extremely slushy snow in spring
It is advisable to use the side wings, because the tiller can produce edge walls as it passes through the snow. Kässbohrer also offers an extra-wide side wing for more efficiency when used in combination with the rear frame steering– this also means that the machine can prepare on one side at a time.
If a satisfactory run cannot be prepared in slushy snow, is might be advisable to wait two or three hours to allow the temperatures to change. Work on preparing slopes at higher altitudes can proceed in the interim.
i
Allow the snow to set-up, so that crystals can form.
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D
RIVING TIPS AND INFORMATION
C
LIMBING ABILITY
The climbing ability of the PistenBully depends on the limit of adhesion of the snow. The machine's centre of gravity is another factor influencing climbing ability. It is important for the driver to ensure that as much of the surface area of the tracks as possible is in contact with the ground, as otherwise there is a risk of the vehicle toppling. The limits are heavily dependent on the way in which the vehicle is used, on load, on the prevailing conditions, and on the skill and ability of the driver.
S = C
ENTRE OF GRAVITY
H = D
OWNGRADE FORCE
Each situation must be assessed with care. Never assume that it is safe to operate in a certain area at any given time merely because a vehicle was in the area in question beforehand.
.Inexperienced drivers, in particular, should familiarise themselves with the vehicle and equipment before undertaking operations in difficult terrain.
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D
RIVING TIPS AND INFORMATION
D
RIVING WITH THE
P
ISTEN
B
ULLY
The basic rule is: Do not use the vehicle until the snow is deep enough to prevent damage to the underlying vegetation.
The objective in preparing a ski-slope is to achieve visually excellent slope quality:
Build up supplies of snow in good time at critical points, so that 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.
If speed is excessive, the tracks will throw snow out sideways and over the auxiliary mounted implement onto the prepared surface.
Regularly remove snow from the load platform. Otherwise, the increase in weight will result in higher fuel consumption.
Always keep the engine revving in the most economical rpm range (indicated by the green zone on the tachometer).
The drive electronics adjust driving speed to suit engine rpm.
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 work from the top down to prepare the first part of the run.
Whenever possible, negotiate slopes by following the line of fall and by keeping steering movements to a minimum.
Do not overrev the engine: use only as much power as is necessary; note the level of traction. Overrevving will cause the tracks to slip, with the result that the vehicle will dig into the snow. If the tracks start to dig in stop immediately and try a different line.
i
Digging in ruins the ski-slope and destroys the surface beneath the snow.
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RIVING TIPS AND INFORMATION
Turning
In order to avoid damaging the surface of the ski-slope, you must turn at or beyond the edge of the prepared slope. You should, of course, use areas that are free of vegetation (forestry plantations and the like) for this purpose.
Always keep the front-mounted and rear-mounted auxiliary driven implements raised when turning.
Turning with counter-rotating tracks:
You can turn the vehicle in its own length by counter-rotating the tracks. This causes the vehicle to dig in to some extent, so you should manoeuvre in this way only when the snow is of adequate depth. It is advisable to employ this method of turning in exceptional situations only. Turning with counter-rotating tracks places very high strains on the rubber belts and the track cleats.
Driving: on downgrades
Always maintain a moderate speed on downgrades. This precaution will enable you to ensure that the engine does not overrev, the vehicle does not drift out of control, and the snow is not dragged downhill by the action of the tracks. Use the speed potentiometer to reduce the speed of descent.
Restrict your steering movements to a minimum. Make sure that both tracks are turning.
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Reduce speed as you crest rises, in order to ensure that you have the vehicle under control as it tips forward. This will prevent the front blade from digging in and the tracks from losing traction.
Invariably, do not negotiate a downgrade unless you are sure that:
- the adhesion of the snow is adequate.
- your run out at the bottom of the slope is adequate and safe.
- there are no skiers in the danger zone.
If the PistenBully starts slipping on a downgrade and drifts at an angle to left or right (vehicle's longitudinal axis drifts off the line of fall), you must immediately apply opposite lock (turning the steering wheel to the right or left, as applicable), counterrotating the tracks if necessary, in order to bring the vehicle's longitudinal axis back onto the line of fall. Briefly increase engine speed in the process.
You can counteract slippage along the line of fall by reversing the tiller shaft's direction of rotation and carefully employing the front blade to re-stabilise the vehicle.
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RIVING TIPS AND INFORMATION
P
REPARING THE SKI
-
SLOPE
When preparing a slope, always make sure that the side finishers overlap onto the prepared surface, in order to ensure a smooth transition from one pass to the next.
Notes on depth of tiller
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 too high: Tiller cannot bite into the snow.
- Slope is not contoured in areas of hard snow.
- Tiller shaft too low: Insufficient snow throughput, 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.
Counter-rotating tiller shaft:
A PistenBully with electronic tiller control enables you to set the tiller shaft to rotate either forward (standard direction of rotation) or backward.
i
It can be helpful to have the tiller counter-rotate, for example as an additional brake in very steep terrain.
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RIVING TIPS AND INFORMATION
Errors in operation and counter measures
Summarised countermeasures
Edge walls forming on left and right:
- Speed of shaft rotation too high.
- Tiller depth set too low.
- Downforce setting selected instead of floating setting.
- Cylinder of carrier plate out of adjustment.
- Tiller shafts not rotating.
- Side finishers retracted.
Visual appearance of prepared slope not satisfactory:
- Tiller depth set too high (depth setting).
- Speed of rotation too low.
- Ball handle not locked in position (floating position).
- Vehicle travelling too fast.
- No smooth surface with the front blade (tiller is on a hump).
Vehicle comes almost to a stop:
- Tiller depth too low.
- Speed of shaft rotation too high.
- Cylinder of carrier plate significantly out of adjustment.
- Tiller shafts are counter-rotating.
- Tiller shafts stopped – clogged, jammed, frozen.
Severe vibrations perceptible in vehicle when the tiller is switched on:
- Shaft imbalanced, tooth missing – have repairs carried out by specialists.
- Frozen with snow – remove.
- Imbalance means vibration – screws work loose, bearings are damaged – have the imbalance rectified.
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OTES
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F
RONT BLADE
through fresh-fallen snow and it can be used as a brake to prevent the vehicle from slipping. Consequently, it is advisable to leave the front blade installed at all times.
Smoothing bumpy ski slopes
The best method of smoothing low bumps or waves is to use the front blade in what is known as the "floating" position. This means that the front blade applies only its own weight to the surface, without being pushed downward by the hydraulics.
Correct usage:
- Use of the front blade on steep slopes covered with freshfallen snow.
- Smoothing heavily worn ski slopes.
- Smoothing bumpy ski slopes.
- Making a location line.
Material wear due to load.
During dozing work (i.e. when pushing snow with the front blade), fully raise rear carrier plate.
A front blade is essential for modern ski-slope upkeep and preparation. It is ideal for smoothing bumpy runs and dozing snow clear. The front blade is also very useful for working uphill
The blade's angle of attack is set by means of the roll cylinder.
Exercise great care when setting the roll cylinder, because if the angle of attack is too steep the front blade will tend to dig into the snow.
Approach large bumps with the blade at approximately half height and the float function switched off, so that the blade will push the snow forward off the bump and into the hollow on the other side. In this case, too, it is best to use the roll cylinder to adjust the depth of cut, instead of raising and lowering the front blade. This is the most dependable way of smoothing out the slope.
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F
RONT BLADE
The ideal configuration is to have a leader snow roller mounted in front of the blade, as this will enable the equipment to adjust automatically to compensate for surface irregularities.
Making a location line
The best way of doing this is to approach the downslope at an angle from above and, with the pusher blade swivelled to one side, doze a flat location line in the snow.
It is advisable to start with no more than a small amount of snow, picking up more and more snow as you proceed along the line. This should enable you to complete the full length in a single run.
The snow you push out on the downhill side inevitably widens your location line, increasing the margin of safety.
Use of the front blade on steep slopes covered with fresh-fallen snow
When you prepare fresh-fallen snow you need the front blade not only to push the snow, but also to distribute the weight and apply pressure to the surface of the snow. You can use the front
150/162 blade to help the vehicle climb steep slopes by stopping just before the PistenBully digs in, and reversing with the front blade lowered. This will smooth out the step. Raise the front blade and drive forward a few meters before repeating the procedure; this is one way of climbing difficult slopes.
Smoothing heavily worn ski slopes
One consequence of modern skiing techniques is that the skiers carry the snow progressively further down the slope, finally depositing it toward the bottom of the slope. The objective, therefore, is to restore the snow to as uniform a depth as possible over the entire length of the slope. This entails pushing the snow back up the slope from the bottom. If necessary, winch the PistenBully into position.
Pivot the front blade to an angle at which the snow can slide along it toward the inside. If you are using a 12-way front blade 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 number of ways to the position that best suits the terrain. The end result is efficient transportation of the snow to the parts of the slope where it is needed.
Less experienced drivers in particular should bear in mind that transporting large amounts of snow quickly is not always the way to achieve the best results. The driver has to assess the
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F
RONT BLADE
terrain and decide whether it would be advisable to push snow downhill, or whether this might result in even more snow being lost.
A well-prepared slope is free of heaps of snow, does not have walls along the edges, and is contoured so as to be attractive to the eye.
ParkBlade
Correct usage:
The ParkBlade is designed for constructing and maintaining funparks and boarder crosses.
Funpark obstacles such as funboxes and rails can be transported on the forks.
ParkBlade
Fork damage caused by side load!
The forks must not be moved / raised sidewise!
WARNING!
Risk of injury by crushing: when extending / retracting the forks.
Make sure there is no-one in the danger zone.
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A
LPIN
F
LEX TILLER
1
The AlpinFlex tiller has been evolved as an even more versatile and practical snow handler.
It can tilt to angles up to 20 0 , so it adapts to the natural contours of the terrain.
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 operating conditions.
Side finishers
(optional)
Side finisher 1 has hydraulic tilt control, facilitating overlap with the prepared part of the run and helping prevent surface irregularities on the slope..
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.
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LPIN
F
LEX TILLER
Setting the Alpinflex tiller to the rigid position
If you want to produce a flat (not following the contours of the terrain), set the Alpinflex tiller to the rigid position.
Tiller in rigid position
(FunPark)
1
2
Hydraulic actuation for "set to rigid"
(FunPark)
Set down the Alpinflex tiller on a firm, level surface.
Press the Tiller, set to rigid button until the hydraulic cylinder is fully extended.
Cancelling "set to rigid" (unlock)
Set down the Alpinflex tiller on a firm, level surface.
Press the button until the hydraulic cylinder is fully retracted.
Manual actuation for "set to rigid" (standard)
Pin 1 and adjusting lever 2 in position.
Insert the retainer to secure the pin.
1
2
Cancelling the "set to rigid" function
Pull the pin and set adjusting lever 2 to position.
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A
LPIN
F
LEX TILLER
Snow-flap adjuster for tiller
The snow-flap adjuster enables you to vary the snow path through the tiller by means of pushbutton controls.
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.
Increasing snow-flap depth
With the snow flap set to this position when the vehicle is used on an ice-covered slope, for example, chunks of ice will be forced to pass the tiller shaft several times and this will help ensure optimum processing.
Snow-flap adjuster for tiller
Top section pressed = Reduce tiller snow-flap depth
Bottom section pressed = Increase tiller snow-flap depth
i
An attempt to operate the tiller at too high a speed will 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.
When descending extremely steep gradients, the tiller shaft can be set to counter-rotate so as to help stabilise the PistenBully.
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Situational help
Snow flaps extended to different settings?
Remedy: Press and hold down the button for 1 - 2 minutes. The cylinders are equalised.
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I
NDEX
A
Accelerator ......................................................................36
Acoustic warning ............................................................39
Active winch ...................................................................69
Adapter ........................................................................136
Additional acoustic warning ............................................39
Adjusting armrest ............................................................93
Adjusting slope contour .............................................73, 78
Adjusting tiller depth .......................................................45
Air temperature .............................................................132
Air-filter monitor .......................................................41, 76
Alpinflex installed ............................................................74
AlpinFlex tiller ...............................................................152
Attachment weights ........................................................30
Attachment weights, towing hitch .................................137
Auxiliary driven implements .............................................96
B
Battery ..........................................................................116
Battery charge indicator ..................................................41
Battery master switch ....................................................116
Battery-charge indicator ................................................134
Blower setting .................................................................87
Braking-air check, parking brake .....................................74
Bumpy runs ...................................................................141
C
Cab heating ................................................ 33, 38, 95, 109
Camera page .................................................................. 72
Cancelling the "set to rigid" function ............................ 153
Centre of gravity ........................................................... 143
Charging the battery ..................................................... 115
Checking coolant level .................................................. 120
Checking electrical system ............................................. 123
Checking engine oil level .............................................. 121
Checking fuel prefilter ................................................... 125
Checking hydraulic fluid level ........................................ 122
Checking parking brake ................................................ 124
Checking wheels ........................................................... 127
Climbing ability ............................................................. 143
Closing the central locking system ................................... 89
Closing the deck railing ................................................. 102
Connecting hydraulics ..................................................... 97
Connecting jump leads ................................................. 116
Contact pressure, tracker plates ...................................... 73
Coolant below the minimum level ............................. 41, 76
Coolant temperature, diesel engine ................................. 45
Counter-rotating tiller shaft ........................................... 146
Custom settings, persons 1 to 3 ...................................... 72
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I
NDEX
D
Daily checks .................................................................. 119
Daily operating hours ...................................................... 77
Data loss ...................................................................... 116
Diagnostics overview ...................................................... 81
Diesel consumption ......................................................... 77
Diesel engine ON / OFF ................................................... 45
Diesel engine over-revved ............................................... 77
Diesel fuel gauge ............................................................ 45
Diesel-engine operating hours ......................................... 77
Direction of travel ........................................................... 74
Direction of travel neutral ............................................... 74
Direction-of-travel pushbutton ........................................ 47
Display ........................................................................... 46
Downgrade force .......................................................... 143
Drive hydraulics for auxiliary driven machinery ................. 39
Driver's cab tilt-locking device not engaged. .................... 41
Driver's seat ................................................................... 90
Driving ......................................................................... 133
on downgrades ..................................................... 145
On upgrades ......................................................... 144
Driving hours .................................................................. 77
Driving with the PistenBully ........................................... 144
Drum winch ON .............................................................. 74
E
Edge walls forming ........................................................147
Emergency mode, direction of travel ................................86
Emergency mode, driving speed .......................................86
Emergency mode, vehicle steering ...................................86
Emergency tiller control ...................................................76
Engine oil pressure ..................................................73, 134
Engine operating temperature .......................................134
Engine speed range .......................................................132
Entering – driving – exiting ...........................................129
Exiting ..........................................................................136
Extended options ............................................................77
Extremely slushy snow ...................................................142
F
Factory default ................................................................72
Fault-code displays ..........................................................81
Filter in hydraulic-fluid tank clogged. ...............................76
Flashing turn indicators, left ............................................37
Flashing turn indicators, right ..........................................37
Floating position, front equipment carrier ........................39
Fluids and lubricants .....................................................119
Fog lights ........................................................................37
Front blade ...................................................................149
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I
NDEX
Front snow blower mounted ............................................74
Front spotlight ..............................................................110
Front worklights ......................................................37, 110
Fuel preheating ...............................................................39
Fuel supply ....................................................................134
H
I
Halogen-xenon ..............................................................111
Hazard warning flashers ..................................................37
Heated windshield wipers ................................................35
High-beam headlight / parking light H7 .........................110
High-beam headlights ...............................................34, 37
High-beam headlights ON ...............................................41
High-priority fault ......................................................76, 83
Horn ...............................................................................39
Hydraulic actuation for "set to rigid" .............................153
Hydraulic fluid level warning light ..................................134
Iced slopes/sheets of ice ................................................141
If it is necessary to repeat the reheating procedure .........131
Ignition lock ....................................................................45
Indicators ........................................................................74
Inside-temperature readout .............................................87
Installing auxiliary driven implements ...............................96
Instructions for checks and maintenance ........................119
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Instructions for engine break-in ..................................... 132
Intake air preheating ....................................................... 76
Intake air preheating ON ................................................. 41
Intermittent-wipe setting ................................................. 35
J
Jump starting ................................................................ 115
K
Key to fault codes ........................................................... 84
Knurled knob for adjusting tiller shaft speed .............. 48, 63
Knurled knob for driving speed .................................. 48, 63
L
Lift out tiller .................................................................... 79
Lights ........................................................................... 110
Lock for steering-column adjustment ............................... 36
Low fuel consumption ................................................... 139
Low-beam headlight H7 ................................................ 110
Lower rear equipment carrier .......................................... 75
Low-priority fault ............................................................ 83
M
Magician mounted .......................................................... 74
Making a location line .................................................. 150
Manual actuation for "set to rigid" ............................... 153
Manual throttle control ................................................... 64
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NDEX
Manually adjusting blower output ................................... 87
Medium-priority fault ................................................ 76, 82
Menu selector ................................................................. 71
Most economical engine speed range ............................ 132
MultiFlex tiller ................................................................. 74
Multifunction joystick ...................................................... 49
multifunction switch ....................................................... 34
N
Nordic-trail tracker plates .................................... 40, 42, 54
O
One-touch lights ON control ........................................... 40
Opening the central locking system ................................. 89
Opening the rear deck railing ........................................ 101
Operating hours .............................................................. 45
Operation of auxiliary driven implement .......................... 99
Outside-mirror adjuster ................................................... 38
Outside-temperature readout .......................................... 87
Overview of settings ....................................................... 84
P
Panel .............................................................................. 37
ParkBlade ......................................................... 39, 40, 151
Parking brake ................................................................. 35
Parking brake applied ..................................................... 74
Parking brake indicator ................................................. 134
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Parking brake not applied ................................................74
Parking lights / driving lights ...........................................37
Pipe Magician .................................................................59
Power Angel .............................................................53, 70
Preparing fresh-fallen snow ...........................................141
Preparing the ski-slope ..................................................146
Program navigator ..........................................................71
Pushbutton for wipers .....................................................35
Pushbutton, drum winch .................................................42
R
Raise rear equipment carrier ............................................75
Raising tracker plates ......................................................45
Rear deck railing ...........................................................101
Rear equipment carrier ....................................................47
Rear equipment carrier horizontal in position ...................75
Rear equipment carrier rigid ............................................75
Rear light ......................................................................110
Rear window heater ........................................................38
Rear window wiper .........................................................38
Rear worklights .......................................................37, 110
Refuelling ......................................................................136
Release seat-belt lock, cockpit .........................................38
Relieve track tension .......................................................39
Remote control ...............................................................89
Remote control, open/close doors ....................................89
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I
NDEX
Removing the auxiliary driven implement .........................98
Replacing fuses .............................................................113
Restraint .........................................................................40
Retracting side finishers ...................................................45
Revolution counter ..........................................................45
Roll ...........................................................................53, 70
Rotary beacon ...............................................................110
Rotating beacon ..............................................................37
S
Saving intermittent-wipe setting ......................................35
Selecting temperature readout in 0C / 0F .........................87
Setting the Alpinflex tiller to the rigid position ................153
Setting the Multiflex tiller to the rigid position ................153
Shuttle ............................................................................71
Side finishers ...............................................52, 69, 79, 152
Side worklights .............................................................110
Smoothing bumpy ski slopes ..........................................149
Snow types ...................................................................140
Snow-flap position for tiller .........................44, 73, 78, 154
Speed reading .................................................................76
Spotlight .........................................................................37
Start procedure .............................................................131
Starting engine ................................................................45
Starting the diesel engine ..............................................130
Starting the engine ........................................................130
Steering sensitivity ...........................................................77
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Steering wheel .......................................................... 46, 84
Stick ......................................................................... 61, 62
STOP button ............................................................. 46, 63
Stopping after use ......................................................... 135
Superstructure lock closed ............................................... 76
Superstructure lock open ................................................. 76
Swing damping ON ......................................................... 79
Switching on tiller ..................................................... 53, 70
T
Taking on fuel ............................................................... 136
TCC Terminal Control Centre ........................................... 71
Temperature of hydraulic fluid too high. .......................... 76
Tension tracks ................................................................. 39
Terminal Control Centre .................................................. 71
Test drive ...................................................................... 126
Tightening torques ........................................................ 127
Tiller - forward operation / counter-rotating ..................... 99
Tiller 2000 ...................................................................... 74
Tiller at standstill ............................................................ 74
Tiller contact pressure ............................................... 73, 78
Tiller control, automatic .................................................. 76
Tiller depth ............................................................... 73, 78
Tiller emergency mode / automatic operation .................. 44
Tiller forward operation / counter-rotating ....................... 39
Tiller in rigid position .............................................. 44, 153
Tiller ON ......................................................................... 74
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NDEX
Tiller ON - OFF .......................................................... 47, 64
Tiller operating hours ...................................................... 77
Tiller page ................................................................ 72, 78
Tiller rigid ....................................................................... 79
Tiller running .................................................................. 74
Tiller speed ............................................................... 73, 78
Tiller Surface control switch ............................................. 73
Tiller-boost function ........................................................ 44
Tilting tiller in raised position .......................................... 78
Topping up battery fluid ................................................ 114
Topping up fluids and lubricants ................................... 119
Total operating hours ...................................................... 77
Touch control for tiller ON ......................................... 53, 70
Touch-sensitive fields ................................................ 72, 79
Towing hitch ................................................................. 137
Towing the PistenBully .................................................. 137
Towing vehicle .............................................................. 137
Track tension ................................................................ 126
Transfer case ................................................................ 128
Turn indicators ........................................................ 34, 110
Turning ......................................................................... 145
Turning with counter-rotating tracks ............................. 145
U
Using teach-in mode for engine ...................................... 84
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V
Vehicle battery ..............................................................114
Vehicle data ..............................................................72, 76
Visual inspection ...........................................................123
Voltage peaks ...............................................................116
W
Warming-up phase ........................................................132
Warning symbols .............................................................41
Warning symbols, drum winch .........................................43
Weekly checks ...............................................................125
Wet snow/slushy snow ..................................................142
Winch operating hours ....................................................77
Windscreen heating .........................................................38
Windscreen wiper, front ..................................................38
Wipers ............................................................................34
X
Xenon ...........................................................................111
Xenon worklight ............................................................110
600.11021.4.de

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Key features
- Powerful engine
- Hydrostatic drive
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- Cab heating
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