Kässbohrer PistenBully 400 4F User manual

Operating Manual
From WKU 824 11319.en
Vehicle

Printed in Germany
Copyright ®
Not to be reprinted, translated or duplicated either wholly or in part without written
permission.
Technical details might not necessarily be exactly as described or illustrated in this
operating manual.
Printed on environmentally friendly paper (bleached without chlorine, recyclable).
Kässbohrer Geländefahrzeug AG
Kässbohrerstraße 11
D-88471 Laupheim

Operation Checks Use Safety Technical data Overview
400 4F_11319.4.enu
3/162
Overview
Technical Customer Service and
Replacement Parts Sales . . . . . . . . . . . . 5
Safety symbols used . . . . . . . . . . . . . . . . . . . . 6
Vehicle and engine numbers . . . . . . . . . . . . 9
Technical data . . . . . . . . . . . . . . . . . . . 10
Fluids and lubricants . . . . . . . . . . . . . . . 12
Safety instructions . . . . . . . . . . . . . . . . 15
Permissible weights of front-mounted
auxiliary equipment. . . . . . . . . . . . . . . . 30
Cockpit. . . . . . . . . . . . . . . . . . . . . . . . . 34
PistenBully transport . . . . . . . . . . . . . . . 91
Attaching auxiliary equipment . . . . . . . . . 96
Tilting the driver's cab/load platform . . 101
Electrics . . . . . . . . . . . . . . . . . . . . . . . 107
Inspections and checks . . . . . . . . . . . . 119
Getting in – driving – getting out. . . . . 130
Starting the diesel engine . . . . . . . . . . 130
Towing vehicle . . . . . . . . . . . . . . . . . . 139
Driving tips and information . . . . . . . . 141
INTRODUCTION
TECHNICAL DATA
SAFETY INSTRUCTIONS
USE
CHECKS
OPERATION
CONTENTS

4/162 400 4F_11319.4.enu
Front blade. . . . . . . . . . . . . . . . . . . . . 151
AlpinFlex tiller . . . . . . . . . . . . . . . . . . 154
– Operating manual: maintenance instructions
– Logbook
– Operating manual for the diesel engine (DVD)
– Operating manual for the front mounted tiller
blower (optional equipment)
– Operating manual for the drum winch (optional
equipment)
AUXILIARY EQUIPMENT OTHER ON-BOARD DOCUMENTS
CONTENTS

Operation Checks Use Safety Technical
data
Overview
400 4F_11319.4.enu
5/162
Your experience is important to us!
We strive relentlessly to create a complete and correct docu-
mentationforyour product. However,weverymuch appreciate
your comments and suggestions for improvement; please do
not hesitate to share this with us.
Kässbohrer Geländefahrzeug AG
Technical Documentation
Kässbohrerstraße 11
88471 Laupheim
Deutschland
Technical Customer Service and Replacement
Parts Sales
You can find the responsible contact person for your applica-
tion / country on the Internet:
Homepage: http://www.pistenbully.com
Your vehicle number is required for technical support and
replacement parts ordering.
Use of genuine spare parts
We recommend using original parts from Kässbohrer
Geländefahrzeug AG and conversion and accessory parts that
have been expressly approved for your vehicle type. We have
subjected these parts to special test procedures to certify their
reliability, safety and suitability specifically for vehicles from
Kässbohrer Geländefahrzeug AG. We are not able to judge the
suitability of for third-party products, even if these have TÜV
approval or an official approval and we shall not be held
responsible for these.
You can obtain original parts at your Kässbohrer
Geländefahrzeug AG service center. Our service personnel can
provide you with complete information about technical modi-
fications and also perform a proper installation.
Any and all warranty claims shall become invalid for the use of
third-party products. We do not accept any responsibility for
consequential damages resulting from this.
INTRODUCTION

6/162
400 4F_11319.4.enu
This operating manual provides:
Information on how to handle, maintain and care for your
PistenBully.
Important instructions concerning correct and economical
operation.
Warnings so that you recognise dangers in good time and
avoid them.
Make sure that the operating manual is always in the
storage compartment in the driver's cab.
e.g. = for example
MA= tightening torque
SP no. = order number for spare part
min./max.= minimum/maximum
Sec. = Section
Important information!
The machine or surroundings may get damaged.
This symbol draws your attention to tips for users
Abbreviations used
i
Symbols used
DANGER!
There is an immediate danger to life and limb
unless appropriate precautions are taken.
WARNING!
Possibly a very dangerous situation!
There is an immediate danger to life and limb unless
appropriate precautions are taken.
CAUTION!
Dangerous situation!
Can result in injuries unless appropriate precautions
are taken.
i
INTRODUCTION TO THE OPERATING MANUAL

Operation Checks Use Safety Technical
data
Overview
400 4F_11319.4.enu
7/162
EC DECLARATION OF CONFORMITY
Manufacturer
Kässbohrer Geländefahrzeug AG
Kässbohrerstraße 11
88471 Laupheim
Deutschland
We herewith declare that the machine described in the
following
and the version available on the market correspond in
design and construction to the fundamental safety and
health requirements stipulated by the EC Directive on
Machinery. This declaration shall become null and void
should any alterations be made to the machine without our
express approval.
Description of the machine
Snow groomer
Machine type
PistenBully 400 4F
Applicable EC directives:
EC Directive for Machinery MRL 2006/42/EC
EMC Directive 2014/30/EU
EC Directive on Noise Emission 2000/14/EC
Measured sound power level
110 dB(A)
Guaranteed sound power level
113 dB(A)
Applied harmonized standards, in particular:
EN ISO 12100:2010
EN ISO 14982:2009
EN 15059:2009 + A1:2015
Applied national standards:
EN ISO 3471:2008
Authorized representative for the compilation of the
technical documents: Jürgen Magg
The detailed EC declaration of conformity can be found in
the delivery/sales documents.
INTRODUCTION


8/162 400 4F_11319.4.enu
NOTE

Operation Checks Use Safety Technical
data
Overview
400 4F_11319.4.enu
9/162
The vehicle number is stamped on the front of the vehicle,
on the face end of the right-hand frame.
This operating manual is for the vehicle
Please insert the appropriate entries
WKU...................................................
The engine number is stamped on the engine type plate.
Vehicle number Engine number
VEHICLE AND ENGINE NUMBERS

10/162 400 4F_11319.4.enu
Dimensions
Weight
Operating parameters
Engine
Width
Without tracks 2500 mm
Across aluminium tracks 4206 mm
Across steel tracks 4206 mm
Across AlpinFlex tiller 5500 mm
Height 2830 mm
Height with cab tilted 3250 mm
Length
With tiller and pusher blade 9010 mm
Load platform 2120 x 1920 mm
Dead weight with aluminium tracks 8045 kg
Dead weight with steel tracks 8645 kg
Permissible gross weight with auxiliary
equipment 11800 kg
Maximum carrying capacity of the load
platform when the tiller/front blade is not
attached 1,500 kg
Continuously variable speed 0 - 21km/h
Ground pressure with aluminium tracks 0.052 kg/cm2
Ground pressure with steel tracks 0.057 kg/cm2
Production rate with tiller
At maximum
93,000 m2/h
126,000 m2/h
Type Cummins QSL9 Tier 4 final
Number of cylinders 6
Displacement 8.9 litres/8900 cc 3
TECHNICAL DATA

Operation Checks Use Safety
Technical data
Overview
400 4F_11319.4.enu
11/162
Technical
data
Brakes
Electrics
Suggested garage dimensions
Output, ECE rating
Maximum torque
298 kW (400 hp)
1,627 Nm at 1,500 rpm
Oil capacity with filter 21 litres
Fuel consumption at least 19 l/h
Tank capacity 2 x 114 (228) litres
Exhaust-emissions
standard TIER 4 final
Wear-free (hydrostatic)
2 multi-plate brakes
Light-current circuit 24 V
Alternator 28 V/140 amperes
Batteries 2 x 12 V/135 Ah
Cold-start power 900 A
Length 11000 mm
Width 6000 mm
Height 3500 mm
Noise emission
measurement
EU Directives
2000/14/EG
Measured sound
power level L wA,m 110 dB(A)
Guaranteed sound
power level L wA,g 113 dB(A)
Maximum sound pressure
level at the work station
A-evaluated emitted
sound pressure level L pA 79 dB(A)
Measured during grooming
(vector sum)
Vibrations at the steering wheel <2.5 m/s2
Vibration at driver's seat <0.5 m/s2
TECHNICAL DATA

12/162 400 4F_11319.4.enu
Designation Grade Capacity Interval between changes
Cummins QSL9 Tier 4 final API CJ-4 (CES 20081)
Avia Turbosynth
LS Plus 5W30
Service Bulletin No. 3810340
21 litres At least: once a year
Every 500 hours
Fuel tank Diesel fuel
Maximum sulphur content of 0.0015%
by weight (ASTM S-15)
2 x 114 (228) litres At least: once a year
Drain condensate.
Cooling/heating system 50% water + 50%
antifreeze
Avia Antifreeze NG
35 litres At least: every 2 years
Every 2,000 hours
AdBluetank/SCR system NOx reducing agent
to DIN 70070
40 litres At least: once a year
Every 1,200 hours
Transfer box Poly-alpha-olefin (PAO)
- CLP HC VG 150/220
ISO VG 220 (for summer operation)
- API GL4, SAE 75 W 90 (PAO)
1.8 litres At least: once a year
Every 800 hours
New vehicle: 100 hours
Wheel drive
(planetary gears) Poly-alpha-olefin (PAO)
- CLP HC VG 150/220
ISO VG 220 (for summer operation)
- API GL4, SAE 75 W 90 (PAO)
1.9 litres At least: once a year
Every 400 hours
New vehicle: 100 hours
TABLE OF FLUIDS AND LUBRICANTS

Operation Checks Use Safety
Technical data
Overview
400 4F_11319.4.enu
13/162
Technical
data
Hydraulics
Propulsion unit + auxiliary equipment
(See maintenance instructions)
HVLP DIN 51524
DEXRON ll D/lll F
ATF Type A Suffix A
< -300C -AVIA Synthofluid PE-B 30 (PAO)
47 l tank
80 l total
At least: once a year
Every 1,200 hours
Hydrostatic vehicle drive
(See maintenance instructions)
OKS 250
Lubricate wheel hubs and rocker arms
Greasing
Calcium-based lubricant
KP2K-30, DIN 51502
e.g. Aviacal 2 LD
Every 400 hours
Other lubrication points Calcium-based lubricant
KP2K-30, DIN 51502
e.g. Aviacal 2 LD
Every 100 hours
Electrical system
Battery terminals Bosch FT 40V1 grease
Designation Grade Capacity Interval between changes
TABLE OF FLUIDS AND LUBRICANTS


14/162 400 4F_11319.4.enu
NOTE

400 4F_11319.4.enu
Operation Checks Use Safety Technical
data
Overview
15/162
Safety
SAFETY INSTRUCTIONS
Intended use . . . . . . . . . . . . . . . 16
Driver . . . . . . . . . . . . . . . . . . . . 16
Danger zone for persons. . . . . . 17
Operation . . . . . . . . . . . . . . . . . 17
Maintenance . . . . . . . . . . . . . . . 21
First-aid box . . . . . . . . . . . . . . . 23
Fire extinguisher . . . . . . . . . . . . 23
Warning signs . . . . . . . . . . . . . . 25
Attached weights . . . . . . . . . . . 30

16/162 400 4F_11319.4.enu
Intended use
Snow groomers may only be used in
accordance with the manufacturer's
operating instructions.
The PistenBully may be used for
the following purposes only:
- Preparing slopes for downhill skiing
- Removing snow from paths
- Removing snow from car parks on
private land
- Tracks in countryside (not public
roads)
- Preparing trails for Nordic skiing
- Transporting people in the special
people-carrier cabin
(optional extra)
If you wish to use the equipment
for any other purpose, you must
obtain prior written approval from
the manufacturer.
Drivers must be specifically ap-
pointed to drive snow groomers.
You may appoint people to drive the
snow groomers on their own only
when you are certain that they will
be able to reliably perform the tasks
assigned to them.
In particular, they must:
Have reached the age of 18 (de-
pending on the law in the relevant
country).
Be physically and mentally equipped
for it.
Be trained in how to drive the snow
groomer and have demonstrated
their driving ability to the operating
company.
Be familiar with snow conditions
and the peculiarities of operating
equipment on ski slopes.
Be familiar with the area where the
vehicle is to be used, especially
with regard to particularly danger-
ous areas.
Be familiar with first-aid procedures
in the event of an accident.
In order to help ensure safe opera-
tion, drivers must wear appropriate
footwear with non-slip soles.
i
DRIVERS
SAFETY INSTRUCTIONS

Operation Checks Use Safety Technical
data
Overview
400 4F_11319.4.enu
17/162
Safety
The driver of the snow groomer may
only operate it when there is nobody
in the immediate vicinity of the vehi-
cle or on its tracks (i.e. in the imme-
diate danger zone).
The driver must issue warnings to
draw attention to potential
dangers.
Special protection measures must
be taken if the snow groomer is be-
ing used in an area where the driver
does not have a clear view of the
surrounding terrain, or the nature
of the terrain is such that the ma-
chine might not be immediately vis-
ible to people in its vicinity.
Depending on the circumstances of
each case, these measures may
take the form of warning signs,
closed runs or off-limit markers.
Complete the daily checks and
maintenance tasks.
Walk right round the vehicle and
make sure that the danger zone is
clear of persons and objects.
Step onto the track!
There is a risk of slipping on the
track when getting in and out of
the driver's cab.
Always take a firm grip on the handle
of the driver's door when entering the
vehicle.
When parking on a slope, be par-
ticularly careful when opening the
door. The door opens suddenly.
Buckle the safety belt.
Never leave the vehicle unattended
with the engine running.
Risk of inhaling poisonous fumes!
Never leave the engine running in
enclosed spaces.
The use of proprietary starting
agents (such as Startpilot, for exam-
ple) is prohibited on account of the
risk of explosion.
Do not attempt to adjust the driver's
seat or steering wheel when driv-
ing.
Snow groomers must be used and
operated in a manner which en-
sures their stability.
Drivers must always restrict the vehi-
cle to a speed at which they can stop
within the distance visible. On slopes
that are so steep that it is not possi-
ble to stop, protective measures
must be taken. Depending on the
DANGER ZONE FOR PERSONS GETTING IN OPERATION
SAFETY INSTRUCTIONS

18/162 400 4F_11319.4.enu
circumstances, these may take the
form of warning signs or barriers.
Drivers may drive the snow groomer
only at a speed at which they can
maintain control at all times. The
speed depends on the snow condi-
tions, terrain and visibility as well as
the effect of the snow groomer's
auxiliary equipment.
Risk of accidents caused by loose
parts moving around!
Do not keep any loose parts in the
driver's cab.
Close the doors!
If you fail to do this, there is a risk of
an accident caused by the doors
slamming shut.
Switch on the rotating beacon.
Check that loads are correctly se-
cured.
When driving past people, slow
down, keep at a safe distance and
always bear in mind that people may
behave unexpectedly.
Always come to a complete stop be-
fore reversing the vehicle.
Make sure that there is nothing be-
hind the machine. When visibility is
poor, the driver needs someone to
act as a banksman.
When a tracked vehicle is being
driven, the traction is so great that
the vehicle may be driven well be-
yond the tipping point; if this hap-
pens, the vehicle may suddenly tip
over.
Use the parking brake only to keep
the vehicle at a standstill.
The PistenBully brakes with full force
when the parking brake is engaged
during operation.
Park in places where the vehicle can
be clearly seen.
Engage the parking brake only when
the vehicle is at a standstill.
Risk of poisoning!
Do not leave the engine running in
an enclosed space.
Turbocharger – risk of overheating!
Do not immediately switch off the
diesel engine after it has been run at
full load. Drive for approx. 2 minutes
in the part-load range and then
switch off.
Lower the auxiliary equipment at the
front and back, switch off the tiller,
and turn the direction-of-travel
switch to "neutral".
Before you get out:
- Engage the parking brake.
- Switch off the engine.
- Remove the ignition key from the
lock.
STOPPING/GETTING OUT
SAFETY INSTRUCTIONS

Operation Checks Use Safety Technical
data
Overview
400 4F_11319.4.enu
19/162
Safety
Swivel up the steering column and
left armrest completely.
Step onto the track!
There is a risk of slipping on the
track when getting in and out of
the driver's cab.. Always take a firm
grip on the handle of the driver's door
when getting out of the vehicle.
Lock the driver's cab.
Before using the snow groomer,
check that the intended terrain is
drivable.
A public road may be crossed di-
rectly only with approval from the
responsible authorities. Comply
with all applicable national regula-
tions.
Risk of breaking through ice
Driving on frozen rivers and lakes is
very dangerous. Consequently, you
are urgently advised not to do this.
Snowdrifts
Risk of an avalanche or rockfall
Where the driver does not have a
clear picture of the surrounding ter-
rain and in poor weather conditions,
the driver must be in constant radio
TERRAIN
SAFETY INSTRUCTIONS

20/162 400 4F_11319.4.enu
contact with the company responsi-
ble for organising rescue efforts in
the event of an emergency. The ex-
ception to this is when a number of
vehicles are being used together or
there is a co-driver.
When snow groomers are used at
night, the driver must have portable
spotlights.
When the winch is in use, the driver
must wear the seat belt at all times.
Only one co-driver may sit in the
driver's cab.
The co-driver must be seated in the
co-driver's seat at all times when
the vehicle is in motion.
Passengers in the passenger cab
(optional equipment) must be in
their seats, wearing seat belts and
holding on tight. See the operating
manual for the passenger cab.
In the case of the rear deck, which is
optional equipment:
Comply with all applicable national
regulations.
Do not allow anyone to ride on:
- The load platform
- The front blade/ParkBlade
- The tiller
- Equipment attached to the snow
groomer
Rear deck (optional equipment)
Intended use
The opened rear deck is developed for
the safe transport of materials and
people.
National regulations must be
complied with when transporting
people.
When the vehicle starts up, everyone
must be standing and have a firm
grip on the open rear deck.
If the inclinometer indicates a longi-
tudinal incline 1of over 300 or a
transverse incline 2of over 250, in
DRIVING WITH PASSENGERS
Inclinometer
1
2
SAFETY INSTRUCTIONS