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FACT01.2013
Why is Regular Care, Maintenance and Inspectionof Winch Equipment Necessary? 2
Care RoutinesWinch System / Wire Rope / Rope Guide 2
Maintenance WorkWinch System / Hydraulics / Hydraulic Hoses 3
Annually recurring Inspection in acc. withthe Provisions of BGV D8 3
ROTZLER Maintenance and Inspection Service 3
Fire Brigades – Care, Maintenance and Inspectionof Winch Systems
FACT
ROTZLER FACT 2
Wire Rope
Rope guide & pulleys
Remote Control
Generator Hydraulics
Winch
Rope Storage Drum
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Why is Regular Care, Maintenance and Inspection of
Winch Equipment Necessary?
Winches that are used by fire brigades and other organisa-
tions for recovery purposes are not constantly in operation.
However, even after longer periods of inactivity, it is critical
that a winch can guarantee 100 % reliability when it is
required. Furthermore, it would be a mistake to assume that
the intervals recommended by the manufacturer for care and
maintenance work can be lengthened just because the winch
is used less often or only sporadically. Both the winch itself
and associated components such as the wire rope, hydraulic
hoses or the hydraulic oil are subject to environmental factors
like dirt or moisture, which can cause corrosion or prevent
the winch from functioning correctly. Especially when it
comes to water-carrying vehicles fitted with winches, pump
and/or tank ventilation must also be taken into consideration.
Any leaked foaming agent that is left on metallic or varnished
surfaces for any length of time can, under certain circum-
stances, cause components to corrode.
Care Routines
Winch System:
ROTZLER TREIBMATIC winches are largely maintenance-free
and require only minimum care. However, after operations
that cause heavy soiling of the chassis (driving in the rain,
over rough terrain, in flooded areas), the winch system
should always be cleaned along with the rest of the vehicle.
Any heavy soiling can easily be washed off using plain water.
After the winch has been superficially cleaned, all moving
parts (rope guidance rollers, rope pulleys) should be tested
for ease of movement and, if necessary, oiled or lubricated.
In order to check and, if required, clean the inside of the rope
storage drum, the full length of the wire rope must be paid
out. As part of a general winch care routine, visual checks
can also be carried out on hydraulic hoses as well as
electrical cables and plugs.
Wire Rope:
Once the wire rope of the ROTZLER TREIBMATIC has been
fully paid out, the condition of the rope can also be checked
for any damage (such as kinks or wire breakage). Heavy
soiling can simply be washed off using plain water. It is not
recommended to use a high-pressure cleaner as the high
pressure of the water forces the lubricating agent out of the
wire rope, thus removing it from the individual strands and
leaving the rope unprotected against corrosion. In the interest
of rope protection following cleaning, the rope can be treated
using the ROTZLER rope conditioning agent, which provides
the rope with additional surface protection against corrosion.
Grease must not be used for corrosion protection purposes.
Rope Guide:
On leaving the ROTZLER TREIBMATIC, the wire rope is
guided through the vehicle chassis to the rope trumpet via
rope-guiding and deflection rollers. As part of the winch
care routine, the rope pulleys should be checked for ease of
movement and, if required, lubricated using commonly
available multipurpose grease.
Annually recurring inspections in acc. with BGV D8can be performed by ROTZLER for all winch models.
View of winch integration with rope guide using the winch ROTZLERTREIBMATIC 030 as an example.
The winch and rope storage drum can be flexibly installed in such a way as to fit the space available in any respective chassis.
Fire Brigades – Care, Maintenance andInspection of Winch Systems
FACT
ROTZLER FACT 3
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Maintenance Work
In addition to the general care a winch needs in relation to
its use, reliable system performance is also dependent on
performing regular maintenance tasks. The nature of these
tasks and the intervals at which they need to be completed
are described in detail in the manual for any ROTZLER
winch system.
Winch System:
The TREIBMATIC winch system is relatively maintenance-free.
If the above-mentioned regular care routine is observed,
a TREIBMATIC winch requires no further maintenance.
Hydraulics:
Since the hydraulic oil in the hydraulic system is subject to
natural ageing, it will need to be replaced even if the winch
system is only rarely used. Due to the hygroscopic properties
of the oil, the hydraulic oil draws humidity from the ambient
air, which in turn impairs the technical properties of the oil
over time. ROTZLER therefore recommends that hydraulic oil
should be replaced after 2 to 3 years. This oil change should
also go hand in hand with replacing the filter insert in the
reverse-flow filter of the oil tank.
Hydraulic Hoses:
Hose manufacturers recommend that hydraulic hoses should
be replaced after 6 years plus a maximum storage periods of
2 years. A hydraulic hose should therefore be replaced after
a maximum of 8 years. Based on customary use of winch
systems by fire brigades and their decades of experience,
the winch manufacturer ROTZLER recommends fire brigades
should replace hydraulic hoses after a 10 years at the very latest.
Annually recurring Inspection in accordance with
the Provisions of BGV D8
The directives issued by both the Employers’ Liability
Association and the Federation for Accident Insurance and
Prevention (BGV D8 and GUV 4.2, respectively) prescribe
annual inspections for winches as well as hoisting and pulling
equipment that must be conducted by a technical expert.
The mandatory inspections must be confirmed in a winch test
book by the expert. In this respect, the relevant provisions
(BGV D8, DIN 15020) clearly lay down the scope and criteria
of these tests, which include a function test, a pulling
test at maximum pulling force as well as a test of all safety
equipment.
Apart from needing expert knowledge to perform the inspec-
tions, additional equipment (e.g. pulling force gauge) is also
required. For these mandatory annual inspections, ROTZLER
provides a convenient inspection service for all winch
systems that complies with all regulations. Apart from the
assurance of having a
winch system expertly
tested directly by the
winch manufacturer, any
smaller problems can
be repaired at the same
time. On prior request,
any other repair work
can also be completed
in the course of annual
inspection, which saves both time and costs since additional
call-outs can be avoided.
ROTLZER Maintenance and Inspection Service
ROTZLER can coordinate regular winch inspection and
maintenance for all fire brigades and emergency services,
for which purpose extensive service packages are available
– right up to an “all-round-no-worries” package.
Some of the winch experts making up the ROTZLER service
team are themselves experienced firemen and will be happy
to answer any questions regarding safe and trouble-free
operation of winch systems on our
Service-Hotline +49 (0) 7627 701-112.
Further information on ROTZLER winches, accessories
and services can be found at
www.rotzler.com.
Fire Brigades – Care, Maintenance andInspection of Winch Systems
Winch inspections in acc. with BGV D8 are entered in the winch inspection book by the technical expert.
FACT
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ROTZLER GMBH + CO. KGWinches, Capstans and Winch systemsRobert-Bosch-Strasse 479585 SteinenGermanyPhone +49(0)7627 701-0Fax +49(0)7627 701-166info@rotzler.dewww.rotzler.com
ROTZLER INC.Unit 122, 7350 - 72nd StreetDelta, B.C. V4G 1H9CanadaPhone +1 604 940-7134Fax +1 604 940-7135rotzler.canada@rotzler.dewww.rotzler.com
ROTZLER KOREA LTD. SK Technopark Mecha Zone #308 77-1, Seongsan-dong, Seonsan-gu, Changwon, Gyeongnam 642-971 Korea Phone +82 55 282 5067 Fax +82 55 600 6220 rotzler.korea@rotzler.com www.rotzler.com
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