BGU FSW 4.5 M User guide
Seite 1
Carefully read these instructions
before starting and using your log winch!
Original Instruction Manual
Südharzer Maschinenbau GmbH
99734 Nordhausen, Helmestraße 94
Service Tel. 0 36 31 / 62 97 104 • Fax 0 36 31 / 62 97 111
Internet: www.bgu-maschinen.de
e-mail: [email protected]
Mechanical Logging Winch
FSW 4.5 M / 5.5 M
- Set-up & installation
- Use
- Maintenance
- Accessories
Seite 2
Südharzer Maschinenbau GmbH
Helmestr. 94
99734 Nordhausen
Tel: 0 36 31 / 62 97-0 Fax: 0 36 31 / 62 97 111
CE – Statement of Compliance
to the EC Machines Directive No. 2006/42, Annex II A and (Low Voltage)
Directive 2004/108
We hereby declare that the equipment described in this manual responds in full to the actual version
brought on the market. We, the manufacturer further declare that this equipment was duly designed and
manufactured in accordance with the actual European Safety and Health Standards settled by the relevant
EEC directives as well as the latest electromagnetic standards issued by the European Council of 3.5.89 and
later enforced by all member states. This statement of compliance does not apply to customer modifications
of the equipment without manufacturer’s written approval. The manufacturer shall not be responsible for
such modified equipment and machines.
Machine type:: Logging winch
Models: Mechanical FSW 4.5 M / 5.5 M
Production No.: see model label
Applicable European Standards: EC Machine Directive (EC 42/2006)
and following amendments and additions
Low Voltage) Directive 2004/108
Other applicable Standards
and technical specifications: EN ISO 12100-1,
EN ISO 12100-2,
EN ISO 4254-1,
EN ISO 14492-1
29.12.2009
................. ....................................
Date Jörg Kernstock
Director
Official user's language: English (User’s release)
Seite 3
List of contents
Seite
1. General information.................................................................................................... 4
1.1 Delivery and transport claims .............................................................................................. 4
2. Safety pictograms and warning labels..................................................................5
3. Safety rules ................................................................................................... 6/7
4. About PTO ................................................................................................. 8
5. Operation.......................................................................................................................... 8
5.1 PTO shaft requirements ........................................................................................ 8
5.2 Connecting the winch to the tractor ...................................................................................... 8
5.3 Connecting the winch to the tractor....................................................................................... 9
5.4 Wire rope installation ..................................................... ..................................................... 9
5.4.1 Checking the wire rope quality.............................................................................................. 10
5.4.2 Spooling of the wire rope......................................................................................................... 10
5.4.2 Unspooling of the wire rope..................................................................................................... 10
5.5 Skidding operations.............................................................................................................. 10
5.6 Settings ................................................................................................................................ 11
5.6.1 Clutch................................. ................................................................................................. 11
5.6.2 Pre-braking arrangement...................................................................................................... 11
5.6.3 Brake.................................................................................................................................... 12
5.6.4 Stretching of the drive chain................................................................................................. 13
5.7 Lubrication....................................................................................................................... 13/14
5.7.1 Visual and functional tersting before first use........................................................................ 15
5.7.2 Effects of overloading or misusing the winch........................................................................ 15
6. Technical specifications.............................................................................................. 16
7. Warranty........................................................................................................................... 16
8. Spare parts list............................................................................................................... 16
9. Warranty for new wire ropes.................................................................................... 20
Seite 4
User's manual
1. General information
Dear customer,
Thank you very much for your trust and preference in choosing our equipment and joining the number of
our best customers in the world. We are confident that our equipment will be up to all your expectations and
assure you a long lasting quality and performance.
Our log winches are available in two different versions of different skidding force.
FSW 4.5 pull force 4,5 tons mechanical operation system
FSW 5.5 pull force 5,5 tons mechanical operation system
All versions are designed and conceived for farming and logging applications. Any other use shall be
considered non-compliant application.
The manufacturer accepts no responsibility for damages caused by non-compliant application. In this case
the operation of the machine is completely at user’s risk.
1.1 Delivery and transport claims
Upon delivery of the machine please check for visual machine damages such as damaged packing or scrat-
ched buckled parts. If so, make a remark on all copies of the delivery bill before signing for acceptance.
The truck driver must absolutely sign all copies of the delivery bill. Should your shipper or the truck driver re-
fuse to accept your claim, fully reject delivery and make sure to inform us (the manufacturer) immediately.
No claims shall be taken into account by the shipper or by the insurance company, if a reservation note is
not made on the delivery bill.
All transport damages must be notified within latest 2 days from delivery. Therefore delivery must be collected
and inspected within this term. Later claims shall be disregarded. In case of assumed but not visually clear
transport damages make sure to mark the following sentence on the delivery bill:” Reserved delivery due to
assumed transportation damages”.
Insurance and shipping companies act with extreme caution in case of transport damages and sometimes
refuse to accept any responsibility. Please make sure to provide clear and exhaustive evidence (photos) of
the claimed damages.
Thank you in advance for your help and understanding in this matter.
Seite 5
2. Safety pictograms and warning labels
1. Warning label
„Never operate or install a winch without reading or understan-
ding the operator’s manual“
This label reminds the user about the importance of reading and
understanding the instructions of the manufacurer and getting
familiar with the winch before first use.
2. Danger sing
“Keep yourself and others at safe distance from the dangerous
area!”
This label reminds operator and bystanders of the dangerous
area between the tractor and the winch.
3. Machine safety label
“ max 540 min”
This label shows the max number of revolutions and the direc-
tion of rotation of the driveshaft connecting the winch to the
tractor.
4. Danger sign
„No hoisting!“
5. Machine operation sign
“Disconnect the winch, read and comply with manufacturer’s
maintenance instructions.”
This is to remind the operator to familiarize himself with the
maintenance procedures of the manufacturer contained in the
user’s manual.
6. Identification label
„Product identification“
This label shows the company details of the manufacturer and
the main machine technical data.
7. Identification label
„BGU-Maschinen” manufacturer’s logo
8. Operator's safety label
„Wear steel-toe safety shoes”
Seite 6
3. Safety rules
Strictly perform installation, set-up, maintenance, cleaning and transportation of the winch with the
power switched off and all moving parts motionless and secured against accidental operation.
The user shall strictly comply with these operation , set-up, maintenance, repair and trouble-shooting
instructions in order to assure safe operation and no damages to the equipment. Moreover, we recommend
to let the machine be run only and strictly by trained and skilled staff who must be familiar with the applicable
occupational safety and health administration rules as well as applicable transportation rules.
No person under school leaving age should operate a forestry winch. Those who have reached school
leaving age but are below the age of 18 may operate a forestry winch if supervised by a competent person
of 18 years or over.
The machine shall be installed and kept in a suitable location selected by the customer for safest operation.
The working area around the machine must be kept as clear as possible from surrounding obstacles and
slippery foundation floors should be duly treated (do not use saw dust or wood ash for this purpose).
Make sure that the equipment stands on a safe stable foundation.
- Due and proper illumination of the working site must be provided at all times.
- Set up the machine on a firm surface and ensure that a wide but confined area is available around the
machine assuring maximum working freedom.
- Mind all operation sings and warning labels on the winch and comply with the instruction given herein.
- Operators must wear steel toe safety shoes, working protective gloves, protective helmet and snug-fitting,
tear-resistant work cloths.
- Never leave the forestry winch unattended
- Before switching power on and putting the winch to work make sure that there are no bystanders in the
dangerous area and that you have good and clear visibility on the work area.
- It very dangerous and strictly prohibited to sit/stand on the winch while transporting it.
- Provide due and correct mounting of the winch.
- Make sure to comply with driving speed requirements for the specific road conditions. Use caution when
changing direction or turning while winching uphill, downhill or across slopes.
- Do not stand in the dangerous area. Assure that nobody stands inbetween winch and tractor, unless the
tractor is safely braked and blocks have been put underneath the wheels to avoid accidental moving.
- Do not remove nor start handling timber before the winch has come to a complete stop.
- Periodically check that all screws and fixations are tightly in place.
- Before putting the winch to work perform a visual checkup of the overall conditions and let a skilled technicial
overhaul and service your winch at least once a year.
- It is strictly prohibited to use the winch for any other application than mentioned in this manual.
CAUTION: do not use the winch for hoisting applications! (Figure 5)
- Make sure that power is fully disconnected from the winch and that the tractor has been switched off before
performing any repair or work on the winch.
- Never operate the winch without its safeties and protections duly in place.
- Strictly use wire rope of adequate crush resistance, strength and quality. Provide for immediate wore rope
replacement, if any fault or anomaly is detected.
- Be sure that your wire rope length provides for a free gap to the upper drum profile of least 1.5 the rope
diameter when fully spooled. In other words, when the rope is fully spooled there should be space left on
the drum for at least two more coils.
- Make sure that your helpers do not put any extra load on the winch without prior informing the tractor
driver.
- Strictly operate the winch from a safe place, at safety distance from the load, the rope and such other
dangers as unfelled trees. The driver seat accounts as a safe place only if a safety screen is provided to
separate the winch from the tractor in such a way that it may not be removed or bypassed.
Seite 7
- CAUTION: it is very dangerous to stand in front of a tree to be felled and winched away. (Figu-
re 1)
( Figure 1) ( Figure 2)
- Winching with a pulley originates a three-sides dangerous area where none is allowed to stand
during winching operations. (Figure 2)
- Never exceed the max admissible pull angle of 30° (Figure 3).
- CAUTION: tip-over risk (Figure 4) when winching on rough terrain or exceeding the maximum
admissible pull angle.
( Figure 3) ( Figure 4) ( Figure 5)
Keep away from the dangerous area!
- You and your helper must establish clear and precise hand signals and review them so everyone clearly
understands.
Pull Stop Release rope
- If your winch is equipped with lower snatch block, use it also for pulling operations.
- The operator should monitor the load throughout the entire pulling operation. Although winches are one-
man equipment, you should never work alone and a second person should be ready to help in the event
of lack of full visibility.
- Attach your winch to any tractor equipped with road transport tires to avoid infringement of road travel
profiles. If this is not available, provide your towing vehicle with protection chains. Chains are mandatory
on all types of tire for travel on icy or snowy foundations.
- Before disconnecting the winch from the tractor, park on a safe and fl at surface. Drive the winch down
on the special stabiliser foot and hang the driveshaft on the special mount provided on board of the winch.
- Pinched-hands and injuries danger in the three-point hitching area!
Read this basic guide carefully, familiarize yourself with the operation of your winch before ha-
ving to maintain it and be constantly safety oriented.
M
M
a
a
M
a
M
x
x
3
3
0
0
°
M
M
M
M
a
a
x
x
3
3
0
0
°
Seite 8
4. About PTO
• Use only and strictly CE approved drivelines duly connected and secured in compliance with
manufacturer’s instructions.
• Never use a PTO driveline without safety shield or with a damaged guard.
• Make sure that the shield is of the correct size and length for the drive shaft and is duly mounted on it.
• Use safety chains to secure the shield agaist dangerous rotation and distortion.
• Before operating the PTO driveshaft make sure the rpm number and direction comply with the one
shown by the arrow-sign on the winch. Take all due measures to avoid unauthorized thirds standing the
the dangerous area of the winch!
• Never run the PTO shaft when the tractor motor is switched off!
• After dismouting the PTO shaft use the special holder on the winch to safely store it away.
5. Operation
This timber winch is designed for logging applications only. The winch comprises a welded frame, a main
shaft, a chain wheel clutch, a drum with wire rope, a brake and a snatch-block.
The wire rope is slipped around the timber, the timber is pulled to the skid and the rope is hung up to the
special grooves in the skid by means of fixation chains. Timber and long tree trunks are so winched to a
parking area for loading on trucks and further delivery.
5.1 PTO shaft requirements
Do not PTO operate winch at any faster speeds than max. 540 RPM.
To mount your winch to the tractor use three-point hitch CAT I and Cat II only.
5.2 Connecting the winch to the tractor
Make sure that nobody stand in the dangerous area while connecting the winch to your tractor
Logging winches can be mounted on any tractor equipped with 3-point hitch of category I or II.
With a special arrangement it is also possible to mount the winch to a tractor with automatic hitch mecha-
nism on the lower hitch points.
Make sure to strictly use approved yypes and that proper shielding with chain fixation is available.
Make sure to perform accurate connection of your PTO driveline both on winch and power input side.
In order to transfer torque from the tractor to the winch you must use a driveline with torque overload
clutch coupler. Mount the winch to the tractor and then secure the stabilisers underneath the lower hitch
points. Finally incline the winch by approximately 20° using the upper hitch bar.
Seite 9
5.3 Positioning the drawbar to the PTO shaft
The length and height of a tractor drawbar may need to be adjusted to ensure that the PTO driveline
does not compress or separate during operation.
To make this adjustment:
• Mount the winch to the tractor!
• Pull the two halves of your shaft apart and respectively mount them to the tractor and to the winch and
perform a crosscheck as shown below (Fig. 6)
• For increased safety make sure that a minimum wrapping of 200mm (b) occurs when pulling the hitch
bar all the way up and down. With the shaft parallel to the ground also make sure that the shaft doesn’t hit
the stand (wrapping (a) should be still at least 20mm).
• For shortening of the PTO shaft, fi rst cut the telescope off and then the external one by the same
length.
• Grind both shaft ends, clear chips and dust away and oil all slinding contact areas before final assembly.
(Fig. 6)
5.4 Wire rope installation
DO! DON'T!!
Remove the small protection grid and then take the cap off (Fig. 8, Pos. 7). Now turn the drum to the right
position for releasing and removing the drum screw (Pos. 8).
Before releasing the fixation screw, make sure to disengage the brake lever (Pos. 1 Fig. 9) by shifting it
on “AUS”.
Insert the wire rope through the inlet fairlead and feed it to the drum by means of the upper block. Fit
the rope into the special groove and tighten the screw (Pos. 8). Now start spooling as described under
skidding procedures.
In order to avoid possible rope damages keep winding up for a while after complete spooling of the entire
rope length, as described under section “spooling of the wire rope”.
Follow exactly these instructions in order to avoid troubles and assure smooth working with your winch.
Make sure to avoid rope pockets, kinks and twirls while unrolling and feeding to the winch.
b
a
Seite 10
5.4.1 Checking the rope quality
• Stricly use brand new ropes.
• Make sure to use ropes of approved quality, suitable strength and compliant to the specifications on the
identification label.
• Do not use longer ropes than instructed in the technical specifications of this manual.
5.4.2 Spooling the wire rope
Completely spool the rope making sure to wind tightly and evenly onto the drum and avoiding both over-
winding and underwinding.
Correct windind is accomplished by:
• keeping a load on the cable
• and firmly attach one end of the cable to a firm stable anchor-point suitable to withstand the pull force
while the rope starts spooling onto the drum pulling tractor and winch towards the anchored rope end.
It may be convenient to carry out this operation either on a slight gradient with the idled tractor facing
uphill or alternatively with braked tractor.
Wind the rope tightly and evenly onto the drum. Before putting your winch to work spool the rope
completely off and then rewind it again! Check the rope over for any signs of damage, flattening,
broken wires, wear and corrosion.
5.4.3 Spooling off the wire rope
After you have correctly installed the winch, you can start spooling the rope off. This is accomplished by
pulling the red line (Pos. 2) till the Lever 1 snaps into the AUS position (Fig. 7).
Release the brake and start spooling the wire rope off. If the wire rope is tangled or badly wounded on the
drum, first unwind the entire rope length.
Keep running the tractor idle while loading the winch and completely rewinding the rope onto the drum.
Stop pulling as soon as the tractor reaches close to the anchor-point where the rope end was attached.
Now disengage the clutch lever.
Make sure that pulling is performed smoothly and without rush movements that could result into tangling,
twirling or kinkling of the rope.
5.5 Skidding instructions
Set the hydraulic cylinder of the tractor three-point hitch in its lowest position. Firmly settle the winch down
on the skid and engage the tractor manual brake.
NEVER start pulling operations before having securely and firmly settled the winch in a stable position.
Pull the green line (Pos. 5) to shift the Lever 12 in its EIN position (Fig. 8). The wire rope will now start to
wind up onto the drum. To stop winding simply release and set the green line loose. When doing so, the
brake immediately stops the drum and keeps the load away.
Changes and self-modifications to the mechanism controlling the brake engagement system (Pos. 1, Fig
7) are STRICTLY PROHIBITED.
Do not raise the hydraulic cylinder of the tractor three-point hitch during skidding! (DANGER: you may
damage your driveline).
Notwithstanding the consistent PTO power speed, the pull force is subject to variations.
This manual suits for next models
1
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