Fransgard HW-3019 User manual

Fransgård
Manual
GB
Hydr. Forestry Winch
HW-3019

Fransgård Maskinfabrik A/S
Fredbjergvej 132, Fredbjerg
DK - 9640 Farsø
Telefon: ..... [phone]
www.fransgard.dk
[email protected]

1
Contents Page
Technical data.......................................................................1
Warning/Caution......................................................................2
Safety precautions ............................................................... 3-4
Instructions for use...................................................................5
Lubrication and maintenance ....................................................6
Setting brakes and free-wheel brake..........................................7
Tractor size .............................................................................7
Instruction for mounting the wire................................................9
Pictogram..............................................................................10
Warnings .............................................................................12
Refilling of oil on the machine..............................................13
Checks prior to start-up/starting/re-tightening......................14
Maintenance of the system..................................................15
Faults and troubleshooting .............................................16-17
Dismantling..........................................................................18
Technical Data
Pulling capacity......................................................3.000 daN.
Clutch ........................................................................315 cm².
Power transmission........................................5/8” roller chain
Max. oilpressure.........................................................170 bar.
Drum capacity...............................................Ø8mm. x 40 mtr.
VDW-PHYTON 6 F-V.
Min. calculated breaking load........................................ 66 kN
Cable speed .......................................................0,5 - 1,2 m/s.
Liftmounting........................Front or rear mounting on tracotr,
Or on front lift.
Power supply.......................................Hydraulic motor 160cc
Pump capacity......................................................40-60 l/min.
Weight .........................................................................177 kg.
Power consumption........................................12 V –75 AMP.

2
WARNING!
Before starting to operate the tractor winch, you must have read this manual thoroughly.
The owner of the winch is responsible for ensuring that all operators and assistants are
familiar with the tractor winch’s operation.
Caution!
1. Never attempt to use this tractor winch without sufficient training.
2. Keep hands, feet and clothing away from moving parts.
3. Before starting the tractor winch, make sure that the cable is in good condition. If the
cable breaks, cable fragments may be thrown in all directions. Ensure that all persons
are at a safe distance from the cable while the tractor winch is in use.
4. Only handle the cable after stopping the PTO.
5. Do not transport logs directly on the cable. Always use the proper chain boom.
6. Inspect the moving parts. They must be correctly fixed and in good condition. All safety
guards must be correctly fitted.
7. This machine has been constructed to skid and push together timber that has been felled
and is lying on the ground and may not be used for other purposes. The machine must
not be used to pull vertical trees or trees that are wedged or jammed, as this is extremely
dangerous.
8. Make sure you are familiar with the controls and know how to turn off the tractor winch
and tractor engine in case of emergency.
9. Children and untrained persons must not be allowed to operate the tractor winch.
10. Do not wear loose clothing, sleeves, ties or long, uncovered hair in the vicinity of the
machine.
11. Prior to working make sure the tractor winch and tractor are standing on a level piece of
ground.
12. When operating the tractor winch with the operating strings you should stand at a
sideways distance of least 5 m from the machine. (page 8 photo E).
13. Do not let the tractor run unattended.
14. Use only original spare parts from Fransgård, and do not alter the equipment in any way.
15. All persons working with the winch must be taught about the dangers and how to prevent
accidents.
16. Be observant at all times! Do not work with the tractor winch when tired or exhausted.
17. Do not operate the winch over side-angles of more than 30(page 8 photo A)
18. Disregard of the warning labels on the machine or the safety precautions in the manual
could lead to serious or fatal injuries.
19. The tractor must not be set in motion while the lower log ends (of the towed logs) are still
resting on the ground. If the logs have not been raised and then strike an obstacle, this
may cause the tractor to tip over, resulting in serious injury.
20. Set the machine on a firm and level basis. It is the responsibility of the owner and user to
make sure that any defects arising from use of the machine are repaired and that the
safety conditions are met.

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SAFETY INSTRUCTIONS FOR FORESTRY SKIDDING WINCHES
1. Work safely!
The relevant health and safety regulations and the operating instructions must be
complied with!
2. Operation and maintenance of the cable winch may only be entrusted to suitable and
reliable persons over 18 years of age who are familiar with this type of work.
3. Wear personal safety equipment (helmet, safety shoes, protective gloves)!
4. Working alone is only permissible if there is a radio emergency call system!
5. The cable winch must be checked before use, but at least once every working day, to
make sure that it is in perfect operating condition (safety guard, dead-man’s circuit,
overload protection, brake function). Any faults must be remedied professionally
6. The winch drive must be turned off when malfunctions are being remedied or repairs
and maintenance are being carried out. It is not enough to disengage the winch drive.
The drive motor of the skidder must be turned off.
7. The safety devices on the winch must not be disabled.
8. Only use load suspension devices, e.g. lifting hooks, choker cables, chains, pulleys
and straps that are suitable for the pulling power of the winch.
9. Only use stress-relieved cables of sufficient strength for pulling as per the
specifications on the cable winch’s name plate and the operating instructions. The
breaking load of the choker and skidding chains must be twice the pulling power
specified on the winch for the first turn.
10. Damaged cables and chains must be replaced promptly.
11. Do not use cables that are too long. When the cable is fully wound, the flange rings
must still project beyond the top turn by at least one and a half times the diameter of
the cable.
12. Before starting the skidding winch, the machine operator must satisfy himself that no
one is in danger.
13. The winch operator must make sure that at least two turns of the cable remain on the
drum under load except in a hazardous situation (adjust overrun brake correctly)!
14. Only wind the cable in under load (unwind cable completely and wind in evenly at
least once a day and more often if necessary)
15. The winch must only be operated from a safe position where the winch
operator is not at risk from the winch itself, the load, the cable or the hitches.
The driver’s cab of the skidder can be regarded as a safe position if there is an
adequate safety guard between the winch and the driver’s seat.
The winch operator must be provided with appropriate protection when
operating the winch from outside the driver’s cab.
The skidder itself might be used as protection or the operator might stand at a
safe distance from the skidder behind a tree, for example.
If radio-controlled winch operation requires the winch operator to accompany the log,
he must stay close to the hitching.
Long logs can be accompanied at the side, next to the hitching, while log sections can
be accompanied from diagonally behind the load, see figure 1.
16. From his position the winch operator must be able to keep the skidding load under
observation at all times; otherwise arrangements must be made to have the path of

4
the load watched by other persons, with constant contact being maintained between
the observer and winch operator by means of pre-arranged signals.
17. When cables are being used, there must be no one between the load and the cable
winch or in the danger zone between the winch, pulley and load, see figure 2.
18. In the case of skidding on slopes, there must be no one below the log hitched to the
cable.
19. When standing trees are being pulled over, the pulling cable must be hitched to the
tree before felling work is commenced. In this case the position of the skidder must
be chosen so as to ensure that the distance from the tree to be pulled over is at least
twice the height of the tree –or the same as the height of the tree if a pulley and
indirect pulling are used, see figure 3. Do not stand in the danger zone when using
pulleys!
20. The tread of the tyres on the skidder on which the winch is mounted must grip well,
i.e. lug treads with at least 40% of the tread depth of new tyres or the vehicle must be
fitted with tyre chains. Tyre chains must always be used on hard-packed snow and in
icy conditions.

5
21. Skidders must be immobilised with a sprag brake or the like. If necessary, secure the
tractor with a cable hitched opposite to the pulling direction should the sprag brake
not provide sufficient hold owing to the soil conditions.
22. The skidding load and speed must be such that, taking the design and nature of the
vehicle, the gradient of the terrain and the soil conditions into account, the vehicle
cannot tip over and steering/braking are not affected.
Make sure that the cable entry is as close to the winch’s pulling direction as possible,
i.e. without lateral deflection if possible. Use a pulley if necessary!
23. Do not approach the logs in order to unhook the load until the cable has been
slackened by releasing the brake!
24. When using a tractor with hydrodynamic drive, make sure that the following vital
precautions have been taken before leaving the driver’s cab to operate the winch
the tractor’s or winch’s sprag brake has been lowered all the way to the ground,
the tractor’s immobilisation brake has been activated
the traction drive is in neutral.
25. Make sure that the winch is only parked on a level surface that is capable of bearing
the load. Deploy the landing gear beforehand. Put the cardan shaft in the
appropriate retainer.
26. The road traffic licensing regulations and road traffic regulations must be complied
with.
The road traffic licensing regulations apply to driving on public roads. Identification
and lighting in accordance with the relevant regulations for mounted implements, for
example, may be necessary.
27. The relevant regulations for mounted implements must be complied with if a drawbar
coupling is used on the mounted winch.
INSTRUCTIONS FOR USE.
Assembling the equipment:
To store the machine, put it on level hard surface, so there is no dangers for the
surroundings.
Attach the tractor winch to the tractor’s three-point suspension. Mount first the tractors lift
arms with the supplied lift arms bolts, there after mount the top link. Lift the machine and rise
the support legs and adjust the lift arms to prevent the winch to swing horizontal too much.
Adjust the length of the top-link so that the machine will not interfere with the tractor cabin
and the winch stands straight.
By mounting the PTO the tractor has to be off and the key removed. Check the length of the
power take-off shaft both in working position and in transport position and if necessary
shorten it.
When the winch is dismounted, put it on level horizontal hard surface. Lower the support legs
and dismount the lift arms. By dismounting the PTO the tractor has to be stopped and the
key removed. The PTO is positioned in the special bracket for it.
Insert the cable via the upper pulley and mount on the drum. Lock the cable to the drum with
the cable fastener (Page 9). Make sure that the cable is properly attached and undamaged.
The cable must be fully rolled out and coiled up under load before being rolled onto the drum.

6
Important! Use only cable type VDW-PYTHON 6 F-V.
Releasing the brake:
Lower the winch so that the slope stabilizers are firmly on the ground, release the brake by
pressing button C. (page 8 photo E).
Remember the safety distance!
Winding/pulling out:
Find a safe position with an unobstructed view of the logs. Then pull
knob A. (page 8 photo E).
Dead man’s switch:
In the event of accident or if feeling unwell, or any similar situation, press button D.
(page 8 photo E). The winch will then stop winding.
Hauling:
Attach the log firmly to the chain tree and lift the tractor winch until the ends of the logs are
free of the ground.
Machines delivered with radio control
The manual for the radio control must be read thoroughly, the manual is in the box together
with the radio control.
LUBRICATION AND MAINTENANCE:
Lubricate all the slide connectors once a week.
All ball bearings are permanently lubricated.
The chain must be greased every 50 working hours or minimum once every year. We
recommend Stuctobis® BHD or oil of same quality. The machines must be detached.
(page 8 photo C)
Take care that no oil or grease falls on the clutch lining.
Grease daily the upper cable roller as required through the lubricating nipple on the
turning plate and put daily grease on the support turning plate.

7
SETTING THE BRAKE
The brake is preset at the factory, so it is not necessary to adjust the start of the application.
After prolonged use, there is some wear on the brake band, so an adjustment or new brake
band is necessary. Adjustment is done when the brake lever is pulled, and the cable can be
pulled out slightly. (page 8 photo D).
SETTING THE FREE-WHEEL BRAKE
When the brake is released, the cable can be pulled out. Important! Set the trailing brake.
(page 8 photo B), so that the drum stops immediately when the log is reached.
ADJUSTMENT OF THE DRIVE CHAINS
After 10 hours operation, the drive chains shall be inspected and if necessary adjusted.
Fluctuations of the chains must be max 4mm. chains inspected every 100 hours of
operation.
TRACTOR SIZE
As recommended size of tractor a four-wheel drive with enough weight on the front axles,
and 10KW engine size for each 10KN maximum pulling capacity.

8
E
A
B
D
C
D
B
A
Max.30°
C

9
Instructions for mounting the cable.
1.) Pull about 1 metre of the cable 1out through hole 2
2.) Mount the wire fixing block 3

10
Carefully read operator’s
manual before handling the
machine.
Observe instructions and safety
rules when operating.
D:
Vor Inbetriebnahme die
Betriebsanleitung und
Sicherheitshinweise lesen und
beachten.
Shut off engine and remove key
before performing maintenance or
repair work.
GB:
D:
Vor Wartungs- und
Reparaturarbeiten Motor abstellen
und Schlüssel abziehen.
Stay clear of darft link
lifting range while
operating rockshaft
controls.
Außerhalb des
Hubbereichs der
Dreipunktaufhängung
bleiben.
Stay clear of swinging area of
machine.
D:
Ausreichend Sicherheits-abstand
zum Schwenkbereich der
Maschine einhalten.
Do not lift only pull
D:
Nicht zum heben nur
Bodenzug.

11

12
WARNINGS
* Hydraulic oil may be harmful to health:
* If the oil comes into contact with the skin, it may cause allergic reactions.
* Inhaling oil vapour can cause respiratory problems.
* Guidelines for the use of hydraulic oil:
Follow the oil supplier’s warnings and recommendations.
During servicing of the machine, oil spillage and oil spray may occur.
The wearing of safety glasses and protective gloves is therefore always
recommended.
The leaking of oil under high pressure is dangerous, as oil jets can
penetrate the skin and eyes.
If a leak is discovered, the machine must be stopped immediately and the
fault rectified.
When dismantling the machine, the accumulator, compressed oil, etc. may
be under static pressure, even if the machine has been stopped. This
pressure can cause sudden jets of hydraulic oil to spurt out.
Remember that when the machine is operating, the oil may be at a
temperature of 70°C or even higher. This can cause a risk of burning
during dismantling or emptying.
* Other important guidelines:
The power supply must be isolated if the cover on the junction box/electric
box is removed or the plugs on the solenoid valves are removed.
Servicing of electrical components must be carried out by an authorised
electrician. Always check the diagram for the hydraulic motor and electrical
control system.
There may be sharp corners and edges on the machine, e.g. on the oil
tank, pump, the blocks or around pipes and hose fittings.
Never start the machine until you have carefully studied all diagrams and
instructions. Only trained personnel must start the machine.

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REFILLING OF OIL ON THE MACHINE
The following procedure must be followed closely when refilling oil:
* Check that the oil tank is completely clean.
* Always use a filtration device when refilling oil, as the container often contains
fine-grained dust and water.
* The hydraulic oil is very important and must be selected carefully, as it is the
oil that transfers the energy and also lubricates the various components in
order to minimise friction and heat generation. The oil is also intended to
protect against corrosion and to transport dirt and heat away from the system.
Always use an appropriate mineral oil with the correct additives which is
suitable for this particular machine. Choosing an oil in this way will ensure
trouble-free operation and a long lifetime for both the oil and the components.
Always read the user instructions on the oil packaging from your oil supplier
carefully.
* Warning: Contact with hydraulic oil can cause rashes on the skin to
develop in the longer term.
* The oil’s properties and requirements concerning the supplier of the oil:
The oil must have good lubricating properties on contact with metals at
both low and high RPM.
If possible, the viscosity (consistency) of the oil must remain constant
regardless of the temperature and operating pressure. Always notify the
supplier of the ambient temperature.
The air solubility must be low and air emissions high, whilst the foaming
tendency must be very low.
The corrosion protection properties must be optimal. The oil must be
viscous and therefore also not aggressive or toxic.
When using vegetable oil, we recommend:
CASTROL : CARELUBE HTG-32
STATOIL : STATOIL M32-68
OK : BIOHYDRAUL 32
SHELL : NATURELLE HF-M 32
When using vegetable oils, no parts must contain zinc, and synthetic filter inserts
must always be used, as paper inserts can cause problems due to viscosity, resulting
in a high pressure drop.
These oils are used for pump systems which operate at ambient temperatures of
between 5°C and 40°C.
These vegetable oils can all be mixed with mineral hydraulic oils, but this reduces the
lifetime and quality of the oil.
Approx. 4.5 litres of oil are added at the factory. The oil level is approx. 3cm below
the top of the oil tank. Use the dipstick on the plug.

14
* Damaged and dirty oils must always be returned to an approved reception
centre and an oil return point respectively.
CHECKS BEFORE START-UP/STARTING
Check the following before final start-up:
That the oil has been correctly refilled and that the oil level is correct.
That all external components have been filled with oil in advance.
Check whether any oil is leaking from components, hoses and fittings and re-
tighten as necessary.
STARTING/START-UP OF THE SYSTEM
It is very important that the start-up procedure is carried out correctly to maximise the
lifetime of the system. Many pumps in particular are damaged during start-up
because the very strict purity requirements are not met or the user manual is not
followed. However, even with the highest purity levels and the greatest care, it is not
possible to completely avoid dirt with an entirely new system, as particles are also
scraped off moving components during the actual start-up and starting processes.
The system must therefore not be subjected to the maximum load until all the dirt in
the filters has been removed. All the filters must be replaced after ever five operating
hours.
Check the oil level frequently and always top up with clean oil.
The oil must not be allowed to drip down onto the ground, floor or similar. The oil
must be collected up in a waste oil tray, bucket or similar. It is important that we
protect the environment.
RE-TIGHTENING THE SYSTEM
Shortly after start-up/starting at the highest operating pressure, all fittings, bolts,
screws, pipes and hoses on the various systems should be re-tightened. Re-
tightening should then be carried out as necessary.
It is important that all hydraulic components and pipe components are re-tightened
due to the high operating pressures and rapid heat generation.

15
MAINTENANCE
Thorough maintenance is vital to ensure the reliability and durability of the hydraulic
system. The system should therefore be checked at regular intervals.
Maintenance instructions:
Inspect the entire system and not just the damaged component. Start with the
pump and then continue on from there until the entire system has been checked.
Check the oil level and the oil. If the oil is dark or black, it must be replaced. If the
oil is whitish and foaming, it may contain water or air. If so, the system must be
checked more thoroughly and the oil must be replaced.
In the case of new equipment, the oil must be cleaned to 5 microns or
alternatively replaced after 10 operating hours. The oil must then be checked by
qualified personnel after every 500 operating hours.
Every component in the high-pressure system must be checked for leaks, noise
and seals. Components should be replaced as necessary.
The lifetime of the oil halves for every 10°C by which the oil temperature exceeds
60°C. Excessively high temperatures can result in excessive wear on the
components. The temperature must therefore be checked carefully. If it exceeds
60°C, contact the component supplier for an assessment of the circumstances.
Under no circumstances must cotton wool or similar be used for cleaning
purposes.
When changing the oil, the system must always be emptied completely. The filter
must also be replaced and the tank cleaned fully. The new oil should then be
added.
If the machine is to be left standing for up to two months, no special precautions
are necessary, but after longer periods of time, all safety valves must be set to the
minimum and the machine operated for 10 to 15 minutes. The piston rod on the
hydraulic cylinders must be in or be surface-treated with a corrosion-resistant
fluid.
The oil must not be allowed to drip down onto the ground, floor or similar. The oil
must be collected up in a waste oil tray, bucket or similar. It is important that we
protect the environment.

16
FAULTS AND TROUBLESHOOTING
Fault Cause Rectification
Noisy pump The pump receives too little or no fluid Suction filter needs cleaning and the suction line
needs a repair.
Fill with fluid. The direction of rotation is Incorrect.
The pump draws in air. Suction filter needs cleaning and the suction line
needs a repair. Replace the seal by the pump shaft.
Air enters the suction line through the return line.
The pump is worn. The pump needs repairing or replacement.
Too high rotational speed. Correct the rotational speed.
Pressure is too high. Reduce the pressure setting.
No pressure The fluid level is too low. Fill with fluid.
The pump is not running. Check the motor, connection and shaft.
The rotation of direction is Incorrect. Switch the direction of rotation.
Safety valve jammed. The valve has to be screwed out and cleaned or
replaced.
The pump is defective. The pump needs repairing or replacement.
Discharged bypass valve. Establish correct power supply.
Insufficient pressure Leakage in valve or cylinder. Repair cylinder or valve.
Too low setting Increase the pressure.
There is a leak in safety valve. It needs repairing or replacement.
There is a leak in valve or cylinder. Cylinder or valve needs repairing.
The fluid foams Leaky suction line. The line needs repairing.
Too large pressure loss in the
suction line. Replace with larger suction line.
Fluid enters the suction line via
The return line. If possible the line has to be extended away from
this line.
Incorrect fluid or water in the fluid. Check and change the fluid.
The return line is too short. This line has to be extended.

17
FAULTS AND TROUBLESHOOTING
Fault Cause Rectification
The fluid temperature is too
high The fluid is too viscous. The fluid needs to be changed.
Safety valve is incorrectly set. Make adjustments.
Overloading of the system. Reduce the load or change to a larger equipment.
Major leak in valve or motor. Repair pump, motor or valve.
Changed operating conditions. Set up larger tank or cooling.
Too small tank. Replace with larger tank.
Too little fluid in the tank. Top up with fluid.
Safety valve is activated too frequently. Operating conditions are changed.
The direction valve does not fully close. The valve needs cleaning or repairing.
Noisy safety valve Too high through flow rate. Fit a new correct valve of the correct size.
There is dirt between the valve
cone and the valve seat. Needs cleaning or repair.
The solenoid valve does not
Operate Electrical fault. Check the entire power supply and end stop
contacts.
The system is operating too
slowly. Cold oil. Replace with a better oil type, for example.
Worn pump. Replace the pump.
The system is worn. Replace with a new system.

18
.
DISMANTLING
When the fault which is causing a malfunction is located, the following guidelines for repair or
replacement of the relevant component should be complied with when dismantling:
The component is cleaned carefully. The immediate surrounding areas are cleaned similarly. This
means that a layer of paint and dirt is removed from all bolt connectors, blocks and hoses.
Dismantle the hydraulic components directly in the open, outdoors
Removed hoses and pipes should be fitted with plastic plugs or other protection during the repair.
They should all be marked, so no errors occur in reassembly.
The components should be marked carefully before being removed, so that is easy to
reassemble the system correctly.
Components are placed on a completely clean work bench, for example with a piece of clean
paper as underlay. Each component is placed on this underlay in the sequence in which they are
removed. This should ensure that the components are re-fitted correctly, without their function
being changed.
A correct spare part drawing should always be available.
All repaired components should be tested in the test stand before being fitted to the equipment. If
this is not possible, they should be fitted without being tested.
Watch out for sharp edges and corners on or in the system.
Make sure that you do not scratch valve sliding surfaces and valve seats and be careful with O-
rings and O-ring seats.
Warning: Note that the fluid is very hot and is under high pressure.
Where in doubt, consult the supplier.