Prinoth 908930245 Operating And Maintenance Manual Download Page 14

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Prohibition signs

Meaning

Symbol

Prohibits certain actions or behavior

The removal of safety devices is prohibited!

Transporting persons is prohibited (except for the parts of the vehicle that are
expressly intended for passenger transport)!

Fire, open flame and smoking are prohibited!

Forbidden for persons wearing heart pacemakers

Hoisting by crane forbidden!

Operating and Maintenance Manual

Snow groomer

BISON

(

255

)

2 - Notes about the documentation

BISON 908930245 - 30367

2.4.3

Summary of Contents for 908930245

Page 1: ...41237353 REV01 Operating and maintenance manual for the BISON BISON X snow groomer Vehicle numbers 908930245 to 908930367 ...

Page 2: ...ehicle as a handy reference for the safe and productive use of the BISON Should you re sell the vehicle leave this manual with it for the next owner This manual is filled with important safety information read and understand the content as well as all safety stickers installed on the vehicle All products and company names are trademarks or registered trademarks of their respective holders Use of t...

Page 3: ...e inclination angle 23 3 4 4 Towing the snow groomer 23 3 4 5 When maintaining the vehicle 23 3 5 Safety equipment in the vehicle 24 3 6 Pictograms and safety instructions on the vehicle 26 3 6 1 Snow groomer 26 3 6 2 Attachments 27 3 7 Danger Zones 28 4 Transport 33 4 1 Weights and lifting points 33 4 2 Securing and transport 35 5 Vehicle 37 5 1 Identification data for the snow groomer and attach...

Page 4: ... 11 Fuses and relays 66 5 11 1 Fuses and relays in the driver s cab 66 5 11 2 Fuses and relays in the accessory support 69 5 12 Control units 71 5 13 Battery disconnect switch 72 5 14 Battery emergency switch 73 5 15 Vehicle lighting 73 5 16 Warning and signaling equipment 73 5 17 Switching the air filter 74 6 Display 75 6 1 Display description 75 6 2 Adjusting the display backlight 75 6 3 Navigat...

Page 5: ... 8 9 Controlling front attachments 119 8 10 Controlling rear attachments 120 9 Attachments 122 9 1 Establish operational readiness of the attachments 122 9 2 Front blade 122 9 2 1 Adjusting the park pusher frame 122 9 2 2 Mounting the front blade 123 9 2 3 Installing and stowing the side cutters 125 9 3 Rear tiller 126 9 3 1 Mounting the POSIFLEX tiller 126 9 3 2 Mounting the POWER tiller with an ...

Page 6: ...10 1 Important notes 166 11 10 2 Handling used engine oil 168 11 10 3 Engine oil and filter replacement 168 11 10 4 Checking the engine oil level 169 11 10 5 Replacing the engine air filter 170 11 10 6 Clean the engine 170 11 11 Battery 172 11 11 1 Safety instructions 172 11 11 2 Transport store and maintain the batteries 173 11 11 3 Clean the battery 174 11 11 4 Removing battery 174 11 11 5 Insta...

Page 7: ...hydraulic hoses 190 11 17 Replacing halogen lamps 191 11 18 Arc welding 192 12 Troubleshooting 193 12 1 Malfunction cause and remedy 193 12 2 General troubleshooting 193 12 3 Electrical fuses 196 13 Technical data 197 13 1 Vehicle dimensions 197 13 2 Vehicle data 197 14 Storing and taking the vehicle out of service 199 14 1 Taking the engine out of service 199 14 2 Disposal of operating fluids 200...

Page 8: ...5 7 7 Rewind the last few meters of cable 230 15 7 8 Winch operation 231 15 7 9 During winch operation 232 15 7 10 Electronic traction control 233 15 7 11 Using the AUTOMATIC winch when ascending or descending slopes 234 15 8 Maintenance 235 15 8 1 General maintenance instructions 235 15 8 2 Checking the winch 236 15 8 3 AUTOMATIC winch maintenance schedule 236 15 8 4 Operating fluids 238 15 8 5 L...

Page 9: ...lation of non approved components or use of third party spare parts Please note that regular inspection and maintenance work can prevent unexpected and unnecessary downtime Report any problems with the snow groomer or its attachments to Prinoth approved repair and mainte nance personnel If there is a possibility of consequential damage the snow groomer must be taken out of service until the fault ...

Page 10: ...safety instructions with the signal word DANGER are followed by respective safety meas ures WARNING Signal word WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury All safety instructions with the signal word WARNING are followed by respective safety meas ures CAUTION Signal word CAUTION Indicates a hazardous situation which if not avoided could res...

Page 11: ...n the cooling system when the coolant temperature is below 40 C Slowly unscrew the cap and release the pressure before opening completely Wear suitable protective gloves clothing and safety glasses when handling coolants Example 2 NOTE NOTICE 1 Information or safety measures 2 Information or safety measures NOTICE Check the first aid kit s use by date regularly and replace the contents as required...

Page 12: ...pes of pictograms Mandatory signs Warning signs Prohibition signs WARNING Risk of accident and injury The pictograms on the snow groomer and attachments indicate possible hazards Ignoring these pic tograms can lead to serious or life threatening injuries The pictograms must be kept in an undamaged condition and must remain clearly visible Replace damaged pictograms immediately Mandatory signs Mean...

Page 13: ...luids Indication of a risk of falling Indication of a risk of crushing Indication of a risk of severing injuries Indication of a risk of splintering Indication of a risk of crushing or sever ing limbs due to rotating parts Indication of a risk of collision wear safe ty belt Snow groomer BISON Operating and Maintenance Manual BISON 908930245 30367 2 Notes about the documentation 15 255 2 4 2 ...

Page 14: ...is prohibited except for the parts of the vehicle that are expressly intended for passenger transport Fire open flame and smoking are prohibited Forbidden for persons wearing heart pacemakers Hoisting by crane forbidden Operating and Maintenance Manual Snow groomer BISON 16 255 2 Notes about the documentation BISON 908930245 30367 2 4 3 ...

Page 15: ...ant to cool down before carrying out mainte nance work Risk of falling risk of crushing and cutting When transporting persons on the loading platform there is a risk of falling and being crushed or cut Fire hazard When handling inflammable fuels and operating fluids there is a risk of fire Do not smoke Do not refuel while the engine is running or warm Avoid direct contact with fuel Risk of cutting...

Page 16: ...ng clothing hand and other body parts away from rotating parts Risk of scalding Hot fluids can cause scalding Do not touch Allow for cool down before carrying out maintenance work Risk of break in The snow groomer is a very heavy vehicle Do not drive on frozen waterways or lakes Failure to observe this regulation will lead to a risk of material damage as well as serious physical injury and in the ...

Page 17: ...r s original spare parts and accessories are used exclusively NOTICE Ensure for the correct operation of the snow groomer Operating and maintenance instructions are to be kept in the driver s cab at all times There is a holder behind the driver seat intended for these Manufacturer s recommended use The following country specific regulations apply for using the snow groomer and its attachments on s...

Page 18: ...ng on snow groomers and ability to provide the employer with documentation of their qualification to drive snow groomers Knowledge of the characteristic properties of snow the causes and devastating effects of ava lanches and in particular proper behavior when there is a risk of avalanche To optimize operating safety the driver must be familiar with the snow groomer the ski slope condi tions and t...

Page 19: ... snow and ice from the snow groomer Make sure all safety devices are in proper working condition Check the lighting system and warning devices Check fluid levels e g engine oil coolant On vehicles with pneumatic tires check the inflation pressure of the running wheels Check track tension Check the steering brakes and auxiliary hydraulics Before starting the engine check the accelerator for ease of...

Page 20: ...acity e g garages bridges snow covered car parks When parking the vehicle or leaving it unattended engage the parking brake lower the attach ments to the ground and remove the ignition key Never leave the engine running unattended Do not drive the snow groomer over ditches knolls or scarps Injuries or mechanical damage can occur as a result When driving on steep ski slopes the snow groomer may ski...

Page 21: ... The vehicle handling must be adapted to the factors specified above at all times in order to en sure for safe driving in terrain and to prevent the vehicle from slipping tilting or falling WARNING Risk of slipping and falling The vehicle handling must be adapted to the changing conditions of the terrain or the sub sur face and the maximum permissible inclination angle at all times Disregarding ma...

Page 22: ...ly Damaged components of the driver s cab suspension and driver s cab mounts must be replaced by original Prinoth spare parts immediately For necessary welding work on the structure or sus pension of the driver s cab refer to the specialized personnel from Prinoth Do not climb on the roof of the driver s cab Service measures on the roof headlights must be carried out at the front of the vehicle us...

Page 23: ... is properly stored in the holder and is secured with the retaining strap First Aid Kit The first aid kit is located on the cab rear wall behind the passenger seat on the right hand side Figure 3 First aid kit NOTICE Check the first aid kit Check the first aid kit s use by date regularly and replace the contents as required Replace used dressing material immediately Snow groomer BISON Operating an...

Page 24: ...er 2 Risk of crushing install safety rod 3 Wear seat belt 4 Risk of impact opening a door applies the brake 5 Do not leave the vehicle unattended 6 Read instruction manual 7 Fall crush and cut hazard 8 Cutting hazard 9 Lower front implement 10 Hot surface 11 Burn hazard 12 Crush hazard 13 Electrical cables and hydraulic hoses 14 Pinch point hazard 15 Fire hazard 16 Hot surface 17 Wear seat belt 18...

Page 25: ...ams and safety instructions on the attachments Pos Name 1 Risk of crushing 2 Rotating parts risk of crushing or severing limbs 3 Risk of splintering 4 Risk of splintering POWER tiller only 5 Rotating parts risk of crushing or severing limbs POWER tiller only 6 Risk of crushing 7 Risk of cutting Snow groomer BISON Operating and Maintenance Manual BISON 908930245 30367 3 Safety 27 255 3 6 2 ...

Page 26: ... X X X X X Under the driver s cabin when tilted X X X X X X Under the attachments X X X X X X Under the track bars X X X Between the links that operate the attachments X X X X X X Under the loading platform when tilted X X X Risk of cut and amputation Around the driver and passenger doors X X X X Under the engine cover X X X X X X X Under the driver s cabin when tilted X X X X X X Under the attach...

Page 27: ...draulic hoses and bolt fittings X X X X X X X X Risks due to mass and stability potential energy Snow groomer tipping over X X Lateral slipping X X Slipping in direction of travel X X Backward slipping X X Falling attachments X X X X X X Loads falling off the loading platform X X X Risks due to mass and speed kinetic energy Running down people present in the working area of the snow groomer X X Ru...

Page 28: ...d by vibration Risk of permanent damage to health Vibrations at driver seat X X Risks due to heat Risk of burn and scalding When touching the engine block X X X X X X When touching the engine exhaust pipe X X X X X X When touching hot surfaces on the turbocharger X X X X X X When touching the radiator X X X X X X When touching the engine oil cooler X X X X X X When touching the hydraulic fluid coo...

Page 29: ...ols X X Stiff controls X X Seat unsuitable for operator physique X X Insufficient lighting X X Psycho physiological effects Controls not arranged clearly X X Insufficient visibility of the work area X X Insufficient visibility of the rear of the snow groomer X X Insufficient visibility when maneuvering the snow groomer X X Human error Insufficient lighting X X X X Unauthorized use of the snow groo...

Page 30: ...rage batteries X X X Leakage from engine oil filters X X X Leakage from hydraulic fluid filters X X X Fuel spillage X X X Engine oil spillage X X X Hydraulic fluid spillage X X X Failure to contain used water when cleaning mechanical components X X X X Coolant leaking from engine X X X Operating and Maintenance Manual Snow groomer BISON 32 255 3 Safety BISON 908930245 30367 ...

Page 31: ...ack 1 use shim plates to protect the frame Lifting points for a crane Weight 6826 kg 15018 lb without AUTOMATIC winch 9203 kg 20248 lb with AUTOMATIC winch Table 1 Snow groomer weights and lifting points Snow groomer BISON Operating and Maintenance Manual BISON 908930245 30367 4 Transport 33 255 4 4 1 ...

Page 32: ...ng points Weight per track Steel version open profile 913 kg 2012 lb Aluminum version 885 kg 1951 lb Table 2 Weights and lifting points of the attachments NOTICE Perform the lubrication of the lowered attachments If the attachments have to be raised during maintenance these must be safeguarded against lowering using appropriate measures Operating and Maintenance Manual Snow groomer BISON 34 255 4 ...

Page 33: ... and loading the snow groomer To lift and load the snow groomer including attachments only use a suitable crane or traveling crane with sufficient load capacity and a suitable implement with a hook for lifting The transport company is required to check whether the load gauge meets the road traffic reg ulations of the country in which the transporting takes place If the external dimensions are such...

Page 34: ... the truck anchors using four lever operated clamps with safety locks Each clamp must be designed to support a 5000 kg 11023 lb load so that the snow groomer is held laterally stable in the direction of travel Operating and Maintenance Manual Snow groomer BISON 36 255 4 Transport BISON 908930245 30367 ...

Page 35: ...lope quality and high operational reliability in continuous operation make the BISON a top quality product The front and rear attachments are operated using the push buttons on the joystick A display positioned on the right hand side control console shows all functions tiller shaft speed tiller cut ting depth and floating position of the link arm All this makes for excellent slope quality while sa...

Page 36: ...defrosting of the front rear and side windows electrically adjustable heated outside mirror and heated front windshield wiper blades The long range illumination of the work area increases the active operating safety Lighting System In addition to the normal lighting system the BISON is fitted with newly designed headlamps which produce a light beam two and half times stronger than the prescribed i...

Page 37: ...sed to go into reverse while the rear attachment is only half raised If the Hydraulic fluid level insufficient warning lamp is lit continuously this indicates a possible malfunction in the hydraulic system In this case the vehicle driver must immediately switch off the engine in order to prevent serious failure of the hydraulic system There are several more warning lamps Warning lamp Insufficient ...

Page 38: ...impacts stresses Tilting the driver s cab DANGER Risk of tipping Tilting the driver s cab changes the vehicle s centre of gravity Park the snow groomer on solid and level ground DANGER Risk of crushing if the driver s cab is lowered accidentally Insert the safety strut NOTICE Risk of contact When tilting the driver s cab can collide with the raised front blade Before tilting the driver s cab drop ...

Page 39: ...ry support frame 1 1 7 Insert the free end of the safety rod into the holding block 1 of the accessory sup port frame 1 1 Lowering the driver s cab DANGER Risk of tipping An unsecured driver s cab can tilt forward while the snow groomer is moving Check the driver s cab s locking status after lowering it Only move the snow groomer if the driver s cab has been secured Snow groomer BISON Operating an...

Page 40: ...block of the accessory support frame 3 Fold the safety rod 1 under the cab and compress the spring again to lock the de vice into the stowed position 1 1 4 Press on the lower part of the push button 1 the driver s cab lowers 1 5 After lowering keep the push button pressed for approx 10 s until the sound changes the driver s cab is automatically secured 6 Check the left and right driver s cab locki...

Page 41: ...draulic oil level without lifting the cover To do so use the cavity 2 locat ed in front of the sightglass of the oil tank To tilt the cover and access the components proceed as follows 1 Remove all objects from the cover 2 Lower the rear attachment to the ground 3 Using the upper cavity 1 raise or lower the cover The cylinder will keep it in the chosen position Snow groomer BISON Operating and Mai...

Page 42: ...visible on picture 6 Backrest release for forward folding not visible on picture 7 Steering console left armrest 8 Left armrest angle adjustment 9 Left armrest swivel locking lever 10 Backrest tilt adjustment 11 Lumbar support adjustment 12 Seat heating switch 13 Seat tilt angle adjustment 14 Seat height adjustment 15 Seat fore aft adjustment Operating and Maintenance Manual Snow groomer BISON 44 ...

Page 43: ...b 3 clockwise or counterclockwise to adjust the side bolsters in a narrower or wider position Switching the seat heating on and off The seat heating can be switched on and off ON OFF by pressing the switch 12 Adjusting seat suspension and height Seat suspension and height can be adjusted by pushing in or pulling out the spring loaded but ton 14 Adjusting the seat tilt angle The tilt angle of the b...

Page 44: ...lly and release the lever in the required position The seat can be swivelled into three different positions 2 Locking screw To lock the seat when sliding the seat manually 3 Threaded hole To place the locking screw and lock it when sliding the seat manually To move the seat sideways press the up per 4 or lower part 5 of the rocker switch on the control console As soon as the rocker switch is relea...

Page 45: ... driver seat can be changed manually Slide the seat man ually to the left or right so that the locking screw 2 can be placed in the threaded hole 3 To lock the seat push the screw and turn it clockwise into the thread To remove the screw turn counterclock wise Snow groomer BISON Operating and Maintenance Manual BISON 908930245 30367 5 Vehicle 47 255 ...

Page 46: ...ssenger seat Pos Name 1 Battery emergency switch 2 Seat belt 3 Radio 4 Storage compartment 5 Cup holders 6 Seat 7 Storage compartment Operating and Maintenance Manual Snow groomer BISON 48 255 5 Vehicle BISON 908930245 30367 5 4 ...

Page 47: ... of injury Do not lean out of the sunroof during operation of the vehicle Open the sunroof Pull the handle 1 until it snaps open and then push it until the glass is lifted up to its maximum opening angle Close the sunroof Pull the handle 1 until the glass is completely closed and the handle snaps into place The glass sunroof can be detached in order to be able to use it as an emergency exit Howeve...

Page 48: ...p 49 The spotlight can be rotated by 360 It can also be tilted 30 forward and 35 backward Steering console Figure 12 Steering console Pos Name Description B78 Left steering lever Operate one or both levers to obtain the desired direction of travel B79 Right steering lev er Operate one or both levers to obtain the desired direction of travel S131 Limit switch The limit switch signals that the steer...

Page 49: ...inclination NOTICE Hand wheel The hand wheel must only be adjusted far enough that the limit switch still makes contact This is required for the snow groomer standby The inclination is adjusted by turning the hand wheel 1 at the back of the bracket Adjust the depth 1 Release the lever 2 located laterally underneath the steering console 2 Push the steering console forward or backward until the desi...

Page 50: ...is reached 3 Tighten the lever 4 Folding up the steering console Lift the steering console until it is folded vertically upwards Control console Figure 14 Control console Pos Name Description 1 A33 Display See Display description p 75 Operating and Maintenance Manual Snow groomer BISON 52 255 5 Vehicle BISON 908930245 30367 5 9 ...

Page 51: ...te stop The snow groomer standby must be switched on again each time to avoid the vehicle being unintentionally put in motion by the engine The snow groomer standby can only be engaged if the following conditions have been met The Emergency OFF switch has not been pressed The cab doors are closed The left steering console is down The ignition is switched on 8 S85 Rocker switch Operation al readine...

Page 52: ...u p 76 With the rotary push button you can also Activate and deactivate the rear view camera manually Press for 2 s rear view camera ON Press for 2 s again rear view camera OFF Activate and deactivate the defrost function Push forward once defrost function ON Push forward again defrost function OFF See Activating the defrost function p 66 Control the driver s cab heating and ventilation Adjust the...

Page 53: ...e and height The console can be folded up to make it easier to get in and out of the cab Adjust the height position The height position of the control console is adjusted by turning the hand wheel 1 Turn hand wheel 1 control console moves up or down Adjust the inclination 1 Pull down the lever 2 and fold up the control console until it locks into place Snow groomer BISON Operating and Maintenance ...

Page 54: ...1 Figure 16 Controls on Keyboard 1 A36 Pos Name Description A36 1 Push button Park ing lights low beam high beam Press push button once parking light ON Press push button again low beam ON Press push button again high beam ON Tap push button with high beam ON switch between low and high beam Press the push button for 2 s OFF A36 2 Push button Work lights front rear Press push button once work ligh...

Page 55: ...t oper ation 5 s can be adjusted in the menu Press push button again rear window wiper ON Press push button again rear window wiper OFF A36 9 Push button Select windscreen and rear window wipers for wiping once dou ble click on Joystick push button S3 The setting Windscreen wiper ON is selected after every start of the snow groomer Press push button once rear window wiper ON Press push button agai...

Page 56: ... is running at more than 1000 rpm The heating operates at fixed intervals if the engine is running at less than 1000 rpm A36 13 Push button Wind screen wiper heat ing Press push button once windscreen wiper heating ON Press push button again windscreen wiper heating OFF The windscreen wiper heating only functions when the engine is run ning A36 14 Push button Left turn signal Press push button onc...

Page 57: ...le free ESC Flat lock Pre mium option Press push button once rear tiller blocked fixed Press push button again rear tiller flexible free Press and hold push button for 3 s Flat lock For menu navigation this push button ESC is used to return to the initial display Keyboard 2 Figure 17 Controls on Keyboard 2 A37 Pos Name A37 1 20 Push buttons not used unless front drive hydraulics or winch is instal...

Page 58: ...iper Double click on push button S3 windscreen and rear window wipers wiping once D Joystick switch Blade angler roll up down button P Vehicle speed rotary switch S1 T Tiller depth control and tiller snow chamber opening control S3 T Winch pulling force front rear winch boom rotation left right Joystick operation The attachments mounted are operated using the joystick Used along with the push butt...

Page 59: ...imply push the joy stick switch D to the left Angle Right To angle the blade in the right direction press and hold push button S1 and push the joystick towards the right side If using the joystick on joystick simply push the joystick switch D to the right Neutral This position holds the blade at the desired roll and angle To se lect Neutral leave the joystick or joy stick switch centered Blade Rol...

Page 60: ... frame vertical displacement con trol button T Raise To raise the tiller move the switch forwards Lower To lower the tiller move the switch backwards Rear lift frame lateral displacement control button T Swivel Left To swivel the tiller in the left direction move the switch to the left Swivel Right To swivel the tiller in the right direction move the switch to the right Right tiller wing control b...

Page 61: ...ral floating To activate the lateral floating option push button S1 once Rear lift frame auto centering To active the auto centering option double click but ton S1 Constant up down pressure push button S5 To activate the rear tiller shaft and the constant up down pressure sys tem at the same time double click push button S5 Control up down pressure To control the up down pressure push the up down ...

Page 62: ...ler cutting depth Press and hold the S1 button then move the T switch to the right Tiller s Chamber Opening Control push button S1 and button T on Posiflex only not available on the POWER tiller Open chamber Press and hold the S1 button then move the T switch backwards Close chamber Press and hold the S1 button then move the T switch for wards Adjusting the outside mirror Both outside mirrors can ...

Page 63: ...ed and are thus able to provide the best possible visibility even in harsh weather conditions The heating of the windscreen wiper blades is independent of the heated windows and from the driver s cab heating Switch on Press the respective push button on Keyboard 1 to switch on the heater See Keyboard 1 p 56 The heating only functions when the engine is running In order to prevent overheating of th...

Page 64: ... turn rotary pushbutton B118 until the required setting has been reached on the display 4 To exit press the escape button on the keypad or wait 3 seconds Activating the defrost function Figure 20 Defrost function on B118 rotary push button The defrost function will turn on the fan speed and the cab temperature heater to the maximum 1 Push the rotary push button B118 forward once 2 Monitor the disa...

Page 65: ...ses 5 to 20 A 3 Fuses 40 to 60 A Figure 22 Schematic on the inside of the electrical box cover under the right passenger seat Fuses under the right passenger seat F3 Side window heating 50 A Snow groomer BISON Operating and Maintenance Manual BISON 908930245 30367 5 Vehicle 67 255 ...

Page 66: ...Power Extension board 60 A F119 Comfort seat 10 A F120 Logic TTC94 TTC48 1 2 3 Winch TSE K107 5 A F121 Keyboard Joystick 5 A F122 Preheating unit control cab heating relay fuel filter heating 7 5 A F124 Automatic Roll out 7 5 A F131 Power TTC48 2 20 A F135 Additional horn 5 A F141 Rpm sensors 12V 2 A F146 Power TTC48 3 20 A F157 Power TSE TTC 48 4 25 A F166 Sliding seat 7 5 A F167 Power TTC30 10 A...

Page 67: ... Debug CAN 0 X219 Debug CAN 3 A40 Central Locking A43 Controller wiper R33 V81 Charging resistor S142 Termination CAN U1 Voltage Converter U5 Voltage Converter V96 Diode warning buzzer for reverse travel Fuses and relays in the accessory support The auxiliary fuses and relays are located in the electrical box inside the cowling To gain access open the right side access panel then remove the two wi...

Page 68: ...se with one of the same rating Next is a picture of the schematic on the cover of the electrical box with a list of the relays and fuses ALTERNATOR Figure 25 Schematic on the inside of the electrical box cover POWER TIMER RELAY 6 minutes IN Terminal 30 FU 8 200 A grid heater Operating and Maintenance Manual Snow groomer BISON 70 255 5 Vehicle BISON 908930245 30367 ...

Page 69: ...l pump 20 A F3 Engine ECM 20 A F4 ALTERNATOR 10 A F5 PETU 1 20 A F6 PETU 2 20 A F7 AC fan 15 A F8 Courtesy light 7 5 A F9 Door lock 10 A F10 Fleet manager 7 5 A Control units Figure 26 Control units behind the right passenger seat Pos Name Description 1 TTC94 Control unit Master 2 TTC48 1 Control unit Input Output rear lift frame wiper fuel 3 TTC48 2 Control unit Input Output rear lift frame blade...

Page 70: ...o quick charge the batteries disconnect the battery terminals Follow the user instructions for the quick charger Battery disconnect switch The battery disconnect switch is located under the right access panel of the rear cowling This switch connects or disconnects the batteries to prevent discharge Operation of the switch is automatic but there is an override control in the cab 1 Figure 27 Under t...

Page 71: ...arking back lights Low and high beam Front blade lighting Work lights on the A pillar Work lights on the cab roof with halogen or LED headlamps Work lights front rear Spotlight on top of the cab controlled from inside Door mirror lights LED Side work lights The work lights can be switched on and off independently from each other using the push buttons on Keyboard 1 Warning and signaling equipment ...

Page 72: ...performance could be reduced in this mode use only when required not as a preven tive action NORMAL mode In the NORMAL mode the engine draws air from outside the cowling Return to the NOR MAL mode or stay in this mode in the following conditions Light snowfall non icing conditions Engine air filter is clear not clogged Outside air temperature is above freezing 0 C 32 F For optimal vehicle performa...

Page 73: ...avigate through the following menus Information Service Operation Password Exit Some menus have restricted access and are only available to service personnel at PRINOTH or trained personnel via the password menu Adjusting the display backlight The backlight of the display is adjusted using the rotary push button B118 Return to the main display if necessary Turn rotary push button B118 clockwise in...

Page 74: ...ed value is displayed 5 Press to confirm 6 In order to exit the menu turn rotary push button B118 until you reach the menu item in the higher level 7 Press to confirm 8 When changing to the next highest level there is a query concerning whether the changed se lection should be saved Confirm by pressing or press the ESC key on keyboard A36 9 Accept change Operating and Maintenance Manual Snow groom...

Page 75: ...dicator lamp indicates when fuel reserve level is reached 3 AdBlue DEF level Display of the AdBlue DEF level 4 Vehicle working hours The operating hours counter starts when the engine is running and as a result also counts the time required for engine preheat ing and the waiting times with the engine running The indicated number of working hours are essential for maintenance 5 Date Indicates the c...

Page 76: ...avel Down arrow continuously lit white Reverse travel 11 12 Travel direction indicator The activation of the travel direction indicator is shown when the respective symbol is lit Right arrow flashing green Right turn signal ON Left arrow flashing green Left turn signal ON Both arrows flashing green Hazard warning lights ON 13 Indicator lamp Regenera tion disabled or Regener ation pending Regenerat...

Page 77: ...erator and voltage regulator 23 Indicator lamp Preheating monitor The indicator light lights up yellow continuously The engine can be started once this indicator lamp has dissapeared 24 Error warning lamp If the warning lamp lights up red continuously this indicates an error If the warning lamp lights up yellow continuously this indicates a fault Open menu item B 20 and identify the fault 25 Parki...

Page 78: ...inuously lit red there is a malfunction 35 Tiller cutting depth in Indicates the tiller cutting depth in the range from 0 to 100 0 Minimum tiller cutting depth 100 Maximum tiller cutting depth 36 Cutter shaft speed in and direction of rotation When the respective symbol is lit the status of the tiller shaft and the set value from 0 to 100 is displayed Tiller shaft blinks green Tiller shaft active ...

Page 79: ...ay A detailed fault description is available in the fault log in menu item B 10 50 Defrost mode 51 Fan speed control 52 BISON X inclinometer The inclination angles of blade and frame are displayed here 53 Track setting plate Arrow up Track setting plate lifted Arrow down Track setting plate lowered Track setting plate continuously lit white Track setting plate ac tive Track setting plate continuou...

Page 80: ...Menu structure Figure 33 Overview of menu structure Operating and Maintenance Manual Snow groomer BISON 82 255 6 Display BISON 908930245 30367 6 5 ...

Page 81: ...groomer A 10 Information engine A 20 Pos Information snow groomer A 10 Pos Information engine A 20 1 Hydraulic fluid pressure forward travel left hydraulic pump bar only for machines with winch 1 Blocked air filter 2 Hydraulic fluid pressure reverse left hy draulic pump bar only for machines with winch 2 Intake charge air bar 3 Hydraulic fluid pressure forward travel right hydraulic pump bar only ...

Page 82: ...9 Fuel temperature C 10 Fuel level 11 Fuel pressure bar 12 Fuel consumption l h 13 Engine load 14 Engine speed rpm 15 Battery charging voltage V 16 Preheating monitor Figure 36 Information engine A 21 Information rear tiller A 30 Pos Information engine A 21 Pos Information rear tiller A 30 1 Air intake system discharge temperature 1 Automatic raising of tiller when reversing Green ON Red OFF 2 Dow...

Page 83: ...avel operating hours 5 Trip 1 Rear tiller operating hours 6 Trip 1 Snow plough operating hours 7 Trip 1 Hoist operating hours 8 Trip 1 Diesel consumption l 9 Trip 1 Area performance Ha 10 Trip 1 Area performance Ha h 11 Trip 1 Kilometres travelled 12 Trip 1 Diesel consumption l h 13 Trip 1 Reset when activated via pass word level 1 Figure 38 Trip 2 Statistics A 50 Total statistics A 60 Pos Trip 2 ...

Page 84: ... Total Area performance Ha 10 Trip 2 Area performance Ha h 10 Total Area performance Ha h 11 Trip 2 Kilometres travelled 11 Total Kilometres travelled 12 Trip 2 Diesel consumption l h 12 Total Diesel consumption l h 13 Trip 2 Reset when activated via pass word level 1 13 Total Engine operating hours Figure 39 Vehicle configuration information page A 70 Pos Vehicle configuration information page A ...

Page 85: ...ller drive 50 Input output winch 60 Connection CAN 0 70 Connection CAN 1 90 Connection CAN 3 100 Input output TTC94 110 Input output TTC48 1 120 Input output TTC48 2 130 Input output TTC48 3 140 Input output TTC60 winch 155 Input output TTC30 160 Backlight 170 Input output Joystick Figure 41 Fault log B 10 Warning symbols display B 20 Snow groomer BISON Operating and Maintenance Manual BISON 90893...

Page 86: ...rake warning lamp red The Eaton and ADM errors are also dis played on this page 13 Warning lamp insufficient coolant level red 14 Coolant temperature too high warning lamp red 15 Warning lamp insufficient engine oil pres sure red 16 Intake air temperature too high warning lamp red 17 Air filter clogged warning lamp red 18 Battery and charge indicator indicator lamp yellow 19 Restore snow groomer s...

Page 87: ...lue sensor is mounted in the hydraulic motor of the tiller 5 Control lever FNR right excursion in 5 Anti stall 6 Control lever FNR position forward neu tral reverse 6 Tiller pump actual command for the tiller pump 7 Control lever FNR default value in 7 Tiller pump RPM Current 8 Drive pump default value in 8 Tiller pump feedback current 9 Pump current 10 Pump current feedback signal RPM final drive...

Page 88: ...ator 7 Winch status Manual AUTO A ECO TTC60W Winch only displayed when winch mounted 8 Recommended winding direction and num ber of rotations 9 Winch locking device 10 Angle encoder cable rocker 11 Winch traction force potentiometer 12 Winch drum brake 13 Rotating winch arm brake 14 Mooring valve mA 15 FW mA Winch pump forward RW mA Winch pump backward 16 Angle encoder winch arm 17 S3 Turning winc...

Page 89: ...2 ECU Engine electronics at the accessory support frame Incl Frame CAN Inclinometer vehicle Incl blade CAN Inclinometer blade Joystick TTC37X Extension board Vision Display indicator Figure 45 Input output TTC94 B 100 Input output TTC48 1 B 110 Pos Input output TTC94 B 100 Pos Input output TTC48 1 B 110 Snow groomer BISON Operating and Maintenance Manual BISON 908930245 30367 6 Display 91 255 ...

Page 90: ...3 B 130 Figure 47 Input output TTC60 AUTOMATIC winch B 140 Input output TTC30 B 155 Pos Input output TTC60 AUTOMATIC winch B 140 Pos Input output TTC30 B 155 Figure 48 Lighting extension board B 160 Input output joystick D B 170 Operating and Maintenance Manual Snow groomer BISON 92 255 6 Display BISON 908930245 30367 ...

Page 91: ...Operation C Pos Main menu Pos Menu level Operation C A Information 10 Tension loosen the tracks B Service 20 Driver s cab operation C Operation 30 Rear tiller operation E Exit 40 Winch operation 50 User profile 60 Front devices 70 Set date time 90 Password entry Figure 50 Tension loosen the tracks C 10 Automatic brake operation C 15 Snow groomer BISON Operating and Maintenance Manual BISON 9089302...

Page 92: ... Pos Driver s cab operation C 20 Pos Rear tiller operation C 30 1 Windscreen wiper s interval duration 1 Rear attachment selection Rear tiller Board No attachment 2 Windscreen wiper heater ON OFF 2 Automatic lowering of rear tiller when trav elling forward ON OFF tiller ON 3 Front windscreen rear window heating ON duration min 3 Automatic raising of rear tiller when revers ing ON OFF tiller OFF 4 ...

Page 93: ... 100 17 Regeneration deactivation ON OFF 18 Regeneration ON OFF Figure 52 AUTOMATIC winch operation C 40 User profile C 50 Pos AUTOMATIC winch operation C 40 Pos User profile C 50 1 Rope traction force control AUTO A ECO MANUAL The following settings are saved Time cycles of window heating inter vals Wiper heating ON OFF Blade control 3 profiles 1 2 3 Automatic raising lowering of tiller Automatic...

Page 94: ...nutes 4 Year 5 Month 6 Day Figure 54 X Function C 80 Entering the password C 90 Pos X Function C 80 Pos Entering the password C 90 1 Driving direction Press rotary pushbutton switch B118 Turn rotary pushbutton B118 until desired position is marked 2 Covered distance 3 Distance measurement START STOP 4 Distance set to 0 ON OFF Operating and Maintenance Manual Snow groomer BISON 96 255 6 Display BIS...

Page 95: ...en you reach the distance 5 7 Angle blade vertical 8 Angle blade horizontal 9 Angle blade set to 0 in each postion possi ble 10 Angle vehicle vertical 11 Angle vehicle horizontal 12 Angle vehicle set to 0 in each postion possi ble Menu level Password level 1 Figure 55 Main menu Menu level Password level 1 D Pos Main menu Pos Menu level Password level 1 D A Information 10 Set vehicle handling B Ser...

Page 96: ...e keyboard the assisted drive get disabled as soon as the accelerator pedal is touched again Figure 57 Rear tiller settings D 20 Rear tiller PF90 V3 settings D 20 Pos Rear tiller settings D 20 Pos Rear tiller PF90 V3 settings D 20 2 Tiller wings ON OFF 7 Flat lock function 40 default 3 Presetting values for the depth of the tiller in millivolt mV 9 Lift timer option now in seconds 10 Downpressure ...

Page 97: ...gine settings D 60 Pos Statistics settings D 50 Pos Engine settings D 60 4 Statistic 1 to zero ON OFF 2 Hand throttle potentiometer limitation 800 2000 rpm function only with brake ap plied 5 Statistic 2 to zero ON OFF 3 Accelerator pedal potentiometer limitation 1500 2000 rpm function only with brake applied 7 Change standard parameters via USB stick ON OFF 12 Downloader for parameter ON OFF Send...

Page 98: ...ation 20 Rear tiller calibration 30 Driver s cab calibration 40 Winch calibration 60 Front blade rear tiller calibration 70 Drive calibration 80 Vehicle parameter overview Figure 61 Rear tiller calibration D 70 20 Driver s cab calibration D 70 30 NOTICE Calibration May only be changed by trained service personnel These changes may influence the driving characteristics Operating and Maintenance Man...

Page 99: ...ATIC winch calibration D 70 40 Pos Drive calibration D 70 70 1 Remove tracks 2 Engage the brake 3 Set the diesel engine to idle speed 5 The OK button appears only after both green checkboxes are visible Figure 63 Drive calibration D 70 70 Drive calibration D 70 70 NOTICE Calibration May only be changed by trained service personnel These changes may influence the driving characteristics Snow groome...

Page 100: ...ion the calibration stops Figure 64 Drive calibration D 70 70 Vehicle parameter overview D 70 80 NOTICE Calibration May only be changed by trained service personnel These changes may influence the driving characteristics Pos Drive calibration D 70 70 Pos Vehicle parameter overview D 70 80 1 Selection of the electronics TTC94 TTC60W 2 Change the page 3 Total Default Reset resets all values to fac t...

Page 101: ...ith the joystick standard setting Actuation with the potentiome ter optional 17 Time until the next regeneration Figure 66 Automatic brake operation C 15 password level 1 Pos Automatic brake operation C 15 pass word level 1 Pos 7 Emergency mode steering lever ON OFF 50 of the maximum vehicle speed 8 Emergency mode accelerator pedal ON OFF 50 of the maximum vehicle speed Snow groomer BISON Operatin...

Page 102: ...e than 30 s See chapter Regeneration for more information about the HEST lamp See Regeneration p 160 Inactivity alarm The software monitors the activity on several controls while the vehicle operates the steering levers the joystick and certain potentiometers To help lower the risk of accident if the driver falls asleep or is distracted while the vehicle is in motion alarms and an automatic engine...

Page 103: ...me If the operator activates one of the controls monitored by the software the alarm will stop and the icon will disappear If the operator does not activate one of the controls the engine speed will be reduced to idle after 5 s and the vehicle will stop The inactivity alarm is only activated when the assisted drive cruise control function is engaged Snow groomer BISON Operating and Maintenance Man...

Page 104: ...ectrical system The electrical system and particularly safety and warning devices must be checked to ensure their functional reliability If any malfunctions are found fuses relays bulbs etc these must be corrected immediately Make sure the parts are working properly Address any problems immediately Checking the batteries Make sure that the batteries and their terminals are securely fastened Checki...

Page 105: ... the engine is hot To avoid severe burns do not inspect the coolant system or attempt to add coolant if the engine is hot NOTICE Risk of damage to the engine If the coolant level is low the engine may overheat This will cause damage to the engine Repair any coolant leaks immediately Observe the coolant change intervals Only use the specified coolant 1 2 Figure 70 Engine coolant reservoir Pos Name ...

Page 106: ...s cool Allow 30 min between engine stop and oil level check 1 To access the oil dipstick reach through the round opening in the central access panel of the rear cowling or open the panel 2 To unlock the dipstick push the yellow handle and turn it a quarter of a turn counterclockwise 3 Check oil level The oil level should always remain within the high and low marks on the dip stick Top up with reco...

Page 107: ...he marks of the dipstick at ambient temperature preferably near the MAX mark Top up with recommended oil if level is low 0275370021 1 Figure 73 Dipstick on pump drive Check oil level daily Access the oil dipstick under the central access panel of the rear cowling To check the oil level perform the following 1 Unscrew and pull out the dipstick 2 Using a clean rag wipe oil from the dipstick 3 Insert...

Page 108: ... water separator The fuel filter water separator can be found under the central access panel of the rear cowling Check for presence of water daily NOTICE Water is heavier than fuel and will flow to the bottom of the clear bowl If water is detected in the clear bowl position a recipient under the valve and turn the valve knob to drain the water Return the valve knob to its original position once wa...

Page 109: ...r away as possible from the fuel Do not smoke Before starting the snow groomer the driver should check around the vehicle to make sure there are no people or obstacles in the hazard area The driver should also check the parking area for any traces of fluids that have come from the vehicle or the attachments Apart from that the following points should be remembered The daily checks and maintenance ...

Page 110: ...n the engine block heating rod in the hydraulic oil tank NOTICE Risk of engine damage The engine may be damaged if the coolant temperature is too low Use the preheating system at an ambient temperature below freezing point Pre heating NOTICE Before getting into the driver s cab check whether the preheating system cable has been dis connected from the mains The preheating system must be connected t...

Page 111: ... will lose its capacity to brake in the following conditions The snow groomer has no tracks mounted The tracks are slack thus not properly tensioned Starting the engine NOTICE Tips for engine start Before starting in low outside temperatures switch off all consumers of electrical power Do not press the accelerator pedal when starting Do not attempt to start the engine longer than 30 s without inte...

Page 112: ...ulic cylinders for a short time so that the hydraulic fluid can warm up in these circuits 1 Press the parking brake toggle switch to activate the parking brake 2 Set both steering levers rotary control for manual engine speed setting and the accelerator pedal to the zero position 3 Turn the ignition switch to position 2 on the main page of the display the indicator for preheat monitoring is contin...

Page 113: ...or 5 minto allow a gradual and uniform cooling WARNING Accident hazard Never shut down the engine while the vehicle is in motion Loss of control could occur Stop the vehicle completely and apply the parking brake before shutting down the engine NOTICE Risk of damage to the aftertreatment system Shutting down the engine when the Wait to stop engine popup is visible can damage the af tertreatment sy...

Page 114: ... Before starting off the driver must make sure that there are no people or obstacles within the swivel range of the vehicle and or the tracks Driver and passenger must always fasten their safety belts Use rocker switch S62 1 on the control console to activate snow groomer standby Press rocker switch upwards snow groomer standby ON Press rocker switch downwards snow groomer standby OFF Driving with...

Page 115: ...the snow plough The warning buzzer and rear work lamps are automatically activated for reverse travel To move forwards push both control levers from the zero position to the front at the same time To move backwards pull both control levers from the zero position to the back at the same time The following points must also be observed when reversing When reversing take care to prevent the snow groom...

Page 116: ... right steering lever forward Left turn forward travel Both steering levers backward Straight reverse Both levers forward Straight forward travel Both levers in neutral position Standstill Driving with the engine speed potentiometer The engine speed potentiometer allows the driver to determine the desired engine speed and to select the speed as well as the steering via the steering lever This func...

Page 117: ...le up to MAX Turn the engine speed potentiometer counter clockwise decrease the speed continuously variable down to MIN Controlling front attachments Front blade NOTICE Risk of contact Due to the large working range of the front blade it may hit the outside mirror or the driver s cab itself Apply the utmost caution when moving the front blade snow plough or loader The front blade attached at the f...

Page 118: ...load and relocate snow With the bucket open compact the snow with the front blade then close the bucket When loading snow the front blade must be raised along with the bucket Controlling rear attachments WARNING Risk of accident If any people or obstacles are located in the work area around the rear tiller this can result in a seri ous accident Take particular care to ensure that no persons or obs...

Page 119: ...on the display If a setting is changed it is saved until the engine is switched off Select the tiller shaft direction of rotation The push button A36 17 on keyboard 1 is used for selecting the tiller shaft direction of rotation See Keyboard 1 p 56 Operating the side wings The side wings are operated with the switches RS1 RS2 on the joystick When the side wings are lowered a time cycle is started w...

Page 120: ...witched on again The engine has been switched off One of the cab doors has been opened The Emergency OFF switch has been pressed Use rocker switch 2 on the control con sole to activate deactivate the operational readiness of the attachments Press rocker switch upwards op erational readiness of attachments ON Press rocker switch downwards op erational readiness of attachments OFF Front blade Adjust...

Page 121: ...es The park position of the roll cylinder 2 is more convenient when pushing snow to build a snow park Mounting the front blade CAUTION Pinch point hazard When moving the snow groomer up to the front blade Keep the danger zone clear of personnel NOTICE Risk of damage to the hydraulic system Even the smallest particles of dirt or impurities getting into oil the when connecting the front attach ments...

Page 122: ...the two threaded rods 3 outwards to the stop 5 Slowly bring the snow groomer up to the front blade 1 6 Connect the front blade at the top 7 Slightly raise the front blade and check if it is properly connected to the mounting point 8 Turn the two side threaded rods 3 inwards 9 Screw the nuts 2 onto the threaded rods 3 and torque to 600 Nm 440 ft lb and secure with locking pin 5 10 Clean the bolt fi...

Page 123: ...ion 1 Lower the front blade to the ground and turn off the engine 2 Remove the locking pins 2 from the bolts 3 3 Hold the side cutter 1 and remove the bolts 3 locking the side cutter to the brackets of the stow position A 4 Position the side cutter vertically at the extremity of the blade wing in the brackets of the work ing position B 5 Insert the bolts 3 in the brackets Secure with the locking p...

Page 124: ... protective caps Figure 80 Mounting the rear tiller Pos Name 1 Articulated arm 2 Nut 3 Threaded rod 4 Top coupling point 5 Tool 6 Locking pin 7 Automatically raise rear tiller when reversing ON OFF The rear tiller is mounted on the rear of the snow groomer using quick connect couplings 1 Clean the contact surfaces between rear tiller and quick connect coupling 2 Grease the top coupling point 4 3 L...

Page 125: ...ten both nuts 2 with the tools 5 supplied to 400 Nm 295 ft lb 13 Secure both nuts 2 using the tools 5 supplied and the locking pins 6 14 Reactivate the function Automatically raise rear tiller when reversing ON in the menu 7 15 Leave the menu and confirm the selection 16 Press the Operational readiness of the attachment switch S85 to OFF See Control console p 52 Mounting the POWER tiller with an a...

Page 126: ...ints 3 Remove the screw bolts 2 of the quick connect coupling 4 Deactivate the function Automatically raise rear tiller when reversing OFF in the menu 5 Leave the menu and confirm the selection 6 Press the switch 8 to ON See Control console p 52 7 Drive the snow groomer slowly up to the rear tiller 8 Connect the rear tiller at the top 9 Slightly raise the rear tiller using button T and push button...

Page 127: ...ve caps Figure 83 Hydraulic hose and electric cable connectors Pos Name 1 Oil return and leak line of the hydraulic motor 2 Connectors of the hydraulic motor 3 Quick connect couplings for snow chamber and wing cylinders 4 Electrical system connector 1 Switch off the engine 2 Clean the fittings 3 Connect the drain line of the tiller Always connect this line first 4 Connect the other hydraulic lines...

Page 128: ... cranes or crane lorries truck mounted cranes are available assemble the tracks as follows 1 Park the snow groomer on level ground 2 Carry out a visual check of sprocket tensioning and running wheels 3 Remove straps from rolled up tracks 4 Roll out the tracks in front of the snow groomer they have to be parallel and set at a distance from each other so the wheels will roll in the track guides of t...

Page 129: ...ft lb on belt overlap ping nuts Properly align belt holes on overlap ped section of the belts Install the clamping locks over the belt holes and keep in place using an appropriate tool C clamp or locking tool Install the nuts Tighten evenly On clamping locks with three nuts tight en centre nut first NOTE if the belt overlap and clamp ing is not properly done the belt could tear apart or sustain pr...

Page 130: ...ack tensioner tool 7 If ice calks are installed ensure they can rotate freely The second track is assembled in the same way Tension and loosen the tracks NOTICE Overtensioning the tracks causes premature wear of the guide clamps and the wheels Due to the greater friction overtensioning also results in increased fuel consumption Go to menu item C 10 on menu level Operation to tension and loosen the...

Page 131: ...ion tracks function Normal use of the snow groomer will loosen the track belts Track tension is important for maintaining the ability to brake If the sprocket wheels jump the tracks the tracks need to be re tensioned Before re tension ing carry out an inspection of the sprocket wheels tension wheels and running wheels The vehicle s tension wheels can be adjusted electro hydraulically In this way t...

Page 132: ...ic acid burn hazard The exhaust gas cooler may contain a small amount of sulfuric acid The use of fuel with sulfur levels greater than 15 ppm may increase the amount of sulfuric acid formed The sulfuric acid may spill from the cooler during service of the engine The sulfuric acid will burn the eyes skin and clothing on contact Always wear the appropriate personal protective equipment that is noted...

Page 133: ... your Prinoth representative for information on maintenance required according the your special needs WARNING Suffocating hazard Engine exhaust contains products which may be harmful to health Failure to follow these instructions may cause personal injury or death Always start and operate the engine in a well ventilated area If in an enclosed area vent the exhaust to the outside Engine warning lab...

Page 134: ...injury or death Sulfuric acid burn hazard may cause serious personal injury or death The exhaust gas cooler may contain a small amount of sulfuric acid The use of fuel with sulfur levels greater than 15 ppm may increase the amount of sulfuric acid formed The sulfuric acid may spill from the cooler dur ing service of the engine The sulfuric acid will burn the eyes skin and clothing on contact Alway...

Page 135: ...er and water separator 3 Transparent bowl 4 Water drain valve 5 Electronic control module ECM 6 Grid heater 7 Fuel injection pump 8 Twin hydraulic pumps 9 Air conditioner compressor option 10 Belt 11 Belt tensioner 12 Turbo unit Snow groomer BISON Operating and Maintenance Manual BISON 908930245 30367 10 Engine system 137 255 10 5 ...

Page 136: ... ventilation breather 2 Alternator 3 Water pump partial view 4 Electric motor 5 Hydraulic pump 6 Hydraulic reservoir 7 Starter 8 Engine oil filter 9 Secondary fuel filters 10 Oil filler cap Operating and Maintenance Manual Snow groomer BISON 138 255 10 Engine system BISON 908930245 30367 ...

Page 137: ... 1 Exhaust inlet tube 2 SCR Selective Catalytic Reduction cylinder 3 Exhaust outlet tube 4 DPF Diesel Particulate Filter cylinder 5 CRS Cat Regeneration System 6 Isolating elbow Snow groomer BISON Operating and Maintenance Manual BISON 908930245 30367 10 Engine system 139 255 10 6 ...

Page 138: ...ver of the en gine The Caterpillar engines are identified by the engine designa tion and engine serial number The Caterpillar service support point requires these numbers to determine which components have been used for the engine The spare part numbers can thus be determined precisely Location of identification plate The engine identification plate contains the following information Identificatio...

Page 139: ...rical systems or hot surfaces Immediately clean up any spilled fuel NOTICE Risk of engine damage Even very small dirt particles can cause engine damage and premature wear Ensure the utmost cleanliness when handling operating fluids Structural components and lubricants must be compatible with each other Therefore only brands tested and approved by Caterpillar must be used Special lubricant additive...

Page 140: ...RNING Fire and explosion hazards Avoid static electricity risk when refuelling Ultra low sulfur diesel ULSD poses a greater static ignition hazard than diesel formulation with a higher sulfur content Follow fuelling standards for proper grounding and bonding practices The following situations can arise if the engine is operated using fuel that does not conform with Cater pillar recommendations Sta...

Page 141: ...w in the fuel supply AdBlue DEF CAUTION Risk of caustic burns and poisoning If you open the AdBlue DEF Diesel Exhaust Fluid reservoir cover at higher temperatures ammonia fumes may be emitted Such fumes have a pungent odour and primarily irritate the skin mucous membranes and eyes Exposure to these fumes may cause burning of the eyes the nose and throat as well as the urge to cough and to tearing ...

Page 142: ...correct filling does occur inform a qualified service centre for a safe solution to the problem Storage Only use containers of the following materials to store AdBlue DEF Cr Ni steels complying with DIN EN 10 088 1 2 3 Mo Cr Ni steels complying with DIN EN 10 088 1 2 3 Polypropylene Polyethylene Containers of the following materials are NOT suitable for storing AdBlue DEF Aluminium Copper Alloys c...

Page 143: ...ature wear Ensure the utmost cleanliness when handling operating fluids Engine oils are especially tested for suitability in our engines Therefore only use the engine oil brands approved for Caterpillar Engine oils are specially tested for suitability in our engines Therefore only use the engine oil types approved for Caterpillar If the SAE class viscosity of the engine oil used is not suitable fo...

Page 144: ...oaming occurs Flush the cooling system with the mixture of water and Caterpillar recommended cleaner drain off the coolant Repeat this process until coolant foaming no longer occurs Fill the cooling system with the specified antifreeze mixture NOTICE Risk of contamination of drinking water Operating fluids engine oil fuel coolant etc can contaminate water resources Operating fluids and components ...

Page 145: ...damage to the cooling system Only use approved anticorrosion antifreeze agents Information can be obtained from every Caterpillar service support point When replenishing coolant after loss of coolant ensure an anticorrosion antifreeze agent ratio is correct Do not use more than 55 by volume max anti freeze anti corrosion anti freeze agent The antifreeze effect will otherwise be reduced and heat di...

Page 146: ... in one of three ways Emit a warning message Reduce the power Shut down the engine In many instances the response actions can limit the engine speed and or restrict power output Many of the parameters are monitored by the control unit The engine monitoring system keeps track of the following parameters Altitude at which the engine is operated Coolant level Coolant temperature Engine oil pressure E...

Page 147: ...al requirements in different countries The customer is asked to contact one of the PRINOTH branches if further information is required NOTICE Correct storage of the operating and maintenance instructions Operating and maintenance instructions are to be kept in the cab at all times A holder for that purpose is provided behind the driver s seat Environmental protection Caterpillar is committed to a ...

Page 148: ...e work Repair work Modifications including installation and removal Work on electronic components Please have guarantee and good will work carried out in the authorised workshops support points Engine servicing Refer to the chapter Engine servicing for instructions on how to maintain the engine The in structions and procedures are compiled in relation to fuel consumption and or service intervals e...

Page 149: ...harging pressure oil pressure coolant temperature etc should also be checked to ensure they are functioning correctly By observing the specified main tenance intervals and carrying out the required maintenance work correctly you will fulfil some of the conditions required for operating the engine safely For startup and maintenance pay particular attention to the Safety Instructions section in this...

Page 150: ...tact with skin or eyes Wear suitable protective gloves clothing and safety goggles Avoid contact with skin eyes or clothing If splashed with acid wash off immediately with clean water and seek medical assistance if nec essary Battery acid should be stored out of reach of children CAUTION Risk of injury Rotating parts can cause injuries Keep a safe distance from rotating parts Wait for them to stop...

Page 151: ... essential that all required identification data are provided The respective data can be found on the data stickers Any defect or damage found during maintenance should be corrected immediately If there is an obvious danger to operating personnel or to the equipment itself the vehicle or accessory should be put out of service immediately and should not be put back into operation until the fault or...

Page 152: ...ve the bolt 1 holding the lower front end of the cowling panel Remove the two bolts 2 holding the rear end of the cowling panel Grab the bottom edge of the panel and carefully pull it up few inches centimeters to disconnect the alignment cones at the top 4 Carefully pull away the panel taking care not to damage the electrical cable between the panel and the accessory support frame 5 Disconnect the...

Page 153: ...ittings before lubricating Replace damaged lubricating fittings immediately The required lubrication intervals are indicated on the maintenance schedule Grease the lubrica tion points indicated with arrows on the following drawings as well as the hydraulic cylinders for tilting the cab and load platform Before lubricating thoroughly clean the lubricating fittings in order to prevent dirt or foreig...

Page 154: ...Figure 93 Lubrication points standard push frame Figure 94 Lubrication points park push frame Operating and Maintenance Manual Snow groomer BISON 156 255 11 Maintenance BISON 908930245 30367 ...

Page 155: ...Figure 95 Lubrication points std or long rear lift frame Figure 96 Lubrication points wheel running gear Snow groomer BISON Operating and Maintenance Manual BISON 908930245 30367 11 Maintenance 157 255 ...

Page 156: ...Figure 97 Front blade lubrication points Figure 98 Lubrication points on the Power Tiller Operating and Maintenance Manual Snow groomer BISON 158 255 11 Maintenance BISON 908930245 30367 ...

Page 157: ... Posiflex tiller A with Preminum option only B on each rotor not visible on picture Figure 100 Miscellaneous lubrication points on the vehicle Snow groomer BISON Operating and Maintenance Manual BISON 908930245 30367 11 Maintenance 159 255 ...

Page 158: ...in HLP Synth 46 York Bio 777 VG 46 130 l 34 3 US gal PUMP DRIVE OIL Synthetic gear oil PAO basis polyalphaolefin Vis cosity ISO 220 SAE 75W 90 or 75W 140 API GL 4 or GL 5 2 7 l 0 7 US gal FINAL DRIVE OIL Synthetic gear oil PAO basis polyalphaolefin Vis cosity ISO 220 API GL 4 or GL 5 each 1 8 l 0 5 US gal GREASE SPECIFICATION AdBlue DEF Filter sealing rings MB Silicon grease Bearing and other lube...

Page 159: ...30 C 86 F A predetermined amount of soot or DEF deposits has accumulated in the CEM The engine runs at idle for a long time more than 1 h The normal duration of an Automatic Maintenance Regeneration is about 17 min but it can be longer In order to deactivate the Automatic Maintenance Regeneration Auto Regeneration mode inhibited for an emergency or for a specific reason use the controls on the veh...

Page 160: ...hten if required X X X X Change oil on planetary gearboxes First 150 hours then every 500 hours Check planetary for leak and damage X HUB WHEEL and TIRE Lubricate grease point on wheel hubs X X X X X X X X X Check retaining bolt torque on all wheels X X X X X X Check and adjust wheel bearings X SUSPENSION Lubricate all grease points X X X X X X X X X Check bolt torque on flexi tors and suspension ...

Page 161: ...ted and tighten if required First 150 hours then every 500 hours Check condition of intake pipe between air filter charge air cooler and en gine as well as check for leak tightness Before operating season Check turbocharger for damage as well as radial and axial play Every 2 years Check air filter for restric tion replace if required X X X X X Check alternator fan belt and tensioner X X X X X Obta...

Page 162: ... fuel fil ters X X X X X Unscrew fuel tank drain plug and drain condensa tion First 150 hours and then every 500 hours Fuel tank check the strenght of the holding straps Seasonal EXHAUST Check condition of engine exhaust system X Check exhaust elbow se curing clamp X X X X X ELECTRICAL Check condition of batteries X X X X X Check alternator and starter X X X X X Check condition of electrical syste...

Page 163: ...oints on cab doors and frame X X X X X X X X X Check oil level in cab rais ing system X Check raising cylinder and its hardware bolt torque etc X X X X X Check rubber supports en gine radiators reservoirs cab etc X REAR LIFT FRAME Lubricate all grease points and perform visual inspec tion X X X X X X X X X BLADE PUSH FRAME Lubricate all grease points and perform visual inspec tion X X X X X X X X ...

Page 164: ...gular maintenance is an essential requirement for possible warranty claims Please observe also the maintenance instructions for optional equipment During maintenance work pay particular attention to the General safety instructions section in this chapter Important notes Improper maintenance and repair work on the engine may result in engine damage or premature wear To avoid damage to the engine co...

Page 165: ...ncreases if personnel are not aware of the possible accidents during maintenance work Before carrying out maintenance work and repairs read the relevant sections of the technical documentation such as the operating and maintenance manual Familiarise yourself with the legal requirements such as health and safety and accident preven tion regulations CAUTION Risk of accident Improper operation of the...

Page 166: ...pplicable to the place of operation Prolonged or repeated contact between skin and any type of engine oil will remove natural skin lipids This may result in dehydration irritation or inflammation Used engine oil also contains hazardous substances When handling used engine oil damage to health can be avoided by following the basic rules of hygiene and safety at work To protect your health you shoul...

Page 167: ... drained 5 Inspect the magnet of the drain plug for excessive wear material The presence of metal debris could indicate a major failure or premature wear Clean the drain plug Replace the O ring on the drain plug if required reinstall the drain plug 6 Remove the filter cartridge from the head 7 Clean the sealing surface of the filter mounting head and apply clean engine oil on the seal of the new o...

Page 168: ...ilter will create restriction in the air flow and potential problems to the turbo and exhaust system 5 Discard the top conical secondary cartridge 6 Clean or replace the rectangular primary cartridge as required 7 Thoroughly clean and inspect the interior surfaces of the filter housing and of the cover Repair any damage 8 Install the new secondary cartridge 9 Install the primary cartridge 10 Insta...

Page 169: ...nner A clean engine makes it easier to identify leaks ensures maximum heat dissipation and allows easier maintenance Clean the engine regularly with a high pressure cleaner to remove oil and lubricating grease In doing so avoid water leakage into air intakes and ventilation openings After cleaning apply preservation agent Protect belt drive from preservative agents Cleaning with high pressure clea...

Page 170: ... instructions Maintain a minimum distance between the high pressure nozzle and the object being cleaned For needle jet nozzles approx 70 cm 28 in For 25 flat jet nozzles and mud cutters approx 30 cm 12 in Battery Safety instructions Observe the following safety instructions when handling batteries WARNING Risk of caustic burns The acid contained in the batteries causes caustic burns to skin and ey...

Page 171: ...un Upright Secured to prevent tilting Leave protective cap on the positive terminal Use the FIFO stock management method First In First Out Check the charge level regularly recharge if necessary Storage Battery performance is reduced in cold conditions for example at 10 C 14 F output is only about 60 of normal level If the engine is out of service for extended period store the batteries in a room ...

Page 172: ...e located on the left under the engine cover behind the driver s cab Keep the batter ies terminal studs and terminal clamps clean 1 Clean the terminal studs and clamps if necessary loosen the terminals and clean the contact surfaces 2 Smear the terminal studs with Vaseline or an acid free non corrosive grease 3 Re tighten the terminal clamps if necessary Removing battery Do not place metal parts s...

Page 173: ...n or fit it with the elbow fitting and hose 1 Ensure good ventilation 2 Open the battery compartment 3 Loosen and disconnect negative terminal clamp 4 Release and disconnect positive terminal clamp 5 Only use suitable DC chargers with electronic regulation of the charging current 6 Connect the positive pole of the battery or 24 V series connection to the positive output of the charger 7 Connect th...

Page 174: ...0 C 14 F it has to be thawed before jump starting Use of cables for starting with a booster battery 1 For jump starting with jumper cables only use vehicles with the same nominal voltage 24 V 2 Turn ignition switch to position 0 switch off all electrical consumers 3 Attach red cable to positive terminal of flat battery 4 Attach other end of red cable to positive terminal of donor battery 5 Attach ...

Page 175: ...erminal Cooling system Checking the coolant level See Engine coolant level p 107 Replacing the coolant WARNING Risk of scalding The cooling system is pressurized Hot coolant can spray out and scald skin and eyes when the cool ing system is opened Only open the cooling system when the coolant temperature is below 40 C 104 F Slowly unscrew the housing cover and completely release the pressure before...

Page 176: ...g the coolant Record the replacement of the coolant in the maintenance booklet Draining the coolant NOTICE Risk of contamination of drinking water Operating fluids oil fuel coolant etc are water contaminating materials Operating fluids and components that come into contact with operating fluids e g filters or seal ing rings should be disposed of in accordance with the environmental regulations Fol...

Page 177: ...ater in order to remove any debris Close the drain valves Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling Sys tem Cleaner Add 0 5 l 1 pint of cleaner per 15 l 4 US gal of the cooling system capacity Install the cooling system filler cap Fill the cooling system no faster than 19 l 5 US gal per minute to avoid air locks Start and run the engine at low idle f...

Page 178: ...ine and let it run for approx 1 min at low speed Fill coolant continuously in the specified composition up to the bottom edge of the filler neck Stop the engine and seal the cooling system again Check the cooling system for leaks and correct the operating temperature Cleaning cooling systems Compressed air is the preferred method for removing loose dirt But pressurised water can also be used for c...

Page 179: ...l system carefully before removing components Put a suitable cover on components removed from the fuel system Checking the water separator See Primary fuel filter water separator p 110 Replacing the primary fuel filter NOTICE Risk of contamination of drinking water Used filter components seals and residual fuel must be disposed of in accordance with local regulations WARNING Fire hazard Fuel leake...

Page 180: ... with clean diesel fuel and install on the transparent bowl 10 Install the transparent bowl on the new filter cartridge Tighten to 15 Nm 11 ft lb 11 Lubricate the seal of the new filter cartridge with diesel fuel Install the new filter cartridge with transparent bowl on the head Tighten by hand 12 Insert the key in the ignition switch and turn it to the accessory position Activate the fuel pri min...

Page 181: ...2 Front filter 3 Filter head 1 Park the vehicle on level ground and turn the key in the ignition switch to the off position 2 If not already done replace the primary fuel filter fuel filter water separator 3 Install a suitable recipient under the filters to collect possible fuel spill 4 It may be required to relieve residual fuel pressure before removing the filters If so loosen the one of the fue...

Page 182: ...r in the fuel lines must be avoided to prevent premature wear and damage to the engine If air is trapped in the system the very high pressure of operation could permanently damage critical engine parts Ensure to follow the priming procedure thoroughly 1 Figure 108 Fuel priming pump switch Pos Name 1 Fuel priming pump switch If the engine shuts down because it ran out of fuel or because a filter wa...

Page 183: ... code helps to pinpoint the problem When the system is properly purged the fuel pressure should reach 2 bar within 5 s of the switch acti vation If it takes 10 s or more air could still be trapped in the system Wheels Check tension wheels running wheels and sprocket wheels 1 2 3 Figure 109 Tension wheels running wheels and sprocket wheels Pos Name 1 Tension wheels mounting torque 340 Nm 250 ft lb ...

Page 184: ...y tighten the nuts on the track treads 95 Nm Tracks Torque values for steel track fasteners 7 6 5 3ab 3ab 2ab 2ab 2ab 4 4 1 Figure 110 Standard and Preminum steel tracks Cross link retaining bolts nuts on rubber belts must be tightened to specified torque after the first 150 hours of operation torque value shown is the tightening torque Then reapply torque at the beginning of every season Name Val...

Page 185: ... of the engine It is required to remove the aluminium side panel to access the reservoir The oil level should be checked when the oil is warm Proceed as follows 1 Park the vehicle on level ground and turn off the engine 2 Lower the front blade and the tiller 3 Remove the aluminum right side panel to access the reservoir 4 Using the appropriate tool unscrew item1 the breather completely 5 Use a cle...

Page 186: ...nspect the magnets of the plugs for excessive wear material The presence of metal debris could indicate a major failure 6 When all the oil is drained reinstall the drain plug Torque M16 plugs to 65 N m 48 lbf ft Tor que M18 plugs to 80 N m 59 lbf ft IMPORTANT Make sure the sealing brass washer is replaced by a new one every time the plug is removed 7 Using new oil fill the housing until oil flows ...

Page 187: ...ulic oil NOTICE Risk of damage to the hydraulic system Even the smallest dirt particles can cause premature wear or damage to the system Ensure the utmost cleanliness when handling operating fluids Only use the specified types of hydraulic oil Observe the hydraulic oil change intervals Check the MAX mark do not overfill NOTICE If the hydraulic oil was contaminated because of an operating fault the...

Page 188: ...perating fluids and components that come into contact with operating fluids e g filters or sealing rings should be disposed of in accordance with the environmental regulations Follow the legal provisions applicable to the place of operation Service life of hydraulic hoses The hydraulic hoses and crush protections installed in the vehicle s high and low pressure lines and in the attachments have a ...

Page 189: ...mp Wear protective gloves and safety glasses CAUTION Risk of injury Halogen lamps are under high voltage and get very hot Do not interrupt the connecting cable to the headlamp When replacing lamps always wear safety goggles and protective gloves CAUTION Risk of splintering Halogen lamps are under high pressure If a halogen lamp bursts in an enclosed space leave the area and allow to ventilate for ...

Page 190: ...procedure minimizes the risk of damage to electronic components while welding 1 Switch off the diesel engine 2 Wait at least 6 min for the battery disconnect switch to turn off 3 Disconnect the battery cable from the negative terminal right side battery 4 Disconnect the battery cable from the positive terminal central battery 5 Isolate the connector of each battery cable previoulsy disconnected 6 ...

Page 191: ...ied out by qualified personnel who have the necessary specialist knowledge and tools to carry out the required work The engine supplier recommends that you use its service support point for this General troubleshooting Symptom Cause Remedy Ref Starter pinion does not turn or turns too slowly 1 Battery is insufficiently charged Charge battery 2 Starter connection cable is loose Tighten cable at ter...

Page 192: ...rge air cooler or radiator Clean charge air cooler and radiator from the outside 19 Engine coolant temperature too high Check temperature sensor replace if necessary check fan speed defective ther mostat consult a professio nal service centre 20 Fuel system defect blocked leaking Check for leaks visually consult a professional serv ice centre 21 Charge air system leaking hose clamp on air inlet ho...

Page 193: ...tive turbocharger 37 Faulty combustion defective injection Consult a professional serv ice centre Blue exhaust gas 38 Engine oil level too high crankcase ventilation defec tive engine oil leaking into combustion chamber Rectify oil level have quali fied personnel check crank case ventilation White exhaust gas 39 Coolant getting into the com bustion chamber or poor fuel combustion Pressure loss tes...

Page 194: ...e supplier or its service support point The fuse allocation chart is vehicle specific and is provided by the vehicle manufacturer See Fuses and relays p 66 If the newly inserted fuse also blows have the cause traced and rectified at a qualified specialist workshop If a circuit fails switch off the consumer equipment and switch the ignition lock to position 0 Checking and replacing a safety fuse 1 ...

Page 195: ...le length without push frame rear lift frame blade and tiller 4035 mm 159 in Vehicle length with attachments 8510 mm 335 in Vehicle width without tracks 2440 mm 96 in Vehicle width with tracks 4216mm 166 in Max vehicle height 3008 mm 118 5 in Min clearance above ground ground clearance 368 mm 14 5 in Recommended garage dimensions for maintenance work Length 11000 mm 433 in Width 8000 mm 315 in Sno...

Page 196: ...ndicated are derived from testing production vehicles under typical operating conditions according to intended use Diesel engine Caterpillar C9 3 TIER 4 Make Caterpillar Model C9 3 Type Turbodiesel with electronic fuel system Total displacement 9 3 L 567 5 in3 Power 298 kW 400 bhp at 1700 to 2000 rpm Max torque 1725 Nm 1273 ft lb at 1400 rpm Fuel tank capacity 266 L 70 2 gal AdBlue DEF tank conten...

Page 197: ... or turbocharger inlet The mixture of VCI oil can be added to the inlet by removing the plug for checking turbocharg er boost pressure The minimum application rate for the VCI oil mixture is 5 5 ml l 3 oz 1000 cu in of engine displacement 5 Use a sprayer to apply a mixture of 50 VCI oil and 50 crankcase oil into the exhaust openings The minimum application rate for the oil mixture is 5 5 ml l 3 oz...

Page 198: ...if urea concentration remains outside the range of 29 to 35 drain the DEF AdBlue from the tank and refill with DEF AdBlue meeting the ISO 22241 specification 4 Ensure un normal shutdown Allow Delayed Engine Shutdown or properly cool the engine pri or to shutting down 5 Ensure a proper DEF AdBlue purge Do not disconnect the battery disconnect switch within 2 min after removing the ignition key 6 Fi...

Page 199: ...local authori ties Definition of hazardous waste Left over and used operating fluids are considered waste For the purpose of these instructions this type of waste is considered hazardous if it has one or more of the following properties Potentially explosive Highly flammable or spontaneously inflammable Combustible Oxidising Toxic or highly toxic Irritant or caustic Generally harmful to health Car...

Page 200: ...th the same waste fluid Transporting waste Only correctly packaged sealed and labelled containers or alternatively containers approved by the environmental officer may be taken to the waste disposal site waste separation PCB based synthetic oils or substitutes containing halogen particularly those used in transform ers condensers and hydraulic systems must be collected and transported separately f...

Page 201: ...self with the pictograms and what they stand for before operating the AUTOMATIC winch See Pictograms and what they stand for p 14 There are three different types of pictograms Instruction signs Prohibition signs Alarm Icons WARNING Danger of death and injury The pictograms on the AUTOMATIC winch indicate possible dangers Ignoring these pictograms can lead to serious or life threatening injuries Th...

Page 202: ...ng ski slopes in extremely steep and difficult terrain The anchoring points should preferably be made of reinforced concrete or metal bars The route to be followed by the snow groomer with mounted AUTOMATIC winch must be taken into account when planning the anchoring points for the cable The cable must be secured to a non rotating anchoring point The AUTOMATIC winch was designed and built for outd...

Page 203: ...d it by the anchoring hook never pull the cable itself 2 The removal of safety devices is prohibited 3 Warning of severing injuries or crushing danger due to rotating parts 4 Warning against hot surfaces components or fluids 5 The cable must be slack before tilting the winch arm 6 During transport secure the winch arm to prevent twisting 7 Lubrication points on the turntable Snow groomer BISON Ope...

Page 204: ... by mechanical parts Pinch point hazard Under the winch arm when tilted X X X X X Risk of cut and amputation Between cable and winder outlet X X X X X X Between cable and cable guide rollers on the winch arm X X X X X X Between cable and winder X X X X X X Between cable and drum X X X X X X Risk of crush and entanglement Cable winding drum X X X X Impact hazard Against the winch arm X X X X X X By...

Page 205: ...und solid or sharp edged objects stones rocks steel etc The cable should nev er come under tension with a sudden jerking movement Examine the cable at regular intervals Do not carry out cutting or welding near the cable When not in use store the cable on a drum to prevent it from being run over and damaged by other vehicles The cable must be cleaned and lightly lubricated regularly The cable shoul...

Page 206: ...tial to read the safety and operating requirements in these operating and maintenance instructions NOTICE Preventing premature wear on the cable An incorrect driving style can jerk the cable and result in premature wear Particularly when there are mounds in the terrain there is a risk that the cable will rest on or dig into the mound when driving downhill and will then be released with a jerk when...

Page 207: ...ned steel cables ski lifts or aerial cableways when ever the AUTOMATIC winch is mounted If the drum is still turning after being deactivated switch off the engine immediately and check the AUTOMATIC winch Exercise the utmost caution when tightening the cable in order to prevent any jerking of the ca ble The cable may be unwound manually only when the engine is in low idle When pulling the cable ta...

Page 208: ... vehicle The cable anchoring must be maintained regu larly by qualified personnel and its condition must be checked The cable must not be wound around anchoring points The cable can only be properly anchored using the anchoring point s eyelet Anchoring points have to be constructed in such a way that the cable will not be twisted If a pilot cable wire rope with sliding hook is used between the anc...

Page 209: ...and a work lamp illuminates the cable magazine The work lights are automatically switched on when the winch is in operation Drum with cable magazine The cable drum with cable magazine is powered by a hydraulic motor and a planetary gear sys tem The hydraulic cable winder ensures that the cable is wound correctly and uniformly onto the drum Pivoting winch arm The winch arm is mounted on the AUTOMAT...

Page 210: ...e AUTOMATIC winch Figure 118 AUTOMATIC winch Pos Name 1 Locking lever 2 AUTOMATIC winch unlocked 3 AUTOMATIC winch locked 4 Push button switch 5 Safety bar 6 Bolt 7 Safety pin Tilt the AUTOMATIC winch CAUTION Risk of tipping Tilting the AUTOMATIC winch changes the snow groomer s center of gravity Park the snow groomer on solid and level ground Do not drive the snow groomer while the AUTOMATIC winc...

Page 211: ...ttons below the right maintenance flap To tilt the AUTOMATIC winch proceed as follows 1 Park the snow groomer on solid and level ground 2 Remove all objects from the loading platform 3 Lower the rear tiller to the ground 4 Turn the AUTOMATIC winch to the rear 5 Turn locking lever upwards AUTOMATIC winch unlocked 2 6 Ignition key position ON 7 Press on the upper part of the push button 4 the AUTOMA...

Page 212: ...cylinder 10 Insert the free end of the safety rod into the bracket 8 Lower the AUTOMATIC winch CAUTION Risk of tipping An unlocked AUTOMATIC winch may tilt back during travel Check the locking device after lowering the AUTOMATIC winch Only move the snow groomer with the AUTOMATIC winch secured Operating and Maintenance Manual Snow groomer BISON 214 255 15 AUTOMATIC Winch BISON 908930245 30367 ...

Page 213: ...buttons below the right maintenance flap To lower the AUTOMATIC winch proceed as follows 1 Compress the safety rod spring to unlock the safety rod 5 from its bracket 8 2 Fold up the safety rod 5 and lock the de vice into the stowed position 3 Press on the lower part of the push button 4 the AUTOMATIC winch lowers 4 Snow groomer BISON Operating and Maintenance Manual BISON 908930245 30367 15 AUTOMA...

Page 214: ...ust come up to the filler hole if necessary top up with the specified oil When swivelled to the rear the winch arm can be tilted to the side The winch arm can only be tilted and aligned using the hydraulic hand pump 1 at the front right on the drum winch frame The pump lever 2 required for this is located on the front side of the drum winch frame If necessary tilt the winch arm to the side e g hei...

Page 215: ... pump lever 2 winch arm tilts Straighten the winch arm 1 Insert the pump lever 2 into the hydraulic hand pump 1 2 Turn the hand pump lever to the right 4 Straighten winch arm 3 Operate the pump lever 2 winch arm is straightened Snow groomer BISON Operating and Maintenance Manual BISON 908930245 30367 15 AUTOMATIC Winch 217 255 ...

Page 216: ... points 2 Locking lever 3 AUTOMATIC winch unlocked 4 AUTOMATIC winch locked 5 Safety pin 6 Hydraulic cylinder Figure 120 Connection sequence Pos Name 1 2 3 20 Nm 4 5 6 7 10 Nm Operating and Maintenance Manual Snow groomer BISON 218 255 15 AUTOMATIC Winch BISON 908930245 30367 15 6 ...

Page 217: ...en connecting the AUTOMATIC winch can cause damage to the hydraulic system Ensure that the quick lock couplings on hydraulic hoses are correctly mounted AUTOMATIC winch mounted store the protective caps in the driver s cab s tool compartment AUTOMATIC winch not mounted cover the quick connect couplings with clean protective caps NOTICE Use suitable hoisting equipment when detaching the AUTOMATIC w...

Page 218: ... AUTOMATIC winch is properly fixed to the snow groomer NOTICE Risk of damage to the hydraulic system Even the smallest particles of dirt or impurities getting into the oil can result in damage to the hydraul ic system AUTOMATIC winch mounted store the protective caps in the driver s cab s tool compartment Figure 121 AUTOMATIC winch Pos Name 1 Belt straps 2 Eyelet 3 Rear bolt 4 Locking lever 5 AUTO...

Page 219: ...eck whether the locking system and the mounting are clean 9 Lubricate locking system mountings and bolt threads using water repellent grease 10 Attach belt straps 1 to the eyelets 2 on the AUTOMATIC winch frame 11 Pre tension the belt straps raise the AUTOMATIC winch and position it correctly over the snow groomer 12 Lower the AUTOMATIC winch slowly into the fittings be careful not to damage the d...

Page 220: ...tings for leaktightness correct any oil leaks immediately 25 Remove the driver s cab safety strut 10 26 Lower and lock driver s cab 27 Carry out the specified checks before putting the AUTOMATIC winch back into service Removing the winch WARNING Risk of accident If not mounted properly the AUTOMATIC winch may come loose and fall off causing injuries Check the condition and load capacity of the AUT...

Page 221: ...been lifted off drive the snow groomer forwards or move the hoisting gear away 16 Check the hydraulic hoses and bolt fittings for leaktightness correct any oil leaks immediately 17 Remove the driver s cab safety strut 10 18 Lower and lock driver s cab 19 Attach the center cover panel to the load floor and middle engine cover Storing the winch NOTICE Risk of damage to the hydraulic system Strong so...

Page 222: ...ection of the cable Check the cable for possible defects e g broken wires deformation Take particular care when examining the cable clamps anchoring hook and cable lock Check the anchoring hook locking Detailed description of the cable inspection See Checking the cable p 239 Operation Indicators and controls on the display Figure 123 Main display with AUTOMATIC winch Pos Name Image Description 1 W...

Page 223: ... AUTOMATIC winch 4 Cable traction force control The active cable traction control mode is displayed as a symbol Manual mode Automatic mode A ECO mode 5 Traction force status MIN or MAX lighting up indicate the status of cable traction force maximum traction force minimum traction force 6 Reduced vehicle speed If the indicator lights up white continuously reduced vehicle speed is activated Winch op...

Page 224: ...tion Pressing the push button switch activates winch operation The menu can be used to select between manual or automatic traction force control If the cab door is opened during winch operation there are two possibilities If the cable is not tensioned winch operation is deactivated Winch op eration must be reactivated again after the door is closed If the cable is tensioned winch operation will re...

Page 225: ...ible to assign the cable traction force function directly on the mini joystick T without pressing push button S3 Go to menu item C 40 and switch the joystick button assignment Figure 125 Joystick Pos Name 1 Mini joystick T 2 Push button S3 Winch arm The AUTOMATIC winch s arm can only be swivelled when winch operation is switched off Figure 126 Functions with operation of push button S3 and mini jo...

Page 226: ...h mini joystick T backward Cable traction force is reduced to MIN Keep push button S3 pressed and push mini joystick T backward again Cable traction force is increased to the preset level You do not have to move the joystick Manual cable traction control If the mini joystick T is pushed forward the cable traction force is increased Keep push button S3 pressed and push mini joystick T forward Cable...

Page 227: ...essing the R0 2 and R0 3 push button switches Before using the R0 2 and R0 3 push button switches to rewind and unwind the cable you must observe the following points The remote control must be switched on The manual cable unwind function must have been activated with the A37 6 push button switch At least one of the cab doors must be opened Pressing the R0 2 push button switch activates the automa...

Page 228: ...ttach the cable and secure it with the locking lever Rewind the cable with the ROLL OUT remote control 1 Drive the snow groomer approx 10 m 32 ft from the anchoring point 2 Press push button switch A37 7 to disable the winch operation mode 3 Engage the snow groomer s parking brake 4 Press the push button switch for unwinding the cable A37 6 until the cable is so slack that it can be detached from ...

Page 229: ...n Winch operation or Rewinding the cable can be activated without first switching Unwinding the cable on and then off again Winch operation CAUTION Risk of accident Tightening the cable with winch operation deactivated will cause brake failure Never pull the cable taut by moving the snow groomer away from the anchoring point without first activating winch operation CAUTION Risk of accident If the ...

Page 230: ...push but ton switch must then be pressed immediately to put the AUTOMATIC winch into operation After getting into and out of the cab both winch operation and drive standby mode must be activated again in order to continue operating the winch Figure 130 Display image The display shows the winch operation symbol for 2 s During winch operation Strictly observe the operating and accident prevention re...

Page 231: ...horing hook is brought to the vehicle the cable can slip and injure the person who brings the hook Always make sure that during transport the anchoring hook is located between the vehicle and the person who is carrying the hook If the cable slips let go of the anchoring hook Electronic traction control The AUTOMATIC winch s functions are controlled by Moving mini joystick T on the joystick Pressin...

Page 232: ...miliar with WARNING Risk of accident Do not make any turns as a suddenly released cable may cause serious damage to the snow groom er and injury to persons Always keep the cable taut even when driving on level terrain to prevent the cable from lying on the ground snow or rocks Cable traction force is automatically adjusted by cable traction control If necessary the cable traction force can be manu...

Page 233: ...ge to property or physical injuries that result from failure to observe the maintenance intervals and carry out the required maintenance work In these cases all warranty claims are void The maintenance work are to be carried out as indicated on the lubrication and maintenance ta bles and according to the intervals specified by the manufacturer In carrying out the maintenance work follow the safety...

Page 234: ...e hydraulic cable guide is functioning correctly Pull at the cable several times to check if the toggle switch is working properly The AUTOMATIC winch s actual working hours are displayed by the AUTOMATIC winch working hours counter Depending on the number of hours carry out the work as indicated in the maintenance table and lubrication schedule AUTOMATIC winch maintenance schedule Table for maint...

Page 235: ...0 h Check bolts and hose clamps tighten if necessary X X every 400 h Replace hydraulic oil filter at least every 2 years X every 800 h Check the groove diameter of the cable guide rollers in the winch arm before operating season and every time the cable is changed This work is also carried out by PRINOTH customer service personnel and does not affect the other maintenance intervals Recommended spa...

Page 236: ...o 110 C 230 F Cable lubrication We recommend CIFAST BRILUBE 30 40 50 60 or equivalent lubricat ing grease Only required for non galvanised cable Cable lubrication at the end of the sea son We recommend using SHELL 2722 or equivalent lubricating greases Only required for non galvanised cable HYDRAULIC PUMP TILT SYSTEM WINCH ARM HYDRAULIC FLUID ATF oil Dexron III Dexron II Type F Type A Suffix A Che...

Page 237: ...lised personnel of any irregularities found in the cable and have it checked CAUTION Risk of injury There is a risk injury when handling the cable Wear protective gloves Only pull the cable by the anchoring hook never pull the cable itself Always keep the cable in front of you Irrespective of the number of working hours on the AUTOMATIC winch the cable must be examined thoroughly in the following ...

Page 238: ...on kinks etc If cable is used in difficult working conditions The following defects may occur in the cable Broken wires and wire strands Clances Crushing Waviness Knoten Bird caging Holes Cuts Kinks Overstretching Operating and Maintenance Manual Snow groomer BISON 240 255 15 AUTOMATIC Winch BISON 908930245 30367 ...

Page 239: ...ill allow you to see and feel how worn the rope is and therefore determine whether it needs to be replaced If the core of the rope is visible the rope must be cut away or at the very least the damaged part must be removed Lateral markings on the rope also indicate whether there is any damage to the core The dis tance between the lateral markings increases as the core tapers off A rope always taper...

Page 240: ... the steel cable due to exposure to heat Excessive stretching Severe damage due to corrosion The number of visible wire breaks on a specified stretch of rope as defined by UNI ISO 4309 All inspections must take the above criteria into account If cable damage is attributed to more than one of the above factors there will be a variety of effects which should be checked by the personnel responsible T...

Page 241: ...ound The winch gear must be shut down for at least 10 min so that the oil can set Always use the oil level screw to check the oil level Figure 134 Winch gear Pos Name 1 Oil filler screw 2 Oil level screw 1 Park the vehicle on a level surface at operating temperature 2 Wait at least 10 min before measurement so that the oil can set 3 Clean the surroundings of the oil filler screw 1 and oil level sc...

Page 242: ... water Operating fluids oil fuel coolant etc are water contaminating materials Operating fluids and components which come into contact with operating fluids e g filters or sealing rings should be disposed of in accordance with the environmental regulations Follow the legal provisions applicable to the place of operation NOTICE Only change the oil when at operating temperature The winch gear must b...

Page 243: ...e it 10 Insert the oil level screw 2 and oil fill screw 1 again 11 Check that all screws are firmly seated Changing gear oil using the winch cooling pump Figure 136 Winch cooling pump Pos Name 1 Ball valve 2 Intake hose 1 Park the vehicle on a level surface at operating temperature 2 Turn the drum until the oil drainage pipe is at the lowest point Remove the plug and drain the oil 3 Open the gear ...

Page 244: ...ked and cleaned without draining the oil from the gearbox 1 Close the ball valve 1 on the suction filter screw in completely 2 Open the gear oil suction filter and check for particles Contact Prinoth customer service if you find any large coarse metallic particles in the filter 3 Clean the suction filter as specified and then reinstall it 4 Reopen the ball valve 1 on the suction filter unscrew com...

Page 245: ...ing a welding torch or electric welding equipment Re install the anchoring hook Attach the cable clamps as indicated in the drawing Check the tightening torques on all bolts After the first 10 operating hours of the AUTOMATIC winch check that the bolts are firmly seated Snow groomer BISON Operating and Maintenance Manual BISON 908930245 30367 15 AUTOMATIC Winch 247 255 ...

Page 246: ...8 lb Cable Diameter 11 mm 0 43 in Minimum breaking strength of cable 116 kN 26080 lbf Max cable length 1200 m 3940 ft Operating data Max frontal climbing ability 100 Max lateral stability 45 Max cable traction force 45 kN 10116 lbf Snow groomer speed with AUTOMATIC winch fitted during winch operation 0 km h 0 mph 17 km h 11 mph Turning radius snow groomer turns on own axis 0 on snow Operating and ...

Page 247: ...owing additional measures Clean the AUTOMATIC winch completely using a warm water jet and a suitable cleaning agent rinsing thoroughly Then let dry Have cleaning carried out by qualified personnel who are aware of the possible hazards Never wash the AUTOMATIC winch cable Unwind cable clean it and have it inspected as per DIN 15020 Sheet2 by qualified and au thorised personnel Lubricate cable using...

Page 248: ...Diesel Particulate Filter ECM Engine Control Module ECU Electronic Control Unit EDC Electronic Diesel Control EN European Standard EP Extreme Pressure EU European Union HP Horse Power ISO International Organization for Standardization LCD Liquid Crystal Display LED Light Emitting Diode MR Engine Control Unit OBD On Board Diagnostics ÖNORM Austrian Standard PAO Poly alpha olefin PCB Polychlorinated...

Page 249: ...nting and removing the winch 219 Mounting position and tightening torques 218 Mounting the front blade 124 Mounting the park pusher frame 123 Mounting the rear tiller 126 128 Mounting the tracks 130 Mounting the winch 219 220 N Navigating in the menu 76 O Operating fluids 141 160 Operating safety 151 Operation of the AUTOMATIC winch 227 Operational readiness of the at tachments 122 Overview of the...

Page 250: ...UTOMAT IC winch 248 W Warm engine 114 Warning labels 135 Waste material 201 Winch arm 211 Winch brake 211 Winch specifications 211 Windscreen wiper heating 65 Operating and Maintenance Manual Snow groomer BISON 252 255 17 Index BISON 908930245 30367 ...

Page 251: ...Snow groomer BISON Operating and Maintenance Manual BISON 908930245 30367 253 255 ...

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