13.05.2013 Views

Operation Manual euro ... - ROPA Fahrzeug

Operation Manual euro ... - ROPA Fahrzeug

Operation Manual euro ... - ROPA Fahrzeug

SHOW MORE
SHOW LESS

Create successful ePaper yourself

Turn your PDF publications into a flip-book with our unique Google optimized e-Paper software.

Mercedes-Benz engine OM 926 LA<br />

Software version: 2007M0112<br />

Printed in Germany 27.09.2007<br />

Innovative technology<br />

for harvesting beets<br />

Translation of the Original<br />

Operating <strong>Manual</strong><br />

<strong>euro</strong>-Maus3 from 2006


Imprint<br />

All rights reserved<br />

© Copyright 2006 by<br />

<strong>ROPA</strong> <strong>Fahrzeug</strong>- und Maschinenbau GmbH<br />

Sittelsdorf 24<br />

D-84097 Herrngiersdorf<br />

Telephon + 49 – 87 85 – 96 01 0<br />

Telefax + 49 – 87 85 – 56 6<br />

Internet www.ropa-maschinenbau.de<br />

E-mail kundendienst@ropa-maschinenbau.de<br />

These operating instructions may only be reprinted or otherwise reproduced<br />

– even in excerpts – with the express approval of <strong>ROPA</strong> GmbH.<br />

Any type of reproduction, distribution or storage on data medium in any form and<br />

of any type not authorized by <strong>ROPA</strong> GmbH forms a violation of current domestic and international copyright law<br />

and will be judicially prosecuted.<br />

Individual illustrations may contain slight deviations from the machine actually delivered. This does not have an<br />

effect on function or operation.<br />

Publisher responsible for content: <strong>ROPA</strong> <strong>Fahrzeug</strong>- und Maschinenbau GmbH<br />

Editing: text und bild Redaktion, -tl-, Bernsteinstraße 17, 84032 Altdorf / Landshut<br />

Layout: text und bild Redaktion, -kk-, Bernsteinstraße 17, 84032 Altdorf / Landshut<br />

Printed in Germany 27.09.2007


EC Declaration of Conformity<br />

In confirmation of conformity with the machine directive<br />

(directive 98/37/EG) and the legislation enacted for its implementation<br />

The company <strong>ROPA</strong> <strong>Fahrzeug</strong>- und Maschinenbau GmbH<br />

Sittelsdorf 24<br />

84097 Herrngiersdorf<br />

Deutschland<br />

hereby declares, as manufacturer, that the machine designated below:<br />

Self-propelled beet loading and cleaning machinet<br />

Designation: <strong>euro</strong>-Maus3<br />

Machine model: e-M<br />

from serial number: 8**550<br />

due to its engineering and mode of construction in the version brought to market by us complies with<br />

the regulations of the machine directive (directive 98/37/EG) and the implementing national legislation.<br />

Directives and standards additionally applied: 89/336 EWG<br />

This declaration becomes invalid in case of any modification to the machine not directly agreed<br />

with <strong>ROPA</strong> <strong>Fahrzeug</strong>- und Maschinenbau GmbH.<br />

Date: 31.07.2006<br />

Signature manufacturer: Ottl Georg<br />

Function of the signer: Leiter Produktion


Table of contents<br />

5<br />

Table of contents<br />

0 Preface ............................................................................. 15<br />

0.1 Name plate and important data ...............................................................17<br />

0.2 Serial number Diesel engine....................................................................18<br />

1 Safety ............................................................................... 21<br />

1.1 General ....................................................................................................21<br />

1.2 Obligations of the entrepreneur ...............................................................21<br />

1.3 General symbols and instructions............................................................22<br />

1.4 Proper use ...............................................................................................22<br />

1.5 Hazard zone ............................................................................................23<br />

1.6 Safety stickers on the machine ................................................................26<br />

1.7 Safety and accident protection ................................................................27<br />

1.8 Requirements for operating and maintenance personnel ........................27<br />

1.9 In the event of accidents ..........................................................................28<br />

1.10 Handling old parts, process materials......................................................28<br />

1.11 Residual risks ..........................................................................................28<br />

1.12 Hazards caused by mechanical influences..............................................29<br />

1.13 Hazards caused by process materials .....................................................29<br />

1.14 Hazards caused by noise ........................................................................30<br />

1.15 Hazards caused by the hydraulics system ..............................................30<br />

1.16 Hazard From the Pneumatic System .......................................................31<br />

1.17 General hints on safety when handling acid batteries .............................31<br />

1.18 General Hints on Safety for the Independent Heating System (Optional) 32<br />

2 Road Traffic ..................................................................... 35<br />

3 General View And Specifications .................................. 41<br />

3.1 General view <strong>euro</strong>-Maus3.......................................................................41<br />

3.2 Specifications ...........................................................................................43<br />

3.3 Transport draft for low-loader transport <strong>euro</strong>-Maus3 ..............................45<br />

3.4 Load-securing points ...............................................................................46<br />

3.5 Transport draft for loading <strong>euro</strong>-Maus3 on a ship ....................................47<br />

3.6 Supporting Points for Wheel Replacement ..............................................48<br />

4 General Description ....................................................... 51<br />

4.1 Function ...................................................................................................51<br />

4.2 Scope of delivery .....................................................................................51<br />

.<br />

Table of contents


Table of contents<br />

.<br />

Table of contents<br />

5 Operating Components .................................................. 55<br />

5.1 Steering column .......................................................................................55<br />

5.1.1 Steering Column Switch ..........................................................................56<br />

5.2 Driver‘s Seat ............................................................................................57<br />

5.2.1 Rotate Cockpit .........................................................................................57<br />

5.2.2 Adjusting the Driver‘s Seat ......................................................................58<br />

5.3 Operating Components on the Floor of the Driver‘s Cabin ......................62<br />

5.4 Operating Console Right .........................................................................63<br />

5.4.1 Switch section 1 .......................................................................................63<br />

5.4.2 Operating Section ....................................................................................64<br />

5.4.3 Switch section 2 .......................................................................................66<br />

5.4.4 Switch section 3 .......................................................................................66<br />

5.4.5 Switch section 4 .......................................................................................67<br />

5.4.6 Right joystick with multi-functional handle ..............................................68<br />

5.4.7 Joystick movements (right joystick) .........................................................71<br />

5.4.7.1 Only in operating mode rabbit..................................................................71<br />

5.4.7.2 Only in operating mode turtle...................................................................72<br />

5.4.8 Left Joystick .............................................................................................73<br />

5.5 Operating Components in the Radio Console on the Cabin Ceiling...............74<br />

5.6 Air Conditioning .......................................................................................76<br />

5.7 Operating Components Outside of the Cabin ..........................................77<br />

6 <strong>Operation</strong> ......................................................................... 81<br />

6.1 Initial Commissioning ...............................................................................81<br />

6.2 Safety Regulations for <strong>Operation</strong> of <strong>euro</strong>-Maus3 ....................................82<br />

6.2.1 Working in the vicinity of power lines .......................................................84<br />

6.2.2 Behaviour during or after contact to an electric power line: .....................85<br />

6.3 Color Terminal ..........................................................................................86<br />

6.3.1 Keyboard and display sectors..................................................................86<br />

6.3.2 Main screen driving on roads...................................................................88<br />

6.3.3 Select function section .............................................................................89<br />

6.3.4 Main menu ...............................................................................................89<br />

6.3.4.1 Loading settings (menu code 1) ..............................................................89<br />

6.3.4.2 System menu (menu code 2)...................................................................90<br />

6.3.4.3 Service menu (menu code 3)...................................................................91<br />

6.3.4.4 Menu basic settings (menu code 4) .........................................................91<br />

6.3.4.5 Submenu special functions (menu code 5)..............................................92<br />

6.3.4.6 Empty menu (menu code 6) ....................................................................92<br />

6.3.5 Operating data .........................................................................................93<br />

6.3.6 Adjusting warning limits ...........................................................................94<br />

6.3.7 Warning and status indications on the color terminal ..............................95<br />

6.4 Air Conditioning .......................................................................................98<br />

6.5 Independent Heating System (Optional)..................................................100<br />

6


7<br />

Table of contents<br />

6.5.1 <strong>Operation</strong> timer ........................................................................................100<br />

6.5.2 <strong>Operation</strong> independent heating system ...................................................100<br />

6.6 Heating Hydraulics Fluid Tank<br />

(only jointly with the independent heating system) ..................................102<br />

6.7 Diesel Engine ...........................................................................................103<br />

6.7.1 Starting the engine...................................................................................103<br />

6.7.2 Starting the engine without booting up the terminal.................................104<br />

6.7.3 Engine speed adjustment ........................................................................104<br />

6.7.3.1 Operating mode „rabbit“...........................................................................104<br />

6.7.3.2 Operating mode „turtle“ ............................................................................105<br />

6.8 Switching Driving Power ..........................................................................105<br />

6.8.1 Switching gears .......................................................................................106<br />

6.8.2 Switching process differential lock ...........................................................107<br />

6.9 Driving ......................................................................................................109<br />

6.9.1 Driving on roads (operating mode rabbit) ................................................110<br />

6.9.1.1 Switching driving direction .......................................................................110<br />

6.9.1.2 Cruise control ...........................................................................................111<br />

6.9.2 Quick description: operating cruise control ..............................................113<br />

6.9.3 Driving in operating mode turtle (loading) ................................................114<br />

6.10 Braking System ........................................................................................115<br />

6.10.1 Operating brake .......................................................................................115<br />

6.10.2 Parking brake ...........................................................................................116<br />

6.10.3 Automatic parking brake (only in operating mode rabbit) ........................116<br />

6.11 Steering ...................................................................................................117<br />

6.11.1 Main steering switch ................................................................................117<br />

6.11.2 Rear axle steering in operating mode Rabbit ..........................................118<br />

6.11.2.1 <strong>Manual</strong> rear axle steering ........................................................................118<br />

6.11.2.2 All-wheel steering ....................................................................................118<br />

6.11.2.3 Setting the rear axle to straight position ..................................................119<br />

6.11.2.4 Quick description: steering in operating mode „rabbit“ ............................120<br />

6.11.3 Steering in operating mode „turtle“ (loading operation) .......................121<br />

6.12 Loading <strong>Operation</strong> ...................................................................................121<br />

6.12.1 Safety circuit for loading operation of <strong>euro</strong>-Maus3 ..................................121<br />

6.12.2 Preparations for loading...........................................................................123<br />

6.12.3 Switching on swing axle support rear axle...............................................124<br />

6.12.4 Swing out pickup......................................................................................124<br />

6.12.4.1 Move pickup to operating depth...............................................................127<br />

6.12.5 Swing out truck conveyor.........................................................................127<br />

6.12.5.1 Loading direction to the right or left .........................................................129<br />

6.12.6 Switching on machine drive .....................................................................131<br />

6.12.7 Relieving pickup/depth setting ................................................................133<br />

6.12.8 Clearing shields .......................................................................................135<br />

.<br />

Table of contents


Table of contents<br />

.<br />

Table of contents<br />

6.12.9 Beet stretch ..............................................................................................136<br />

6.12.9.1 Truck conveyor (in the drawing drive A) ..................................................137<br />

6.12.10 Recleaner (in the drawing drive B) ..........................................................138<br />

6.12.10.1 Beet brake (only for 8-fold pinch roller cleaner) .......................................141<br />

6.12.11 Infeed conveyor (in the drawing drive C) .................................................142<br />

6.12.12 4-fold pinch rollers in the pickup (in the drawing drive D) .......................143<br />

6.12.13 Pickup rollers (in the drawing drive E) .....................................................144<br />

6.12.14 Automatic reversing function for all roller drives ......................................145<br />

6.12.15 Loading transporting vehicle ....................................................................147<br />

6.12.16 Continued loading function ......................................................................147<br />

6.12.17 Pile pickup/picking up residual beets ......................................................148<br />

6.12.18 Change from working to transporting position .........................................149<br />

6.12.19 Special conditions during loading ............................................................155<br />

6.12.19.1 Frozen beet pile .......................................................................................155<br />

6.12.19.2 Extremely narrob beet pile .......................................................................156<br />

6.12.19.3 Very strongly soiled beets and sticky ground conditions/<br />

water spraying system (option) ...................................................................156<br />

6.13 Diesel Enginer .........................................................................................160<br />

6.13.1 Modifications respectively amendments of the engine operating<br />

manual of Mercedes-Benz .......................................................................162<br />

6.14 Pump Distributor Gears (PVG) ................................................................163<br />

6.15 Hydraulics System ...................................................................................164<br />

6.16 Compressed Air System ..........................................................................167<br />

6.16.1 Compressor .............................................................................................169<br />

6.16.2 Air drier ....................................................................................................169<br />

6.16.3 Compressed air reservoir ........................................................................169<br />

6.17 Central Lubricating System......................................................................170<br />

6.17.1 Filling up the grease gun .........................................................................171<br />

6.17.2 Intermediate lubrication ...........................................................................171<br />

6.18 Printer ......................................................................................................173<br />

6.18.1 Description of the keyboard functions......................................................173<br />

6.18.2 Which thermally-sensitive paper is suitable ............................................174<br />

6.19 Video Monitoring ......................................................................................175<br />

6.20 Electrics ...................................................................................................175<br />

6.20.1 Sockets ....................................................................................................175<br />

6.20.2 Main battery switch ..................................................................................176<br />

6.20.3 Voltage monitoring ...................................................................................177<br />

6.20.4 Fuses .......................................................................................................177<br />

6.21 Tire Pressures .........................................................................................178<br />

6.22 Immobilizing up to One Week ..................................................................179<br />

8


9<br />

Table of contents<br />

7 Maintenance and Service ............................................... 183<br />

7.1 Engine ......................................................................................................183<br />

7.1.1 Dry Air Filter .............................................................................................184<br />

7.1.2 Oil change for the engine.........................................................................188<br />

7.1.3 Fuel Supply ..............................................................................................190<br />

7.1.3.1 Fuel Prefilter Separ ..................................................................................192<br />

7.1.3.2 Replace Standard Prefilter Element/Drain Water ...................................194<br />

7.1.3.3 Microorganisms in the fuel system ..........................................................196<br />

7.1.3.4 Fuel fine filter at the engine .....................................................................197<br />

7.1.3.5 Other maintenace work on the Diesel engine ..........................................198<br />

7.1.4 Radiator System ......................................................................................199<br />

7.1.4.1 Reversing fan drive ..................................................................................199<br />

7.1.4.2 Cleaning the radiator system ...................................................................199<br />

7.1.4.3 Checking coolant .....................................................................................202<br />

7.1.4.4 Replacing coolant ....................................................................................205<br />

7.2 Air Conditioning System ..........................................................................206<br />

7.3 Pump distributor gears .............................................................................208<br />

7.4 Hydraulics system ....................................................................................211<br />

7.4.1 Hydraulic fluid tank ..................................................................................212<br />

7.4.1.1 Hydraulic fluid change .............................................................................213<br />

7.4.1.2 Check intake strainers .............................................................................214<br />

7.4.1.3 Replacing the hydraulic fluid filter ...........................................................215<br />

7.4.2 Replacing the pressure filter element .....................................................216<br />

7.5 Mechanical drive of the two steering axles ..............................................217<br />

7.5.1 Cardan shafts from the transfer gear to the steering axles......................217<br />

7.5.2 Maintenance cardan joints of the axles ...................................................218<br />

7.6 <strong>Manual</strong> transmission ................................................................................218<br />

7.7 Axles ........................................................................................................219<br />

7.7.1 Planetary gear (applies to both axles) .....................................................219<br />

7.7.2 Differential gears on the front and rear axles ...........................................221<br />

7.8 Pneumatics System – Maintenance and Service ....................................222<br />

7.9 Brake System – Maintenance and Service ..............................................223<br />

7.10 Pickup ......................................................................................................223<br />

7.10.1 Stop switch of the pickup .........................................................................223<br />

7.10.2 Central mark ..................................................................................................224<br />

7.10.3 Pickup roller gears ...................................................................................225<br />

7.10.4 4-fold pinch roller gears ..........................................................................226<br />

.<br />

Table of contents


Table of contents<br />

.<br />

Table of contents<br />

7.11 Uninstalling and Installing Rollers ............................................................227<br />

7.11.1 Uninstallation and installation of the pickup roller and<br />

the cleaning roller ....................................................................................228<br />

7.11.2 Exchanging the pig tails of the pickup rollers/build-up welding ..............229<br />

7.11.3 Deinstallation and installation feed rollers ...............................................231<br />

7.11.4 Deinstallation and installation tapered roller and pinch rollers.................231<br />

7.11.5 Replacing the wear flange .......................................................................232<br />

7.11.6 Assembling/setting bearing of pinch rollers or tapered roller ..................233<br />

7.12 Pile Pickup With Residual Beet Pickup ...................................................234<br />

7.13 Infeed Conveyor ......................................................................................235<br />

7.13.1 Tightening the infeed conveyor ................................................................236<br />

7.13.2 Replacing the infeed conveyor drive wheels (finger disk)........................237<br />

7.14 Recleaner ................................................................................................237<br />

7.14.1 Strainer chain cleaner – maintenance .....................................................237<br />

7.14.2 8-fold pinch roller cleaner – maintenance ...............................................239<br />

7.15 Truck Conveyor – Maintenance ...............................................................240<br />

7.15.1 Tightening of the truck conveyor ..............................................................240<br />

7.15.2 Rotating drives of the swivel arm and truck conveyor .............................241<br />

7.16 Printer (Option) ........................................................................................243<br />

7.17 Heating and Ventilation System ...............................................................244<br />

7.17.1 Fresh air intake filter ................................................................................244<br />

7.17.2 Circulating air filter ...................................................................................245<br />

7.17.3 Draining condensed water from the air conditioning system ...................245<br />

7.18 Immobilization for a longer period of time ................................................246<br />

8 Fault and Remedy ........................................................... 251<br />

8.1 Safety Circuits ..........................................................................................251<br />

8.2 Electric System ........................................................................................252<br />

8.2.1 Fuses .......................................................................................................252<br />

8.2.2 Schedule of Fuses (Fuses) .....................................................................254<br />

8.2.3 Electronic Cutouts ....................................................................................256<br />

8.2.4 Schedule of Electronic Cutouts................................................................256<br />

8.3 Schedule of Relays ..................................................................................257<br />

8.4 Color Code for Electrical Wiring ...............................................................258<br />

8.5 Fault Search Using the Color Terminal ....................................................259<br />

8.5.1 Overview of Diagnostic Menus ...............................................................260<br />

8.6 Error Codes Diesel Engine Mercedes-Benz ............................................268<br />

8.6.1 Error Codes of Diagnostic Version 202....................................................268<br />

8.6.2 Error Codes of Diagnostics Version 203 ..................................................269<br />

8.6.3 Error Codes of Engine Cont rol (PLD-MR) ..............................................270<br />

8.7 Main Battery Switch .................................................................................276<br />

8.8 Jumpstarting and Charging the Battery ...................................................276<br />

8.9 Welding Work on the Machine .................................................................279<br />

10


11<br />

Table of contents<br />

8.10 Towing ......................................................................................................279<br />

8.11 Coupling of Salvaging Aids ......................................................................280<br />

8.12 <strong>Manual</strong> Release of the Parking Brake .....................................................281<br />

8.13 Adjust Brake ............................................................................................283<br />

8.14 Hydraulics Valves ....................................................................................283<br />

8.15 Central Lubricating System – Bleeding and Removal of Blocks ..............284<br />

8.16 Emergency <strong>Operation</strong> Fan Drive .............................................................286<br />

8.17 Independent Heating System (Optional) – Measures in Case of Faults .................287<br />

9 Schedules and Tables/Plans and Diagrams/<br />

Maintenance Slips .............................................................. 291<br />

9.1 Lubricants and Operating Supplies <strong>euro</strong>-Maus3 .....................................291<br />

9.2 Wartungstabelle <strong>euro</strong>-Maus3 ...................................................................292<br />

9.3 Lubricating Plan <strong>euro</strong>-Maus3 (Lubrication Using Grease Gun) ...............296<br />

9.4 Filter Cartridges, V-Belts <strong>euro</strong>-Maus3 with Mercedes OM926 LA ..........297<br />

9.5 Maintenance Slips ...................................................................................298<br />

9.5.1 Software updates .....................................................................................298<br />

9.5.2 Maintenance Certificate ...........................................................................298<br />

9.5.3 Maintenance Slip Oil Change + Filter Change (only Disel engine) ..........299<br />

Maintenance Slip Oil Change + Filter Change ........................................300<br />

9.6 Torque Table for Bolts and Nuts (Nm) ......................................................301<br />

9.7 Lubricating Plans .....................................................................................302<br />

9.7.1 Machine Recleaner With Version Infeed Conveyor .................................302<br />

9.7.2 Machine With Recleaner Version 8-Fold Pinch Roller ............................303<br />

9.8 Lubricant Translation Table for <strong>ROPA</strong> Machines .....................................304<br />

9.9 Excerpt From the Mercedes-Benz Works Standard<br />

Operating Supplies, Engine Oils and Refrigerants/Antifreeze Agents ...305<br />

9.9.1 Multigrade Engine Oils (Specification 228.5) ...........................................305<br />

9.9.2 Corrosion Protection/Antifreeze Agents (Specification 325.0) ................311<br />

9.10 Approved Lubricating Greases ................................................................312<br />

9.10.1 Recommended Greases for the Central Lubricating System ..................312<br />

9.10.2 Recommended Biologically Degradable Greases for<br />

the Central Lubricating System................................................................312<br />

9.11 Safety Information ....................................................................................313<br />

9.12 Confirmation of Driver Instructions ..........................................................314<br />

Driver Instructions Loading Mouse ..........................................................315<br />

Safety Instructions for Farmers for Loading Beets ..................................315<br />

9.13 Remarks on Beet Harvest ........................................................................316<br />

9.13.1 Practical Hints ..........................................................................................316<br />

9.13.2 Erection Plan for a Beet Pile ....................................................................317<br />

Index ................................................................................ 323<br />

.<br />

Table of contents


13<br />

0 Preface<br />

Chapter 0<br />

Preface<br />

Chapter.0.<br />

Preface


0 Preface<br />

15<br />

0 Preface<br />

We congratulate you to your new <strong>ROPA</strong> machine. Please take the time and thoroughly<br />

read the operating manual. The operating manual is mainly directed at the machine<br />

operator. It contains all information required for safe operation of this machine, informs<br />

about safe handling and gives hints on practical use as well as for self-help and<br />

servicing. The respective safety hints are based on the safety, accident prevention and<br />

health protection regulations applicable at print of this operating manual. In case of<br />

questions about the machine, on operation of the machine or on ordering of spare parts,<br />

please contact the dealer in your vicinity or the manufacturer directly:<br />

<strong>ROPA</strong> <strong>Fahrzeug</strong>- und Maschinenbau GmbH<br />

Sittelsdorf 24<br />

D-84097 Herrngiersdorf<br />

Telephone + 49 – 87 85 – 96 010<br />

Telefax + 49 – 87 85 – 566<br />

Internet www.ropa-maschinenbau.de<br />

E-Mail Kundendienst@ropa-maschinenbau.de<br />

Important information<br />

– Original <strong>ROPA</strong> parts have been especially developed for your machine. They<br />

conform to the high <strong>ROPA</strong> standards for safety and reliability. We would like to point<br />

out that parts and accessories not approved by <strong>ROPA</strong> may not be used on <strong>ROPA</strong><br />

machines, because otherwise the safety and operability of the machine may be<br />

impaired. We cannot assume any responsibility for such installations, additions or<br />

reconstructions. In case of unauthorized modifications to the machine, any warranty<br />

claim lapses! This also applies if seals or sealing wax applied by the works are<br />

removed.<br />

Warning!.In rare cases, massive interference of vehicle electronics or malfunctions of<br />

the machine may occur due to operation of improperly installed electronic appliances<br />

(for instance radios or other appliances emitting electromagnetic radiation). In case<br />

of such interference, the complete machine may suddenly stop operating or execute<br />

unwanted functions. In such cases, immediately shut off the sources for interference and<br />

immediately shut down the machine. In case of need, notify the company <strong>ROPA</strong> or the<br />

nearest authorized customer service of <strong>ROPA</strong>.<br />

Chapter.0.<br />

Preface


0 Preface<br />

Chapter.0.<br />

Preface<br />

– Servicing and specific maintenance work on the engine may only be performed by<br />

companies or persons expressly authorized for this purpose by DaimlerChrysler.<br />

This work must be acknowledged accordingly in maintenance vouchers of<br />

DaimlerChrysler by these persons or companies. Without these maintenance<br />

vouchers properly completed, any warranty or statutory warranty of the engine<br />

manufacturer lapses.<br />

– Technical modifications serving improvement of our machines or increasing the<br />

safety standards are expressly reserved by us – even without specific notification.<br />

– All information about directions given in this operating manual (front, rear, right, left)<br />

refer to the driving direction forward.<br />

– Please always state the chassis number of the machine for any orders for spare<br />

parts and technical enquiries. You will find the chassis number on the name plate<br />

and on the vehicle chassis above the name plate.<br />

– Please have the machine serviced according to regulations. Comply with the<br />

information given in this operatings manual and have parts subject to wear replaced<br />

in due time respectively ensure timely repairs.<br />

– Have the machine services respectively repaired according to regulations.<br />

Employ the decades of experience collected by <strong>ROPA</strong> in sugar beet lifting and<br />

loading technology and implemented in this machine, by correct operation of this<br />

machine. Remember that any neglect in maintenance and servicing inevitably leads<br />

to loss of performance and therefore to loss of time.<br />

– Listen for suddenly occurring unusual noises and have their cause remedied before<br />

the machine is operated further, since otherwise heavy damage or costly repairs to<br />

the machine may be caused.<br />

– Generally comply with the respective applicable regulations for road traffic and the<br />

applicable regulations on employment safety and health protection.<br />

We expressly point out that any damage caused by the fact that this operating manual is<br />

not or not completely complied with is in no case covered by the guarantee respectively<br />

statutory warranty of <strong>ROPA</strong>. Even though this operating manual is comprehensive, in<br />

your own interest you should completely and carefully read it and slowly attain familiarity<br />

with the machine using this operating manual.<br />

16


0.1 Name plate and important data<br />

17<br />

0 Preface<br />

The name plate (2) of <strong>euro</strong>-Maus3 is located on the right side of the vehicle, on the<br />

vehicle frame near the front wheel below the factory number (1).<br />

1<br />

2<br />

Please enter the data for your machine in the following image of the name plate. You will<br />

need this data for ordering spare parts.<br />

Chapter.0.<br />

Preface


0 Preface<br />

Chapter.0.<br />

Preface<br />

0.2 Serial number Diesel engine<br />

The serial number of the engine is located at the top of the engine block below the<br />

exhaust manifold.<br />

Serial number<br />

18


19<br />

1 Safety<br />

Chapter 1<br />

Safety<br />

Chapter.1.<br />

Safety


1 Safety<br />

1.1 General<br />

21<br />

1 Safety<br />

<strong>euro</strong>-Maus3 has been manufactured according to the current state of technology and<br />

been tested for safety.<br />

The machine is CE compliant and therefore conforms to the respective European<br />

regulations for free movement of goods within the European Union respectively the<br />

European economic region.<br />

Modifications to this machine may only be performed with the express approval of the<br />

manufacturer, since otherwise the manufacturers‘ warranty lapses.<br />

In addition, the road traffic registration may lapse and other registrations of the machine<br />

may become invalid. The operating manual supplied must be strictly observed. The<br />

manufacturer shall not be liable for damage caused by incorrect handling, inappropriate<br />

application or incorrect repairs respectively missing maintenance and service carried out<br />

by the customer. The machine may only be operated in a technically perfect condition,<br />

for its intended purpose and with due consideration of the risks involved<br />

1.2 Obligations of the entrepreneur<br />

The entrepreneur employing the machine respectively his agent are obliged:<br />

– to observe the applicable European employment safety regulations.<br />

– to instruct the machine operators about their special obligation for safe driving of the<br />

machine. These instructions must be given anew before the start of each season.<br />

Records must be prepared about giving of these instructions, which must be signed<br />

by the entrepreneur and the instructed machine operator. These records must be<br />

kept for at least one year by the entrepreneur.<br />

– before first use of the machine, to instruct the machine operators about operation<br />

respectively about safe handling of the machine.<br />

Forms for these instructions may be found in Chapter 9 of this operating manual<br />

(documentation of instructions given to the driver). In case of need, please copy these<br />

forms before completing them.<br />

Chapter.1.<br />

Safety


1 Safety<br />

Chapter.1.<br />

Safety<br />

1.3 General symbols and instructions<br />

The following symbols are used for safety instructions in this operating manual. They<br />

serve as a warning against possible personal injury or material damage, or provide help<br />

in facilitating work.<br />

Danger! This symbol warns of imminent danger of fatal accident or serious injury. This<br />

hazard may always occur if the operating or work instructions are not complied with or<br />

only complied with unprecisely.<br />

Warning! This symbol warns you of a possibly dangerous situation which may lead<br />

to grave injury or to death. These hazards may occur if the operating or working<br />

instructions are not or only unprecisely observed.<br />

Attention! This symbol warns of possible hazardous situations which may lead to<br />

heavy injuries and of damage to the machine or other heavy damage. Non-observance<br />

of these remarks may lead to loss of warranty. This hazard may always occur if the<br />

operating or working instructions are not or only unprecisely observed.<br />

Information! This icon warns you of damage to materials or draws your attention to<br />

specific characteristics. This makes your work easier.<br />

This icon points out matters of special importance. If you observe these hints, then you<br />

will work more comfortably or contribute to a longer service life of the machine.<br />

1.4 Proper use<br />

This machine is exclusively meant for loading and cleaning of sugar beets or similar<br />

crops.<br />

Included in proper use is that the machine is driven under compliance with the applicable<br />

road traffic regulations on public roads. This includes driving forward and backward.<br />

Any other use of the machine is deemed improper and is therefore prohibited. We would<br />

expressly like to point out that this machine may not be used for pulling trailers, for<br />

towing or salvaging other vehicles or for pulling respectively pushing or transport of any<br />

loads or any goods.<br />

22


1.5 Hazard zone<br />

23<br />

1 Safety<br />

Nobody may be present within the hazard zone during operation of the machine. In case<br />

of danger, the operator must immediately shut down the machine and ask the people<br />

concerned to immediately leave the hazard zone. He may only restart the machine when<br />

no people are located within the hazard zone anymore.<br />

People wanting to close on the machine during operation must clearly communicate their<br />

intentions to the operator (for instance by calling or by agreed hand signals) to avoid<br />

misunderstanding.<br />

The hazard zone shown in the following drawing applies as soon as the machine is<br />

started up. When a person enters this zone, the machine must be immediately shut<br />

down and the corresponding person asked to immediately exit the hazard zone. The<br />

machine may only be restarted when there are no longer any people located in the<br />

hazard zone.<br />

Only specifically authorized people may enter the hazard zones for discharging<br />

maintenance and monitoring tasks after precise agreement with the operator. These<br />

people must be informed precisely about hazards possibly occurring before entering<br />

the hazard zones. All activities made between the operator and these people must be<br />

precisely agreed on before starting these activities. All maintenance, adjusting and<br />

monitoring work on this machine must – to the extent as technically possible – be<br />

always performed with the machine standing totally still and engine shut off. In this<br />

case, the operator of the machine is responsible for the fact that the machine may not<br />

be, by unauthorized people, be put into operation inadvertently or in contrary to prior<br />

agreements.<br />

Danger!.There is the hazard of severest or even deadly injury for people staying in the<br />

hazard zone. Especially in the sector of the pickup, people or objects may be drawn<br />

into running shafts by body parts or clothing. This may lead to body parts being torn off<br />

and fragmented. Objects may be pulled in by the shafts and destroyed or cause severe<br />

damage to the pickup of the machine. The operator is obliged to immediately shut down<br />

the machine as soon as people or animals enter the hazard zone or reach into the<br />

hazard zone with objects.<br />

Picking up sugar beets not caught by the pickup by hand or using tools and putting them<br />

into the pickup is expressly prohibited while the machine is running. The engine must be<br />

shut off and the ignition key pulled off before any maintenance and repair work. Please,<br />

in any casae, read the operating manual and comply with the hints on safety. In the past,<br />

these activities have lead to the severest accidents. Staying under lifted machine parts<br />

or within the swiveling perimeter of machine parts is hazardous and therefore prohibited.<br />

Chapter.1.<br />

Safety


1 Safety<br />

Chapter.1.<br />

Safety<br />

We recommend that the operator of the macine informs all people present during lifting<br />

about the possible hazards. You will find an information sheet for this purpose in the<br />

appendix. In case of need, you should copy this sheet and hand it out to the people<br />

concerned. For your own safety and as protection against possible recourse (liability)<br />

claims, you should obtain written confirmation about receipt of this sheet in the space<br />

provided.<br />

All parts of the machine which may cause specific hazards are additionally marked<br />

using warning labels (pictographs). These pictographs point out possible hazards.<br />

They form a part of this operating manual. They must always be kept in clean and well<br />

legible condition. Damaged or illegible safety stickers must immediately be replaced.<br />

The meaning of each individual pictograph is explained below. In addition, a six-figure<br />

number is given for each pictograph. This is the <strong>ROPA</strong> order number. Stating this<br />

number, you may reorder the respective pictograph from <strong>ROPA</strong>. The number stated<br />

in brackets is printed on the respective sticker. This enables simple allocation of the<br />

pictograph to the order number and the explanation.<br />

24


355070 (34)<br />

Shut down the engine before<br />

performing maintenance and repair<br />

work and pull off the ignition key.<br />

Read the operating manual and<br />

comply with remarks on safety.<br />

355069 (41)<br />

Burning hazard due to hot surfaces!<br />

Keep sufficient distance to hot<br />

surfaces!<br />

355071 (1)<br />

Before starting up, read the operating<br />

manual respectively the maintenance<br />

manual and observe all remarks on<br />

safety.<br />

355073 (50)<br />

Hazard due to machine parts<br />

swinging down. Never step into the<br />

hazard zone of raised and unsecured<br />

machine parts.<br />

355065 (37)<br />

Falling hazard! Riding on steps or<br />

platforms is prohibited.<br />

355064 (52)<br />

Hazard due to the machine<br />

inadvertently rolling away. Secure<br />

machine against inadvertently<br />

rolling away using a wedge before<br />

uncoupling or parking it.<br />

25<br />

1 Safety<br />

355068 (39)<br />

Hazard due to electrical current! Observe<br />

a sufficiently safe distance to high-voltage<br />

power lines.<br />

355078 (11)<br />

Hazard of lowering machine parts! Staying in<br />

the hazard zone is only admissible when the<br />

safety lock for the lifting cylinder is engaged.<br />

355081 (40)<br />

The hazard of discharge of liquids under high<br />

pressure. Before performing maintenance<br />

and repair work, read the operating manual<br />

and comply with remarks on safety.<br />

355063 (33)<br />

Hazard from parts being flung away with<br />

the engine running. Keep a sufficient safety<br />

distance!<br />

355072 (15)<br />

Hazard from rotating<br />

parts. Never reach into the<br />

operating auger or pinching<br />

rollers. Hazard of clothing<br />

or body parts being pulled<br />

in. Do not open or remove<br />

protective equipment<br />

during operation.<br />

Chapter.1.<br />

Safety


1 Safety<br />

15<br />

Chapter.1.<br />

Safety<br />

25<br />

4 6<br />

355080 (42)<br />

Explosion hazard. The<br />

pressure reservoir is under<br />

very high pressure. Perform<br />

removal and repair only<br />

following instructions from<br />

the manual.<br />

355075 (9)<br />

Chain drive! Hazard of body<br />

parts or clothing being pulled<br />

in with running drive. Before<br />

opening the cover, shut down<br />

the machine and secure it<br />

against inadvertent startup!<br />

1.6 Safety stickers on the machine<br />

1 34 39 40 33<br />

25<br />

355067 (44)<br />

Never step in<br />

the hazard area<br />

between attached<br />

device and<br />

machine.<br />

26<br />

41<br />

42<br />

11<br />

15<br />

37<br />

41<br />

15 33<br />

on the rear wall<br />

6 50<br />

41<br />

15<br />

42 on the rear wall<br />

In case of numbers highlighted in grey, you will find the corresponding stickers at the<br />

opposite position on the machine on the rear wall as well.<br />

355076 (24)<br />

Only touch machine<br />

parts after they have<br />

come to a complete<br />

stop.<br />

355066 (9)<br />

Avoid serious bodily injury from<br />

rotating machine parts.<br />

Do not enter this area until rotating<br />

parts have completey stopped.<br />

Stop engine and remove key.<br />

6<br />

37<br />

4 50


1.7 Safety and accident protection<br />

The stipulations and regulations listed below must be rigorously observed in order<br />

to reduce the risk of personal injury and/or damage to materials. Furthermore, the<br />

regionally applicable regulations and instructions on safety at work and for safe<br />

27<br />

1 Safety<br />

handling of self-propelled processing machines must be observed in any case. For<br />

safety reasons, anyone working with the machine must have read and understood the<br />

operating instructions at hand. He must also be familiar with the relevant labor protection<br />

and health protection regulations. For safe operation of the machine, the applicable<br />

health protection regulations, the relevant national labor protection regulations, or<br />

equivalent relevant national labor protection and health protection regulations of other<br />

member states of the European Union or other states which have signed the agreement<br />

on the European Economic Area, must be rigorously applied.<br />

The operator is obliged to provide the applicable regulations in their current versions free<br />

of charge to the machine operator.<br />

– The machine may only be used for its intendend purpose and in compliance with<br />

these operating instructions.<br />

– The machine must be used and operated in such a manner that its stability is<br />

guaranteed at any time.<br />

– The machine may not be operated in enclosures.<br />

– The effectiveness of operating and adjusting elements may not be influenced or<br />

nullified in an impermissible manner.<br />

1.8 Requirements for operating and maintenance personnel<br />

The independent operation and maintenance of the machine is restricted exclusively to<br />

persons who are of age and:<br />

– must have a required and valid drivers‘ license (when driving on public roads),<br />

– are physically and mentally suitable,<br />

– are not under the influence of drugs, alcohol or medicine, which may impair the<br />

reactions of the machine operator in any manner,<br />

– have been instructed about operation and maintenance of the machine and have<br />

proven their ability to the entrepreneur,<br />

– have been instructed by the entrepreneur about their special obligation for safe<br />

driving of the machine,<br />

– are familiar with the vicinity and it may be expected that they will reliably discharge<br />

the tasks bestowed on them, and<br />

– who are specifically authorized by the entrepreneur.<br />

Operating personnel must have read and understood the operating instructions of the<br />

machine.<br />

Chapter.1.<br />

Safety


1 Safety<br />

Chapter.1.<br />

Safety<br />

All maintenance work which is not specifically the responsibility of the operator may only<br />

be carried out by instructed or trained maintenance personnel.<br />

Some activities may only be performed by people expressly authorized by <strong>ROPA</strong> for<br />

these activities. In case of doubt, ask the manufacturer whether you may perform a<br />

specific activitiy yourself without hazard.<br />

Remark! Forms for proof of proficiency and instruction on safety given for operating and<br />

maintenance personnel are included in this operating manual. In case of need, please<br />

copy these forms before completing them.<br />

1.9 In the event of accidents<br />

In the event of accidents involving personal injury, the machine must be shut down<br />

immediately. To the extent required, immediately necessary first aid measures must be<br />

initiated, medical assistance called in and possibly the next accessible superior should<br />

be informed.<br />

1.10 Handling old parts, process materials<br />

– When handling process materials the appropriate protective clothing must always be<br />

worn to prevent or reduce skin contact with these materials.<br />

– Defective, dismantled parts shall be sorted according to material type and passed on<br />

for proper recycling.<br />

– Residues of oil, grease, solvents or cleaning agents must be reliably and<br />

1.11 Residual risks<br />

environmentally compatibly collected in suitable and prescribed containers and<br />

stored before being disposed of in an environmentally compatible manner in<br />

accordance with the local regulations.<br />

Residual risks are special hazards involved in the use of the machine which cannot be<br />

fully eliminated despite of safety conscious design. These residual risks are not evidently<br />

recognizable and may result in injury or damage to health.<br />

In the event of such unforeseen residual risks becoming apparent, the machine must be<br />

shut down immediately and possibly the responsible supervisor informed accordingly.<br />

The supervisor then makes any further decisions and initiates the necessary measures<br />

for elimination of the hazard. If required, the machine manufacturer must be informed.<br />

28


1.12 Hazards caused by mechanical influences<br />

Attention! Hazard of damage to the environment by leaking fuel or oil! Hazard of<br />

pollution of ground or water bodies.<br />

29<br />

1 Safety<br />

Danger!.With the machine running, there is hazard to life by rotating shafts and attached<br />

parts jutting out. Rotating machine parts and breaking attached parts may lead to<br />

severest injuries like contusions, detachment of body parts and broken bones. These<br />

injuries may be deadly in especially severe cases. During loading, there is extreme<br />

hazard to life in the sector of pickup due to rotating pickup shafts.<br />

You can protect yourself against these hazards by keeping a sufficient safety distance,<br />

by constant attention and by wearing suitable protective clothing.<br />

1.13 Hazards caused by process materials<br />

Warning!.Oil, fuel and grease can cause the following damage:<br />

– Poisoning by inhalation of fuel vapors,<br />

– Allergies due to skin contact with fuel, oil or grease,<br />

– Fire and explosion hazard due to smoking or the use of fire or naked flame when<br />

handling fuel, oil or grease.<br />

Protective measures<br />

– When handling fuel or oil, smoking or the use of open fire or naked flame is strictly<br />

forbidden. Oil and fuel may only be kept in suitable, approved containers.<br />

– Do not expose fuel containers to direct sunlight.<br />

– Always keep fuel containers in the shade.<br />

– Great caution must be exercised when handling fuel. The relevant safety regulations<br />

for handling of fuel must be strictly observed.<br />

– Clothing soaked in fuel must be removed immediately and ventilated in a suitable<br />

place.<br />

– Rags soaked with fuel or oil must be kept in suitable, approved containers and<br />

disposed of in an environmentally compatible manner. Always use a suitable funnel<br />

for filling fuel or oil.<br />

– Skin contact to fuel oil, oils or grease must be avoided in any case!<br />

– In case of need, wear suitable protective gloves.<br />

– Only decant fuel oil or oil in the open or in well ventilated rooms.<br />

Chapter.1.<br />

Safety


1 Safety<br />

Chapter.1.<br />

Safety<br />

Prevention<br />

– Always close containers containing fuel or oil carefully.<br />

– Dispose of empty containers in accordance with regulations and in an<br />

environmentally compatible manner.<br />

– Keep a supply of a suitable binding agent and use immediately as required.<br />

1.14 Hazards caused by noise<br />

Warning!.Noise can cause loss of hearing (deafness), hearing defects, health disorders<br />

such as loss of balance or consciousness disorders, as well as disorders of the heart<br />

and circulation. Noise may lead to reduction of the attention of people. In addition, noise<br />

may interfere with verbal communications among operating personnel as well as to the<br />

outside world. Perception of acoustic warning signals may be impaired or blocked.<br />

Possible causes:<br />

Pulse noise (< 0,2 s; > 90 dB(A))<br />

Machine noise in excess of 90 dB (A)<br />

Protection<br />

Wear ear protection (cotton wool, earplugs, capsules or helmets); keep sufficient<br />

distance to operating machines.<br />

1.15 Hazards caused by the hydraulics system<br />

Warning!.Hydraulics fluid may cause irritation of the skin; emitting hydraulics fluid<br />

may damage the environment. High pressure and partially high temperatures exist<br />

within hydraulics systems. Hydraulics fluid emitting at high pressure may enter the<br />

body through the skin and cause the heaviest tissue damage and scalding. In case of<br />

improper working on the hydraulics system, tools or machine parts may be flung away<br />

with great power and cause heavy injuries.<br />

Protection<br />

Regularly check all hydraulics hoses for their condition and immediately have damaged<br />

hoses exchanged by trained specialist personnel. Have work on the hydraulics system<br />

performed only by especially trained personnel. When working on the hydraulics system,<br />

first render it pressureless! Avoid skin contact to hydraulics fluid. Have hydraulics<br />

hoses regularly checked following the recognized rules of technology and the regionally<br />

applicable safety regulations, and in case of need, have them replaced. Have work on<br />

the hydraulics system only performed by especially trained personnel. When working on<br />

the hydraulics system, first render it pressureless! Avoid skin contact to hydraulics fluid.<br />

30


1.16 Hazard From the Pneumatic System<br />

31<br />

1 Safety<br />

In case of damage to the pneumatic system, the lifted warning signs on the pile pickup<br />

may suddenly come down and cause severe injury to people being in this sector.<br />

In case of faults of the pneumatic system, shut down the machine as quickly as possible<br />

and then have the cause for this damage repaired by specialist personnel being familiar<br />

with handling pneumatic systems.<br />

1.17 General hints on safety when handling acid batteries<br />

– Fire, sparks, smoking and open flames prohibited. Avoid generation of sparks<br />

formed by connecting and disconnecting electrical loads or measuring devices<br />

directly to battery terminals. Before connecting and disconnecting batteries, switch<br />

off the main battery switch. First remove the ground connection. Avoid short circuits<br />

by connecting false polarity and working with spanners. When connecting, connect<br />

the ground cable last.<br />

– Wear eye/face protection!<br />

– Keep children away from acids and batteries!<br />

– Batteries contain corrosive acid. Wear appropriate protective clothing and acid-<br />

resistant rubber gloves. Do not tilt the battery, acid may emit from the ventilation<br />

opening.<br />

– Comply with instructions from the battery manufacturer.<br />

Explosion.hazard!.Increased care is required after longer operation respectively<br />

charging the battery using a charging device. Charging may create highly explosive<br />

oxyhydrogen gas. Make sure of good ventilation. Make sure that acid batteries are only<br />

charged using the admissible charging current.<br />

Chapter.1.<br />

Safety


1 Safety<br />

Chapter.1.<br />

Safety<br />

1.18 General Hints on Safety for the Independent Heating System<br />

(Optional)<br />

– The heating appliance may not be operated in enclosed rooms, not even under<br />

timer control or „Telestart“ (for instance garage or workshops without exhaust-gas<br />

extraction).<br />

– Due to the explosion hazard, the heating system must be switched off at gas<br />

stations and fuel dispensing systems.<br />

– Due to explosion hazard, the heating system must be shut off in any place where<br />

combustible fumes or dust can form (for instance near fuel, coal, wood dust or grain<br />

storage or similar).<br />

– The heating system must be checked by a specialist at the latest at start of the<br />

heating season.<br />

– In case of lasting, strong generation of smoke, unusual combustion sounds or smell<br />

of fuel fumes, the heating system must be shut down by removal of the fuse and<br />

may only be recommissioned after inspection by personnel trained by Webasto for<br />

this work.<br />

– Suitable fuel is the fuel prescribed by the vehicle manufacturer. Only Diesel fuel may<br />

be used.<br />

– Near the heating system, a temperature of 120 °C (storage temperature) may not be<br />

exceeded. Excess temperature may cause permanent damage to the electronics.<br />

32


33<br />

2 Road Traffic<br />

Chapter 2<br />

Road Traffic<br />

Chapter.2.<br />

Road Traffic


2 Road Traffic<br />

35<br />

2 Road Traffic<br />

<strong>euro</strong>-Maus3 is regarded to be a self-propellant processing machine within the territory<br />

of the European Union. This type of vehicle is subject to very specific regulations and<br />

conditions which may differ between countries. Differences are also possible within a<br />

country in the individual conditions established by the respective competent road traffic<br />

authorities. Upon individual request, <strong>euro</strong>-Maus3 may also be registered as a motor<br />

vehicle. In this case, partially regulations apply, which are different from those listed<br />

here. In any case, the operator must make sure that <strong>euro</strong>-Maus3 is furnished with<br />

the regionally required equipment and aids for securing, for instance warning triangle,<br />

warning lamp, etc. and that these devices are always carried in functional condition.<br />

Remark!.<strong>ROPA</strong> expressly wants to point out that the driver and owner of <strong>euro</strong>-Maus3<br />

are always alone responsible for compliance with the respective regulations and<br />

conditions of the competent road traffic authorities.<br />

<strong>euro</strong>-Maus3 in Stellung Straßenfahrt<br />

The following generally applies before driving on public roads in the territory of<br />

the Federal Republic of Germany:<br />

– The truck conveyor must be moved to transporting position (move stop screw on the<br />

swivel arm to the stop).<br />

– Move pickup up to the stop.<br />

– The two lateral parts of the pickup must be swung up and secured using one chain<br />

each.<br />

– The supporting feet must be completely swung into the vehicle profile.<br />

– The pile pickup must be swung into central position, set to horizontal position and<br />

pulled in up to the central mark.<br />

– The residual beet pickup must be turned laterally to the driving direction.<br />

– The fuel tank must be swung in to the central vehicle axis and locked.<br />

– Axle support for the rear axle must be released.<br />

Chapter.2.<br />

Road Traffic


2 Road Traffic<br />

Chapter.2.<br />

Road Traffic<br />

– The operating mode must be set to rabbit II.<br />

– The driver‘s seat must be locked in driving direction.<br />

– The wheels of the rear axle must be aligned in straight position.<br />

– Rear axle steering must be locked (switch off main steering switch).<br />

– All work lights must be switched off.<br />

– The machine must be cleaned until:<br />

- the admissible total weight is not exceeded,<br />

- all warning signs can be easily recognized,<br />

- all turn indicators and lighting fixtures are clean and in operating condition.<br />

– The safety of the vehicle during operation and in traffic, especially that of steering<br />

and lighting, must be reviewed and reinstated, if necessary;<br />

– The additional axle (this ONLY applies, if your <strong>euro</strong>-Maus3 is fitted with an<br />

additional axle) must be lowered for driving on public roads and paths.<br />

– In any case, make sure BEFORE lowering the additional axle, that no people are<br />

staying within range of the additional axle!<br />

The axle may not be used for driving off roads, and must therefore be lifted up for driving<br />

off roads. When you switch from operating mode Rabbit to operating mode Turtle, while<br />

the additional axle is lowered, the color terminal displays the following warning icon .<br />

To raise or lower the additional axle, select position 9 on the rotating selector switch on<br />

the operating console.<br />

If the additional axle is lowered, then the color terminal displays the icon . Ist die If<br />

the additional axle is raised, then the color terminal displays the icon .<br />

key = rise<br />

key = lower<br />

36


37<br />

2 Road Traffic<br />

When driving on public roads and paths, the yellow rotating beacons must be switched<br />

on independent of the time of day.<br />

As self-propellant processing machine with a top speed of at max. 20 Km/h,<br />

<strong>euro</strong>-Maus3 is not subject to the registration and license plate duty. But a sign must<br />

be fastened to the machine on its left side which contains the following information<br />

unobliterable and clearly legible:<br />

– First and last name of the owner as well as town of residence and the full address of<br />

the owner.<br />

In the model variant with a top speed of 25 km/h, <strong>euro</strong>-Maus3 is subject to the<br />

registration and license plate duty. Furthermore, the vehicle must be insured against<br />

damage from vehicle owners’ liability according to the locally applicable regulations.<br />

For both variants, the following conditions must always be fulfilled:<br />

– A guide giving the directions required for safe driving of the vehicle to the driver must<br />

always be used, if otherwise safe driving of the vehicle (for instance at intersections<br />

and road junctions, when backing up, or in case of unfavorable weather conditions)<br />

cannot be ensured.<br />

– Rear wheel steering may only be switched on for a short time for passing narrow<br />

turns at low vehicle speed.<br />

– Only persons familiar with the vicinity, experienced and reliable may be used as<br />

driver and accompanying personnel.<br />

– The vehicle may only be moved on public roads and paths by drivers having the<br />

required and valid drivers‘ license. Besides the valid drivers‘ license, the driver also<br />

has to carry the general type approval of <strong>euro</strong>-Maus3 and the existing and valid<br />

exceptional permit.<br />

– No people may ride on the platform in front of the drivers‘ cabin.<br />

– Case before beginning a working period about his special obligation for safe driving<br />

of the vehicle. The instructions given must be acknowledged by the drivers with their<br />

signature. The vehicle owner must keep these acknowledgements for at least one<br />

year.<br />

A form for these instructions is included in Chapter 9. <strong>ROPA</strong> reccommends copying<br />

this form before completing it.<br />

– As already mentioned, the regionally competent road traffic authorities may establish<br />

additional conditions or conditions deviating from the regulations listed. It is the<br />

sole responsibility of the vehicle owner and the driver to gain knowledge of these<br />

regulations and to comply with them.<br />

– If parts or functions of the vehicle are subsequently modified, whose condition<br />

respectively sequence has been prescribed, then „general type approval“ lapses<br />

and a new „general type approval“ must be applied for with the authorities specific to<br />

each country.<br />

Chapter.2.<br />

Road Traffic


39<br />

3 General View And Specifications<br />

Chapter 3<br />

General View And<br />

Specifications<br />

Chapter.3.<br />

General View And Specifications


3 General View And Specifications<br />

3.1 General view <strong>euro</strong>-Maus3<br />

5 6<br />

3 4<br />

2<br />

1<br />

7<br />

8<br />

41<br />

3 General View And Specifications<br />

(1) Central electric system<br />

(2) Rear wall of the platform<br />

(3) Air filter<br />

(4) Intake grid for cooling air<br />

(5) Swivel arm<br />

(6) Small rotating assembly<br />

(7) Articulation of the truck conveyor<br />

(8) Truck conveyor<br />

(9) Fuel tank<br />

(10) Storage compartment<br />

(11) Recleaning wire mesh or<br />

8-fold-pinch roller (option)<br />

(12) Large rotating assembly<br />

(13) Engine housing<br />

(14) Battery box<br />

(15) Compensating tank for coolant<br />

(16) Hydraulic fluid tank<br />

(17) Stepladder<br />

(18) Cabin platform<br />

(19) 4-fold pinch rollers<br />

(20) Swivel plates<br />

(21) Supporting foot<br />

(22) Clearing shield<br />

(23) Pickup rollers<br />

(24) Central mark<br />

(25) Residual beet pickup<br />

(26) Central belt<br />

(27) Stack remover (telescopic tube)<br />

9<br />

11<br />

10<br />

27<br />

26<br />

12<br />

13<br />

15<br />

14<br />

16<br />

18<br />

25<br />

17<br />

19<br />

23<br />

20<br />

23<br />

21<br />

22<br />

Chapter.3.<br />

General View And Specifications


3 General View And Specifications<br />

Chapter.3.<br />

General View And Specifications<br />

42


3.2 Specifications<br />

Vehicle model: e-M3<br />

Valid from series: 2006<br />

Daimler Chrysler engine model: Mercedes Benz OM926LA E3A/2<br />

Certificate: E 3A/2<br />

Exhaus emission stage: Euromot 3a<br />

Exhaus emission standard: 97/68/EG Stage 3a<br />

Power: 220 kW at 2200 min -1<br />

Max. torque: 1200 Nm / 1300 - 1600 min -1<br />

Nominal speed: 2200 min -1<br />

43<br />

3 General View And Specifications<br />

Drive type: Diesel engine 4-stroke, direct fuel injection<br />

Displacement: 7.201 cm³<br />

Driving power: Continuously variable, hydrostatic in three operating<br />

Operating mode „turtle I“:<br />

Operating mode „rabbit I“:<br />

„rabbit II“:<br />

modes<br />

0 - 0.7 km/h<br />

0 - 10.3 km/h<br />

0 - 20 km/h (respectively 25 km/h)<br />

Two mechanically driven axles with differential lock swing axle support rear. One additional axle<br />

(series in FRG; optional in all other countries).<br />

Curb weight, depending on<br />

equipment variant:<br />

24700 kg to 26550 kg<br />

Maximum permitted weight: refer to type label<br />

Tank content: 1340 l<br />

Fuel consumption: 0.12 - 0.20 l/loaded ton<br />

season average max. 20 l/h<br />

Tires front and rear: 710/75 R34 178A8<br />

Additional axle (option): 235/75 R17.5<br />

Chapter.3.<br />

General View And Specifications


3 General View And Specifications<br />

Chapter.3.<br />

General View And Specifications<br />

Vehicle model: e-M3<br />

Loading performance: on average 200 t/h<br />

Generators: 2 x 100 A<br />

Voltage electric system: 24 V<br />

Battery capacity: 2 x 143 Ah<br />

Length (setting driving on roads): 13350 mm<br />

Width: 3000 mm<br />

Height (setting driving on roads): 4000 mm<br />

Driving noise (driving by): 88.7 dB (A)<br />

Refrigerant air conditioning system: R134a<br />

Refrigerant content about: 1.7 kg<br />

44


45<br />

3 General View And Specifications<br />

3.3 Transport draft for low-loader transport <strong>euro</strong>-Maus3<br />

roller cleaner<br />

3 rd axle<br />

rear axle<br />

Remark: For transportation on a deep-loading semitrailer, the max.<br />

Fur Tiefladertransport max. zul. Kraftstoffmenge im Tank: 990 Liter<br />

admissible fuel quantity in the tank: 990 liters<br />

heaviest equipment: total weight 26.5 t<br />

(=fuel tank full (1320 l) and roller cleaner)<br />

- without roller cleaner: about –1.0 t<br />

- without additional axle: -0.45 t<br />

Chapter.3.<br />

General View And Specifications<br />

07.08.2007 11:53:23, Hermann


3 General View And Specifications<br />

Chapter.3.<br />

General View And Specifications<br />

3.4 Load-securing points<br />

Front axle from the front Front axle from the rear<br />

Tie-down using a tension chain<br />

46<br />

Rear axle<br />

Front axle from the rear<br />

Proper transportation on a special deep-loading semitrailer (make Goldhofer)


47<br />

3 General View And Specifications<br />

3.5 Transport draft for loading <strong>euro</strong>-Maus3 on a ship<br />

container tie-down<br />

max. 8° aslant<br />

max. 8° aslant<br />

roller cleaner<br />

max. 200 l Diesel<br />

fuel in the tank<br />

tires: min. 2.0 bar<br />

1x<br />

centrally<br />

Remark<br />

lLading by crane only using the cargo gear shown.<br />

Ropa order number: 018306 allowed!<br />

The scope of delivery includes the top shackle on the supporting tube.<br />

Cargo gear not included in the scope of delivery of the machine.<br />

Chapter.3.<br />

General View And Specifications<br />

08.08.2007 10:33:00, Hermann


3 General View And Specifications<br />

3.6 Supporting Points for Wheel Replacement<br />

Chapter.3.<br />

General View And Specifications<br />

Wheel replacement<br />

– When working on tires, make sure that the device is parked safely and has been<br />

secured against rolling away (wheel chocks).<br />

– Work on tires and wheels may only be performed by specialists and using suitable<br />

mounting tools!<br />

– Check wheel nuts for tight fit after every wheel replacement!<br />

Tighten using torque as per table.<br />

48


Chapter 4<br />

General Description


4 General Description<br />

4.1 Function<br />

51<br />

4 General Description<br />

<strong>euro</strong>-Maus3 is a self-propellant processing machine for picking up, cleaning and<br />

loading of sugar beets in stacks at the side of the field.<br />

Picking up of sugar beets is performed using a roller system. The first roller, the pickup<br />

roller, works several centimeters in the ground, picks up the sugar beets and lifts them<br />

over a cleaning roller onto two conveyor rollers. The conveyor rollers perform transport<br />

of the beets to the outside. Fingers are attached top the feed rollers. These preclean<br />

the sugar beets and move the beets to the four contrarotating worm rollers. The front<br />

and rear rollers may be individually adjusted in their speed. he rotating direction is<br />

reversible. Operating trouble due to pinched stones are largely automatically detected<br />

and remedied by the machine.<br />

In case of need, the final sugar beets may be pulled onto the pickup rollers using the<br />

residual beet pickup controlled via joystick in the drivers’ cabin. No manual assistance is<br />

required.<br />

Main cleaning action is on the rollers at the front of the machine. The contrarotating<br />

rollers pull out soil, weeds and other material. Further cleaning is then performed,<br />

depending on furnishings, using a wire mesh or a roller cleaner transporting the sugar<br />

beets to the loader. The loader moves the sugar beets to the transport vehicle.<br />

Picking up and loading of the sugar beets is controlled and monitored from the cabin by<br />

a single operator.<br />

4.2 Scope of delivery<br />

The scope of delivery of <strong>euro</strong>-Maus includes a fire extinguisher, a medical kit, two<br />

wedges and a set of tools including small parts package.<br />

The medical kit is located in the cabin; the fire extinguisher is located on the cabinet of<br />

the central electric system.<br />

The tool box containing the tool set is located in the lateral storage compartment in front<br />

of the Diesel fuel tank; the spare parts package as well.<br />

Chapter.4.<br />

General Description


5 Operating Components<br />

Chapter 5<br />

Operating Components<br />

53<br />

Chapter.5.<br />

Operating Components


5 Operating Components<br />

5.1 Steering column<br />

Danger!.Hazard of deadly injuries, if the steering column is adjusted while driving. You<br />

may lose control of the machine and cause severest damage. Therefore, NEVER adjust<br />

the steering column while driving!<br />

Clamp screw (1) inclination adjustment<br />

Loosen clamp screw (1) and pull or push steering column into the desired position.<br />

Retighten clamp screw (1). Check, if the steering column has been securely fixed in the<br />

desired position.<br />

55<br />

5 Operating Components<br />

1<br />

Chapter.5.<br />

Operating Components


5 Operating Components<br />

Chapter.5.<br />

Operating Components<br />

5.1.1 Steering Column Switch<br />

– Push lever to the right: Turn indicator right (R)<br />

– Push lever to the left: Turn indicator left (L)<br />

– Lever up/down:<br />

driving light/high beam/headlight flasher (F)<br />

– Pressure switch at the end: horn (H)<br />

– Slider below the horn:<br />

– Washing system (W)<br />

– Turning the slider to the first register position:<br />

interval wiping<br />

– Wiper front (S). The duration of the wiping interval<br />

may be set at the color terminal, menu „basic settings“,<br />

line „interval period wiper“.<br />

– Turning the slider to the second register position:<br />

continuous operation wiper front (S).<br />

Remark! To avoid damage to the wiper motor, you should not be running the wiper on<br />

dry windows.<br />

56


5.2 Driver‘s Seat<br />

5.2.1 Rotate Cockpit<br />

The rotating driver‘s seat hat a pneumatic seat brake. This seat brake is operated using<br />

the switch (20) on the left joystick. This enables you to fix the seat in the position most<br />

favorable for you.<br />

An additional mechanical lock always locks the seat in the position prescribed by law<br />

when driving on roads.<br />

Warning! When driving on roads, the driver‘s seat must be secured against inadvertent<br />

rotation by using the mechanical seat lock on the bottom of the driver‘s seat. The seat<br />

may not be adjusted while driving, because otherwise there is increased accident hazard<br />

and danger to your health.<br />

Mechanical seat lock for driving on roads<br />

Using the large pushbutton (20) (ratchet button) at the front of the left joystick locks the<br />

seat (press 1 x) or release lock (seat brake) (press again).<br />

57<br />

20<br />

5 Operating Components<br />

Chapter.5.<br />

Operating Components


5 Operating Components<br />

Chapter.5.<br />

Operating Components<br />

5.2.2 Adjusting the Driver‘s Seat<br />

Safety instructions:<br />

– To prevent damage to the driver’s back, the seat must be adjusted for the driver’s<br />

weight before use and before every change of driver.<br />

– To prevent injury, no objects should be placed within the moving area of the driver’s<br />

seat.<br />

– To eliminate any risk of accident, the settings must be checked to ensure they are<br />

correctly engaged before the vehicle is driven.<br />

– Adjustments must not be made while driving.<br />

– When the backrest upholstery has been removed, the backrest frame must be<br />

supported, for example held in place, before the backrest adjuster is operated. If you<br />

fail to do so, there is a danger that the backrest frame may jerk forward and cause<br />

injury.<br />

– If you make any changes to the standard seat (e.g. not using original retrofitting and<br />

spare parts made by Grammer) it may no longer meet the safety standards to which<br />

it is tested. Functions may be impaired, threatening your safety. For this reason, any<br />

structural change to the driver‘s seat must be approved by Grammer.<br />

– Fasteners must be checked regularly for tightness. If the seat wobbles there may be<br />

loose bolts or other faults.<br />

If the seat does not function correctly (for example the seat suspension), contact a<br />

specialist workshop immediately to arrange for repairs to be carried out.<br />

– The driver‘s seat may only be installed, maintained and repaired by specialist staff.<br />

If you fail to do so, your health may be affected and the risk of accident increased.<br />

Weight adjustment<br />

The seat should be adjusted for the driver’s weight by briefly<br />

pulling the actuator lever of the automatic weight and height<br />

adjuster (arrow) with the vehicle at a standstill and the driver<br />

sitting on the seat.<br />

The driver must sit absolutely still during adjustment.<br />

To prevent damage to the health, the setting for the driver’s<br />

weight must be checked and adjusted as necessary before<br />

the vehicle is driven.<br />

58


Height adjustment<br />

The seat height can be set pneumatically and is infinitely<br />

adjustable.<br />

The seat height can be altered by pulling or pressing the<br />

actuator lever fully out or in (arrow). If the adjustment<br />

reaches the top or bottom end stop, the height is adjusted<br />

automatically in order to guarantee a minimum spring travel.<br />

In order to avoid damage, do not operate compressor for<br />

more than 1 minute.<br />

Seat depth adjustment<br />

The depth of the seat pan can be individually adjusted.<br />

To adjust the depth of the seat cushion, lift the R/H handle<br />

(see arrow). By moving the seat cushion backwards or<br />

forwards the desired seating position can be reached.<br />

Seat pan angle adjustment<br />

The angle of the seat pan can be individually adjusted.<br />

To adjust the angle of the seat pan, lift the L/H handle (see<br />

arrow). By exerting pressure on or off the seat pan it can be<br />

moved to the desired angle position.<br />

Longitudinal adjustment without control lever handle<br />

Lateral adjustment of the seat is released by pressing the<br />

locking lever upward.<br />

The locking lever must latch into the desired position. It<br />

should not be possible to move the driver’s seat into another<br />

position when it is locked.<br />

59<br />

5 Operating Components<br />

Chapter.5.<br />

Operating Components


5 Operating Components<br />

Chapter.5.<br />

Operating Components<br />

Longitudinal adjustment with control lever handle<br />

Moving the locking lever upward releases lateral<br />

adjustment.<br />

The locking lever must latch into the desired position.<br />

It should not be possible to move the driver’s seat into<br />

another position when it is locked.<br />

Headrest<br />

The headrest can be individually adjusted for height by<br />

pulling it upward over the various increments up the end<br />

stop.<br />

By pushing forward or rearward the angle of the headrest<br />

can be adjusted individually.<br />

To remove the headrest, pull it over the end stop.<br />

Lumbar support<br />

By turning the adjustment knob to the left or right, both<br />

the height and curvature of the backrest cushion can be<br />

individually adjusted.<br />

This increases both the seating comfort and the<br />

performance of the driver.<br />

Armrests<br />

The armrests can be folded up if required and the height<br />

individually adjusted.<br />

To adjust the armrests for height, separate the round cap<br />

(see arrow) from the cover, loosen the hexagon nut (size<br />

13mm) and adjust the armrest to the desired position and<br />

tighten the nut again.<br />

60


Armrest adjustment<br />

The inclination of the armrests can be modified by turning the<br />

adjustment knob (arrow).<br />

Backrest adjustment<br />

The backrest is adjusted using the locking lever (arrow).<br />

The locking lever must latch into the desired position. It<br />

should not be possible to move the backrest into another<br />

position when it is locked.<br />

Front/rear attenuation<br />

Under certain driving conditions, it is useful to activate the<br />

front/rear attenuation. This means that shock impacts in the<br />

driving direction can be better absorbed by the driver seat.<br />

Position 1 = front/rear attenuation on<br />

Position 2 = front/rear attenuation off<br />

Cleaning<br />

Dirt can impair the function of the seat, so make sure you<br />

keep your seat clean!<br />

Upholstery can be quickly and simply removed from the<br />

seat frame for easy cleaning, or replacement. To remove the<br />

upholstery, turn the clips (arrow) and remove the upholstery.<br />

Attention!.Take care with the backrest frame – it may jerk forward and cause injury!<br />

Hold onto the backrest before adjusting.<br />

61<br />

5 Operating Components<br />

Chapter.5.<br />

Operating Components


5 Operating Components<br />

Chapter.5.<br />

Operating Components<br />

5.3 Operating Components on the Floor of the Driver‘s Cabin<br />

Opener for the<br />

cleaning flap<br />

Foot switch<br />

looking forward<br />

62<br />

Foot switch<br />

driving direction<br />

Gas pedal<br />

Brake pedal


5.4 Operating Console Right<br />

1<br />

You will find comprehensive explanations in Chapter 6 „<strong>Operation</strong>“. The console is<br />

divided into different operating sections:<br />

(1) Switch section 1<br />

(2) Operating part<br />

(3) Ignition lock (see page 103)<br />

(4) Switch section 2<br />

(5) Switch section 3<br />

(6) Switch section 4<br />

(7) Joystick with multi-functional handle<br />

(8) Color terminal<br />

5.4.1 Switch section 1<br />

8<br />

7<br />

2 3 4<br />

6<br />

63<br />

5 Operating Components<br />

1 Main steering switch<br />

5<br />

– Main steering switch flipped<br />

downward = unlocked:<br />

steering of rear axle possible.<br />

– Main steering switch flipped<br />

upward = locked:<br />

steering of the rear axle<br />

blocked (see page 117).<br />

2 Flasher indicator<br />

3 High beam indicator<br />

Chapter.5.<br />

Operating Components


5 Operating Components<br />

Chapter.5.<br />

Operating Components<br />

5.4.2 Operating Section<br />

(1) Switching operating mode turtle/rabbit: see page 106<br />

(2) Switching I st /II nd gear: see page 106<br />

(3) Differential lock front axle ON/OFF: see page 107<br />

(4) Differential lock rear axle ON/OFF: see page 107<br />

(5) Water spraying system (option) ON/OFF/AUTOMATIC: see page158.<br />

(6) Air conditioning system ON/OFF: see page 98<br />

(7) key:<br />

This executes functions or increases speeds selected using the rotating selector<br />

switch.<br />

(8) key:<br />

This executes functions or decreases speeds selected using the rotating selector<br />

switch.<br />

1<br />

6<br />

5<br />

8<br />

64<br />

2<br />

3<br />

4<br />

7<br />

9


(9) Rotating selector switch with 12 selectable positions:<br />

Pos. 6: Swivel fuel tank:<br />

see pages 130, 151.<br />

key pressed = left,<br />

key pressed = right.<br />

Pos. 5: Not used<br />

Pos. 4: Adjust beet brake (only in case of option roller recleaner):<br />

see page 141.<br />

key pressed = brake beets more,<br />

key pressed = brake beets less.<br />

Pos. 3: Speed recleaning: see page 139<br />

key pressed = more caring,<br />

key pressed = more aggressive.<br />

Pos. 2: speed 4-fold pinching rollers pickup: see page 143<br />

key pressed = slower,<br />

key pressed = faster.<br />

Pos. 1: Speed pickup rollers see page 144.<br />

key pressed = slower,<br />

key pressed = faster.<br />

Pos. 7: Fuel tank lock: see page 130<br />

key pressed = lock tank,<br />

key pressed = unlock tank.<br />

Pos. 8: Swivel plate: see page 152.<br />

key pressed = swing down,<br />

key pressed = swing up.<br />

Pos. 9: Additional axle (option) up/down: see page 36.<br />

key pressed = additional axle down,<br />

key pressed = additional axle up.<br />

Pos. 10: Set speed cruise-control: see page 112.<br />

key pressed = slower,<br />

key pressed = faster.<br />

Pos. 11: Set desired temperature air conditioning: see page 98.<br />

key pressed = lower desired temperature,<br />

key pressed = increase desired temperature.<br />

Pos. 12: Fan speed of ventilation control: see page 98<br />

set using the / keys.<br />

65<br />

5 Operating Components<br />

Chapter.5.<br />

Operating Components


5 Operating Components<br />

Chapter.5.<br />

Operating Components<br />

5.4.3 Switch section 2<br />

5.4.4 Switch section 3<br />

(1) Switch fast speed truck conveyor/in-feed conveyor see page 138<br />

(2) Switch reverse fan drive see page 199<br />

(3) Connector for USB stick<br />

(4) Switch swing axle support on/off see page 124<br />

(5) Switch swing axle load to right/left see page 131<br />

The following message must apper on the screen after inserting a USB stick: „ the<br />

USB stick is ready for operation“. This message must be acknowledged by the driver<br />

by pressing on the rotating switch. If this message is not displayed, then the USB stick<br />

must be removed immediately. This USB stick is incompatible and may not be used on<br />

this machine. You can obtain compatible USB sticks from <strong>ROPA</strong> under the item number<br />

320706.<br />

5<br />

1 2<br />

4<br />

66<br />

Switch parking light/low beam<br />

up: off<br />

center: parking light<br />

down: parking light and low beam<br />

Hazard warning system<br />

3


5.4.5 Switch section 4<br />

(1) EMERGENCY-OFF<br />

This is used to switch off all drives – with the exception of the Diesel engine.<br />

Applies from chassis number 8**561: turn the emergency off switch by about one<br />

quarter rotation clockwise for unlocking.<br />

(2) Steer rear axle right/left (only in operating mode turtle).<br />

(3) Parking brake<br />

1 2<br />

3<br />

67<br />

5 Operating Components<br />

Chapter.5.<br />

Operating Components


5 Operating Components<br />

1<br />

Chapter.5.<br />

Operating Components<br />

5.4.6 Right joystick with multi-functional handle<br />

You can comfortably control a number of functions of <strong>euro</strong>-Maus3 with one hand using<br />

the right joystick, without distracting the attention of the driver. For improved orientation,<br />

there are stickers on the side window of the cabin containing a schematic diagram of all<br />

functions of the left joystick.<br />

X-Y switch (1) forward/backward<br />

X-Y switch (1) left/right<br />

FORWARD Lower pickup<br />

BACKWARD Raise pickup<br />

ONLY in operating mode rabbit<br />

On the right joystick, it is possible to switch by sliding the X-Y switch (1) to the<br />

right/left between driving with manual engine speed control (to the left) and<br />

automotive driving (to the right). To switch, the X-Y switch (1) must be slid in the<br />

corresponding direction and shortly held in the end position (see page 104).<br />

68


1<br />

2<br />

3<br />

X-Y switch (1) left/right<br />

ONLY in operating mode turtle<br />

Preselect loading direction left/right. For this purpose, slide the switch in the<br />

corresponding direction and shortly hold it in the end position (see page 128).<br />

LEFT Loading direction to the left (the truck is located on<br />

the left side of <strong>euro</strong>-Maus3)<br />

RIGHT Loading direction to the right (the truck is located on<br />

the right side of <strong>euro</strong>-Maus3)<br />

If the X-Y switch (1) is pressed to the left/right and shortly held there, then the<br />

rotating direction of the large rotating assembly changes in each instance.<br />

Key (2) driving forward<br />

Tipping on this key, you switch on driving power forward in operating mode turtle.<br />

Pressing this key again stops driving power (see page 114).<br />

Key (3) driving backward<br />

Using this key, you switch on driving power backward in operating mode turtle for as<br />

long as you keep the key pressed. If <strong>euro</strong>-Maus3 is driving forward during loading,<br />

then you stop forward movement by tipping on this key (see page 114).<br />

X-Y switch (4) supporting feet<br />

FRONT LEFT raise supporting foot left<br />

FRONT RIGHT raise supporting foot right<br />

X-Y switch (5) swing pickup<br />

4<br />

5 Operating Components<br />

(= pickup rollers operate deeper in the ground)<br />

(= pickup rollers operate deeper in the ground)<br />

FRONT LEFT Swing out pickup side part left.<br />

FRONT RIGHT Swing out pickup side part right.<br />

REAR LEFT Swing in pickup side part left.<br />

REAR RIGHT Swing in pickup side part right.<br />

69<br />

Chapter.5.<br />

Operating Components


5 Operating Components<br />

Chapter.5.<br />

Operating Components<br />

14<br />

With this, you also change the release pressure of the pickup side parts<br />

(see page 125).<br />

7 8 5 6<br />

Key (6) machine drive On/off (see page 131).<br />

Key (7) drive pickup rollers On/off/reverse (see page 144)<br />

Key (8) drive 4-fold pinch rollers On/off/reverse (see page 143)<br />

Key (9) drive recleaner On/off/reverse (see page 138)<br />

Key (10) drive in-feed conveyor On/off (see page 142)<br />

Multi-key (11) ONLY in operating mode rabbit<br />

Move rear axle to central position (see page 120)<br />

Multi-key (11) ONLY in operating mode turtle AND in combination with<br />

X-Y switch (4) bzw (5)<br />

4<br />

Adjust both supporting feet simultaneously or<br />

9<br />

10<br />

11<br />

12<br />

13<br />

swing both pickup side parts simultaneously (see page 125)<br />

Keys (12) and (13) ONLY in operating mode rabbit<br />

Shortly press both keys simultaneously<br />

Activate all wheel steering<br />

(see page 120)<br />

Handpoti (14) ONLY in operating mode rabbit<br />

Engine speed adjustment with manual speed control<br />

Handpoti (14) ONLY in operating mode turtle<br />

Change driving speed when loading.<br />

70<br />

14


5.4.7 Joystick movements (right joystick)<br />

5.4.7.1 Only in operating mode rabbit<br />

FORWARD Cruise-control on<br />

BACKWARD Cruise-control off (see page 115)<br />

LEFT Steer rear axle to the left<br />

RIGHT Steer rear axle to the right (see page 118)<br />

71<br />

5 Operating Components<br />

Chapter.5.<br />

Operating Components<br />

.e-M3/e-BM3 Rop.Art. 355250


5 Operating Components<br />

Chapter.5.<br />

Operating Components<br />

5.4.7.2 Only in operating mode turtle<br />

Multi-key (11) NOT pressed<br />

Press Multi-key (11) and keep it pressed<br />

.e-M3/e-BM3 Rop.Art. 355250<br />

This is exclusively used to turn the two rotating assemblies!<br />

Joystick FORWARD turn swivel arm (large rotating assembly)<br />

Joystick BACKWARD turn swivel arm (large rotating assembly)<br />

The rotating direction of the swivel arm always depends on the selected<br />

loading direction!<br />

.e-M3/e-BM3 Rop.Art. 355250<br />

Joystick LEFT turn truck conveyor to the left<br />

(small rotating assembly)<br />

Joystick RIGHT turn truck conveyor to the right<br />

(small rotating assembly)<br />

(see page 129)<br />

This is used to raise or lower the truck conveyor or articulation<br />

Joystick FORWARD lower truck conveyor<br />

Joystick BACKWARD raise truck conveyor<br />

Joystick LEFT<br />

.e-M3/e-BM3 Rop.Art. 355250<br />

swing down truck conveyor articulation<br />

Joystick RIGHT swing up truck conveyor articulation<br />

72<br />

(See page 127)


5.4.8 Left Joystick<br />

When the left joystick console has been swung up, machine drive and driving power are<br />

automatically stopped.<br />

Joystick movements<br />

FORWARD extend pile pickup (telescopic tube)<br />

BACKWARD retract pile pickup (telescopic tube)<br />

RIGHT swing pile pickup (completely) to the right<br />

LEFT swing pile pickup (completely) to the left<br />

Turn grip molding of the joystick<br />

to the RIGHT Turn residual beet pickup to the right<br />

(same function as using the keys (18) and (19))<br />

to the LEFT Turn residual beet pickup to the left<br />

(15) push-button potentiometer (red)<br />

DOWN lower pile pickup<br />

UP raise pile pickup<br />

(same function as using the keys (18) and (19))<br />

(16) gas key reduce speed Diesel engine (see page 105)<br />

(17) Gas key increase speed Diesel engine (see page 105)<br />

(18) turn residual beet pickup to the right<br />

(19) turn residual beet pickup to the left<br />

.e-M3 Rop.Art. 355251<br />

All functions may only be executed with the joystick if the seat console is swung down<br />

all the way and the machine is operated in operating mode turtle I or turtle II. Or if the<br />

main steering switch is released.<br />

(20) set/release ratchet button rotating seat brake (see page 57)<br />

73<br />

5 Operating Components<br />

17<br />

16<br />

18<br />

19<br />

15<br />

20<br />

Chapter.5.<br />

Operating Components


5 Operating Components<br />

Chapter.5.<br />

Operating Components<br />

5.5 Operating Components in the Radio Console on the Cabin Ceiling<br />

All loads switched using the switches on the radio console are operational even with the<br />

ignition switched off. Please do not forget to switch off these loads in due time, when the<br />

engine is not running.<br />

(1) Microphone for public address system (optional)<br />

(2) Radio (for operation, refer to separate operating manual)<br />

(3) Rotating switch for swinging the left rear view mirror in/out<br />

(4) Rotating beacons<br />

(5) Mirror heating system<br />

(6) Side window wiper/washer left<br />

(7) Power outlet 24 V/8 A max. (for small automobile plug)<br />

8<br />

9<br />

1 2 3<br />

4<br />

10<br />

11<br />

(8) Switch work light central mark<br />

(9) Switch work light ROOF bottom<br />

12 13 14 15 16 17<br />

(10) Switch work light ROOF top center<br />

(11) Switch work light ROOF top outside<br />

(12) Switch work light ROOF rear left<br />

(13) Switch work light ROOF rear right<br />

(14) Switch work light cleaning and truck conveyor<br />

(15) Switch work lights bottom left and right on the vehicle frame<br />

(16) Fuse box with flat-type fuses F30 - F37<br />

(17) Fuse box with flat-type fuses F38 - F45<br />

74<br />

7<br />

6<br />

5


23<br />

22<br />

21<br />

20<br />

(18) Video display (refer to the operating manual enclosed)<br />

(19) 12 V power outlet 5 A max (for small automobile plug)<br />

(20) Rotating switch for swinging the right rear view mirror in/out<br />

(21) Switch central mark camera/truck conveyor camera (only in case of optional truck<br />

conveyor camera)<br />

(22) Side window wiper/washer right.<br />

(23) Four-way switch for electrical adjustment of the external rear view mirrors (option).<br />

Remark!.If the 12 V power outlets are overloaded, then this may lead to damage to the<br />

voltage transformer.<br />

(24) Internal lights<br />

(25) Wiper/washer rear window<br />

(26) Storage compartment<br />

Warning! Do not place any heavy or sharp-edged objects in the storage compartment.<br />

In case of jerky movement of the machine or driving curves, these may fall out and<br />

severely injure the driver. If possible, place such objects in the storage compartment on<br />

the rear cabin wall.<br />

(27) 12 V power outlet 5 A max (for large automobile plug)<br />

(28) Installation space for radio set<br />

24 25 26 27 28 29<br />

(29) Timer for independent vehicle heater (optional)<br />

75<br />

5 Operating Components<br />

18<br />

19<br />

Chapter.5.<br />

Operating Components


5 Operating Components<br />

Chapter.5.<br />

Operating Components<br />

5.6 Air Conditioning<br />

Air vents in the radio console<br />

Rotating switch circulating air<br />

grid open/closed<br />

Circulating air grid in the rear wall<br />

Air vent in the footwell<br />

76<br />

Temperature sensor for the air conditioning system<br />

By example: air vents in the right<br />

A column of the driver‘s cabin


5.7 Operating Components Outside of the Cabin<br />

The main battery switch (1) is located on the left vehicle side, below the cover between<br />

stepladder and battery box. The vehicle electric system is separate from the batteries as<br />

soon as you switch off this switch.<br />

Remark! To avoid damage to the vehicle electric system or vehicle electronics system,<br />

the main battery switch may NEVER be switched off with the engine running or the<br />

ignition switched on.<br />

Main battery switch (1)<br />

2<br />

1<br />

The motor housing contains the switch (2) for motor housing lighting and a power outlet<br />

24 V (3).<br />

77<br />

5 Operating Components<br />

3<br />

Chapter.5.<br />

Operating Components


79<br />

6 <strong>Operation</strong><br />

Chapter 6<br />

<strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

81<br />

6 <strong>Operation</strong><br />

In this chapter, you will receive all information for safe operation of <strong>euro</strong>-Maus3. For<br />

most work in the agricultural sector, the mode of working and the work results are<br />

affected by many individual and diverse factors. It would exceed the scope of this<br />

operation manual if we were to address all conceivable situations (ground conditions,<br />

sugar beet varieties, weather, local landscape, etc.). This operation manual cannot be<br />

a complete instruction manual on loading sugar beets or replace driving instructions for<br />

driving on roads. Precondition for operation of this machine and for optimum harvesting<br />

results are, besides driving training offered by the manufacturer, solid basic agricultural<br />

knowledge and some experience with sugar beets and the associated work processes.<br />

This chapter will inform you about operation processes and the context in operation of<br />

the machine and gives hints on setting of the machine.<br />

Remark! Before any operation of <strong>euro</strong>-Maus3, obtain in-depth information about<br />

safety measures for operating this machine. If any people should be present who are<br />

not informed about the hazard zones and safety distances applying, then inform these<br />

people about safety distances and hazard zones. In any case, instruct these people that<br />

you will immediately put the machine out of operation if anybody unauthorized closes on<br />

the hazard zones.<br />

6.1 Initial Commissioning<br />

For the sake of safety, check all oil levels, the level of coolant and the available fuel<br />

quantity. Otherwise, all work and measures are required for initial commissioning which<br />

also have to be performed for daily commissioning.<br />

All bolted connections must be checked for tight fit after the first 10 operating hours<br />

and retightened in case of need. In addition, the complete hydraulics system must be<br />

checked for leaks. Possible leaks must be repaired immediately. Furthermore, all hose<br />

clamps on coolant lines, charge air lines and air intake lines must be checked for tight fit<br />

(visual inspection).<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.2 Safety Regulations for <strong>Operation</strong> of <strong>euro</strong>-Maus3<br />

– Before starting work, make yourself familiar with the machine and the operating<br />

components. In case of need, obtain instructions from a person already having<br />

sufficient experience in handling of the machine.<br />

– Before every startup of the machine, check the machine for traffic and operating<br />

safety.<br />

– Inform all people staying near the machine about the hazard zones and the<br />

applicable safety regulations for handling of the machine. Strictly prohibit all people<br />

from entering the hazard zones when the machine is running. In the appendix to this<br />

operation manual, you will find a drawing showing the hazard zones of the machine.<br />

If needed, copy this sheet and hand it out to all people present during operation of<br />

the machine. Obtain a confirmation of receipt of this sheet by signature from each<br />

person.<br />

– Generally, transporting people on the cabin platform is not allowed, neither when<br />

driving on roads nor when loading. If deviation from this regulation is made for<br />

training purposes, then this is at own risk and responsibility of the participants.<br />

– The effectiveness of operating or setting components may in no case be impaired<br />

or defeated. Safety attachments may not be circumvented nor bridged or otherwise<br />

rendered ineffective.<br />

– When working with and on the machine, always wear tightly fitting and suitable<br />

protective clothing respectively approved personal protective equipment. Depending<br />

on the activities, the following personal protective equipment is required: warning<br />

vest, protective helmet, safety shoes, hand protection, ear protection, face<br />

protection.<br />

– Rollers and conveyors may never be stepped on when the engine is running.<br />

– Staying under raised machine parts is prohibited, even if the machine is shut off.<br />

These parts may suddenly come down and severely injure people.<br />

– Staying in the swivel range of machine parts is prohibited.<br />

– Only especially authorized people after exact agreement with the operator may<br />

enter the hazard zones for maintenance or monitoring work. These people must<br />

be precisely informed about possibly occurring hazards before entering the hazard<br />

zones. All activities between the operator and these people must be exactly agreed<br />

before beginning these activities. All maintenance, adjustment and monitoring work<br />

on this machine must – to the extent technically possible – always be performed<br />

with the machine standing totally still and engine shut off. The operator of the<br />

machine is responsible for the fact, that the machine cannot be put into operation by<br />

unauthorized people, inadvertently or in contrary to prior agreements.<br />

82


83<br />

6 <strong>Operation</strong><br />

Danger!.There is a hazard of severest or even deadly injuries for people staying in the<br />

hazard zone. Especially near the pickup, objects or people may be drawn into rollers<br />

by body parts or pieces of clothing. In this case, body parts may be ripped off and<br />

fragmented. Objects may be drawn in by the rollers and destroyed or cause severe<br />

damage to the pickup of the machine. The operator is obliged to immediately shut down<br />

the machine, as soon as people enter the hazard zone or ingress into it with objects. It is<br />

expressly prohibited to place sugar beets not having been lifted by the machine into the<br />

machine manually or using tools, as long as the machine is running. The engine must<br />

be shut off before maintenance and repair work and the ignition key must be removed.<br />

Read the operating manual and observe safety information. In the past, these activities<br />

have lead to severest accidents.<br />

– Shut off the engine when refuelling. Smoking, fire and naked flame are strictly<br />

prohibited when handling fuel. Explosion hazard! Do not use wireless telephones or<br />

radios while refuelling.<br />

– Always shortly sound then horn before starting up the engine. By this, you draw the<br />

attention of all people in the vicinity to the necessity of leaving the hazard zones.<br />

Assure yourself that no people are staying within the hazard zones anymore at<br />

startup of the machine.<br />

– Always make sure of sufficient fire protection by keeping the machine free of dirt,<br />

grease residue and other combustible items.<br />

– Immediately remove spilt fuel or spilt oil using suitable binding materials.<br />

– Do not operate the machine in enclosed rooms. There is a poisoning hazard from<br />

poisonous engine exhaust gases. If the engine is to be run in an enclosed room<br />

for maintenance or tuning work, then the exhaust gases must be routed into the<br />

environment using suitable measures (exhaust device, exhaust gas hoses, exhaust<br />

pipe extensions, etc.).<br />

– In your own interest, when driving on public roads and paths, comply with applicable<br />

laws and regulations.<br />

– Safe operation of the machine requires the full concentration and attention of the<br />

driver. Do not wear headsets for listening to the radio and for monitoring radio sets,<br />

etc.<br />

– While driving, do not use radio sets, wireless telephones (cell phones), etc.<br />

– Should there be operational reasons for having to use such devices while driving,<br />

then please always use a suitable hands-free unit for this purpose.<br />

– Set the external rear view mirrors before starting up the machine.<br />

– Before starting to drive, always check if people are staying in the immediate vicinity<br />

of the machine. Inform these people about your plans and instruct these people<br />

to stay at a safe distance. The individual driving behaviour of the machine always<br />

depends on the road conditions respectively depends on the ground conditions.<br />

Always match your driving style to the respective environmental and ground<br />

conditions. Never leave the driver‘s seat when the machine is running.<br />

– When working in sloped terrain and working on slopes, always make sure of<br />

sufficient stability of the machine.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.2.1 Working in the vicinity of power lines<br />

Danger! Hazard to life due to electrical current! Due to the dimensions of the machine,<br />

the landscape and the construction of power lines, the prescribed safety distance may<br />

be violated when passing under power lines or while working in the vicinity of power<br />

lines. This causes the greatest hazard to life for the driver and bystanders.<br />

– When working in the vicinity of power lines, indispensably comply with the applicable<br />

minimum distances. These minimum distances between the outside edge of the<br />

machine and the power line may amount to up to 8.5 m. The size of this minimum<br />

distance always depends on the voltage of the power line. The greater the voltage,<br />

the greater the prescribed minimum distance. Obtain information from the power<br />

company responsible about the technical situation in due time before starting loading<br />

work. If needed, agree a voltage shut down with the power company for the power<br />

line for the time in which you perform work using the machine.<br />

– Precisely observe the agreements closed with the power company for possible<br />

voltage shutdown. Only start work after you have assured yourself, if needed by<br />

calling the power company, that voltage has actually been shut off.<br />

– Especially when working at night or in dreary weather, exactly inform yourself about<br />

the routing of power lines. In case of need, have warning and safety sentries set up,<br />

which will warn you in due time using suitable signals (visual or acoustical signals) of<br />

hazardous closing on power lines.<br />

– During work, make sure that you do not fall below the prescribed minimum<br />

distances.<br />

– When installing antennas or other attachments, always make sure that the total<br />

height of the machine does not exceed the dimension of 4 m.<br />

Memorize the following behavioural rules well, if you work near electric power lines.<br />

Exact compliance with these rules may save your life.<br />

84


6.2.2 Behaviour during or after contact to an electric power line:<br />

– Immediately try to interrupt contact to the electric power line by backing up.<br />

– Try to swing down the truck conveyor.<br />

85<br />

6 <strong>Operation</strong><br />

– Stay calmly seated on the driver‘s seat – no matter what happens around you!<br />

– Do not walk around in the cabin.<br />

– In case of electric shock or after contact to an electric power line, in no case leave<br />

the driver‘s cabin. There is extreme hazard to life outside of the cabin.<br />

– Wait until help arrives.<br />

– In no case use a cell phone or radio connected to an external antenna.<br />

– Warn people closing on the machine by hand signals and loud shouting of the<br />

danger.<br />

– Only leave the driver‘s cabin after you have been asked to by rescuers.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.3 Color Terminal<br />

The color terminal is the information and command center of <strong>euro</strong>-Maus3. You can<br />

monitor the complete machine from here, obtain information about operating status and<br />

performance data and set parts of the machine.<br />

Before working with <strong>euro</strong>-Maus3, you should indispensably familiarize yourself with the<br />

color terminal and the different warning and status indications on the color terminal to be<br />

able to safely and effectively use the machine.<br />

6.3.1 Keyboard and display sectors<br />

The terminal is operated using the keyboard and the potentiometer (1). You can move up<br />

and down in all menus by rotating the potentiometer. A blue bar or a field highlighted in blue<br />

(cursor) in a menu or in a function selection shows your current position.<br />

You confirm the current position of the cursor by lightly pressing on the middle of the<br />

potentiometer (Enter function).<br />

You can move laterally in the menu or in the line using the keys „left arrow“ (3) or<br />

„right arrow“ (4). In some menus, you can comfortably modify the values shown using the<br />

potentiometer without having to input individual characters.<br />

You can exit the current menu or the line selected by pressing the ESC key (5)<br />

(up by one level).<br />

You can interrupt input by pressing the key C (6).<br />

You input numbers, characters or letters using the number keys – as on the numbers<br />

pad of your telephone.<br />

Different functions are stored for the F1 key (7), depending on the respective display on<br />

the screen. The respective function of this key is either stated directly on the screen or is<br />

explained at the corresponding function within this manual, if needed.<br />

86<br />

7<br />

3<br />

4<br />

1<br />

6<br />

5


A Display section steering status (see page 117)<br />

B Display section operating parameters<br />

Engine cooling water temp.<br />

G H I<br />

Hydraulics fluid temp.<br />

F<br />

E<br />

C Display section scales and order management (option from 2008)<br />

D Dialog field operating section (see page 64)<br />

87<br />

J<br />

6 <strong>Operation</strong><br />

Compressed air system pressure reservoir<br />

Battery voltage<br />

E Fields for status displays (see page 97)<br />

K<br />

F Display section beet section (see page 136)<br />

A<br />

B<br />

C<br />

D<br />

E D<br />

Engine oil level<br />

Pressure driving power<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

G Display section driving speed (see page 103)<br />

H Display section Diesel engine (see page 160)<br />

I Display section function selection<br />

J Quick overview loading parameters<br />

Stage speed pickup rollers<br />

Drive pressure pickup rollers<br />

Stage speed 4-fold pinch rollers<br />

Drive pressure 4-fold pinch rollers<br />

Stage speed 8-fold pinch roller cleaner<br />

Drive pressure 8-fold pinch roller cleaner<br />

Stage speed recleaner strainer chain<br />

Drive pressure recleaner strainer chain<br />

K Display section for warning indications and hints (see page 95)<br />

6.3.2 Main screen driving on roads<br />

When driving on roads, the main screen shows the machine in setting driving on roads in<br />

the display section F (beet section). If the tank should be shown swung out to the left or<br />

right in this display, then the tank lock is not engaged.<br />

88


6.3.3 Select function section<br />

6.3.4 Main menu<br />

89<br />

6 <strong>Operation</strong><br />

Place the blue field on the desired function section using the potentiometer and confirm<br />

by pressing on the center of the potentiometer.<br />

Main menu<br />

selected<br />

All submenus of the main menu may be directly called up by entering the respective<br />

menu code.<br />

6.3.4.1 Loading settings (menu code 1)<br />

Operating data<br />

selected<br />

Menu code 1<br />

Menu code 2<br />

Menu code 3<br />

Menu code 4<br />

Menu code 5<br />

Menu code 6<br />

After confirmation of the selection, the following menu is displayed:<br />

Warning limits<br />

selected<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

The desired menu item is navigated using the potentiometer and selected by pressing<br />

on the potentiometer. This activates the associated bar graph.<br />

The recommendation of the manufacturer is always the value of 0. Deviations may be<br />

set by the driver, if desired, from -10 to +10.<br />

- values = the hydraulics circuit reacts more sluggishly<br />

+ values = the hydraulics circuit reacts more aggressively<br />

You may comfortably store your personal loading settings (those are all settings<br />

displayed on the color terminal) on your specific USB stick using the function „export“.<br />

This way, your settings are not lost in case of possible change of drivers. When starting<br />

your next work shift, you can transfer these settings from the USB stick to the machine<br />

using the function „import“.<br />

6.3.4.2 System menu (menu code 2)<br />

The submenus are largely self-explaining.<br />

It is possible to switch between the standard display and the expert mode in the<br />

submenu display type. We generally recommend standard display, since this is much<br />

clearer. The export mode does not offer any additional functions or advantages for<br />

everyday work; it is mainly meant for maintenance personnel or development purposes,<br />

to show specific operating conditions in detail.<br />

90


6.3.4.3 Service menu (menu code 3)<br />

91<br />

6 <strong>Operation</strong><br />

Of meaning to the operator in the service menu are only the submenus version and<br />

diagnostics (see chapter faults and remedies (from page 313 and after). The submenus:<br />

tuning and teach in are only accessible after input of a service code.<br />

Danger! Access to these menus is locked using a specific code for safety reasons. If<br />

wrong settings are mad ein these menus, or if the applicable safety regulations are not<br />

or not sufficiently complied with, then this may lead to severest accidents with deadly<br />

injuries. In many cases, severe damage may be caused to the machine, which lead to<br />

expensive repairs or long stand-still periods. Access to these menus is therefore only<br />

allowed during direct contact by telephone to the manufacturer or to people expressly<br />

authorized for this purpose by the manufacturer.<br />

6.3.4.4 Menu basic settings (menu code 4)<br />

Most submenus are comprehensively described at the respective function.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.3.4.5 Submenu special functions (menu code 5)<br />

Central lubrication (see page 171)<br />

Engine oil change (see page 188)<br />

6.3.4.6 Empty menu (menu code 6)<br />

This menu only serves to inform people who are working on continued development of<br />

the control program. No input is possible for the operator here. The information displayed<br />

cannot be sensibly used by the operator.<br />

You can exit this menu respectively the function section using the ESC key.<br />

92


6.3.5 Operating data<br />

93<br />

6 <strong>Operation</strong><br />

Operating data may be selected using the potentiometer and the selection confirmed by<br />

pressing on the center of the potentiometer.<br />

Operating data<br />

selected<br />

The following menu is displayed after calling up the function section operating data:<br />

Operating data engine = Total engine service hours<br />

Oper. hrs Loading = Total active period machine drive<br />

Distance = Driven distance in km in operating modes „turtle“<br />

and „rabbit“.<br />

Time = Total time in hours in operating modes „turtle“<br />

and „rabbit“.<br />

Consumption = Total fuel consumption in Liters<br />

in operating modes „turtle“ and „rabbit“.<br />

Recording of operating data is performed per season (values may be deleted) as well<br />

as over the whole service life of the machine (values may not be deleted). The values<br />

recorded are generally evaluated differentiated for the operating modes „turtle“ and<br />

„rabbit“.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

The „season statistics“ may only be deleted if the keys and are pressed one<br />

after the other before deletion. This avoids inadvertent deletion.<br />

No input may be made nor values deleted or modified in „machine statistics“.<br />

The functions „scales“ and „order management“ are available from model year 2008.<br />

The description is contained in a separate operating manual.<br />

6.3.6 Adjusting warning limits<br />

Select the function section warning limits using the potentiometer and confirm the<br />

selection by pressing on the center of the potentiometer.<br />

Warning limits<br />

selected<br />

This function section may be used to modify the warning limits for drives of pickup<br />

rollers, 4-fold pinch rollers and recleaner.<br />

Warning limit<br />

Value warning limit in %<br />

Select the display bar for the desired drive by rotating the potentiometer and confirm<br />

selection by pressing on the center of the potentiometer. Then, by rotating the<br />

potentiometer, scroll the red mark for the warning limit and confirm the setting by<br />

pressing on the center of the potentiometer.<br />

Exit the menu respectively the function section using the ESC key.<br />

94


6.3.7 Warning and status indications on the color terminal<br />

Warning indications<br />

95<br />

6 <strong>Operation</strong><br />

Engine oil pressure too low Recleaner rollers blocked<br />

Engine oil level too low<br />

Drive central mark/truck<br />

conveyor blocked<br />

Cooling water level too low Pickup rollers overloaded<br />

Cooling water temperature too<br />

high<br />

Grave engine problems,<br />

immediately shut off engine<br />

4-fold pinch rollers overloaded<br />

Recleaner rollers overloaded<br />

Engine starting block Recleaner conveyor overloaded<br />

Lubrication pump distributor<br />

gears failed<br />

Clutch pressure pump distributor<br />

gears<br />

Hydraulics fluid level too low<br />

Hydraulics fluid too hot<br />

Releasing pressure parking<br />

brake too low<br />

Battery voltage too low or too<br />

high (below 24 V/higher than<br />

30 V)<br />

Drive cental mark/truck<br />

conveyor overloaded<br />

Generator 1 (upper generator)<br />

defective<br />

Generator 2 (lower generator)<br />

defective<br />

Fault in Mercedes engine<br />

control<br />

Fuel prefilter soiled<br />

Fuel fine filter soiled<br />

WARNING! Injury hazard Air filter soiled<br />

Pickup rollers blocked (stone<br />

jammed)<br />

4-fold pinch rollers blocked<br />

Recleaner conveyor blocked<br />

Differential lock front axle not<br />

released<br />

Differential lock rear axle not<br />

released<br />

Reservoir pressure<br />

compressed air system too low<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

Remarks on operation<br />

Please close engine<br />

compartment hatch<br />

96<br />

Please swing fuel tank to central<br />

position and lock<br />

Please close rear platform wall Please unlock fuel tank<br />

Start engine respectively let go of<br />

the ignition key<br />

Please swing down left joystick<br />

console<br />

Please lock main steering switch<br />

Please unlock main steering<br />

switch<br />

Please press foot switch „line of<br />

vision front“<br />

Please release foot switch „line<br />

of vision front“<br />

Please press foot switch „line of<br />

vision front“ or lift pile pickup<br />

Please swing out truck conveyor<br />

further<br />

Please set rear axle straight Please switch off axle support<br />

Please set pile pickup to central<br />

position<br />

Please raise pickup further<br />

Please release parking brake<br />

Please release driving pedal for<br />

switching on the differential lock<br />

Please lower pickup further Please release foot brake<br />

Please swing out pickup<br />

Please release driving pedal to<br />

change gears<br />

Please press driving pedal Please change gears<br />

Please release driving pedal<br />

Please driver more slowly<br />

Please switch to operating mode<br />

turtle 1. Change gears<br />

Please switch to operating mode<br />

rabbit 2. Change gears<br />

Please drive faster Please raise additional axle<br />

EMERGENCY-OFF pressed,<br />

please reset<br />

Please turn in front axle less<br />

Please set rear axle straight Please turn in rear axle less<br />

Please activate driving power<br />

forward


Status indications<br />

Cruise control activated Additional axle raised<br />

Machine drive switched on Additional axle lowered<br />

Driving power loading forward<br />

activated<br />

Driving power loading backward<br />

activated<br />

All-wheel steering active<br />

Automatically set rear axle<br />

straight active<br />

Operating mode rabbit active<br />

(driving on roads)<br />

Operating mode turtle active<br />

(loading operation)<br />

97<br />

6 <strong>Operation</strong><br />

Central lubrication operating<br />

Automotive driving active<br />

<strong>Manual</strong> engine speed control<br />

active<br />

Loading direction left active<br />

Loading direction right active<br />

Differential lock front engaged<br />

1 st gear active Differential lock rear engaged<br />

2 nd gear active Parking brake engaged<br />

Water spray system in<br />

automated mode<br />

Water spray system in<br />

permanent mode<br />

Please refill fuel tank<br />

Axle support switched on<br />

Hints on electronics problems<br />

Automatic parking brake active<br />

Please, when switching on the<br />

machine drive, press the „foot<br />

switch line of sight front“<br />

Height indicator pile pickup in<br />

percent<br />

Fault driving pedal sensors Fault data backup<br />

Analog signal in prohibited range Wrong machine configuration<br />

Line break or short circuit<br />

detected<br />

Internal memory fault in<br />

EEPROM<br />

Speed signal in prohibited range<br />

Communications problem with<br />

control device<br />

No connection to operating<br />

section<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.4 Air Conditioning<br />

The air conditioning system provides optimum climatic conditions in the driver‘s cabin, if<br />

possible. For setting the desired temperature, select position 11 on the rotating selector<br />

switch.<br />

The setting range is between 15 and 30 °C. The desired temperature is lowered by<br />

pressing the key; the desired temperature is increased by pressing the key. You<br />

can read the respective set temperature on the color temperature.<br />

Setting the fan speed is performed using the and keys in the operating section. For<br />

this purpose, select position 12 on the rotating selector switch.<br />

Fan stage 0: STOP<br />

Fan stage 1: Cooling switched off<br />

Fan stage 2-5: Cooling possible depending on setting of the ECO key<br />

Fan stage AUTO: Automated air conditioning with infinitely variable<br />

control of fan speed. The cabin temperature is adjusted<br />

to the preset desired temperature.<br />

98


EC key = air conditioning system ON/OFF<br />

99<br />

6 <strong>Operation</strong><br />

Press key 1 x: LED is lit, no cooling, only fresh air respectively heating. Keep key<br />

pressed for several seconds: LED is flashing, defroster function for freeing windows. Fan<br />

and heater run at maximum power, simultaneously, the air is dried at maximum power.<br />

1<br />

Circulating air grid in the rear wall<br />

Temperature sensor for air conditioning<br />

Air jet in the foot well<br />

To reach the desired cabin temperature as quickly as possible, open the circulating air<br />

grid on the right side in the rear wall using the rotating switch (1).<br />

In case of cold weather, open the ventilation jet of the fan cover for heating up the foot<br />

well. When you have opened this jet, the air volume of the other ventilation openings<br />

substantially decreases.<br />

Observe that fogged windows are only freed quickly if you keep the jet in the foot well<br />

closed until the windows are free.<br />

Make sure that the temperature sensor (1) on the rear cabin wall is always unobstructed<br />

and is not covered by pieces of clothing or other objects, because otherwise, the air<br />

conditioning system will not work correctly.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.5 Independent Heating System (Optional)<br />

6.5.1 <strong>Operation</strong> timer<br />

Time display<br />

Alarm display<br />

Memory<br />

Time of day<br />

The time of start of heating may be preselected using the timer within a period of up to<br />

7 days. Programming of 3 startup times is possible, of which only one may be activated.<br />

The timer has an alarm function.<br />

With the ignition switch on, the clock shows the current time of day and the day of the<br />

week. If the heating system is operating, then the display and the keys are lit. After<br />

connecting up power supply, all icons of the display flash. The time of day and the day of<br />

the week must be set.<br />

6.5.2 <strong>Operation</strong> independent heating system<br />

<strong>Operation</strong> of the clock is designed so that all flashing icons may be set using the keys<br />

and . If no key is pressed for 5 seconds, then the time displayed is stored. If the<br />

keys and are pressed for more than 2 seconds, then fast mode is activated.<br />

If the ignition is switched off, while the heating system is in permanent heating mode,<br />

then the display shows a residual operating time of 15 minutes and the heating system<br />

remains in operation.<br />

Day of the week <strong>Operation</strong> indication<br />

Program selection<br />

Return<br />

Immediate<br />

Feed heating<br />

Switching on<br />

<strong>Manual</strong>ly: by pressing the key (permanent heating mode)<br />

Automatic: by programming of the start of heating<br />

Ausschalten<br />

<strong>Manual</strong>ly: by pressing the key<br />

Automatic: by programming the operating time<br />

With the heating system operating: by setting the residual operating time<br />

Setting the time of day/day of the week<br />

Press key for more than 2 seconds – time of day flashes – set time of day using the<br />

keys and – day of the week flashes – set day of the week.<br />

100<br />

Timer<br />

Forward<br />

Return


Query time of day<br />

When ignition is switched off: press key .<br />

Program start of heating<br />

101<br />

6 <strong>Operation</strong><br />

Press key – flashes – set start of heating using the keys and dday of the week<br />

flashes – set day of the week.<br />

The memories 2 and 3 may be programmed or a switch may be made to the time of day<br />

mode by pressing the key several times.<br />

Query/delete the preselect times<br />

Press key several times, until the desired memory is displayed. Deleting of the<br />

preselect time – press the key several times, until the time of day and no memory is<br />

displayed.<br />

Program operating period<br />

The heating device must be switched off. Press the key for 3 seconds – operating<br />

period flashes – set the desired operating time using the keys and<br />

(10 to 120 minutes).<br />

Set remaining operating time<br />

Set the desired remaining operating time using the keys and B (1 to 120 minutes).<br />

The remaining operating time is the time the heating device remains in operation. It may<br />

only be modified while the heating device is operating and the ignition is switched off.<br />

Set alarm time<br />

The alarm time is not tied to a day of the week. Press the key several times, until the bell<br />

icon appears on the display. Set the desired alarm time using the keys and .<br />

The alarm switches off after 5 minutes or when one of the keys is pressed.<br />

Query / delete alarm time<br />

Press the key several times, until the bell icon appears on the display– read alarm<br />

time. Deleting the alarm time – press key , until the bell icon no longer appears on<br />

the display.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.6 Heating Hydraulics Fluid Tank (only jointly with the<br />

independent heating system)<br />

If your <strong>euro</strong>-Maus3 is fitted with the optional independent heating system, then the<br />

fluid in the hydraulics fluid tank may be preheated using the fluid tank heater. A heat<br />

exchanger is located in the hydraulics fluid tank, which is connected to the cooling water<br />

circuit of the Diesel engine.<br />

The heater of the hydraulics fluid tank should be switched on for each cold start.<br />

1<br />

For this purpose, move the lever of the ball cock (1) on the outside wall of the hydraulics<br />

fluid tank up. To switch off the fluid tank heater, move this lever to the front.<br />

Remark! Use the fluid tank heater. Preheated hydraulics fluid reduces wear of the<br />

hydraulics system.<br />

For as long as the independent heating system is operating, the main battery switch<br />

may only be switched off in emergencies, because in this case, the heating system is<br />

switched off without running on (danger of overheating!).<br />

Switch off the fluid tank heater before starting the Diesel engine, but at the latest as soon<br />

as the color terminal displays a hydraulics fluid temperature of 40° C or more. Otherwise,<br />

the hydraulics fluid is constantly heated up by the cooling water of the Diesel engine and<br />

unnecessarily heated up.<br />

102<br />

Art. Nr. 355172


6.7 Diesel Engine<br />

6.7.1 Starting the engine<br />

103<br />

6 <strong>Operation</strong><br />

If the driving pedal is not in resting position during starting, then for safety reasons,<br />

driving power is blocked. The block is upheld for so longe until the driving pedal is<br />

completely released and pressed again.<br />

The engine is started and shut off using the ignition lock.<br />

The ignition lock has four switching positions:<br />

Position 0: Switch off engine/ignition off – key may be pulled off<br />

Let the engine idle for a short time before shutting off the engine.<br />

If the engine is shut off at too high speed, then the turbocharger will<br />

run on after the oil pressure has already dropped.<br />

This leads to lack of lubricant and therefore to unnecessary bearing<br />

wear at the quickly rotating turbocharger.<br />

Position I: Ignition on, engine is ready for starting<br />

Position II: Not connected<br />

Position III: Starting the engine<br />

The green color in the display field for the Diesel engine indicates the starting process.<br />

After each start of the engine, the fan of the radiator system is automatically reversed for<br />

a short time. This frees the radiator system of loose dirt (leaves, etc.).<br />

Attention! The use of chemical starting aids (for instance Startpilot, etc.) is expressly<br />

prohibited, since this may lead to injuries and to damage to the engine.<br />

If the engine should not start immediately, then the electronic system switches off the<br />

starter after a certain period of time. Then, wait at least 2 minutes until the next try to<br />

start, so that the starter can sufficiently cool down.<br />

If the engine cannot be started due to a starting block, then the following warning icon is<br />

displayed on the color terminal: .<br />

This warning icon and one of the following alternately flash on the color terminal:<br />

Close engine Swing up rear<br />

housing cover platform wall<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.7.2 Starting the engine without booting up the terminal<br />

When the parking brake is engaged (toggle switch pressed to the rear), then the engine<br />

may also be shut off by pressing the EMERGENCY-OFF switch. For this method, the<br />

color terminal continues to operate. After resetting the „EMERGENCY-OFF“ switch, the<br />

engine may be started new.<br />

6.7.3 Engine speed adjustment<br />

6.7.3.1 Operating mode „rabbit“<br />

On the right joystick, it is possible to switch, by sliding the X-Y switch (1) to<br />

the right/left, between driving with manual engine speed control (to the<br />

left)<br />

and automotive driving (to the right). To switch, the X-Y switch (1) must<br />

be slid into the respective direction and shortly held in this position.<br />

1<br />

14<br />

Automatic engine speed adjustment (automotive driving)<br />

During automotive driving (display on the color terminal: ), adjustment of the engine<br />

speed is exclusively performed using the driving pedal = gas pedal.<br />

<strong>Manual</strong> adjustment of the engine speed<br />

In the operating mode rabbit, with manual engine speed adjustment,<br />

adjusting of the engine speed is only performed using the manual<br />

potentiometer (14). The highest engine speed is at about 1500 min -1 . This<br />

variant is best suited for driving on uneven track.<br />

104


6.7.3.2 Operating mode „turtle“<br />

16<br />

17<br />

Engine speed control is manually performed using the gas (17) / gas key<br />

(16) on the left joystick.<br />

Shortly press the gas key: The engine speed increases by 25 min -1 each<br />

time it is pressed.<br />

Shortly press the gas key: The engine speed reduces by 25 min -1 each<br />

time it is pressed.<br />

Press the gas / gas key and keep it pressed: the speed changes for so<br />

long until you release the key.<br />

Operating mode „turtle“ machine drive On/Off<br />

After switching off the machine drive, the speed of the Diesel engine is<br />

automatically set to the value, which had been set before last switching off<br />

of the machine drive. After switching off of the machine drive, the engine<br />

speed is automatically reduced to idling speed (exception „recharging“ see<br />

page 147).<br />

Actual<br />

engine<br />

speed<br />

6.8 Switching Driving Power<br />

<strong>euro</strong>-Maus3 may be operated in the following operating modes:<br />

„Turtle I“ = loading operation<br />

„Turtle II“ = This operating mode may be switched on,<br />

but it does not make sense in practical operation,<br />

since all-wheel drive is switched off.<br />

„Rabbit I“ = Slow driving on roads with all-wheel drive<br />

„Rabbit II“ = Quick driving on roads witout all-wheel drive<br />

105<br />

Set engine speed<br />

6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.8.1 Switching gears<br />

The manual transmission is used to switch between the operating modes „turtle“ and<br />

„rabbit“ as well as between gear I and gear II. The color terminal displays the icon of the<br />

currently active combination of operating mode and gear. In the operating mode turtle,<br />

the climbing ladder is swung out and the warning signs on the pile pickup swing up.<br />

Driving speeds:<br />

Operating mode „turtle I“: 0 - 0.7 km/h<br />

Operating mode „rabbit I“: 0 - 10.3 km/h<br />

Operating mode „rabbit II“: 0 - 20.0 km/h (respectively 25 km/h)<br />

Switching process<br />

– Engage the parking brake.<br />

– Set the engine to idling speed.<br />

– Select the desired combination of operating mode and gear using the keys (1) and<br />

(2) of the operating section:<br />

Key (1) „turtle“/„rabbit“);<br />

Key (2) gear I/II.<br />

LED 1 2 LED<br />

– When switching to a different operating mode, a sound may be heard („clack“).<br />

– If one of the two key LEDs and the icon on the color terminal are flashing after<br />

switching, then the transmission is under tension. Release the parking brake and<br />

drive very carefully (!) and very slowly forward or backward. The transmission<br />

will now audibly switch. Inspite of this, check if the icon for the selected operating<br />

mode is visible on the color terminal and if the key LED of the operating section is<br />

constantly lit.<br />

Remark! Danger of severe damage to the transmission.<br />

In any case, observe the hints given above! Transmission damage caused by non-<br />

compliance or imprecise compliance is excluded from any guarantee or warranty!<br />

The keys for switching between the operating modes may ONLY be used if the machine<br />

is standing completely still (0.0 km/h). In addition, sufficient pressure must be available<br />

in the compressed air system. This is the case, when the icon is no longer displayed<br />

on the color terminal. If you do not observe this hint, then the manual transmission may<br />

be destroyed.<br />

106


107<br />

6 <strong>Operation</strong><br />

If it should not be possible to move the vehicle, then the cause for this is displayed on<br />

the color terminal:<br />

Ignition key is in the position „start engine ”.<br />

Please release the parking brake by pressing the toggle switch<br />

„parking brake“.<br />

Please release the foot brake.<br />

Reservoir pressure of the compressed<br />

air brake too low!<br />

Release pressure of the parking brake<br />

too low!!<br />

Fault of the driving pedal sensors!<br />

6.8.2 Switching process differential lock<br />

A lit LED (light emitting diode) within the respective key and an icon on the color terminal<br />

show which differential lock is switched on.<br />

LED<br />

3<br />

LED<br />

call in customer service!<br />

A flashing LED shows that the corresponding switching process cannot be executed,<br />

either because the axle is locked up or the engaging position has not been reached.<br />

Remedy: move steering back and forth in the central range or drive forward and<br />

backward for a short stretch.<br />

It is not possible to lock the rear axle alone. The lock of the rear axle can only take<br />

effect, if the differential lock of the front axle has been switched on. If, on the other hand,<br />

the differential lock for the front axle is switched off, then automatically the differential<br />

lock for the rear axle is switched off as well.<br />

Only switch the differential locks when the machine is standing still (0.0 km/h) and the<br />

wheels on the axles are approximately aligned straight!<br />

Only switch on the differential locks if they are actually needed. For normal pile ground<br />

as well as correctly set pickup depth and pickup relief, no use of the differential locks is<br />

required.<br />

4<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

Remark! If traction of the machine should be insufficient under extreme conditions, then<br />

at first, only switch on the differential lock of the front axle. The rear axle lock may only<br />

be used if continuation of work would otherwise be impossible. To avoid damage to the<br />

axle, the wheels must in any case be steered to about straight alignment.<br />

The rear axle is subject to uneven loads during the loading process. The wheel on the<br />

side of the truck conveyor swung out has to bear up to 80 % of the rear axle load during<br />

loading. The greatest share of the overall feed pressure is assumed by this one rear<br />

wheel with the large wheel load. The power transmitting components (differential drive,<br />

jointed shaft, planetary gears, etc.) are subject to very heavy strain. Never steer the<br />

wheels with a too great angle with the differential lock engaged! When you increase<br />

the steering angle too much, one of the following warning icons is displayed on the<br />

color terminal. In addition, a warning signal sounds. Before switching on, always set the<br />

wheels straight!<br />

If the front or rear axle has a too great steering angle, then the differential lock cannot be<br />

engaged.<br />

Remark!.The rear axle is only able to perform limited steering tasks with the differential<br />

lock engaged. If larger steering movements of the rear axle are required, then first shut<br />

off the differential lock of the rear axle.<br />

When switching to operating mode rabbit II, the differential locks are automatically<br />

switched off.<br />

If the differential lock should be accidentally switched on while driving, the following<br />

warning icon is displayed on the color terminal: .<br />

To switch on the differential lock, completely release the driving pedal and stop the<br />

machine.<br />

108


6.9 Driving<br />

109<br />

6 <strong>Operation</strong><br />

Hydrostatic drives are deemed very safe. The following measure additionally increases<br />

this safety, if there should be any operating faults of the drive. If, when releasing the<br />

driving pedal, the machine should neither reduce driving speed nor stand still, then a<br />

safety circuit is activated by engaging the parking brake.<br />

2.<br />

This safety circuit defeats the standard control behaviour of the hydraulics system and<br />

opens a safety valve quickly shutting off driving power.<br />

If, in the extremely improbable case of failure of all safety devices, the machine should<br />

still not stop, then shut off the Diesel engine as quickly as possible.<br />

Danger!.Danger of severe rear-end collisions with injuries hazardous to life or even<br />

deadly when engaging the parking brake or shutting off the Diesel engine, while the<br />

machine is driving. Therefore, take this EMERGENCY-STOP measure only in extreme<br />

emergencies and try to warn following traffic by pressing the foot brake pedal several<br />

times and switching on the hazard warning system.<br />

1.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.9.1 Driving on roads (operating mode rabbit)<br />

In the operating mode rabbit, the electronic control relieves the driver as well as the<br />

environment by means of automotive driving.<br />

Automotive driving means that the driving speed is set by pressing on the driving pedal.<br />

The electronics controls the hydrostatic drive and the Diesel engine so that the set<br />

speed is always driven at the lowest possible engine speed, independent of the fact,<br />

whether you are driving uphill or downhill.<br />

You control the driving speed of the machine using the driving pedal. The further you<br />

push down on the pedal, the faster the machine drives. When you completely release<br />

the pedal, the machine strongly brakes down due to the hydrostatic drive. If the vehicle,<br />

after switching to operating mode „rabbit II“, should only be moving very slowly, then the<br />

color terminal will display the following icon .<br />

At this time, at the latest, swing the fuel tank in central position and lock it in this position.<br />

6.9.1.1 Switching driving direction<br />

Foot switch driving direction::<br />

NOT PRESSED Driving direction „forward“<br />

PRESSED Driving direction „reverse“<br />

Foot switch driving<br />

direction<br />

110<br />

Driving pedal


111<br />

6 <strong>Operation</strong><br />

Only in operatin gmode „rabbit II“, the driving pedal must be released completely for<br />

switching to driving in reverse. Wait, until the machine is standing completely still<br />

(0.0 km/h). Only then may the „foot switch driving direction“ be pressed and held in this<br />

position. When the driving pedal is now pressed, the machine will drive in reverse.<br />

In operating mode „rabbit I“, the driving direction may be changed at low driving speed.<br />

A warning signal always sounds when driving backward, which draws the attention<br />

of other people to backward movement. Simultaneously, both backup lamps are<br />

automatically switched on.<br />

6.9.1.2 Cruise control<br />

<strong>euro</strong>-Maus3 is fitted with cruise control to relieve the driver. This enables control of the<br />

driving speed, only in operating mode „rabbit II“, either by pressing the driving pedal or<br />

by switching on cruise control. Especially when driving for longer stretches, this relieves<br />

the driver.<br />

Switching on cruise control<br />

Cruise control may only be switched on if the following conditions are met:<br />

– Operating mode „rabbit II“ switched on<br />

– Left joystick console swung down<br />

– Driving speed greater than 10 km/h.<br />

.e-M3/e-BM3 Rop.Art. 355250<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

Input the desired speed using the driving pedal. When this speed has been reached,<br />

press the right joystick all the way forward and hold it in this position, until the display<br />

field for the driving speed turns green on the color terminal.<br />

Cruise control takes over the speed set by the driving pedal at the time at which the<br />

joystick has been moved forward.<br />

This speed is not necessarily the currently driven speed.<br />

Example: the currently driven speed amounts to 11 km/h. The driver quickly presses the<br />

driving pedal to the stop – the driving pedal sets maximum speed for the machine.<br />

The machine begins to accelerate. In this moment, cruise control is switched on.<br />

Cruise control takes over the speed set by the driving pedal (= maximum speed).<br />

If you want to increase speed for a short time while driving, you can override<br />

cruise control at any time by pressing on the driving pedal. If you drive faster than<br />

set for cruise control, then cruise control is switched on, but the effect can only<br />

be found when you reduce pressure on the driving pedal. When you release the<br />

driving pedal, the machine again drives on at the speed set for cruise control.<br />

Adjusting cruise control speed<br />

When cruise control is switched on and the driving pedal is released, then driving speed<br />

of <strong>euro</strong>-Maus3 may be changed as follows:<br />

– Turn the rotating selector switch to position 10.<br />

– The driving speed may be modified in steps of about 1.0 km/h by pressing the or<br />

key.<br />

112


Switching off cruise control<br />

113<br />

6 <strong>Operation</strong><br />

Before switching off cruise control, you should always press down the driving pedal<br />

so far until you take over the speed driven under cruise control using the pedal. This<br />

prevents sudden braking of the machine when switching off cruise control.<br />

To switch off cruise control, shortly pull the right joystick completely back. Further options<br />

for switching off cruise control are:<br />

Pressing the footbrake pedal or pressing the footswitch driving direction.<br />

6.9.2 Quick description: operating cruise control<br />

Start engine.<br />

Select operating mode „rabbit II“ .<br />

Drive faster than 10 km/h.<br />

Push right joystick forward all the way until<br />

the field for display of the driving speed<br />

turns green .<br />

Cruise control is switched off by pulling back the right joystick,<br />

pressing the footbrake pedal, pressing on the „footswitch driving direction“, pressing<br />

the EMERGENCY-OFF button, engaging the parking brake or raising the left joystick<br />

console.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.9.3 Driving in operating mode turtle (loading)<br />

In operating mode turtle, driving power is operated almost exclusively using the keys (2)<br />

and (3) and the potentiometer (14) on the right joystick.<br />

If driving forward is activated using key (2), then the terminal displays the icon .<br />

This key is used to switch on driving forward. Pressing this key again stops driving<br />

power.<br />

Switching off machine drive also switches off driving power.<br />

The driving speed (= feed speed) for loading operation is set using the manual<br />

potentiometer (14).<br />

The speed set may be overridden up to maximum speed using the driving pedal. This<br />

function enables quicker driving to the beet pile.<br />

If reverse driving is active using the key (3), then the terminal displays the icon .<br />

This key is used to switch on driving power reverse for so long as the key is kept<br />

pressed. If <strong>euro</strong>-Maus3 is driving forward during loading, then you can stop this<br />

movement by pressing this key. While driving in reverse, speed control using the manual<br />

potentiometer is not possible. The machine always drives backwards at the maximum<br />

possible speed.<br />

In addition, driving power may be stopped as follows:<br />

– Pressing the EMERGENCY-OFF button<br />

– Shortly pressing the footswitch driving direction<br />

2<br />

3<br />

14<br />

– Engaging of the parking brake.<br />

114


6.10 Braking System<br />

6.10.1 Operating brake<br />

115<br />

6 <strong>Operation</strong><br />

The braking system of <strong>euro</strong>-Maus3 is designed as a pneumatically operated dry drum<br />

brake. For safety reasons, it consists of two independent braking circuits:<br />

The operating brake operated using the brake pedal on the cabin floor, and the parking<br />

brake, which is operated using the toggle switch.<br />

Danger! Hazard to life in case of defective brakes. Check functioning of the brakes<br />

before each drive! The braking systems must regularly be thoroughly checked! Setting<br />

and repair work on the brakes may only be performed by trained specialist personnel.<br />

The operating brake is activated using the left pedal (1) on the cabin floor. It takes<br />

effect on the front wheels and only works if there is enough pressure in the compressed<br />

air system. If an optional additional axle is present, then this is also braked down. If<br />

the operating brake should not be working well enough (for instance too low reservoir<br />

pressure), then the following warning icon is displayed on the color terminal .<br />

Driving pedal<br />

Brake pedal (1)<br />

Danger! When a warning icon is displayed on the color terminal referring to problems<br />

with the braking system, there is the greatest hazard to life for the driver and people<br />

standing by as well as other participants in traffic. <strong>Operation</strong> of <strong>euro</strong>-Maus3.must<br />

ceased immediately in this case. The machine must be parked in such a manner that<br />

nobody is endangered or impaired. The machine must be secured against rolling away<br />

by engaging the parking brake. It may only be moved when the cause for the fault of the<br />

brake has been remedied by specialist personnel and the machine has been released<br />

for operation by the corresponding specialist personnel.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

Constant throttle brake<br />

The operating brake is needed only in exceptional cases. Normally, braking using the<br />

hydrostatic drive is sufficient. The Diesel engine is fitted with a constant throttle brake.<br />

This brake automatically activates itself when releasing the driving pedal or when<br />

driving downhill on steep slopes – when the set engine speed is greatly exceeded – and<br />

increases the braking effect of the hydrostatic drive.<br />

The color orange iin the display zone for the Diesel engine indicates the active constant<br />

throttle brake.<br />

6.10.2 Parking brake<br />

<strong>Operation</strong> of the parking brake is performed using the toggle switch on the console. The<br />

parking brake only takes effect on the front wheels. Even if the ignition is switched off<br />

and the pneumatics system is pressureless, the parking brake is automatically engaged<br />

and takes effect.<br />

For safety reasons, the parking brake is only released if there is sufficient pressure in the<br />

pneumatics system. If the releasepressure of the parking brake is too low, then the color<br />

terminal displays the following warning icon .<br />

If the parking brake is engaged, then the color terminal displays the following icon<br />

. For as long as the parking brake is engaged, pressure on the driving pedal remains<br />

without effect. In emergencies, the spring-loaded cylinders of the parking brake may be<br />

manually mechanically released. You can find instructions for this in Chapter 8 „Faults<br />

and Remedies“.<br />

6.10.3 Automatic parking brake (only in operating mode rabbit)<br />

116<br />

3<br />

When the machine is standing still (driving pedal released for several seconds), then<br />

the parking brake is automatically engaged. As soon as the automatic parking brake is<br />

active, the color terminal displays the following icon: .<br />

This avoids inadvertent rolling away of the machine, especially on sloped ground.<br />

If the driving pedal is pressed again, then the automatic parking brake is released.


6.11 Steering<br />

The front axle is generally steered using the steering wheel.<br />

active<br />

steering mode<br />

6.11.1 Main steering switch<br />

117<br />

6 <strong>Operation</strong><br />

Position indication<br />

front axle steering<br />

Position indication<br />

rear axle steering<br />

The main steering switch (1) is used to block steering of the rear axle. If the main<br />

steering switch is unlocked, then the rear axle may be steered.<br />

Danger! Hazard of deadly injuries when driving with unlocked main steering switch<br />

and driving speeds of in excess of 8 km/h. This may lead to uncontrolled swinging<br />

movements of the vehicle. This may seriously endanger or even cause deadly injuries<br />

to people. The main steering switch may therefore only be unlocked for driving through<br />

very tight curves, at low speed (below 8 km/h) and only as long as indispensably<br />

required.<br />

If operating faults occur at higher speeds than 8 km/h, or if hydraulics or electrical<br />

components fail, then driving safety is no longer ensured. Severe accidents would be the<br />

consequence.<br />

1<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

12<br />

6.11.2 Rear axle steering in operating mode Rabbit<br />

6.11.2.1 <strong>Manual</strong> rear axle steering<br />

In operating mode „rabbit“, the rear axle may be steered independent of the<br />

front axle by moving the right joystick right/left. For this purpose, the main<br />

steering switch must be unlocked. When driving in operating mode rabbit<br />

at a speed of more than 8 km/h, the main steering switch must generally be<br />

locked.<br />

6.11.2.2 All-wheel steering<br />

13<br />

All-wheel steering may be used to be able to simultaneously steer the rear and front<br />

axles without further activities of the driver. For this purpose, the rear axle steers in<br />

contrary to the front axle. This steering type facilitates navigating of the machine for<br />

drivers with less experience.<br />

The following conditions must be met for switching on all-wheel steering:<br />

– Operating mode rabbit switched on<br />

– Main steering switch unlocked<br />

– Speed at least 0.5 km/h and at maximum 8.0 km/h<br />

For activating, press the keys (12) and (13) on the right joystick simultaneously, until the<br />

color terminal displays the following icon .<br />

118<br />

.e-M3/e-BM3 Rop.Art. 355250<br />

When all-wheel steering is activated, then the speed of <strong>euro</strong>-Maus3 is limited to about<br />

8.0 km/h. All-wheel steering may be switched off either by moving the right joystick<br />

right/left, by activating straight setting of the rear axle, or by locking the main steering<br />

switch.


11<br />

6.11.2.3 Setting the rear axle to straight position<br />

– Switch on operating mode „rabbit“.<br />

– Drive slowly (below 8 km/h).<br />

– Unlock main steering switch.<br />

– Drive at least 0.5 km/h and shortly press the multi-key (11) on the joystick.<br />

119<br />

6 <strong>Operation</strong><br />

Then, the rear axle steers in straight position. The color terminal displays the following<br />

icon .<br />

Then, the main steering switch must IMMEDIATELY locked again.<br />

If the rear axle is not locked in straight position, then during driving in operating mode<br />

„rabbit II“, the color terminal displays the following warning icon .<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.11.2.4 Quick description: steering in operating mode „rabbit“<br />

11<br />

12<br />

13<br />

The rear axle may be steered to<br />

the left (L) or right (R) using the<br />

joystick.<br />

Drive at least 0.5 km/h.<br />

Press multi-key (11).<br />

Rear wheels are set straight and<br />

remain in this position.<br />

Drive slowly (below 8 km/h).<br />

Unlock main steering switch.<br />

Important: lock main steering switch.<br />

120<br />

Start engine.<br />

Select operating mode „rabbit“ .<br />

L R<br />

If the rear axle is not in straight position or the main steering switch is not locked,<br />

then corresponding warning messages are displayed on the color terminal:<br />

or<br />

Activate all-wheel steering. For this<br />

purose, press keys (12) and (13)<br />

simultaneously while driving, until the color<br />

terminal displays the icon .


6.11.3 Steering in operating mode „turtle“ (loading operation)<br />

121<br />

6 <strong>Operation</strong><br />

During loading operation, the rear axle is steered using the toggle switch (2) in switch<br />

section 4. Condition for this is that the main steering switch is unlocked. There are the<br />

following limitations for this type of steering:<br />

– The steering angle is very limited, when the differential lock is activated.<br />

– The rear axle should be steered as little as possible, to avoid excess wear of the<br />

cardan joints.<br />

6.12 Loading <strong>Operation</strong><br />

2<br />

Danger! There is an acute hazard to life for all people staying in the hazard zone during<br />

the loading process! No people may be staying in the hazard zone during loading. When<br />

people close on the hazard zone, the machine must be immediately immobilized and the<br />

loading process must be interrupted. The people must be strictly instructed to leave the<br />

hazard zone. The loading process may only be continued when all people are located<br />

outside of the hazard zone. If these people do not leave inspite of being requested to do<br />

so, then the loading process may neither be begun nor continued.<br />

6.12.1 Safety circuit for loading operation of <strong>euro</strong>-Maus3<br />

<strong>euro</strong>-Maus3 is fitted with a protective safety circuit. This may neither be bridged nor<br />

defeated. The circuit is the result of accident analyses and is to contribute to further<br />

increasing the safety for people in especially critical phases of the loading process.<br />

Simultaneously, the driver is always reminded of his personal responsibility.<br />

Anyone who tries to manipulate this circuit in any manner is completely<br />

responsible for his activities, knowingly violates safety requirements and is acting<br />

gross negligently. He is fully responsible for all consequences and also liable!<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

Safety circuit when switching on the machine drive<br />

The „foot switch line of sight forward“ must indispensably be pressed, when you switch<br />

on the machine drive. This forces you, when switching on the machine drive, to look<br />

forward and to convince yourself, that there are really no people staying in the hazard<br />

zone of the pickup.<br />

This circuit has a cooling off period. If you shut down the machine drive only for a short<br />

time (less than 30 seconds for truck change without waiting period), then you may restart<br />

the machine drive without pressing the „foot switch line of sight forward“ again.<br />

If the cooling off period has expired, then the following indication is displayed on the<br />

color terminal:<br />

Safety circuit for residual beet pickup<br />

Pile pickup up<br />

As long as the pile pickup is lifted up sufficiently high, the indication for the pile pickup<br />

on the color terminal is displayed highlighted in green. The green color indicates, that<br />

the safety circuit has no effect during loading. As long as a certain minimum height is not<br />

undercut, the pile pickup may be used without restrictions (for instance in a half-frozen<br />

pile).<br />

Pile pickup down<br />

If the height indication for the pile pickup is displayed highlighted in orange, because<br />

the pile pickup is lowered, then the telescopic arm may only be moved left/right and<br />

up/down without additional measures. When the telescopic arm is to be extended or<br />

retracted, the driver‘s seat must be turned to the front and the „foot switch line of sight<br />

forward“ on the cabin floor must be pressed.<br />

This „foot switch line of sight forward“ must always be pressed and held, when residual<br />

beets are picked up. When this foot switch is released, all rollers of the pickup stop.<br />

They can only be switched on using the right joystick if the driver‘s seat is rotated fully<br />

forward and the „foot switch line of sight forward“ is pressed.<br />

122<br />

Height indication pile pickup<br />

Foot switch<br />

line of sight forward


123<br />

6 <strong>Operation</strong><br />

If the rollers of pickup are rotating and the pile pickup is lowered below the height limit<br />

already mentioned, then you have a little time to rotate the driver‘s seat forward and<br />

press the „foot switch line of sight forward“. The safety circuit only takes effect after a<br />

couple of seconds. You are informed about expiry of this cooling-off period by a visual<br />

indication on the color terminal and an acoustic warning signal.<br />

If the „foot switch line of sight forward“ is permanently pressed (for instance electrically<br />

bridged or constantly loaded mechanically), then the machine drive cannot be switched<br />

on any more.<br />

6.12.2 Preparations for loading<br />

Before starting work, familiarize yourself with the local ground and landscape conditions.<br />

Even before loading, check whether the pile conforms to the requirements of the pile<br />

design plan in the appendix. Especially make sure that the pile is not wider than 8.5 m<br />

in any place. If this should be the case, make sure that the pile is as evenly as possible<br />

brought to a maximum width of 8 m.<br />

Ideal pile width Beet losses by exceeding the max. admissible<br />

pile width<br />

IInform people present before starting to work about the most important safety<br />

regulations, especially about the hazard zones and about the required safety distances.<br />

Have these instructions given confirmed by signature on the form in the appendix (make<br />

a copy before completing the form!).<br />

Indispensably point out to all people present that you are obliged to immediately stop the<br />

machine and immediately cease work if a person enters the hazard zones or does not<br />

exit them upon request.<br />

Drive to a distance of about 1 meter to the beet pile.<br />

Switch on operating mode turtle I (see page 106).<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.12.3 Switching on swing axle support rear axle<br />

– Swing switch (3) down and thereby switch on swing axle support for the rear axle.<br />

Indication swing axle support on<br />

6.12.4 Swing out pickup<br />

– Remove securing chains for the pickup and insert them into the hooks on the vehicle<br />

frame provided for this purpose.<br />

Attention! Danger of severe injuries due to chain links flung away. Do not forget, before<br />

swinging out pickup, to remove the safety chains on the lateral parts of pickup. During<br />

hydraulic lowering of the pickup, the links of the safety chains are busted with great<br />

force. Chain lings flung away may cause severest injuries to bystanders.<br />

– Slightly extend the telescopic tube of the pile pickup and raise the pile pickup as<br />

much as possible.<br />

124<br />

3


5<br />

– Swing out both lateral pickup parts horizontally.<br />

For this purpose: move X-Y key (5) to the<br />

FRONT LEFT swing out lateral pickup part left<br />

FRONT RIGHT swing out lateral pickup part right<br />

125<br />

6 <strong>Operation</strong><br />

For swinging out faster, press the multi-key (11) and keep it pressed. If you then<br />

slide the X-Y key (5) to the front left or right, then both lateral pickup parts are<br />

simultaneously swung out. When both lateral pickup parts are completely swung out<br />

and this is not displayed on the color terminal, please check the control rods of the<br />

limit switches (see page 223).<br />

11<br />

– Turn rotating selector switch to position 8 and swing up the swivel plates all the way<br />

by pressing the key. When swinging up the swivel plates, the supporting feet are<br />

simultaneously extended all the way.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

Swinging up the swivel plates is only possible, when the color terminal shows that<br />

both lateral pickup parts are swung out. This is indicated as follows on the color<br />

terminal:<br />

Both lateral parts completely swung out<br />

Only the left lateral part is swung out<br />

Only the right lateral part is swung out<br />

The relief pressure of the lateral pickup parts is displayed even if the lateral part is not<br />

completely swung out.<br />

126


6.12.4.1 Move pickup to operating depth<br />

127<br />

6 <strong>Operation</strong><br />

– Slide the X-Y key (4) diagonally to forward right and retract the right supporting foot<br />

to the estimated operating height of the pickup.<br />

– Slide the X-Y key (4) diagonally to forward left and retract the left supporting foot to<br />

the estimated operating height of the pickup.<br />

1<br />

For retracting quicker, press the multi-key (11) and keep it pressed. If you now<br />

slide the X-Y key (4) forward to the left or right, then both supporting feet are<br />

simultaneously retracted.<br />

– Check again, whether both safety chains have been removed.<br />

– Press X-Y key (1) forward and lower the complete pickup to the ground. This makes<br />

it almost impossible to get the machine to tip over during swing out of the truck<br />

conveyor.<br />

Remark! Danger of damage to the pickup. In any case, avoid pressing pickup so much<br />

into the ground when lowering it, so that the front axle is unloaded. This may damage<br />

the pickup.<br />

Lowering of the pickup is only possible when the color terminal indicates that both<br />

lateral pickup parts are swung out.<br />

6.12.5 Swing out truck conveyor<br />

4<br />

Danger!.Staying under the truck conveyor swung out is strictly prohibited. There is<br />

hazard to life! The machine operator must make sure that no people are staying within<br />

the swiveling range of the truck conveyor.<br />

In any case, take care of power lines within the swiveling range of the truck conveyor.<br />

Always keep a sufficient safety distance to these lines. This is always determined by the<br />

type of power line and must be enquired with the competent power company.<br />

All people staying in the sector of the transporting vehicle have the duty of wearing an<br />

approved hard hat. In case of operating error of the truck conveyor, sugar beets may fall<br />

off the transporting vehicle and severely injure bystanders.<br />

11<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

The recleaner is pneumatically swung into the truck conveyor when swinging out the<br />

truck conveyor. Swinging out the truck conveyor may only be begun when the icon for<br />

reservoir pressure warning is no longer displayed on the color terminal. As long as<br />

this warning is displayed on the color terminal, the truck conveyor may not be rotated,<br />

because otherwise the recleaner may be damaged!<br />

When rotating the truck conveyor from the position „driving on roads“ to the position<br />

„loading operation“, make sure that the recleaner moves and also swings out. If this is<br />

not the case, then immediately stop swinging out and remedy the malfunction.<br />

Remark!.For loading, the truck conveyor must be swung out at least so far that the<br />

recleaner may completely swing into the truck conveyor.<br />

– Press the multi-key (11) on the right joystick and keep it pressed; simultaneously,<br />

lightly pull back on the right joystick, to slightly (about 3 cm) lift the truck conveyor<br />

above the transport support.<br />

11<br />

– Release the multi-key (11). Then, carefully push the right joystick a little to the right,<br />

and by this, rotate the truck conveyor out of the vehicle profile.<br />

– Press the multi-key (11) on the right joystick and keep it pressed, simultaneously<br />

press the right joystick to the right and thereby swing up the truck conveyor<br />

articulation so far, until sufficient distance to the ground is reached.<br />

– Determine loading direction:<br />

– Preselect loading direction left/right. For this purpose, slide the X-Y key (1) in the<br />

corresponding direction and shortly hold it in the end position.<br />

Loading direction to the right The truck is standing on the right side of the machine.<br />

Loading direction to the left The truck is standing on the left side of the machine.<br />

If the X-Y key (1) is pressed to the left/right and shortly held, then the rotating<br />

direction of the large rotating assembly is reversed.<br />

128<br />

1


6.12.5.1 Loading direction to the right or left<br />

Loading direction left Loading direction right<br />

Pickup<br />

Joystick<br />

Driver‘s<br />

Pickup<br />

Driver‘s<br />

seat<br />

seat<br />

Joystick<br />

Infeed<br />

conveyor<br />

Swivel arm<br />

Truck conveyor Truck conveyor<br />

.e-M3/e-BM3 Rop.Art. 355250 .e-M3/e-BM3 Rop.Art. 355250<br />

129<br />

Infeed<br />

conveyor<br />

Swivel arm<br />

6 <strong>Operation</strong><br />

Danger! Assure yourself before any swivelling of the fuel tank, that there are no people<br />

staying in the swivel range of the tank. If a person is seized during swivelling of the tank<br />

and penned in, then this person may sustain deadly injuries!<br />

Hazard of deadly injuries, if the machine tips over. NEVER swing the fuel tank into the<br />

direction of the truck conveyor.<br />

When rotating the truck conveyor, make sure that you neither damage nor destroy the<br />

driver‘s cabin with the truck conveyor!<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

Loading direction to the right<br />

Unlock fuel tank/lock fuel tank<br />

Swivel fuel tank<br />

– Unlock fuel tank. For this purpose, move the rotating selector switch on the<br />

operating section to position 7 and unlock the fuel tank by pressing the key.<br />

– Move rotating selector switch on the operating section to position 6 and swivel the<br />

fuel tank so fahr to the left, until the weight of the truck conveyor is balanced out, by<br />

pressing the key.<br />

– Raise the truck conveyor so far using the right joystick and rotate it, until the drop<br />

point is positioned above the loading space of the transporting vehicle.<br />

– Set the height of the truck conveyor so, using the right joystick, that the articulation<br />

reaches level to lightly sloped upward over the loading space of the transporting<br />

vehicle.<br />

The fuel tank is always pointing in the direction opposite to the selected loading direction. The truck<br />

conveyor is always pointing in the selected loading direction.<br />

130


Loading direction to the left<br />

131<br />

6 <strong>Operation</strong><br />

– First, swivel the truck conveyor across the center of the vehicle to the left vehicle<br />

side.<br />

– Unlock the fuel tank, as described for the loading direction to the right, and then<br />

swing the fuel tank to the right.<br />

– Align the machine – if required – in parallel to the ground. For this purpose, set the<br />

4<br />

swing axle support for the rear axle accordingly using switch (4).<br />

Remark!.Always operate swing axle support carefully and „sensitively“. Make sure,<br />

that the tire tread of both rear wheels is always completely touching the ground, since<br />

one-sided load on the machine may cause severe damage to the tires or the rear axle.<br />

In addition, the forward feed force of the machine cannot be sufficiently used, inspite of<br />

engaged differential lock.<br />

6.12.6 Switching on machine drive<br />

Danger! There is acute hazard to life for all people staying in the hazard zone during<br />

the loading process! Before switching on the machine drive, therefore perform a diligent<br />

visual inspection to make sure that no people are staying in the hazard zone of the<br />

machine – especially within range of the pickup. No people may be staying in the hazard<br />

zone during loading. When people close on the hazard zone, the machine must be<br />

immediately immobilized and the loading operation must be interrupted. The people<br />

must be strictly instructed to leave the hazard zone. The loading process may only be<br />

begun or continued, when all people are at a sufficient distance to the machine. If these<br />

people do not leave inspite of being requested to do so, then the loading process may<br />

not be begun or continued.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

Foot switch line of<br />

sight forward<br />

Turn the driver‘s seat forward. First, emit a short but clear horn signal to point out to all<br />

bystanders that you are starting the machine drive and that sufficient distance to the<br />

machine must be observed immediately. Only switch on the machine drive, if there are<br />

no people staying in the hazard zones.<br />

– Shortly press the yellow button (6) on the right joystick. After expiry of the cooling-<br />

off period, the machine will only react if you simultaneously press the „foot switch<br />

line of sight forward“ using your foot and therefore confirm, that you have convinced<br />

yourself by visual inspection, that nobody is staying within the hazard zone.<br />

– Set the speed of the truck conveyor using the keys (16) Gas and (17) Gas as<br />

desired (recommendation: engine speed between 1200 and 1500 min -1 ).<br />

The cooling-off period has expired. To switch<br />

on the machine drive, please turn the driver‘s<br />

seat forward and press the foot switch line of<br />

sight forward.<br />

132<br />

16 17<br />

6<br />

Machine drive is switched on.


6.12.7 Relieving pickup/depth setting<br />

133<br />

6 <strong>Operation</strong><br />

– Depth guide of the pickup is assumed by the two supporting feet adjustable in<br />

height (except for external side of the two lateral parts of pickup) and the central part<br />

(central mark).<br />

– Drive into the beet pile (see pagees 148 and 316).<br />

– Set the pickup depth.<br />

The pickup should be set to such a height that the fingers of the pickup roller enter<br />

the ground for their whole length. This pickup depth is the optimum for preserving,<br />

power saving work.<br />

1 4 5<br />

The X-Y key (1) on the right joystick is used to set the height of the central pickup<br />

section and therefore also the height of the inside section of the lateral pickup parts.<br />

The X-Y key (4) is used to set the height of the supporting feet and therefore the<br />

height of the lateral pickup parts outside right and left.<br />

The pickup must be relieved so that it does not sink into the ground too deeply<br />

during loading. This means that the supporting feet are only required to partially<br />

carry the weight of the lateral pickup parts. The greatest share of the load is to be<br />

transferred to the chassis.<br />

Used for this are the hydraulics cylinders swing the lateral pickup parts in and out (X-<br />

Y key (5) on the right joystick). The lateral parts must be relieved so much by raising<br />

them until the support feet only apply little weight to the ground.<br />

left<br />

Pickup height in %<br />

relief pressure<br />

center<br />

right<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

To relieve the pickup, press the X-Y key (5) only shortly, until the desired relief pressure<br />

is achieved. The relief pressure is indicated on the color terminal. As a non-binding<br />

recommendation, it should be at least 80-100 bar. The relief pressure of the central part<br />

should be as high as possible, to put as much weight as possible on the front axle. This<br />

improves traction of the front tires and the drive train is more evenly loaded.<br />

If the pickup is correctly relieved, then you will see only shallow dragging tracks behind<br />

the two supporting feet in case of normal ground conditions.<br />

There is no guide value for the relief pressure of the central part. The display on the<br />

video display is decisive. You should see here that all beets are picked up and that no<br />

beet losses occur.<br />

The pickup height is displayed on the color terminal. This indication only serves as a<br />

rough orientation.<br />

Working too deep in the ground increases the power requirements of the pickup drive<br />

and substantially increases roller wear!<br />

The depth setting must constantly be adjusted to the ground profile and the load on the<br />

pickup by the beet weight.<br />

134


6.12.8 Clearing shields<br />

Extension plate<br />

135<br />

6 <strong>Operation</strong><br />

The clearing shields limit the pickup width and guide the beets on the side onto the<br />

pickup roller.<br />

During first operation of the machine, set the extension plates and wear rails to the<br />

correct height, so that the extension plates are just above the ground. The wear rails<br />

should just be touching the ground for their full length.<br />

During loading, especially watch out for frozen ground and built-up bulging soil in the<br />

course of the clearing shield. Do not drive through obstacles with the clearing shields!<br />

The swinging mechanism could be damaged.<br />

In case of overload, the piston rod of the swivel plate cylinder will break at the beginning<br />

of the thread. Such damage is excluded from any guarantee or warranty.<br />

Predetermined<br />

breaking point at the<br />

swivel plate cylinder<br />

Wear rail<br />

Clearing shield<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.12.9 Beet stretch<br />

This section of the color terminal symbolizes the flow of beets through the machine. This<br />

clearly presents all important operational parameters to you.<br />

A A<br />

B B<br />

C<br />

D<br />

The following general meaning is allocated to the individual colors and icons:<br />

white = section is switched off<br />

green = section is active, but not moving<br />

green with black arrows = section is moving in working direction<br />

grün with orange arrows = section is overloaded<br />

red = section is blocked<br />

orange with arrows = section is being reversed; it is moving<br />

136<br />

against working direction<br />

– Set the speed of the complete beet path as optimally as possible. Match the speeds<br />

of the pickup rollers to the 4-fold pinch rollers. Set the speeds of the pickup rollers<br />

and 4-fold pinch rollers to such a high speed, that the beets picked up are moved to<br />

the infeed conveyor without buildup. When selecting the speed, consider the degree<br />

of soiling of the beets. In case of very soiled beets and wet ground, you should<br />

select a higher speed. This means that the rollers should be running faster than<br />

under „good“ conditions.<br />

E


137<br />

6 <strong>Operation</strong><br />

– The feed speed is used to additionally take effect on the degree of cleaning:<br />

Low feed speed means thin beet cover on the rollers means all beets pass through a<br />

double cleaning path = greater cleaning effect.<br />

High feed speed means a thick beet cover on the rollers means only some of the<br />

beets pass through the double cleaning path = lower cleaning effect and more caring<br />

treatment of the beets.<br />

The greater your experience with <strong>euro</strong>-Maus3, the greater your precision at<br />

estimating the optimum speeds.<br />

6.12.9.1 Truck conveyor (in the drawing drive A)<br />

The truck conveyor moves the beets from the recleaner to the transporting vehicle. The<br />

beets should be treated as carefully as possible during this process.<br />

6<br />

This drive is switched on or off jointly with the machine drive using the key (6) on the<br />

right joystick. The speed depends on the speed of the Diesel engine. If this drive is<br />

stopped, then the drives B through E (see drawing) are also stopped. This drive cannot<br />

be reversed. For machines from model year 2007, the color terminal displays the<br />

following icon , if this drive is overloaded. If the truck conveyor is blocked, then the<br />

color terminal displays the following icon .<br />

If the truck conveyor is blocked, then the cause for this is either found in the section of<br />

the truck conveyor or in the section of the central mark. The oil motors for drive of the<br />

central mark and drive of the truck conveyor are connected „in series“. Therefore, if the<br />

central mark is blocked, then the oil motor for the truck conveyor is also not running.<br />

Usually, you will find the cause for blocks in the central mark.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

Fast speed truck conveyor<br />

Sometimes, a larger quantity of soil sticks to the conveyor – for instance when loading<br />

under unfavorable conditions. To be able to fling this soil off the conveyor, the truck<br />

conveyor is fitted with a fast speed. Then, the truck conveyor runs at double speed.<br />

You can switch on the fast speed using the toggle switch (1). For this purpose, move this<br />

switch upward and hold it for so long, until soiling is removed.<br />

To avoid unnecessary jerking loads on the strainer chain, the speed of the Diesel engine<br />

is shortly automatically reduced when switching on fast speed.<br />

Only switch on fast speed when the conveyor is empty and no beets are on the truck<br />

conveyor any more. The infeed conveyor is automatically stopped for as long as the<br />

truck conveyor is switched to fast speed.<br />

For as long as the truck conveyor runs at fast speed, the central mark is also running at<br />

double speed. If large quantities of dirt are sticking to the top of the central mark, then<br />

you should use fast speed only for a short time, because otherwise, the drive for the<br />

central mark may be damaged.<br />

6.12.10 Recleaner (in the drawing drive B)<br />

9<br />

1<br />

Depending on equipment, your <strong>euro</strong>-Maus3 has a strainer chain cleaner or an 8-fold<br />

pinch roller cleaner. This performs recleaning of the beets. The recleaner is located<br />

between the infeed conveyor and the truck conveyor. The drive for the recleaner is only<br />

operating when the machine drive has already been switched on. Press the key (9) on<br />

the right joystick once shortly to switch on the recleaner.<br />

If this key is pressed shortly again, then the drive for the recleaner is switched off. When<br />

this key is pressed and held pressed, then the rotating direction of the recleaner is<br />

reversed. Reversing of the recleaner is only possible for the version with a pinch roller<br />

cleaner.<br />

138


The speed of the strainer chain cleaner may be set to one of 10 stages.<br />

For this purpose, set the rotating selector switch to position 3.<br />

You can change the speed of the recleaner by pressing the / key.<br />

key = more agressive recleaning<br />

key = more caring recleaning<br />

139<br />

6 <strong>Operation</strong><br />

If the recleaner is designed as an 8-fold pinch roller cleaner, then the speed may be set<br />

in 11 stages (0-10 and additionally „MAX“).<br />

To treat the beets as caringly as possible, the speed of the recleaner should not be<br />

selected higher than necessary.<br />

The stage „MAX“ should only be used in case of extremely sticky soil. In this stage,<br />

the speed of the pinch roller cleaner is exclusively dependent on the speed of the<br />

Diesel engine. To switch on the stage „MAX“, press the key for so long until the color<br />

terminal displays the stage „MAX“.<br />

Strainer chain cleaner<br />

Warning!.Never climb onto the machine, as long as the drive is running. When the<br />

strainer chain is running, there is the hazard, that people are caught by the strainer<br />

chain on body parts or pieces of clothing. This can lead to severest injuries. Never touch<br />

the running strainer chain with your hands, with tools or objects, they could be dragged<br />

along by the strainer chain. This could lead to injuries to people and heavy damage to<br />

the machine. Before all work on the strainer chain, switch off the machine and secure it<br />

against starting (pull off the ignition key and carry it on your body).<br />

For the strainer chain cleaner, the cleaning effect is mainly achieved by the fact that the<br />

conveyor is moving faster forward than the beet flow. The beets start to roll and are so<br />

cleaned.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

If the warning limit of the strainer chain cleaner is exceeded, then the following icon is<br />

displayed on the color terminal .<br />

If the strainer chain is blocked, then the following icon is displayed on the color terminal<br />

.<br />

In case of blocks of the recleaner, the drives C / D / E are switched off.<br />

If the strainer chain is blocked by a foreign object, then this foreign object must be<br />

manually removed. For this purpose, always shut off the engine and secure it against<br />

inadvertent restarting (carry the ignition key on your body).<br />

8-fold pinch roller cleaner<br />

Danger!.Never climb onto the machine as long as the machine is running. When the<br />

pinch rollers are rotating, there is the hazard that people are caught on body parts or<br />

pieces of clothing and drawn in. This may lead to severest or deadly injuries. Body parts<br />

may be ripped off or crushed. Never touch the running pinch rollers with your hands, with<br />

tools or objects; these may be drawn in by the pinch rollers and destroyed. You could<br />

be severely injured and the machine heavily damaged. Switch off the machine before<br />

all work on the pinch roller cleaner and secure it against starting (pull off the ignition key<br />

and carry it on your body).<br />

140


141<br />

6 <strong>Operation</strong><br />

If the warning limit is exceeded at the pinch roller cleaner, then the following icon is<br />

displayed on the color terminal .<br />

If the pinch roller cleaner is blocked, then the following icon is displayed on the color<br />

terminal .<br />

In case of blocking of the pinch roller cleaner, the drives C / D / E are switched off.<br />

Blocking foreign objects may usually be removed from the pinch roller cleaner by<br />

reversing.<br />

6.12.10.1 Beet brake (only for 8-fold pinch roller cleaner)<br />

Beet brake<br />

For the roller cleaner, the cleaning effect is mainly achieved by the fact, that the rollers<br />

pull dirt and trimmings off downward.<br />

In addition, a swiveling beet brake is mounted. Braking bars mounted to the frame of the<br />

roller cleaner, pile up the beets. Due to this, the beets additional rub against each other<br />

and the cleaning effect is increased.<br />

Submersion of the braking bars into the beet flow and therefore the intensity of<br />

recleaning may be set at the operating section.<br />

For this purpose, set the rotating selector switch to position 4.<br />

You change the braking effect of the beet brake by pressing the / keys:<br />

key = The beet flow is braked more (more intense cleaning).<br />

key = The beet flow braked less (more caring cleaning).<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.12.11 Infeed conveyor (in the drawing drive C)<br />

The infeed conveyor moves the beets from the pickup to the recleaner. This drive is<br />

switched on or off using the key (10) on the right joystick.<br />

1<br />

You can switch on fast speed using the toggle switch (1). For this purpose, tip this switch<br />

downward and hold it for so long, until soiling is removed. The infeed conveyor then runs<br />

at double speed.<br />

To avoid unnecessary jerking loads on the infeed conveyor, when switching on the fast<br />

speed, the speed of the Diesel engine is shortly reduced.<br />

Only switch on fast speed, when the infeed conveyor is empty and no beets are on the<br />

infeed conveyor any more.<br />

10<br />

The infeed conveyor only runs when the recleaner is already running. The speed<br />

exclusively depends on the speed of the Diesel engine. If this drive is stopped, then the<br />

drives D and E also stop. This drive may not be reversed.<br />

Fast speed infeed conveyor<br />

Sometimes, a larger quantity of dirt sticks mainly in the section of the infeed and the<br />

deflection rollers of the infeed conveyor. This usually happens when loading under very<br />

unfavorable conditions. Therefore, the infeed conveyor is fitted with the fast speed<br />

gear 1 to be able to fling away this dirt from the strainer chain.<br />

142


143<br />

6 <strong>Operation</strong><br />

Shortly switch on fast speed, when in the section behind the deflecting roller a „roll“<br />

made of soil and dirt builds up. Fest speed removes this roll of dirt, as long as it does not<br />

exceed a specific size. Otherwise, the dirt must be manually removed.<br />

If the recleaner is blocked, then the infeed conveyor automatically shuts off. When the<br />

block of the recleaner is removed, then the infeed conveyor may be started again by<br />

shortly pressing on the key (10) on the right joystick.<br />

6.12.12 4-fold pinch rollers in the pickup (in the drawing drive D)<br />

8<br />

The 4-fold pinch rollers in the pickup move the beets to the center of the pickup<br />

onto the infeed conveyor. They are only then moving in feed direction, when the<br />

machine drive is switched on and the infeed conveyor is running.<br />

These pinch roller may also be reversed when the infeed conveyors stops.<br />

To switch on the 4-fold pinch rollers, shortly once press the key (8) on the right<br />

joystick.<br />

If this key is shortly pressed again, then the 4-fold pinch rollers stop.<br />

If this key is pressed and held pressed, then the rotating direction of the 4-fold pinch<br />

rollers is reversed.<br />

Move the rotating selector switch to position 2 to adjust the speed of the 4-fold<br />

pinch rollers.<br />

You can change the speed of the 4-fold pinch rollers by pressing the / keys.<br />

key = Increase speed (more agressive cleaning and transport).<br />

key = Reduce speed (more caring cleaning and transport).<br />

The speed of the 4-fold pinch rollers may be adjusted in 11 stages (0-10 and additionally<br />

„MAX“).<br />

To treat the beets are carefully as possilbe, the speed of the 4-fold pinch rollers should<br />

not be selected higher than necessary.<br />

The stage „MAX“ should be used only for extremely sticky soil. In this stage, the speed<br />

of the 4-fold pinch rollers only depends on the speed of the Diesel engine. To switch on<br />

the stage „MAX“, press the key for so long until the color terminal indicates the stage<br />

„MAX“.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

If the warning limit is exceeded for the 4-fold pinch rollers, then the following warning<br />

icon is displayed on the color terminal .<br />

If the 4-fold pinch rollers are blocked, then the color terminal displays the following<br />

warning icon .<br />

In case the 4-fold pinch rollers are blocked, drive E is switched off.<br />

6.12.13 Pickup rollers (in the drawing drive E)<br />

7<br />

The pickup rollers have different tasks. They pick up the beets from the ground and<br />

transfer them to the cleaner rollers. These forward the beets to the feed rollers and<br />

simultaneously clean the pig tails of the pickup rollers.<br />

The feed rollers preclean the beets and guide them to the outside, to achieve a<br />

greater cleaning effect due to the longer route.<br />

The pickup rollers always move in operating direction, when the 4-fold pinch rollers<br />

also move in operating direction.<br />

To switch on the pickup rollers, press the key (7) on the right joystick once shortly.<br />

When this key is shortly pressed again, the pickup rollers stop.<br />

If this key is pressed and held pressed, then the rotating direction of the pickup<br />

rollers is reversed.<br />

Move the rotating selector switch to position 1 to adjust the speed of the pickup<br />

rollers.<br />

You change the speed of the pickup rollers by pressing the / keys:<br />

key = Increase speed (pickup rollers rotate quicker).<br />

key = Decrease speed (pickup rollers rotate slower).<br />

The speed of the pickup rollers may be set in 11 stages (0-10 and additionally „MAX“).<br />

144


145<br />

6 <strong>Operation</strong><br />

To treat the beets as caringly as possibly, the speed of the pickup rollers should not be<br />

selected higher than necessary.<br />

The stage „MAX“ should only be used for extremely sticky soil. At this stage, the speed<br />

of the pickup rollers only depends on the speed of the Diesel engine. To switch on the<br />

stage „MAX“, press the key for so long until the color terminal indicates the stage<br />

„MAX“.<br />

If the warning limit is exceeded for the pickup rollers, then the color terminal displays the<br />

icon .<br />

If the pickup rollers are blocked, then the color terminal displays the icon .<br />

When the pickup rollers stop or are reversed, the driving power is also automatically<br />

stopped.<br />

6.12.14 Automatic reversing function for all roller drives<br />

You can set the automatic reversing function in the menu „basic settings“ (menu<br />

code 45) to „ON“ or „OFF“ for all roller drives. The automatic reversing function<br />

detects blocks on all roller drives of the beet route.<br />

When the system detects a block, then the automatic reversing function immediately<br />

stops all drives located in front of the blocked drive. Simultaneously, driving power is<br />

stopped. The automatic reversing function now several times reverses the rotating<br />

direction of the blocked drive (at maximum 5 times), until the block is overcome.<br />

Then, all drives – including driving power – are automatically switched on again.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

7<br />

8 9<br />

If it should not be possible, using the five tries by reversing, to release the block,<br />

then all drives are switched off.<br />

You can manually start additional tries by reversing using the keys (7), (8) or (9) on<br />

the right joystick. If this is also unsuccessful, then the cause for the block must be<br />

manually removed.<br />

For this purpose, switch off the machine and secure it against inadvertent starting.<br />

Warning! Danger of severe injuries when removing blocks of drives. In any case, before<br />

removing blocks, completely shut down the machine and secure it against starting by<br />

third parties. For this purpose, pull off the ignition key and lock the driver‘s cabin. Secure<br />

the ignition key against access by third parties!<br />

146


6.12.15 Loading transporting vehicle<br />

147<br />

6 <strong>Operation</strong><br />

When loading on transporting vehicles, in any case complay with the following hints for<br />

treating the beets as caringly as possible during loading.<br />

– In any case, avoid a change of direction of the beet flow of 90° or more between<br />

infeed conveyor, recleaner and truck conveyor!<br />

– Set up the overall beet cleaning system as caring as possible (lowest possible<br />

speeds).<br />

– Work at the lowest possible Diesel engine speed to save fuel and to protect the<br />

environment.<br />

– Avoid letting the beets fall into the loading compartment of the transporting vehicle<br />

deeper than indispensably required. For this purpose, lower the truck conveyor as<br />

far as possible and at start of loading, let the articulation go as deep as possible<br />

between the walls of the transporting vehicle.<br />

The function described below only exists if your machine is fitted with an 8-fold pinch<br />

roller cleaner, because it is substantially wider than a strainer chain cleaner.<br />

The truck conveyor is turned too far forward, if the color terminal displays the following<br />

icon . Due to this, the recleaner swings out of the input section of the truck conveyor,<br />

and part of the beets fall to the ground. To avoid these beet losses, the machine drive is<br />

completely shut off. In this case, swing the truck conveyor back a little and switch on the<br />

machine drive again.<br />

6.12.16 Continued loading function<br />

6<br />

If, after switching off the machine, you would like to place a slight quantity on the<br />

transportation vehicle,well dosed, then you may comfortably do this using the continued<br />

loading function.<br />

Continued loading is always performed using a low engine speed programmed fixed,<br />

which the driver cannot take influence on.<br />

For this purpose, press the key (6) machine drive ON/OFF on the right joystick and<br />

keep it pressed, until the desired beet volume has been loaded using continued loading.<br />

When you release the key, the drive stops.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.12.17 Pile pickup/picking up residual beets<br />

The pile pickup can be used to clear the end of a beet pile to the outsides of the pickup.<br />

The residual beet pickup (rubber shield) is fitted to the pile pickup. It is used to pull the<br />

last beets of a pile into the pickup. The pile pickup is controlled using the left joystick.<br />

Picking up residual beets<br />

Before picking up residual beets, we recommend lowering the pickup, at very slow<br />

speed, by a few centimeters, and picking up the residual beets as follows:<br />

– Always pull the residual beets onto the pickup rollers near the central mark.<br />

For this purpose, move the residual beet pickup in parallel to the tapered roller and<br />

wait for so long, until the beets have been transported to the infeed conveyor.<br />

– Then, also pull the beets lying on the outside across the tapered roller.<br />

With a little experience, you should have the residual beets picked up in four passes.<br />

Tip! When picking up residual beets, always work near the central mark and always from<br />

the center of the pickup to the outside.<br />

Remark! When loading, always make sure tha t no lumps of frozen beets reach the<br />

infeed conveyor, because this may lead to blocks of the beet flow and to damage on the<br />

strainer chains during loading.<br />

148<br />

.e-M3 Rop.Art. 355251


149<br />

6 <strong>Operation</strong><br />

If the color terminal displays the following icon , then the pile pickup must be turned<br />

to the center and raised before raising the pickup.<br />

If the pile pickup is to be swung far to the right or left, then the pickup must first be<br />

lowered. If the pickup is not lowered far enough, then the color terminal displays the<br />

following icon .<br />

Warning signs with limit lamps are fitted to the pile pickup. When you switch to operating<br />

mode turtle, these warning signs are automatically swung up.<br />

6.12.18 Change from working to transporting position<br />

When changing from working to transporting position, do not forget to first swing in the<br />

truck conveyor and only then swing in the pickup.<br />

Swinging in the truck conveyor<br />

When swinging in the truck conveyor, work very diligently and concentrated, since<br />

otherwise, you could severely damage the machine. <strong>ROPA</strong> therefore urgently<br />

recommends to call in a second, reliable person as flagman for the first tries. This<br />

person may in no case be staying in the rotating and swivelling range of the truck<br />

conveyor or the fuel tank.<br />

Danger! While swivelling the truck conveyor or the fuel tank, no people may be<br />

staying in the rotating and swivelling range of the machine. During all work with the<br />

truck conveyor, all people being near the machine must wear a suitable and approved<br />

hardhat.<br />

Perform the individual machine movements only in little steps and constantly convince<br />

yourself, that<br />

– no people are entering the hazard zone.<br />

– you do not damage the machine by uncontrolled or imprudent switching or steering<br />

actions.<br />

Proceed as follows for swinging in the truck conveyor:<br />

– In any case, swing in the articulation to the stop. For the standard truck conveyor,<br />

the apron only completely swings in, when the articulation has already reached the<br />

stop.<br />

- Raise the truck conveyor so far until it is just above the height of the lateral transport<br />

support.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

– Rotate the swivel arm so far, until, when looking back from the driver‘s cabin, the<br />

wall thickness (1) of the large rectangular tube is aligned to the center of<br />

the sight (2).<br />

2<br />

– Rotate the truck conveyor so far, until the stop screw (3) touches the impact plate<br />

of the swivel arm (the rotating movement automatically stops, when the stop screw<br />

reaches the impact plate provided). Check by visual control, whether the recleaner<br />

after contact to the incoming truck conveyor evenly moves out of the profile of the<br />

truck conveyor.<br />

1<br />

3<br />

Careful! During swivelling, always make sure that the truck conveyor is raised only as<br />

slightly as required above the lateral transport support and that the articulation is not<br />

able to damage the machine. The truck conveyor may in no case be lifted too high.<br />

150


– Lower the truck conveyor so far, until it rests on the support.<br />

– Swing the fuel tank to the center and lock it<br />

Fuel tank<br />

151<br />

6 <strong>Operation</strong><br />

Warning!.The tank must always be locked when driving on public roads. The machine<br />

may not be moved on roads or moved to another place, if the tank is not locked. Do not<br />

climb onto the fuel tank! No people may be staying in the swivel range of the tank during<br />

operation of the machine.<br />

– Set the rotating selector switch on the operating section to position 6 . You swivel the<br />

fuel tank by pressing the or key.<br />

key pressed = swivel tank to the left,<br />

key pressed = swivel tank to the right.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

1<br />

Chapter.6.<br />

<strong>Operation</strong><br />

– Set the rotating selector switch on the operating section to position 7. Now, press the<br />

key and keep it pressed for several seconds, so that the locking cam is pressed<br />

against the locking profile. Swivel the tank as exactly in the center as possible<br />

(visual control in the rearview mirrors).<br />

– Set the rotating selector switch to position 6 again and swivel the fuel tank slightly<br />

to the left and right by pressing the or key, until the locking cam discernably<br />

engages the groove in the locking profile. Then, the fuel tank can no longer be<br />

moved.<br />

Swing in pickup<br />

– Swing the pile pickup to the center and raise it as far as possible.<br />

– Raise the central part of the pickup as far as possible. For this purpose, pull the<br />

X-Y key (1) on the right joystick backwards.<br />

– Set the rotating selector switch to position 8.<br />

Press the key for so long, until the swivel plates are fully swung down and the<br />

supporting feet are fully retracted.<br />

Remark! You may only swing in or out the lateral pickup parts, when the central section<br />

of the pickup has been raised to the stop! If the central part of the pickup is not at the<br />

upper stop, then the lateral parts can only be swung in for two thirds.<br />

152


11<br />

5<br />

Relief pressure<br />

153<br />

6 <strong>Operation</strong><br />

– Completely swing in the lateral pickup parts. For this purpose, pull the X-Y key (5)<br />

on the right joystick back diagonally.<br />

To swing in faster, press the multi-key (11) and keep it pressed. If you then pull the<br />

X-Y key (5) diagonally to the rear left or right, then both lateral pickup parts are<br />

simultaneously swung in.<br />

After swinging in, hold the X-Y key (5) for so long, until the pressure indication on<br />

the color terminal shows at least 120 bar relief pressure for the lateral parts, so that<br />

they are pressed against the stop.<br />

If, for a machine standing on a slope to the side, a very soiled pickup should not be able<br />

to be swung in, then at first park the machine with the front slope up or slope down.<br />

Then, swing in the pickup.<br />

Relief pressure<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

Inserting the safety chains and securing the pickup<br />

The is one safety chain each on the right and left front of the chassis. These chains must<br />

be fastened to the two lateral parts for driving on public roads.<br />

Danger! Staying under the raised and unsecured pickup is prohibited! There is hazard<br />

to life if the pickup parts suddenly swing down. Make sure that no people are staying in<br />

the hazard zone during swinging in and out of the lateral pickup parts. Additionally, no<br />

people may be staying on the cabin platform.<br />

Fasten the chains on the central part of the pickup, when you have swung in the pickup<br />

and are leaving the machine. In case of a malfunction of the hydraulics system, the<br />

pickup then cannot unexpectedly come down. Otherwise, severe damage to the cabin<br />

will be the consequence! Such damage is excluded from any guarantee or warranty.<br />

The safety chain fastened to the central part of the<br />

pickup<br />

154<br />

Safety chain fastened to the<br />

lateral part


6.12.19 Special conditions during loading<br />

6.12.19.1 Frozen beet pile<br />

155<br />

6 <strong>Operation</strong><br />

A lightly frozen beet pile may be broken up or loosened using the pile pickup. A tightly<br />

frozen beet pile may never be broken up using the pile pickup. Always use suitable<br />

heavy-duty equipment for this purpose (for instance excavator, wheel loader, etc.).<br />

The telescopic tube of the pile pickup may only be pressed into the pile using its own<br />

force. Additionally driving the vehicle forward invariably leads to destruction of the<br />

telescopic tube.<br />

Remark!.A frozen beet pile may not be loosened by raising the complete pickup. This<br />

may lead to severe damage to the pickup.<br />

When loading lightly frozen beet piles, always place the frost breakers in the infeed<br />

conveyor intake and the lateral pickup parts. When the machine is delivered, the frost<br />

breakers are located in the tool box in front of the fuel tank. The frost breakers help to<br />

break up frozen lumps of beets, and so make sure of largely uninterrupted flow of beets<br />

through the machine.<br />

Without frost breaker Frost breaker lateral part and center<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.12.19.2 Extremely narrob beet pile<br />

Even in case of a very narrow beet pile, for which, from its appearance, half of the<br />

pickup width would be sufficient for loading, the pickup must be completely swung out<br />

and used for loading.<br />

6.12.19.3 Very strongly soiled beets and sticky ground conditions/water spraying<br />

system (option)<br />

Composition and function<br />

The water spraying system serves to moisten the pinch rollers in case of especially<br />

sticky ground conditions.<br />

The water needed for moistening is filled from above into the tank, which is at first<br />

pressureless. The pressure required for moistening is generated by the compressed air<br />

compressor of <strong>euro</strong>-Maus3.<br />

Switching the water spraying system on and off is comfortably performed from the<br />

driver‘s seat.<br />

Attention!.Injury hazard by dirt particles and water spraying out. Before filling up the<br />

water tank, slowly and carefully open the stopcock to relieve any pressure existing in the<br />

water tank. Do not bend over the filling opening for so long until the pressure has been<br />

completely relieved.<br />

Filling up the water tank<br />

Before filling up, close the ball cock 1<br />

(position OFF).<br />

Before filling up the water tank, slowly open the ball cock (7) on the filler neck to relieve<br />

possibly existing pressure.<br />

Fill up only clean water without pollutants into the vessel.<br />

Close the ball cock (7), when the vessel is filled up.<br />

.<br />

156<br />

7


Position of the four ball cocks in the four operating modes<br />

157<br />

6 <strong>Operation</strong><br />

Whenever filling up, check the strainer filter in the filter bowl (6) for dirt and clean the<br />

strainer if needed.<br />

To open the filter, first close the ball cock 2 , then the ball cock 4 . Then, open the ball<br />

cock 3 so that the pressure can escape. Only unscrew the filter bowl, when the ball<br />

cocks are closed. If the strainer filter is damaged, you can obtain a new strainer filter<br />

under the item number 208032.<br />

6<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

<strong>Operation</strong><br />

A lit LED indicates that the water valve has been<br />

opened and the system is spraying.<br />

The water spraying system is switched ON and OFF using the key (5) on the operating<br />

section. Move the four ball cocks to the operating mode desired.<br />

Operating mode I OFF Close ball cock 1 for as long as the water spraying<br />

system is not needed.<br />

Operating mode II ON If you need the water spraying system, set the four<br />

ball cocks as required for operating mode II.<br />

Press key (5) for so long, until the color Water spraying system on. The<br />

terminal displays the following icon system constantly sprays, when the<br />

158<br />

machine drive is switched on.<br />

Press key (5) for so long, until the color The water spraying system runs in<br />

terminal displays the following icon automatic mode. When exceeding<br />

a pressure limit preset by the works<br />

for the 4-fold pinch rollers or the<br />

8-fold pinch rollers, the water spraying<br />

system begins to spray. If the pressure<br />

falls below this pressure limit, then<br />

spraying is stopped.<br />

Press key (5) again, until the icon is no Water spraying system switched off.<br />

longer displayed on the color terminal.<br />

5<br />

The water pressure is set as required (max. 5 bar) at the pressure reducer of the water<br />

spraying system.<br />

Pressure reducer for the water spraying system


3<br />

8<br />

Operating mode III Draining water and emptying tank<br />

In case of frost hazard or before longer periods of standstill, we<br />

recommend, to avoid damage to the water spraying system, to<br />

159<br />

6 <strong>Operation</strong><br />

Attention!.The response pressure for the safety relief valve (8) has been preset fixed to<br />

6 bar by the works. The setting for this safety component may in no case be changed,<br />

since this may lead to severe injuries or damage to materials. When replacing it, only a<br />

corresponding equal spare part may be installed, which must be obtained directly from<br />

the manufacturer of <strong>euro</strong>-Maus3.<br />

completely drain water from the system in due time. For quicker<br />

emptying of the tank, the engine of <strong>euro</strong>-Maus3 should be running<br />

(for compressed air supply).<br />

Operating mode IV Blowing out spraying jets and pressure lines<br />

Blowing out of pressure lines and spraying jets is required in case of<br />

frost hazard. The machine drive must be switched on for blowing out the<br />

spraying jets. Set the ball cocks to the positions as for operating mode<br />

IV and switch on the water spraying system using the key (5)<br />

(permenant operation). Leave the system switched on for so long, until<br />

all spraying jets only emit air without water mist. Then, open the water<br />

filter and empty the filter bowl. Screw the filter bowl including strainer<br />

filter to the filter head again.<br />

2<br />

1<br />

Spray jet<br />

Spray jet<br />

Shutoff cocks for the spray jets, if not all are needed<br />

simultaneously::<br />

1 = recleaner;<br />

2 = pickup left;<br />

3 = pickup right;<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.13 Diesel Enginer<br />

A summary of the required maintenance work on the engine is found in Chapter 7, in the<br />

original operating instructions and the original maintenance booklet of Mercedes-Benz.<br />

You will find information about measures to take in case of malfunctions in Chapter 8<br />

„Faults and Remedies“ and in the original operating manual from Mercedes-Benz.<br />

The contents of the fuel tank is displayed on the color terminal in percent. When the<br />

engine has been shut off for at least one minute, then the color terminal displays the<br />

approximate engine oil level in percent of the filling volume. This indication also serves<br />

as a rough orientation. Decisive is always the oil level determined using the oil dipstick.<br />

This indication is not displayed with the engine running, since for technical reasons, oil<br />

level monitoring is not possible with the engine running.<br />

Actual speed<br />

Set speed<br />

Contents fuel tank<br />

160<br />

Constant throttle intervention (orange)<br />

Starter control (green)<br />

Current fuel consumption in l/h<br />

Cooling water temperature<br />

Engine oil level


161<br />

6 <strong>Operation</strong><br />

The following warning indications are displayed on the color terminal in case of engine<br />

trouble:<br />

Engine oil pressure too low. IMMEDIATELY SHUT OFF and fill up engine oil.<br />

Engine oil level too low. IMMEDIATELY fill up engine oil.<br />

Coolant temperature too high. Shut off engine, determine and remedy cause<br />

(for instance clean radiator).<br />

Coolant level too low. Shut off engine and immediately fill up coolant.<br />

Severe engine problems!<br />

IMMEDIATELY shut off engine and call in Mercedes-Benz customer service.<br />

Remark! Danger of severe engine damage. When one of the above warning icons<br />

is displayed on the color terminal, immediately shut off the engine and determine the<br />

cause for the warning. The engine may be started again only after the cause has been<br />

removed.<br />

Fault in Mercedes-Benz engine control.<br />

Air filter soiled! Immediately perform maintenance on the air filter!!<br />

Fuel prefilter soiled! Replace filter, since soon loss of engine power<br />

is to be expected.<br />

Fuel fine filter blocked! Replace filter, since soon loss of engine power<br />

is to be expected.<br />

Reserve fuel quantity reached!<br />

The fuel reserve set by you has been reached,<br />

when this warning icon is displayed on the color terminal.<br />

You can set the warning limit for fuel<br />

reserve in the menu „Basic settings“,<br />

line „Fuel reserve warning at (%)“.<br />

Input this figure in percent of the<br />

overall tank content.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.13.1 Modifications respectively amendments of the engine operating manual of<br />

Mercedes-Benz<br />

In case of engines from Mercedes-Benz, which are installed in <strong>ROPA</strong> machines, the<br />

items listed below must also be considered:<br />

– Currently, only engine model OM 926 LA <strong>euro</strong>MOT 3a<br />

(Variante 220 kW at 2200 -1/min) are installed. Therefore, only those parts of the<br />

operating manual from Mercedes-Benz referring to this engine model and those<br />

parts generally applying to all engine models apply.<br />

– All engines are supplied without flame starting system, but with constant throttle<br />

brake. Control is performed using the ADM2 control device via the CAN bus. This<br />

control device is located in the switching cabinet of the central electric system.<br />

– The „warning lamp electronics“ mentioned in the operating manual from Mercedes-<br />

Benz and the „stop lamp“ are replaced by warning indications on the color terminal<br />

for <strong>ROPA</strong> machines. The meaning of these indications is identical to the lamps<br />

described in the operating manual from Mercedes-Benz.<br />

When the STOP indication is displayed on the color terminal, then the engine must<br />

be IMMEDIATELY shut off, because a severe engine fault has occurred, which could<br />

lead to total loss of the engine in case of continued operation.<br />

The control lamp „charging current“ is also replaced by a warning indication on the<br />

color terminal for <strong>ROPA</strong> machines.<br />

– The diagnostics socket (X-340) for engine electronics is located at the rear side of<br />

the switching cabinet for central electrics on the cabin platform.<br />

– The START button and the STOP button on the engine are defeated by securing of<br />

the hatch on the engine compartment.<br />

– On the engine, instead of the original oil drain screw, there is a specific oil drain<br />

valve. This serves to make work easier for engine oil change.<br />

– <strong>ROPA</strong> machines are fitted with two generators with a power of 100 A each.<br />

– If the engine is to be operated using Biodiesel fuel, then exclusively the following<br />

quality may be used:<br />

FAME (= fatty acid methyl ester) as per DIN EN 14214.<br />

When operating using Biodiesel fuel, immediately before ending the sugar beet<br />

campaign, at least two complete tank fillings of pure, unmixed Diesel fuel must be<br />

consumed. If, during the standstill period, Biodiesel remains in the fuel lines respectively<br />

in the injectors, then this may lead to substantial damage to the whole fueling system<br />

and to the engine.<br />

– Please have confirmation for maintenance work of Mercedes-Benz customer service<br />

made on the enclosed original documentation from Mercedes-Benz.<br />

The operating manual from Mercedes-Benz is absolutely binding and was supplied as<br />

an original with the machine.<br />

162


6.14 Pump Distributor Gears (PVG)<br />

6<br />

If the machine drive is switched on and the oil pressure of the multi-disk clutch<br />

163<br />

6 <strong>Operation</strong><br />

The pump distributor gears are directly connected to the Diesel engine and transfers<br />

engine power to the hydraulics pumps. Those hydraulics pumps are switched in, which<br />

are needed for loading, using a multi-disk clutch. This clutch and therefore the machine<br />

is drive is switched on or off by shortly pressing the yellow key (6) on the right joystick.<br />

The pump distributor gears are fitted with pressure circulation lubrication. If lubrication is<br />

insufficient, then a warning signal sounds. The following warning icon is displayed on the<br />

color terminal .<br />

Remark! Hazard of severe damage to the machine. Immediately shut off the engine,<br />

when the warning signal sounds.<br />

is too low, then the the color terminal displays following warning icon (clutch<br />

pressure pump distributor gears). In this case, the machine drive must be switched off<br />

immediately and the cause for low oil pressure must be determined and removed. If<br />

the drive continues to operate inspite of low oil pressure, then the multi-disk clutch is<br />

invariably destroyed.<br />

Multi-disk clutch<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.15 Hydraulics System<br />

Warning!.The hydraulics system is under high pressure. Hot hydraulics fluid may<br />

emit from leaks and cause severe injuries! Work on the pressure reservoirs of the<br />

machine may only be performed by specialist personnel. When working on the pressure<br />

reservoirs, the system must therefore be rendered completely pressureless. The<br />

pressure reservoirs may in no case be damaged or opened, because the constant<br />

preloading pressure may severely injure people. The preloading pressure in the<br />

pressure reservoirs exists even then, due to their design, when the remaining hydraulics<br />

system is already rendered pressureless. During all work on the hydraulics system, the<br />

utmost cleanlyness must be ensured. When dirt – and even if only minute quantities<br />

– enter the hydraulics system, this may lead to severe damage to the overall hydraulics<br />

system.<br />

The hydraulics system is ready for operation after the Diesel engine has been started. To<br />

spare the hydraulics system, the engine speed should not exceed the figure of<br />

1300 min -1 during the first minutes (about 5 min.) after starting the cold engine.<br />

Even shortly higher speeds should be avoided. If your <strong>euro</strong>-Maus3 is fitted with an<br />

independent heating system, then use it for preheating the hydraulics fluid<br />

(see page 100). In case of environmental temperatures of below +10 °C, at the start of<br />

work, for first starting of the machine drive, proceed as follows:<br />

Before switching on the machine drive, switch off the drives of the recleaner and pickup.<br />

For this purpose, press the keys (9) (8) and (7) on the right joystick one after the other.<br />

These drives are then displayed in white on the color terminal. Switch on the machine<br />

drive by shortly pressing key (6) on the right joystick. The hydraulics system is operating,<br />

the rollers are standing still. Wait for two to three minutes, before you switch on the<br />

drives again, one at a time, one after the other.<br />

7 8 6<br />

9<br />

Hydraulics fluid temperature<br />

The temperature of the hydraulics fluid may be read on the terminal.<br />

After starting the cold engine, the temperature is only correctly displayed on the color<br />

terminal if it is greater than 45 °C.<br />

Only then, the thermal valve in the hydraulics fluid circuit is opened and the hot<br />

hydraulics fluid flows around the temperature sensor in the output of the hydraulics fluid<br />

cooler.<br />

164


165<br />

6 <strong>Operation</strong><br />

If the temperature of the hydraulics fluid should be 70 °C or more, then clean the<br />

hydraulics fluid cooler. The color terminal displays the following warning icon .<br />

If the temperature displayed should be lower and still the above warning icon is<br />

displayed on the color terminal, then this may be caused by a fault of the thermal valve.<br />

In this case, please contact the service of <strong>ROPA</strong>.<br />

If the hydraulics fluid level is too low, then the color terminal displays the following<br />

warning icon .<br />

IMMEDIATELY shut down the engine!<br />

Determine the cause for the lack of fluid and fill up hydraulics fluid, if needed. In case of<br />

a ruptured hydraulics hose, under unfavorable conditions, the system will run dry within<br />

30 sec.<br />

Regularly check the hoses of the hydraulics system! Immediately replace damaged<br />

or aged hoses. Only use original hoses from <strong>ROPA</strong> or hoses fully complying with the<br />

technical specifications of the original hoses! Comply with the regional safety regulations<br />

on the service life of hydraulics hoses.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

Hydraulics pumps:<br />

Item Function<br />

101 Driving power<br />

102 Working hydraulics + front axle steering<br />

103 Fan drive radiator/charged air/oil coolers<br />

104 Drive pickup rollers<br />

105 Drive 4-fold pinch rollers<br />

106 Drive recleaner<br />

107 Drive for central mark/truck conveyor/infeed conveyor<br />

108 Lubrication PVG + shifting multi-disk clutch<br />

<strong>euro</strong>-Maus3 has 8 hydraulics circuits serviced by six axial-piston pumps, one tandem<br />

pump and one gear pump. Pump number 108 only serves the clutch and transmission<br />

lubrication. It is not connected to the hydraulics system.<br />

The pumps 101/102/103/108 are always operating when the Diesel engine is running.<br />

The pumps 104/105/106/107 only operate when the Diesel engine is running, the<br />

machine drive is switched on and the flow of power is engaged using the multi-disk<br />

clutch.<br />

166


6.16 Compressed Air System<br />

167<br />

6 <strong>Operation</strong><br />

The compressed air system supplies the braking system and the working pneumatics<br />

system with compressed air. The following processes of <strong>euro</strong>-Maus3 are performed by<br />

the working pneumatics system:<br />

– Switching of operating modes „turtle“/„rabbit“ for the manual transmission.<br />

– Switching between the gears „I“ und „II“.<br />

– Switching off all-wheel drive.<br />

– Switching on differential locks.<br />

– Fixing of the rotating seat.<br />

– Swivelling of the recleaner.<br />

– Swinging of the two rearview mirrors.<br />

– Swinging the warning signs UP/DOWN.<br />

– Swinging of the climbing ladder.<br />

Besides the working pneumatics system, the compressed air compressor also supplies:<br />

– the compressed air tap on the machine.<br />

– the blowing out gun in the driver‘s cabin (from model year 2007).<br />

In any case, make sure that the stopcock (1) of the working pneumatics system is<br />

always open, since otherwise a large share of the working pneumatics system is out of<br />

operation.<br />

Compressed air coupling<br />

In the position shown, the stopcock is<br />

open. Turn by 90° for closing.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

The exact reservoir pressure of the compressed air system may be read on the color<br />

terminal. All shifting processes under pneumatic control may only be performed reliably if<br />

there is enough pressure available in the compressed air system.<br />

If the pressure of the compressed air system is insufficient, then the color terminal<br />

displays the following warning icon .<br />

As long as this icon is displayed on the color termin, the machine may not be moved at<br />

all.<br />

Indication reservoir pressure<br />

Attention! Injury hazard from parts flung away. When working on the compressed<br />

air system, it must be rendered pressureless before starting work. For as long as<br />

the system is under pressure, people may be injured from parts flung away. Work<br />

on the compressed air system may only be performed by people knowing about the<br />

specific hazards and risks when handling pneumatics systems and who have received<br />

corresponding training.<br />

168


6.16.1 Compressor<br />

6.16.2 Air drier<br />

169<br />

6 <strong>Operation</strong><br />

The overall pneumatic system of the machine is supplied with compressed air by a<br />

compressor. The compressor is directly connected to the engine. The air is sucked<br />

in by the compressor through the air filter of the engine. If the set maximum pressure<br />

is reached, then the pressure regulator automatically blows off. The compressor is<br />

maintenance-free.<br />

The air drier is located below the right lateral hatch. It separates condensed water,<br />

before the air reaches the compressed air reservoir. The air drier contains a heating<br />

element, which prevents freezing in case of low temperatures. The heating element of<br />

the air drier is automatically switched on, if needed.<br />

6.16.3 Compressed air reservoir<br />

Compressed air coupling on the rear compressed air<br />

reservoir (only for the version without water spraying system)<br />

<strong>euro</strong>-Maus3 has three compressed air reservoirs. The two large compressed air<br />

reservoirs supply the braking system and the working pneumatics with compressed air.<br />

The small compressed air reservoir serves to regenerate the air drier. Depending on<br />

equipment, a compressed air jack is located either directly at the rear compressed air<br />

reservoir or below the hatch of the water spraying system.<br />

Compressed air coupling of the water spraying system<br />

Air drier<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.17 Central Lubricating System<br />

<strong>euro</strong>-Maus3 is fitted with a central lubricating system and in the variant with strainer<br />

chain cleaner has two or in the variant with 8-fold pinch roller cleaner has three<br />

lubricating circuits.<br />

One lubricating circuit supplies the pickup, a second the chassis and a third the<br />

optionally present recleaner rollers with lubricating grease.<br />

All lubricating points connected (about 58 respectively 65 pieces) are automatically<br />

supplied with lubricating grease. The lubricating pump supplies the grease to the main<br />

distributors. The main distributors distribute the grease to the subdistributors and from<br />

there, the individual lubricating points are supplied. With every switching on of the<br />

machine drive, the lubricating pump is switched on for the period of time entered by the<br />

operator in the menu „basic settings“. For as long as the lubricating pump is running, a<br />

stirring blade rotates in the grease reservoir, and the color terminal displays the following<br />

icon . When this period of time has expired, the lubricating pump stops.<br />

This period of time is set to 150 seconds by the works. It may be extended by the driver<br />

to up to 300 seconds. When loading up to 20 tons per transporting unit, we recommend<br />

the standard setting of 150 seconds lubricating period (pump operating period). When<br />

loading transporting units of about 28 tons, we recommend a pump operating period of<br />

about 200 seconds, for larger transporting units corresponding longer pump operating<br />

periods.<br />

In any case, make sure that there is always a sufficient supply of grease in the reservoir.<br />

In no case may the grease supply be used up so much that air ingresses the line<br />

system!<br />

170


171<br />

6 <strong>Operation</strong><br />

The 2 kg supply reservoir of the grease pump is filled up using the lever on the large<br />

grease bucket. Never completely fill up the 2 kg supply reservoir of the grease pump.<br />

Only fill up the supply reservoir of the grease pump for 90 %. By this, you avoid<br />

blockage of the bleeding pipe on the 2 kg supply reservoir. If the bleeding pipe is filled<br />

up with grease, then the system is no longer able to supply grease to the grease points<br />

anymore.<br />

6.17.1 Filling up the grease gun<br />

Shutoff cock<br />

There is a shutoff cock with a plug-in coupling in the supply hose to the grease pump.<br />

By this, the grease gun from vehicle tools may be filled up directly from the grease<br />

bucket. For this purpose, press the grease gun into the connecting nipple and close the<br />

shutoff cock. When you press the lever on the grease bucket, the grease gun is filled up<br />

with lubricating grease.<br />

6.17.2 Intermediate lubrication<br />

Nipple for filling up the<br />

grease gun<br />

The lubricating system may at any time be manually activated. For this purpose, call<br />

up the menu „special functions“ on the color terminal. In the line „central lubrication“,<br />

change the selection from „Auto“ to „On“.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

After an operating period of 20 minutes, the central lubricating system switches back to<br />

„Auto“ (automatic).<br />

Regularly check the lubricating pipe system. Perform a daily check whether the<br />

lubricating system works without faults. One possibility is controlling the two respectively<br />

three main distributors. An indicator pin is installed there as functional control. This<br />

indicator pin moves slowly, when grease flows through the main distributor. This<br />

indicates whether the pump element of this lubricating circuit works.<br />

Main distributor chassis front<br />

Subdistributor<br />

chassis front<br />

Main distributor pickup<br />

172<br />

Indicator pin<br />

Main distributor recleaner rollers


ïì Ì¿­¬»²º«²µ¬·±²»² 6 <strong>Operation</strong><br />

ç Ì¿­¬»²º«²µ¬·±²»²<br />

Þ»­½¸®»·¾«²¹ ¼»® Ì¿­¬»²º«²µ¬·±²»²<br />

ÑÚÚ ñ ÒÛÈÌ Ì¿­¬» øí÷<br />

Ü·» Ì¿­¬»²º«²µ¬·±²»² ¸¿¾»² » ²¿½¸ Æ«­¬¿²¼ P Ò±®³¿´ó Ü«®½¸ â í Í»µ«²¼»² ܮŽµ»² ¼»® ÑÚÚñÒÛÈÌ ©–¸® »²¼<br />

¾»¬®·»¾ ±¼»® Û·²­¬»´´³»²Å ó ª»®­½¸·»¼»²» Þ»¼»«¬«²¹ò ¼»­ Þ»¬®·»¾»­ ©·® ¼ ¼·» Þ¿¬½¸óÜ¿¬»· Ìî ¿«­¹»ºÅ¸®¬ò ׳<br />

Ü¿¾»· ©·® ¼ ¿«½¸ ¼·» Ì¿­¬»²¼®«½µ¼¿«»® ¾»©»®¬»¬ò<br />

kóÐóÚ´¿­¸ ­¬»¸¬ ·² ¼»® Þ¿¬½¸¼¿¬»· Ìî ¼»® Þ»º»¸´ ºÅ® бó<br />

6.18 Printer<br />

©»® Ѻ º ø²¿½¸ »·²»® Í»µ«²¼»÷ò Ü¿³·¬ ©·®¼ ¼·»­» Ì¿­¬»<br />

ÚÛÛÜ ñ ÛÒÌÛÎ øï÷<br />

¿´­ ßËÍóͽ¸¿´¬»® ºÅ® ¼»² Ü®«½µ»® øݱ²¬® ±´´»® ³·¬ бó<br />

š¾»® ¼·»­» Ì¿­¬» µ¿²² ¼»® Ü®«½µ»® ¿«­ ­»·²»³ Í´»»°ó ©»®óѺºóÓ±¼»÷ °®±¹®¿³³·»®¬ò Ü·» ޮŽµ» ÞÎç ³«­­<br />

6.18.1 ³±¼» ¿«º¹»©»½µ¬ Description «²¼ of ¼¿­ the п°·»® keyboard ª±®¹»­½¸±¾»² functions ©»®ó ¼¿¦« ±º º»² ­»·²ò<br />

¼»²ò<br />

The keyboard functions differ depending on the status – normal operation or setup<br />

Ó·¬ ܮŽµ»² ¼»® Ú»»¼ Ì¿­¬» ©·® ¼ ¦«²–½¸­¬ »·²» Æ»·´» ×Î Ú»²­¬»® øî÷å ͬ¿¬«­ ÔÛÜ øì÷ ­ò Õ¿°ò Í¿¬«­³»´¼«²¹»²<br />

¼»­ ¿µ¬«»´´ menu. »·²¹»­¬»´´¬»² This is also Ú±²¬ controlled ª±® ¹»­½¸±¾»² by the «²¼ length ó ©»²² of time the key is pressed.<br />

´–²¹»® ¿´­ FEED/ENTER(1)<br />

î Í»µ«²¼»² ¹»¼®Å½µ¬ ©·®¼ ó °»®³¿²»²¬ ª±®ó<br />

¹»­½¸±¾»²ò<br />

Í»´¾­¬¬»­¬ This key may be used to wake the printer from sleep<br />

Ü»® Ü®«½µ»® mode ©·®¼ and ¼«® to ½¸ feed ͬ¿®¬»² paper. »·²»­ ß«­¼®«½µ»­ ·³<br />

Í»´¾­¬¬»­¬ ¿«º ­»·²» ·²²»®» Ú«²µ¬·±² ¸·² ¹»°®Åº¬ò Ü¿¦«<br />

©·®¼ ¾»·³ When É»½µ»² the ¿«­ feed ¼»³ key б©»® is pressed, ÑÚÚ ³·¬¬»´­ at first п°·»®ó one line of the<br />

ª±®­½¸«¾¬¿­¬» currently ¥ÚÛÛÜ£ set font øï÷ ¼·»­» is fed ºÅ® and ³·²¼»­¬»²­ – if it is pressed í for more<br />

Í»µ«²¼»² ¹»¼®Å½µ¬ ¹»¸¿´¬»²ò Ü·» ͽ¸²·¬¬­¬»´´»² ©»®¼»²<br />

than 2 sec. – then feeding is performed constantly.<br />

¼¿¾»· ²·½¸¬ ¹»°®Åº¬ò ͱº¬©¿®»ª»®­·±² «²¼ Æ»·½¸»²­¿¬¦<br />

©»®¼»² ¹»¼®«½µ¬ò ÚÅ® ÑÛÓ µ†²²»² ¾»·³ Í»´¾­¬¬»­¬ ó íò<br />

¿«½¸ ͱ²¼»®¿«­¼®«½µ»<br />

Self-test:<br />

¿µ¬·ª·»®¬ ©»®¼»²ò<br />

The printer is tested for functioning by starting a<br />

printout in self-test. For this purpose, when waking<br />

the printer from power OFF, the feed key {FEED} (1)<br />

is pressed for at least 3 sec.<br />

Ì¿­¬» ÚÛÛ ÜñÛÒÌÛÎ Ì¿­¬» ÑÚÚ ñÒÛÈÌ ßµ¬·±²<br />

¹»¼®Å½µ¬<br />

²·½¸¬ ¹»¼ ®Å½µ¬<br />

п°·»®ª±®­½¸«¾ «³ »·²» Æ»·´ »<br />

Key ¹»¼®Å½µ¬ FEED/ENTER â î­<br />

²·½¸¬ Key ¹»¼ OFF/NEXT ®Å½µ¬<br />

µ±²¬·²«·»®´·½¸»® Activityп°<br />

·»®ª±®­½¸«¾<br />

pressed Ù»¼®Å½µ¬ ¾»· Û·²­ ½¸¿´¬»² ä ï­ not ²·½¸¬ pressed ¹»¼ ®Å½µ¬<br />

Paper ß«º©»½µ»²ô feed by one µ»·² line п° ·»®ª±®­½¸«¾<br />

pressed ¹»¼®Å½µ¬ > 2 s ¾»· Û·²­½¸¿´¬»² not ²·½¸¬ pressed ¹»¼ ®Å½µ¬<br />

Continuous Ìð ¿«º®«º»² paper øÍ» ´¾­¬¬»­¬÷ feed<br />

Gedrückt п°·»® bei »·²¹ Einschalten »´»¹¬ â î­ < 1 s not pressed Wake up, no paper feed<br />

pressed ¹»¼®Å½µ¬ on power ¾»· Û·²­½¸¿´¬»² on<br />

±¸²» п° ·»® â î­<br />

paper inserted > 2 s<br />

¹»¼®Å½µ¬ ·³ Ø»¨ ¼«²°óÓ±¼»<br />

not ²·½¸¬ pressed ¹»¼ ®Å½µ¬<br />

²·½¸¬ ¹»¼ ®Å½µ¬<br />

Call up ß«º®«º TO Ø»¨ (self-test) ¼«³°óÓ±¼»<br />

Ø»¨¼«³°óÓ±¼» Û²¼ »<br />

pressed ±¸²» on п° power ·»® on<br />

not pressed Call up hexdump mode<br />

without ²·½¸¬ paper ¹»¼ ®Å½µ¬ > 2 s<br />

Ì¿­¬» ´±­´ ¿­­»² ²¿½ ¸ ä ï­ ·³ Ò±®ó Ìï ¿«º®«º»²<br />

pressed in hexdunp mode<br />

³¿´°¿°·»®³±¼»<br />

not pressed<br />

øã ¼»º¿ «´¬ Ú±® ³º»»¼ ï Ô·²· »÷<br />

End hexdump mode<br />

²·½¸¬ ¹»¼ ®Å½µ¬<br />

without paper<br />

Ì¿­¬» â í­ ¹»¼ ®Å½µ¬<br />

Ìî ¿«º®«º»² ø¼»º ¿«´¬ ã ß«­­½¸¿´¬»² ²¿½ ¸ »·ó<br />

²»® Í»µ «²¼»÷<br />

not pressed ¹»¼®Å½µ¬<br />

Release ¹»¼®Å½µ¬ key after < 1 s Call up Û·²­¬»´´³»²Å T1 ¿«º ®«º»²<br />

in normal paper mode (= default form feed 1 line)<br />

not pressed Key pressed > 3 s Call up T2 (default = shutdown<br />

Ù»ÞÛ Û õ Ú Ù³ ¾Ø { ©© ©ò±»³ó°®·²¬»®ò½±³ { Ù» ÞÛ Ü± µòÒ®òæ ÍÓ ßÒóÜóìïîóÊíòð Û¿­ §óÔ±¿¼·²¹ ̸»®³±¼®«½µ»® ÙÐÌóìíëî<br />

173<br />

îò<br />

after one second)<br />

pressed pressed Call up setup menu<br />

ïò<br />

ìò<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

è Þ »¼·»²«²¹ «² ¼ É¿®¬«²¹<br />

èòï É»´½¸»­ ̸»®³±°¿°·»® ·­¬ ¹»»·¹²»¬á<br />

6.18.2 Which thermally-sensitive paper is suitable<br />

The printer is designed for a paper width of 57.5 ± 0.5 mm,<br />

at 60 g/m 2 . <strong>ROPA</strong> offers the suitable paper roll as standard<br />

equipment ¹»»·¹²»¬»² (<strong>ROPA</strong> ̸»®³±°¿°·»®­ item no. 206068). ¹»® ²» ¾»¸·´º´·½¸ò Other paper may cause<br />

malfunctions. Thermally-sensitive paper is available for<br />

specific tasks, which is water, grease and alcohol-resistant.<br />

We will gladly assist you in the selection of suitable<br />

thermally-sensitive paper.<br />

Which side ͬ¿²¼¿®¼æ of the ÙÐÎóÌðïóðëéóðíïóððéóð thermally-sensitive êðß paper can be printed<br />

on? On the paper roll, almost always the outside is the<br />

printable side. If you should still have doubts, make the<br />

finger nail test: quickly run over the paper with the tip of a<br />

finger nail, exerting pressure. The thermally-sensitive side is<br />

blackened ¾»¼®«½µ»²ò due to the frictional heat.<br />

Þ»¼·»²«²¹ «² ¼ É¿®¬«²¹<br />

Ü»® Ü®«½µ»® ·­¬ ºÅ® »·²» п°·»®¾® »·¬» ª±² ëéôë o ðòë ³³ô ³·¬ êð ¹ñ³îô ­°»ó<br />

¦·º·¦·»®¬ò Ù»ÞÛ ¾·»¬»¬ ­¬¿²¼¿® ¼³–y·¹ ¼·» °¿­­»²¼» п°·»®®±´´» ÙÐÎóÌðïó<br />

ðëéóðíïóððéóðêðß ¿²ò ß²¼»® » п°·»®» µ†²²»² ͬ†®«²¹»² ª»®«®­¿½¸»²ò<br />

ÚÅ® ¾»­±²¼»® » ß«º¹¿¾»² ­·²¼ ̸»®³±°¿°·»® » »®¸–´¬´·½¸ô ¼·» ® »­·­¬»²¬ ¹»ó<br />

¹»² É¿­­»®ô Ú»¬¬ «²¼ ß´µ±¸±´ ­·²¼ò É·® ­·²¼ ׸²»² ¾»· ¼»® ß«­©¿¸´ »·²»­<br />

É»´½¸» Í»·¬» ¼»­ ̸»®³±°¿°·»®­ µ¿²² ¾»¼®«½µ¬ ©»®¼»²á<br />

ß«º ¼»® п°·»®®±´´» ·­¬ º¿­¬ ·³³»® ¼·» ß«y»²­»·¬» ¼·» ¾»¼®«½µó<br />

¾¿®» Í»·¬»ò ͱ´´¬»² Í·» ¼»²²±½¸ Æ©»·º»´ ¸¿¾»²ô ³¿½¸»² Í·» ¼»²<br />

Ú·²¹»®²¿¹»´¬»­¬æ Ó·¬ ¼»® Í°·¬¦» »·²»­ Ú·²¹»®²¿¹»´­ «²¬»® Ü®«½µ<br />

­½¸²»´´ ž»® ¼¿­ п°·»® º¿¸® »²ò ß«º ¼»® ¬¸»®³±­»²­·¬·ª» Í»·¬»<br />

»®¹·¾¬ ­·½¸ ­± ¼«® ½¸ λ·¾«²¹­©–®³» »·²» ͽ¸©–®¦«²¹ò<br />

É·» ©·® ¼ ¼¿­ п°·»® »·²¹»´»¹¬á<br />

Ê»®©»²¼»¬ ©·® ¼ ¿«y»² ¾»­½¸·½¸¬»¬»­ п°·»®ô ëéôë ³³ o ðôë³³ ¾® »·¬ ³·¬<br />

»·²»³ É·½µ»´¼«®½¸³»­­»® ª±² íï ³³ò<br />

ïò É·½µ»´² Í·» »¬©¿ ïð ½³ п°·»® ª±² ¼»® α´´» ¿¾ò Ø¿´¬»² Í·» ¼·» Ô¿¹»²<br />

­¬®¿³³ ¹»©·½µ»´¬ò<br />

îò ›º º²»² ­·» ¼»² Ü»½µ»´ ¼»­ Ü®«½µ»®­ô ·²¼»³ Í·» ¼»² ÔÛÊÛÎ ·³ Ü»½µ»´<br />

´»·½¸¬ ²¿½¸ ±¾»² ¼®Å½µ»²ò Ü·» Ü®«½µ©¿´¦» ©·®¼ ¦«­¿³³»² ³·¬ ¼»³ Ü»½µ»´<br />

¿«­ ¼»³ Ü®«½µ©»®µ ¹»¸»¾»´¬ò Ü»® Ü»½µ»´ ´–­­¬ ­·½¸ »¬¦¬ ´»·½¸¬ †º º²»²ò<br />

íò Ô»¹»² Í·» ¼·» п°·»®®±´´» ­± ·² ¼·» п°·»®ª±®®¿¬­³«´¼»ô ¼¿­­ ¼·» ß«­ó<br />

­»²­»·¬» ¦«³ Ü®«½µ©»®µ ¦»·¹¬ò Ò«® ¼·»­» ß«y»²­»·¬» ´–­­¬ ­·½¸ ·³ Ü®«½µ»®<br />

ìò ͽ¸´·»y»² Í·» ¼»² Ü»½µ»´ ³·¬ »·²»³ µ®–º¬·¹»² Ü®«½µò Û® ­½¸²¿°°¬ ¼¿²²<br />

¸†®¾¿® »·²ô ­± ¼¿­­ Í·» »¬¦¬ ¼¿­ п°·»® ¿² ¼»® ß¾®»·yµ¿²¬» ¿¾®»·­­»² µ†²ó<br />

²»²ô ±¸²» ¼¿­­ ­·½¸ ¼»® Ü»½µ»´ ©·»¼»® †º º²»¬ «²¼ ±¸²» ¼¿­ п°·»® ¼«® ½¸<br />

How is the ¼»² paper Ü®«½µµ±°º inserted? ®«¬­½¸¬ò<br />

1. Unwind about 10 cm of paper from the roll. Keep the<br />

paper wound tight.<br />

2. Open the cover of the printer by lightly pressing the ìò<br />

LEVER in the lid upward. The platen is levered out of the<br />

printing mechanism together with the lid. The lid may now<br />

be easily èòî É¿®¬«²¹ô opened. λ·²·¹«²¹<br />

Ò¿½¸ ¹®†y»® »² Ü®«½µ´»·­¬«²¹»²ô ¿¾¸–²¹·¹ ª±² ¼»® п°·»® ¯«¿´·¬–¬ «²¼<br />

3. Insert ©·¼®·¹»² the paper ˳¹»¾«²¹­»·º´Å­­»²ô roll into the ·­¬ paper »­ «²¬»® bowl ˳­¬–²¼»² in such ²†¬·¹ a ¼»² Ü®«½µó<br />

µ±°ºô Í»²­±® «²¼ ¼·» ß²¬®·»¾­©¿´¦» ¦« ®»·²·¹»²ô ·²­¾»­±²¼»® » ¼¿²² ©»²²<br />

manner, ͬ»´´»² that ²·½¸ the ³»¸® outside ±®¼»²¬´·½¸ shows ¹»¼®«½µ¬ in ©»® direction ¼»²ò of the printing<br />

{ п°·»®ª±®®¿¬­óÜ»½µ»´ †º º²»² «²¼ п°·»®® ±´´» »²¬º»® ²»²ò<br />

mechanism. { Ó·¬ »·²»² Only µ´»·²»² this з²­»´ outer Ê»®­½¸³«¬¦«²¹»² side may ¿² be п°·»®ô printed Í»²­±® by ­±©·» the ¼»® printer.<br />

ß¾® »·­­µ¿²¬» ´†­»²ò<br />

4. Close { Õ®–º¬·¹ the lid ·² ¼·» by п°·»®ª±®®¿¬­óÓ«´¼» strongly pressing °«­¬»²ô on «³ it. ¼»² It audibly ¹®±¾»² ͬ¿«¾ engages, ¦« »²¬ó so that you can now rip<br />

º»® ²»²ò<br />

off paper { É¿¬¬»­¬–¾½¸»² at the cutting ³·¬ ×­±°® edge, ±°¿²±´ ß´µ±¸±´ the lid ø×Ðß÷ opens again and slides through the printing<br />

¬®–²µ»² «²¼ ¼·» Ü®«½µ´»·­¬» ® »·²·¹»² ±¼»® Ü®«½µµ±°ºóλ·²·¹«²¹­­¬·º ¬ ñ<br />

head without the paper.<br />

λ·²·¹«²¹­µ¿®¬» ª»®©»²¼»²ò<br />

{ É»·¬»®» ­¬¿®µ» Ê»®­½¸³«¬¦«²¹»² »¾»²º¿´´­ ³·¬<br />

»·²»³ É ¿¬¬»­¬–¾½¸»² ø×Ðß÷ »²¬º»® ²»²ò<br />

Ê»®©»²¼»² Í·» ²·»³¿´­ ­½¸¿®º» Ù»¹»²­¬–²¼» ¦«® λ·²·ó<br />

¹«²¹ò Ü·»­ µ†²²¬» ¼»² Ü®«½µµ±°º ¾»­½¸–¼·¹»²ò<br />

Ù»ÞÛ Û õ Ú Ù³ ¾Ø { ©© ©ò±»³ó°®·²¬»®ò½±³ { Ù» ÞÛ Ü± µòÒ®òæ ÍÓ ßÒóÜóìïîóÊíòð Û¿­ §óÔ±¿¼·²¹ ̸»®³±¼®«½µ»® ÙÐÌóìíëî<br />

174<br />

ïò<br />

îò<br />

íò<br />

ïí


6.19 Video Monitoring<br />

175<br />

6 <strong>Operation</strong><br />

<strong>euro</strong>-Maus3 is fitted with a video camera as standard equipment. This camera is<br />

located at the front, below the central mark, and serves to determine the correct working<br />

depth. When loading, always switch on lighting for the camera in the central mark using<br />

switch (8) in the radio console.<br />

Optionally, <strong>euro</strong>-Maus3 may be fitted with a further video camera on the truck conveyor<br />

to monitor the loading process.<br />

Switching between the two cameras is performed manually using the switch (19) in the<br />

radio console.<br />

This can be used to switch between the cameras at any time.<br />

The cameras are maintenance-free. When the image quality deteriorates, you should<br />

clean the lens cover of the camera using a soft, clean and slightly moist cloth. When<br />

cleaning, make sure that the lens cover is not scratched.<br />

6.20 Electrics<br />

6.20.1 Sockets<br />

Socket 24 V<br />

19<br />

To connect external loads, the machine is fitted with two further 24 V sockets for<br />

automobile plugs small on the outside.<br />

Socket 24 V<br />

One socket is located in the engine compartment on the engine frame. The second<br />

socket is located at the rear right in front of the tank above the stopcock for the fuel line.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.20.2 Main battery switch<br />

The electrical system (with the exception of the timer for the independent heating<br />

system) may be completely separated from the batteries using the main battery switch.<br />

The main battery switch is located in the cover between the climbing ladder and the<br />

battery box.<br />

Main battery switch<br />

Remark! To avoid damage to the vehicle electrics or vehicle electronics, the main<br />

battery switch may NEVER be switched off with the engine running or the ignition<br />

switched on.<br />

If the timer for the independent heating system should also be separated from power<br />

supply, then the sliding switch S86 next to the fuse F03 in the switch box of central<br />

electrics must be pulled.<br />

S 86<br />

176


6.20.3 Voltage monitoring<br />

177<br />

6 <strong>Operation</strong><br />

The battery voltage is monitored by the system. In case of too high or too low voltage,<br />

the color terminal displays the following warning icon .<br />

The battery voltage may not exceed 30 V and may not fall below 23 V. In case of a<br />

battery voltage of below 23 V, experience has shown that the machine cannot be started<br />

anymore.<br />

6.20.4 Fuses<br />

Indication battery voltage<br />

When a generator fails, the color terminal displays the following icon for generator 1<br />

(upper generator) and for generator 2 (lower generator).<br />

Most fuses are located in the switching cabinet of the central electric system.<br />

Further fuses are located at the radio console and in the seat console. The main fuses<br />

are located in the battery box. Details on this are found in the Chapter Faults and<br />

Remedies from page 251.<br />

In case of problems with the electric or electronic system, please contact service of<br />

<strong>ROPA</strong>.<br />

Chapter.6.<br />

<strong>Operation</strong>


6 <strong>Operation</strong><br />

Chapter.6.<br />

<strong>Operation</strong><br />

6.21 Tire Pressures<br />

Regularly check it using the tire pressure meter supplied during the campaign!<br />

Tire model independent<br />

of the manufacturer min. Recommendation max.<br />

1 Front axle<br />

710/75R34 TL 178A8<br />

2 Rear axle<br />

710/75R34 TL 178A8<br />

3 Additional axle (option)<br />

235/75R17.5 TL143J<br />

1<br />

178<br />

3<br />

2<br />

2.2 2.2 3.2<br />

2.2 2.2 3.2<br />

– 7.5 –


6.22 Immobilizing up to One Week<br />

Park <strong>euro</strong>-Maus3 so that nobody is impaired or endangered. Also make sure of<br />

sufficient safety distance to power lines routed above ground.<br />

– Engage the parking brake.<br />

– Raise the pickup all the way up.<br />

– Switch off the engine.<br />

– Fasten the safety chains to the central part of the pickup.<br />

– Switch off all electrical loads.<br />

– Pull off the ignition key.<br />

– Leave the machine and lock the driver‘s cabin.<br />

179<br />

6 <strong>Operation</strong><br />

Remark!.Due to lowering pressure in the hydraulics system, the pickup may come down<br />

during langer standstill periods and severely damage the driver‘s cabin. Therefore, when<br />

parking the machine, always fasten the safety chains on the left and right of the central<br />

pickup part.<br />

– Do NOT switch off the main battery switch, so that the independent heating system<br />

remains operations.<br />

– Secure the machine against rolling away using the chocks.<br />

Remark! In case of need, consider an additional child safety catch.<br />

Chapter.6.<br />

<strong>Operation</strong>


181<br />

7 Maintenance and Service<br />

Kapitel 7<br />

Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

183<br />

7 Maintenance and Service<br />

Warning! There is the hazard of severe or severest injuries and the hazard of damage<br />

to the machine during all maintenance work. Never climb over the rear wall of the<br />

platform.<br />

7.1 Engine<br />

During all maintenance work, make sure that nobody is able to inadvertently start up<br />

the machine (pull off the ignition key, lock the driver‘s cabin, always carry the ignition<br />

key on your body and to the extent possible, switch off the main battery switch, pull it off<br />

and also carry it on your body). Only perform maintenance work you have been trained<br />

for and for which you have the required knowledge and tools. During all maintenance<br />

work, strictly comply with all regionally applicable regulations on safety for protection of<br />

health and the environment. Never forget: when you do not comply with the applicable<br />

regulations on safety, protection of health or the environment, you endanger yourself,<br />

other people and the environment. In addition, you may lose insurance coverage. Always<br />

use approved and safe ladders and climbing aids.<br />

Perform a daily check, with the machine standing on level ground and cold engine not<br />

running, of the engine oil level using the oil dipstick. You engine contains sufficient oil if<br />

the oil level is in the middle between the minimum and maximum mark. In case of need,<br />

fill up with a corresponding quantity of approved engine oil. Always make sure that you<br />

do not fill up too much oil.<br />

Below, you will find excerpts of a maintenance manual of Mercedes-Benz. To wholly<br />

preserve guarantee and warranty claims concerning Mercedes-Benz, the operator of<br />

the engine must ensure, that the maintenance work prescribed by Mercedes-Benz<br />

are performed in due time and completely by people expressly authorized for this by<br />

Mercedes-Benz. These people are obliged to confirm correct and timely performance of<br />

maintenance work on the original maintenance slips.<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

7.1.1 Dry Air Filter<br />

The engine is fitted with a dry air filter, consisting of the main filter element and the<br />

safety cartridge.<br />

The main element must be replaced:<br />

– Once annually (urgently recommended).<br />

– When the icon is displayed on the terminal.<br />

– When the cartridge shows signs of damage.<br />

The safety cartridge is accessible after uninstalling the main element. It protects<br />

engine from dirt during maintenance of the main element or when the main element is<br />

damaged. The safety cartridge cannot be cleaned. It must be replaced if needed, but at<br />

the latest every two years.<br />

Remark!.Danger of damage to the engine. When replacing filters, always ensure<br />

the utmost cleanliness. Furthermore, the engine may never be operated without filter<br />

elements.<br />

The dry air filter is located above the hydraulics fluid tank and is accessible from the<br />

climbing platform. When uninstalling and installing, make sure of the utmost cleanliness<br />

and correct fit of the cartridge. A damaged air filter cartridge must be immediately<br />

replaced by a new, undamaged filter cartridge.<br />

The filter cartridge may only be uninstalled when the engine is standing still.<br />

The safest, quickest and cleanest method of performing maintenance on a filter cartridge<br />

is to replace it with a new cartridge.<br />

The main element may, as described below, be cleaned. Since slight damage is only<br />

difficult or even impossible to detect, we recommend to always use a new filter cartridge<br />

to protect the engine. We do not assume warranty for cleaned elements and the<br />

consequences caused by them.<br />

184


45 XXX XX XXX<br />

ent warten<br />

ng des Hauptelements nur bei<br />

rechen des Wartungsigers/-schalters<br />

bzw. nach<br />

tung des Geräte- oder<br />

renherstellers durchführen.<br />

ment ausbauen<br />

verschlüsse entriegeln und<br />

rteil abnehmen (siehe Bild 3).<br />

äuseunterteil abnehmen<br />

nt unter leichten Drehbewetändig<br />

vom inneren Stützrohr<br />

n (siehe Bild 4).<br />

185<br />

7 Maintenance and Service<br />

- Zur Reinigung Bild ein 4: Rohr Hauptelement auf eine Druckluft- entnehmen Bild 5: Hauptelement reinigen<br />

pistole – aufsetzen, Carefully and dessen diligently Ende clean um ca. the 90° inside of the housing, especially at the sealing<br />

gebogen surface ist. Das for Rohr the filter muss cartridge. so lang Diligently sein, ensure that no dirt can reach the clean air<br />

dass es side bis zum of the Boden filter. des Hauptelementes<br />

reicht. Hauptelement mit trockener<br />

– Never rinse or brush out the main element. When blowing it out, strictly make sure<br />

Druckluft (maximal 5 bar) vorsichtig durch<br />

Auf- und that Abbewegen no dust reaches des Rohres the inside im Haupt- of the main element.<br />

element – Blow so lange out using von a innen compressed-air nach außen gun. Install a pipe on this gun, which is angled by<br />

ausblasen, bis keine Staubentwicklung<br />

90° at the lower end (see illustration).<br />

mehr auftritt (siehe Bild 5).<br />

MANN+HUMMEL Industriefilter 7<br />

uptelement entnehmen Bild 5: Hauptelement reinigen<br />

– This pipe is not commercially available, but it may be made by yourself without any<br />

problem. It should be so long that it reaches the cartridge bottom.<br />

oft sehr schwer oder gar nicht<br />

erkennbar sind, empfehlen wir zum<br />

Schutz der Motoren oder Geräte<br />

stets neue Elemente zu verwenden.<br />

Für gereinigte Elemente können wir<br />

keine Gewährleistung übernehmen.<br />

- Zur Reinigung ein Rohr auf eine Druckluftpistole<br />

aufsetzen, dessen Ende um ca. 90°<br />

gebogen ist. Das Rohr muss so lang sein,<br />

Gehäuseinnenseite mit einem<br />

dass es bis zum Boden des Hauptelemen-<br />

feuchten Tuch sorgfältig auswites<br />

reicht. Hauptelement mit trockener<br />

schen. Dabei darauf achten, dass<br />

Druckluft (maximal 5 bar) vorsichtig durch<br />

In case kein of Staub exchange, oder dispose Schmutz of auf the polluted die filter cartridge Auf- in und compliance Abbewegen with des the Rohres locally im Haupt-<br />

applicable Reinluftseite regulations des Filters for protection gelangt. of the environment: element so lange von innen nach außen<br />

Bild 3: Gehäuseunterteil abnehmen<br />

ausblasen, bis keine Staubentwicklung<br />

– Open the filter housing.<br />

mehr auftritt (siehe Bild 5).<br />

5.2.2 Hauptelement – Carefully pull reinigen the main element from the bracket, slightly turning it, and place it so<br />

Hauptelement<br />

- Hauptelement unter leichten Drehbewe-<br />

that gungen it cannot vollständig be damaged. keinesfalls aus-<br />

vom inneren Stützrohr<br />

waschen oder ausbürsten.Beim<br />

herunterziehen (siehe Bild 4).<br />

Ausblasen darf kein Staub auf die<br />

Innenseite des Hauptelementes<br />

gelangen.<br />

Das Hauptelement kann wie nachfolgend<br />

beschrieben gereinigt<br />

werden. Da kleine Beschädigungen<br />

oft sehr schwer oder gar nicht<br />

erkennbar sind, empfehlen wir zum<br />

Schutz der Motoren oder Geräte<br />

stets neue Elemente zu verwenden.<br />

Für gereinigte Elemente können wir<br />

keine Gewährleistung übernehmen.<br />

dustriefilter 7<br />

– Set the pressure reducer to at max. 5 Bar and blow out the filter cartridge using<br />

dry compressed air for so long until no dust develops anymore. When blowing out,<br />

constantly move the compressed-air gun up and down and constantly turn the filter<br />

Chapter.7.<br />

Maintenance and Service


Europiclon Baureihe 45 XXX XX XXX<br />

Vor dem Wiedereinbau muss das<br />

gereinigte Hauptelement sorgfältig<br />

7 Maintenance and Service auf Beschädigungen am Papierbalg<br />

und an den Gummidichtungen<br />

geprüft werden.<br />

n Baureihe 45 XXX XX XXX<br />

bau<br />

r in die Halterung einsetzen und in die<br />

ünschte Einbaulage drehen/verschiedarauf<br />

achten, dass der Filter in der<br />

rung einrastet (siehe Bild 1).<br />

nnfeder zuklappen und auf der<br />

chlussseite einrasten.<br />

Die Spannfeder muss sich ohne<br />

Werkzeug mit der Hand einrasten<br />

lassen. Andernfalls nochmals Lage<br />

des Filters kontrollieren.<br />

Zum Öffnen der Spannfeder einen<br />

Schraubendreher auf der Verschlussseite<br />

zwischen Spannfeder<br />

und Halter einstecken und Spannfeder<br />

aushebeln (siehe Bild 2).<br />

Bei Ausführung mit Staubaustragsventil<br />

und waagrechter<br />

MANN+HUMMEL Industriefilter<br />

Einbaulage<br />

Chapter.7.<br />

muss das Staubaustragsventil<br />

Maintenance nach and unten Servicezeigen<br />

(± 15° Abweichung der „OBEN/<br />

TOP“-Markierung ist zulässig, siehe<br />

Bild 1); ggf. Gehäuseunterteil<br />

Jede Falte des Papierbalges mit<br />

Hilfe einer geeigneten Stablampe<br />

auf Risse und Löcher untersuchen<br />

(siehe Bild 6). Damit auch kleinere<br />

Beschädigungen erkennbar sind,<br />

sollte die Untersuchung nicht bei<br />

direkter Sonneneinstrahlung,<br />

sondern z.B. in einem abgedunkelten<br />

Raum durchgeführt werden.<br />

Bild 6: Hauptelement kontrollieren<br />

Examine each fold individually and carefully using a suitable flashlight. Damaged filter<br />

cartridges may not be reused in any case. Use the secondary element only independent<br />

Unabhängig von der Einsatzdauer,<br />

müssen Hauptelemente spätestens<br />

nach 2 Jahren ausgewechselt werden.<br />

Beschädigte Hauptelemente<br />

auf keinen Fall weiterverwenden. Im<br />

Zweifelsfall immer ein neues Hauptelement<br />

einbauen.<br />

of the term of use, original MANN + Hummel filter cartridges (main element <strong>ROPA</strong> item<br />

no. 301225; safety cartridge <strong>ROPA</strong> item no. 3012226). In no case install filter elements<br />

with metal sheathing.<br />

– Slide the main element with the open side into the housing.Install lid and observe the<br />

position of the just ejection valve (see illustration). The dust ejection valve must point<br />

downward (±15° deviation of the „OBEN/TOP“ mark is allowable); if needed, take off<br />

the lower part of the housing and reinstall after turning it.<br />

5.2.3 Hauptelement einbauen<br />

– - Reclose the wire snap-fastener.<br />

Nur Original MANN+HUMMEL<br />

Elemente verwenden! Auf keinen<br />

Fall Elemente mit Metallaußenmantel<br />

einbauen!<br />

- Hauptelement mit der offenen Seite zuerst<br />

vorsichtig in das Gehäuseoberteil einschieben.<br />

- Bei Vakuumausführung Dichtung zwischen<br />

Gehäuseober- und Gehäuseunterteil auf<br />

Beschädigungen kontrollieren, ggfs.<br />

austauschen.<br />

186<br />

- Gehäuseunterteil aufsetzen (La<br />

Staubaustragventils beachten, sie<br />

Abschnitt 4).<br />

- Drahtspannverschlüsse in die Nut d<br />

sches am Gehäuseoberteil ansetz<br />

spannen (sinngemäß umgekehrt B<br />

– Then, check the cartridge for damage to the paper bellows and to the rubber seals.<br />

5.3. Sekundärelement wechseln<br />

In case of damage (cracks, buckling, dents, etc.), a new cartridge must be used.<br />

Cracks or holes in the paper bellows may be very easily detected by testing using<br />

a hand lamp (see illustration). So that smaller damage becomes visible as well, this<br />

examination should not be performed in direct sunlight or bright daylight, but in a<br />

darkened room, if available.<br />

Bild 1: Filter einsetzen<br />

Das Sekundärelement ist b<br />

5. Wartung des Haupteleme<br />

nach spätestens 2 Jahren z<br />

seln.<br />

5.3.1 Hauptelement ausbauen<br />

(siehe Abschnitt 5.2.1)<br />

5.3.2 Sekundärelement wechseln<br />

Das Sekundärelement da<br />

gereinigt und nach Ausba<br />

wiederverwendet werden.<br />

Je nach Ausführung Sekundärelem<br />

folgt ausbauen:<br />

Ausführung A:<br />

Siegel (Schwimmhaut) des Sek<br />

elements mit einem geeigneten W<br />

(z. B. Schraubendreher) von inne<br />

außen durchstoßen und die<br />

Laschen hochziehen (siehe Bild 7)<br />

(Schwimmhaut) nur öffnen, u<br />

Sekundärelement auszuwechsel<br />

Bild 7: Siegel öffnen (Ausführung


Replacing the safety cartridge<br />

Storing of filter cartridges<br />

187<br />

7 Maintenance and Service<br />

The safety cartridge must be exchanged at every fifth maintenance of the main element<br />

or at the latest after two years for a new safety cartridge. The safety cartridge may not<br />

be cleaned or reused after deinstallation.<br />

– Uninstall main element as just described.<br />

– Grip the safety cartridge at the recessed grip and pull it out.<br />

– Slide in the new safety cartridge.<br />

Filter elements must be stored standing upright, protected from dust and moisture in<br />

original packaging, so that they cannot be damaged. We recommend having at least one<br />

replacement filter element in stock for each filter element being used.<br />

Dust ejection valve<br />

Dust ejection valves are largely maintenance-free. Possible dust deposits are easily<br />

removed by compressing the rubber valve several times. The valve must be installed<br />

so that it is always unobstructed and does not abut anywhere. A damaged dust ejection<br />

valve must be exchanged immediately.<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

7.1.2 Oil change for the engine<br />

Remark! VExclusively use approvel high-performance engine oils complying with the<br />

DaimlerChrysler works standard 228.5.<br />

hen using bio Diesel (FAME), the oil change intervals must be reduced from 400 hours to<br />

150 hours.<br />

The first oil change for the engine is required after 400 operating hours – when using<br />

FAME (RME bio Diesel), after 150 operating hours. Further oil changes are required<br />

after every 400 operating hours – when using FAME (RME bio Diesel), after every<br />

150 operating hours. The engine oil filter must be replaced at each oil change.<br />

The oil change should only be performed with the engine at operating temperature.<br />

Before performing the oil change, park the machine on level ground and secure it<br />

against rolling away.<br />

Attention! Scalding hazard! When changing the engine oil, do not touch hot<br />

components of the engine. Wear suitable and closely fitting protective clothing.<br />

To drain the old oil, place a catch pan of sufficient size, oil-resistant and temperature-<br />

resistant underneath. Screw off the closure cap of the oil drain valve.<br />

Oil filler neck Oil dipstick<br />

Oil drain valve engine<br />

188<br />

Engine oil filter


189<br />

7 Maintenance and Service<br />

The valve opens when you have screwed the oil drain hose supplied onto the valve.<br />

When the old oil has completely drained, reclose the oil drain valve by unscrewing the oil<br />

drain hose from the valve.<br />

Replacing the oil filter inser<br />

– Unscrew oil filter lid using ratchet and hexagonal box wrench insert SW36.<br />

– When the oil has drained from the oil filter bowl, pull out the oil filter lid including the<br />

oil filter insert.<br />

– Release the oil filter insert by lateral pressure on the lower edge and dispose of<br />

compatible with the environment.<br />

– Replace the sealing ring on the screw-on lid. Wet the new sealing ring with engine oil<br />

before inserting it.<br />

– Insert the new oil filter insert in the oil filter lid and fit it into the lid by pressing it<br />

laterally.<br />

– Place the oil filter lid including oil filter insert onto the oil filter bowl and screw tight<br />

(tightening torque 25 Nm).<br />

Filling up engine oil<br />

– Fill up fresh engine oil through the oil filler neck.<br />

Filling volume about 23-28 Liter (Min-Max mark).<br />

– Switch on the ignition from the driver‘s seat and call up the submenu „special<br />

functions“ from the main menu of the color terminal. Here, in the line „engine oil<br />

change Start/Stop active“ select the option „yes“.<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

190<br />

Start button<br />

Stop button<br />

Climb onto the open lid of the battery box and reach across the engine. Simultaneously<br />

press the START and the STOP button on the engine for about 10 seconds. During<br />

this time, the engine is turned over without load and without starting. Close the engine<br />

housing. When the ignition is switched off or the engine is started, the setting „oil change<br />

START/STOP active“ is automatically reset. Then, start the engine from the driver‘s seat<br />

and let it idle for about one minute. Then, switch off the engine.<br />

About 5 minutes, after the engine has been shut off, check the oil level using the oil<br />

dipstick. When the oil has collected in the oil pan, the oil level should have levelled off in<br />

the middle between the min. and max. mark on the oil dipstick. Do not fill up too much<br />

engine oil.<br />

Check engine and oil filter for leaks (visual inspection).<br />

7.1.3 Fuel Supply<br />

Remark!.Danger of damage to the environment due to leaking fuel. When working on<br />

the filter, first place a catching pan underneath and properly dispose of caught fuel.<br />

Attention! Fire hazard when handling Diesel fuel. Smoking, fire and open flames are<br />

prohibited when handling Diesel fuel, since fuels and fuel fumes are easily combustible<br />

and explosive. Always make sure of sufficient supply of fresh air when handling fuels.<br />

Danger of skin injuries and poisoning hazard. Diesel fuel may cause damage to the skin<br />

in case of direct contact. When handling Diesel fuel, always wear suitable protective<br />

gloves, avoid inhaling fuel fumes, since this may lead to symptoms of poisoning.


Shutoff cock<br />

Standard prefilter<br />

Separ filter: is only installed in machines for CIS states<br />

191<br />

7 Maintenance and Service<br />

The Diesel fuel is drawn in by the fuel pump through a rough prefilter (Separ filter is<br />

only installed in machines for CIS states) and a standard prefilter (with integrated water<br />

separator and manual pump) and fed to the fine fuel filter at the engine. The Separ filter<br />

is fitted with an extra large water separator.<br />

The filter cartridges must be cleaned respectively exchanged as per maintenance plan.<br />

The fine fuel filter at the engine must be immediately replaced, independent of the<br />

service life, when the following icon is displayed on the color terminal.<br />

On the other hand, if the following icon is displayed on the color terminal, then the<br />

Separ filter must be cleaned respectively the filter cartridge of the standard prefilter must<br />

be replaced.<br />

Before all work on the fuel system respectively on teh fuel filters, the tank lid must<br />

be shortly opened and immediately closed again. This serves to reduce any possibly<br />

existing pressure in the fuel system. Only use original fuel filters approved by<br />

Mercedes-Benz respectively <strong>ROPA</strong>.<br />

After all work on the fuel prefilters, bleed these using the manual pump at the standard<br />

prefilter.<br />

Separ filter<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

7.1.3.1 Fuel Prefilter Separ<br />

Maintenance Separ filter (drain water and flush)<br />

Draining of the water collected is required when the water collection vessel is full,<br />

freezing threatens or the exchange filter is replaced. For this purpose:<br />

– Shut off the engine.<br />

– Close the shutoff cock at the input of the filter.<br />

– Open the bleeding screw on top of the filter.<br />

– Open the drain cock at the bottom of the filter.<br />

– Let the water and dirt drain from the transparent bowl and properly dispose of it. The<br />

filter strainer is flushed and cleaned by draining of the water.<br />

– Close the drain cock.<br />

– Close the bleeding screw.<br />

– Open the shutoff cock.<br />

– Start the engine. The air in the filter is moved off into the tank.<br />

Shutoff cock<br />

Lid<br />

Drain cock for<br />

water<br />

192<br />

Bleeding screw<br />

Cap screw


Cleaning the filter insert<br />

193<br />

7 Maintenance and Service<br />

Cleaning of the filter insert (metal strainer with 60 Mikron filter mesh; <strong>ROPA</strong> item no.<br />

301231) in the Separ filter is required once annually or when the intake resistance is too<br />

high. The following icon is displayed on the color terminal .<br />

Clean the filter insert as follows:<br />

– Shut off the engine.<br />

– Close the shutoff cock to the filter.<br />

– Unscrew the lid screws (4 pieces).<br />

– Take off the lid.<br />

– Take off the spring housing and then take out the filter insert.<br />

– Clean the filter insert using clean Diesel fuel. Do not use any other cleaning agents,<br />

since otherwise damage to the filter may occur.<br />

– Insert the cleaned filter insert and clip the spring housing onto the filter insert.<br />

– Check the lid gasket and replace it if needed.<br />

– Fill up the filter as far as possible using clean Diesel fuel (shorter bleeding time).<br />

– Put on the lid and make sure of correct fit.<br />

– Retighten the lid screws.<br />

– Open the shutoff cock.<br />

– Start the engine.<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

7.1.3.2 Replace Standard Prefilter Element/Drain Water<br />

Exchange of the filter insert is required annually or when the intake resistance is too high<br />

(the following icon is displayed on the color terminal ) and the engine shows loss of<br />

power.<br />

<strong>Manual</strong> feed pump<br />

(diaphragm pump)<br />

Replace the filter cartridge as follows:<br />

– Shut off the engine.<br />

– Close the shutoff cock before the fuel prefilter.<br />

– Uninstall the old filter cartridge. The old filter cartridge may stick to the filter head.<br />

– Loosen the old filter cartridge using suitable tools.<br />

– Unscrew the water collection vessel.<br />

– Dispose of the old filter cartridge in compliance with the local disposal regulations.<br />

– Oil the gasket.<br />

– Screw on the filter by hand, until the gasket is touching.<br />

– Keep turning by hand, until the filter has tight fit (about 3/4 revolution).<br />

– Open the shutoff cock before the fuel prefilter.<br />

– Bleed for so long using the manual pump, until no air bubbles are visible any more.<br />

– Check the filter unit for leaks (visual inspection).<br />

194<br />

Standard prefilter with diaphragm<br />

pump until model year 2007<br />

Standard prefilter with piston pump from model year 2008


Draining water from the water collecting vessel<br />

195<br />

7 Maintenance and Service<br />

Draining of water collected is required when the water collecting vessel is full, freezing<br />

threatens or the exchange filter is replaced.<br />

– Open drain screw (2) at the bottom<br />

of the water collecting vessel (1).<br />

– Let the water drain.<br />

– Retighten the drain screw.<br />

Bleed prefilter using the manual pump<br />

Bleeding of the filter is necessary when work has been performed on the fuel system<br />

near the prefilter or the fuel tank has been run completely dry.<br />

– Switch off the engine.<br />

Only applies to prefilters with diaphragm pump:<br />

– Pump for so long until a noticeable counterpressure can be felt.<br />

– Immediately start the engine.<br />

Only applies to prefilters with piston pump:<br />

– Unlock the bayonet cap of the piston pump on the fuel prefilter.<br />

– The pump piston is pushed outward by the spiral spring. Fuel supply from the tank is<br />

interrupted then.<br />

– Pump using the piston pump. For this purpose, push the piston into the filter head<br />

up to at maximum 15 mm before reaching the suspension point. In this manner, you<br />

achieve the best pumping performance.<br />

– Pump for so long until a noticeable counterpressure is felt (maybe up to<br />

200 strokes).<br />

– To start the engine, completely press the pump piston into the filter head and let the<br />

bayonet engage by about one quarter of a revolution to the right.<br />

– Immediately start the engine.<br />

opening<br />

closing<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

7.1.3.3 Microorganisms in the fuel system<br />

Occasionally, at first inexplicable obstructions in the fuel system filled with Diesel or bio<br />

Diesel fuels will be found. These obstructions are often caused by microorganisms.<br />

These microorganisms (bacteria, mushrooms, yeast) may multiply very much under<br />

favorable conditions: needed for growth are water, which is found in every storage or<br />

vehicle (fuel) tank as condensing water, and vital elements in chemically bound form,<br />

like sulfur, phosphor, nitrogen, oxygen and trace elements. Fuel additives may also<br />

contribute to microorganism growth.<br />

Depending on the temperature, growth is stronger or less strong, which leads to the<br />

formation of fiberous mushroom meshes and sludge.<br />

The consequences: obstruction of the fuel prefilter by rust and fibers (mushroom mesh)<br />

and frequent filter exchange. This leads a loss of power of the engine and in extreme<br />

cases to breakdown of the vehicle.<br />

Remedial measures<br />

If infestation with microorganisms is found for storage or vehicle (fuel) tanks, then we<br />

recommend the following disinfecting agents to fight it:<br />

Product: GrotaMar 71 or:.<br />

Manufacture: Schülke & Mayr<br />

D-22840 Norderstedt<br />

0 40 / 5 21 00 - 0<br />

Fax: 0 40 / 5 21 00 - 244<br />

In case of need, please contact the manufacturers<br />

(for instance to enquire about sources abroad).<br />

196<br />

Product: BAKZID<br />

Manufacture: Bode Chemie Hamburg<br />

Melanchthonstr. 27<br />

D-22525 Hamburg<br />

0 40 / 5 40 06 - 0<br />

Fax: 0 40 / 5 40 06 - 200


7.1.3.4 Fuel fine filter at the engine<br />

1<br />

197<br />

7 Maintenance and Service<br />

The fuel fine filter at the engine must be replaced after the first 400 operating hours,<br />

thereafter at least annually.<br />

When the warning icon is displayed on the color terminal, the fuel fine filter must<br />

also be replaced.<br />

To exchange the fuel fine filter, proceed as follows:<br />

– Park vehicle and shut off engine.<br />

– Close the shutoff cock before the fuel prefilter.<br />

– Place a vessel of sufficient size and being fuel-resistant under the filter bowl to<br />

catch emitting fuel.<br />

– Swing the tommy bar of the 3-way cock (1) upward (this blocks fuel supply and<br />

the content of the filter bowl can drain into the vessel placed underneath).<br />

– Unscrew the screw-on lid (2) of the fuel fine filter using a ratchet and a box<br />

wrench insert (SW 36).<br />

– Slightly pull the screw-on lid (2) including the filter cartridge from the filter housing<br />

and let the fuel drain.<br />

– Take off the screw-on lid including filter insert.<br />

– Remove the filter insert by lateral pressure on the lower edge.<br />

In any case, make sure that no foreign objects ingress the filter housing. Do not wipe the<br />

inside of the filter housing. Avoid any ingress of water into the filter housing.<br />

– Replace the gasket for the fuel fine filter (slightly grease it).<br />

– Clip the new filter insert into the screw-on lid (2).<br />

– Screw on the screw-on lid (2) including filter insert on the filter bowl and tighten<br />

using a tightening torque of 25 Nm.<br />

2<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

– Swing the tommy bar of the 3-way cock (1) to the front (this reopens fuel supply and<br />

drain of the filter bowl is closed.<br />

– Open the shutoff cock before the fuel prefilter).<br />

– Bleed the fuel system by activating the manual pump at the fuel prefilter.<br />

There must be sufficient battery capacity available during the starting process for<br />

bleeding of the fuel line at the engine.<br />

Let the engine run for about 1 minute, so that the fuel system can be bled. Then:<br />

– Check the fuel filter for leaks (visual inspection).<br />

7.1.3.5 Other maintenace work on the Diesel engine<br />

During each maintenance service on the Diesel engine, the following work must be<br />

carefully additionally performed in compliance with the Mercedes-Benz maintenance<br />

regulations (see maintenance booklet for the engine):<br />

– Leak and condition examination of all pipes and hoses of the engine.<br />

– Checking the intake lines between the air filter and engine, and the lines for the<br />

cooling and heating system for condition and leaks.<br />

– Checking all lines and hoses for undamaged condition as well as chafe-free and<br />

proper routing and fastening.<br />

– Checking all hose clamping collars, flanged connections and air intake manifolds for<br />

tight fit.<br />

Checking respectively adjusting of valve clearance is required after the first 400<br />

operating hours and then once annually respectively every 1200 operating hours. This<br />

work may only be performed by people expressly authorized for this work by<br />

Mercedes-Benz. The work process is described in the Mercedes-Benz maintenance<br />

instructions.<br />

Valve-clearance for cold engine:<br />

– Inlet valves 0.40 mm<br />

– Outlet valves 0.60 mm<br />

198


7.1.4 Radiator System<br />

199<br />

7 Maintenance and Service<br />

The radiator system must be regularly checked for cleanliness and cleaned if needed.<br />

If the admissible maximum temperature of the coolant or the hydraulics fluid is<br />

repeatedly exceeded during very high environmental temperature, then the complete<br />

cooling system must be checked for cleanliness and, in case of need, be immediately<br />

cleaned.<br />

7.1.4.1 Reversing fan drive<br />

Always make sure that the air intake grids are free of dirt or adherent leaves, etc.<br />

To clean the intake grid of loose pollutants, the fan drive for the radiator system is<br />

automatically reversed at each start of the engine. The fan largely blows the intake grid<br />

free.<br />

If automatic reversing should not be sufficient to keep the intake grid free, then the fan<br />

drive may be manually reversed during operation.<br />

For this purpose, press seitch (2). You achieve the best cleaning effect if you increase<br />

the engine speed to maximum speed during reversed fan drive.<br />

7.1.4.2 Cleaning the radiator system<br />

2<br />

The radiator system is located above the Diesel engine. After swing down the rear<br />

platform wall, the radiator system is easily accessible from the climbing platform. Always<br />

shut off the engine for cleaning work on the air intake girds or the radiators and secure it<br />

against inadvertent starting (pull off the ignition key and carry it on your body).<br />

Warning! Burning hazard. Each radiator is heated up during operation. Wear protective<br />

gloves! Before all work on the radiator systems, let the machine cool down sufficiently!<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

Charge air cooler<br />

Proceed as follows for cleaning the radiator system:<br />

– Switch off the engine and secure the machine against inadvertent starting (pull off<br />

the ignition key and carry it on your body).<br />

– Swing down the rear platform wall.<br />

– Clean the air intake grid using a brush and – if necessary – using the water jet from<br />

a water hose of possibly sticking dirt.<br />

– Swing up the air intake grid.<br />

Hydraulics fluid cooler<br />

200<br />

Water cooler<br />

Rear platform wall<br />

Air intake grid


201<br />

7 Maintenance and Service<br />

– Swing up the rear platform wall, close the cabin door and start the engine.<br />

Attention!.Hazard of eye and skin injuries due to foreign objects blown out. Nobody may<br />

be staying on the climing platform during manual reversal. Due to the strong air current<br />

of the fan, eye and skin injuries can be caused by dirt particles flung away by the air<br />

current.<br />

– Reverse the fan manually for about one minute. You achieve the best cleaning effect<br />

if you let the Diesel engine run at maximum speed.<br />

– Switch off the Diesel engine and secure the machine against inadvertent starting<br />

(pull off the igntion key and carry it on your body).<br />

– Pull the locking lever for the engine air box and swing it up.<br />

Locking lever<br />

engine air box<br />

Attention! Hazard of skin injuries due to sharp edges on the air conditioning condenser.<br />

When working on the open fan housing, always wear suitable protective clothing<br />

(protective gloves, hard helmet, closely fitting working clothing).<br />

Engine air box<br />

swung up<br />

Air conditioning<br />

condenser<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

– Check the radiator system for soiling. Remove coarse dirt by manual collection, by<br />

7.1.4.3 Checking coolant<br />

cleaning the radiator system using a water hose (NOT high pressure cleaner) or<br />

by blowing out using compressed air. You will find a plug-in coupling for connecting<br />

a blow gun – depending on the equipment of your machine – on the right, at the<br />

compressed air reservoir, or below a cover for the ball cocks of the water spraying<br />

system. During all work on the radiator system, make sure that you do not damage<br />

the fins of the air conditioning condenser.<br />

– After completion of cleaning work, close the fan housing and the intake grid. Swing<br />

up the rear platform wall again.<br />

Warning! Poisoning hazard and hazard of damage to the skin. Corrosion protection<br />

and antifreeze agents contain hazardous materials. There is an acute poisoning hazard<br />

when swallowing. In case of contact to the skin, irritation or cauterization/burns may<br />

occur. Never fill corrosion protection/antifreeze agents into drinking vessels or beverage<br />

bottles. Always store these agents so that children do not have access to the agents.<br />

In any case, comply with the hints on safety of the manufacturer of these agents. Hazard<br />

of damage to the environment. Corrosion protection/antifreeze agents are hazardous for<br />

the environment. When handling these materials, always make sure that the corrosion<br />

protection/antifreeze agents do not enter the environment, but are disposed of in a<br />

manner compatible to the environment.<br />

Always make sure of sufficient antifreeze and only use corrosion protection/antifreeze<br />

agents expressly approved in the Mercedes-Benz company standards 325.0 or 326.0<br />

(see page 298).<br />

If the liquid level in the cooling-water expansion tank is too low, then the warning icon<br />

is displayed on the color terminal.<br />

The cooling-water expansion tank with the filler neck for coolant is located on the<br />

climbing platform behind the hydraulics liquid tank.<br />

202


Filler lid<br />

203<br />

7 Maintenance and Service<br />

Warning! As long as the engine is hot, the cooling system is under high pressure. There<br />

is a scalding hazard due to emitting steam or hot cooling liquid spraying out! Wear<br />

protective gloves and protective goggles. Carefully open the radiator lid when the engine<br />

has cooled down.<br />

Expansion tank for coolant for <strong>euro</strong>-Maus3<br />

Check cooling liquid level and corrosion protection/antifreeze agent, if needed,<br />

correct<br />

Only check the coolant level at a coolant temperature of below 50 °C. Before correcting<br />

the coolant level, check corrosion protection/antifreeze.<br />

Checking of the coolant level is performed by visual control at the expansion vessel. The<br />

coolant level is correct if the cold coolant reaches the lower edge of the filler opening.<br />

The correct share of 50 Vol.% corrosion protection/antifreeze agents in the coolant is<br />

warranted if it is frost-proof up to -37 °C. If less antifreeze is indicated, then correct the<br />

mixture ratio.<br />

If the concentration is too low, there is the hazard of damage to the engine due to<br />

corrosion/cavitation in the cooling system!<br />

Avoid concentrations of more than 55 Vol.-% corrosion protection/antifreeze agents,<br />

because otherwise the maximum frost protection of up to -45 °C is not achieved.<br />

For refilling, only use prepared coolant with 50 Vol.-% corrosion protection/antifreeze<br />

agents, which are expressly approved by Mercedes-Benz.<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

Remarks of Mercedes-Benz on the cooling agent (general information):<br />

Normally, coolant consists of water and corrosion protection/antifreeze agent. The<br />

corrosion protection/antifreeze agents (ethylene glycol with corrosion inhibitors) have<br />

the following tasks in the cooling system:<br />

– Sufficient corrosion and caviation protection for all components of the cooling system<br />

– Lowering of the freezing point (frost protection)<br />

– Raising of the boiling point.<br />

For reasons of corrosion protection, the cooling liquid must be added about<br />

50 Vol.-% corrosion protection/ antifreeze agents, if the environmental temperatures to<br />

be expected do not require an even higher concentration. This concentration (50 Vol.-%)<br />

offers antifreeze protection up to about -37 °C. A higher concentration is only sensible for<br />

even lower environmental temperatures. Even in case of extremely low environmental<br />

temperatures, do not use more than 55 Vol.-% of corrosion protection/antifreeze agents,<br />

since the maximum frost protection is achieved then, and an even greater share in<br />

the mixture again reduces frost protection and worsens heat dissipation (55 Vol.-%<br />

corresponds to frost protection up to about -45 °C). If these coolant regulations are not<br />

complied with, then corrosion and damage to the cooling system are inevitable. Adding<br />

of corrosion protection/antifreeze agents raises the boiling point. Increased pressure<br />

further increases the boiling temperature. Both physics coherences are used in modern<br />

cooling systems – the maximum coolant temperature is increasedwithout increasing<br />

the hazard of boiling. Corresponding to the higher temperature level, the cooling<br />

performance increases. Only approved products (sheet 325.0/326.0) offer reliable<br />

protection of the cooling system.<br />

204


7.1.4.4 Replacing coolant<br />

205<br />

7 Maintenance and Service<br />

Only use corrosion protection/antifreeze agents approved by Mercedes-Benz. The<br />

coolant must be exchanged every three years. In any case, comply with the regionally<br />

applicable regulations on environmentally compatible disposal of coolant.<br />

– Before renewal of coolant, check the cooling and heating system for leaks and<br />

condition.<br />

– Slowly open the closure cap of the engine cooling system; relieve excess pressure<br />

and take off the closure cap.<br />

Drain valve for<br />

coolant<br />

The valve for draining the cooling liquid is located above the starter motor behind the<br />

exhaust pipe of the Diesel engine.<br />

Attention!.Burning hazard on the hot engine block and the hot exhaust pipe. Wait for<br />

so long for changing the cooling liquid until the engine has sufficiently cooled down. To<br />

protect against burns, wear suitable protective clothing (working clothing and protective<br />

gloves).<br />

– Screw the drain hose onto the coolant drain valve on the engine block.<br />

– Drain the coolant and catch it in a suitable vessel.<br />

– Fill up with premixed and approvel coolant<br />

(filling volume about 25 Liter).<br />

– Set the desired temperature of the air conditioning system to the maximum<br />

temperature, so that the control valve of the heating system is opened.<br />

– Switch on the heating system of the hydraulics fluid tank (lever up).<br />

– If you machine is fitted with an independent heating system, then switch it on.<br />

– Fill up coolant in the prescribed composition to the lower edge of the filler neck.<br />

– Start the engine and let it run for about 1 minute at different speeds.<br />

– Check the coolant liquid level and fill up coolant liquid, if required.<br />

– Close the cooling system (this process may have to be repeated several times).<br />

– Have replacing of the coolant confirmed on the maintenance slip.<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

7.2 Air Conditioning System<br />

Attention!.Hazard of damage to health and hazard of damage to the environment.<br />

Maintenance work on the air conditioning system requiring opening of the coolant<br />

circuit (for instance refilling of coolant, exchange of the collector dryer, etc.) may only be<br />

performed by an authorized specialist workshop.<br />

The air conditioner condenser is located in the ventilator air box. It is attached in front<br />

of the radiator. Use compressed air or a water hose for cleaning (in no case a high-<br />

pressure cleaner!). The air conditioner condenser is swung up with the air box for<br />

cleaning.<br />

Warning! Burning hazard! Every radiator is heated up during operation. Wear protective<br />

gloves! Let the machine cool down sufficiently before all work on the cooling systems!<br />

206<br />

condenser<br />

air conditioning<br />

If the air conditioning system has a too low cooling performance, then the following<br />

causes may apply:<br />

– Air conditioning condenser dirty.<br />

Remedy: blow out the air conditioning condenser using compressed air<br />

(max. 5 bar). During blowing out, make sure that the fins of the condenser are not<br />

damaged.


– Coolant circuit insufficiently filled.<br />

207<br />

7 Maintenance and Service<br />

Remedy: Possible only by specialist personnel using the required specialist tools.<br />

Filling is sufficient, if at the inspection glass of the collector drier coolant without<br />

bubbles is visible. The collector drier is located in the engine compartment behind<br />

the engine and in front of the vehicle frame. It is accessible by a housing hatch in the<br />

segment of the infeed conveyor.<br />

Danger!.Hazard to life when opening the hatch while the machine is running. Before<br />

opening the hatch, switch off the engine and secure the machine against switching on.<br />

For this purpose, pull off the ignition key and carry it on your body. Additionally, switch off<br />

the main battery switch.<br />

Maintenance hatch<br />

Inspection glass of the collector drier<br />

If the air conditioning system has a too low cooling performance, then the following<br />

causes may apply:<br />

– Circulating air grid in the cabin not open<br />

Remedy: Open circulating air grid.<br />

– Circulating air grid in the cabin blocked<br />

Remedy: Clean circulating air grid.<br />

Maintenance annually:<br />

– Have the air conditioning system checked by an authorized specialist workshop and<br />

repaired if needed.<br />

Maintenance every two years:<br />

– Have refrigerant and collector drier (<strong>ROPA</strong> item no. 301191) changed/replaced<br />

by an authorized specialist workshop, even if no bubbles should be visible in the<br />

inspection glass of the collector drier.<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

Hint.for.the.specialist.workshop! When exchanging or refilling of refrigerant, the<br />

following oil must be added: Fuchs Reniso PAG 46 (<strong>ROPA</strong> item no. 435046). The air<br />

conditioning system may in no case be operated using other oil additives. Filling volume<br />

refrigerant about 1.7 kg.<br />

10 ml oil must be circulating in the refrigeration circuit for every 100 ml refrigerant.<br />

All machines are added a fluorescent agent to the refrigerant during initial filling by<br />

<strong>ROPA</strong>. This enables quick and cost-effective detection of leaks possibly occurring on<br />

the air conditioning system.<br />

7.3 Pump distributor gears<br />

The pump distributor gears (PVG) is directly connected to the engine and transfers the<br />

engine power to the individual hydraulics pumps.<br />

The oil level of the pump distributor gears must indispensably be checked daily. Check<br />

the oil level before starting the Diesel engine! When the Diesel engine has been started,<br />

oil level monitoring is no longer possible.<br />

The machine must be standing on even and level ground to read the oil level and the<br />

engine must have been shut off for at least five minutes.<br />

When the oil level rises or falls without any apparent reason, call in a customer service<br />

mechanic.<br />

The oil level can be read at the inspection glass; it must be within the inspection glass<br />

range (in no case above the upper edge of the inspection glass!). The inspection glass is<br />

located on the left side of the pump distributor gears.<br />

208


Inspection glass<br />

209<br />

7 Maintenance and Service<br />

The first oil change is required after 50 operating hours. Thereafter, the oil must be<br />

changed annually. At each oil change, the intake filter of the pump distributor gears and<br />

the pressure filter cartridge must be replaced.<br />

Oil and filter change<br />

– Before performing the oil change, extensively clean the section around the intake<br />

and pressure filters.<br />

– Change the oil only with the gears at operating temperature.<br />

– Place a catching vessel resistant to oil and of sufficient size underneath.<br />

– Open the closure cap of the drain valve of the pump distributor gears.<br />

– Screw the oil drain hose supplied onto the drain valve of the pump distributor gears.<br />

(the valve opens and the gear oil drains).<br />

– Unscrew the cap nut of the intake line from the filter flange on the internal side of the<br />

gears (this requires a box wrench SW 36).<br />

– Loosen the hexagonal bolted connection on the filter flange (the bolted connection<br />

may ONLY be loosened.<br />

– In no case completely separate the bolted connection (this requires a box wrench<br />

SW 46).<br />

Intake line<br />

Filter flange intake filter<br />

Oil drain valve<br />

– Unscrew the 4 bolts on the filter flange (SW13) and pull out the filter insert.<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

– Replace the filter insert with a new one (<strong>ROPA</strong> item no.: O-40320010)<br />

(for installation, always use a new paper gasket (<strong>ROPA</strong> item no.: O-20350003) and<br />

coat this gasket with oil before installation).<br />

– Retighten the bolted connection of flange and hose.<br />

– Unscrew the pressure filter bowl using a wrench SW24 from the inside of the gear<br />

valve manifold and replace the filter insert with a new one (<strong>ROPA</strong> item no.: 270442).<br />

– The O ring at the filter bowl must also be replaced with a new O ring.<br />

– First, completely screw the pressure filter bowl into the valve manifold, and then<br />

unscrew by one sixth of a revolution.<br />

– Unscrew the oil drain hose and screw on the closure cap.<br />

– Open the oil filler screw and fill up with fresh oil at the filler opening until the oil level<br />

is in the upper range of the inspection glass. Do not use the opening of the bleeding<br />

screw.<br />

Oil filler screw<br />

Gear valve manifold with pressure<br />

filter on the inside<br />

Pressure filter bowl<br />

Prescribed oil type: ESSO ATF D 21611<br />

Filling volume: about 10 Liter<br />

Start the engine and watch the color terminal. The warning icon must disappear<br />

within 10 seconds from the color terminal. If the warning icon does not disappear within<br />

10 seconds, immediately shut off the engine and bleed the gears.<br />

210<br />

Bleeding screw


Bleeding the gears<br />

– Place an oil catching vessel under the valve manifold.<br />

– Remove the closure plug at the connection MP (see illustration).<br />

7.4 Hydraulics system<br />

211<br />

7 Maintenance and Service<br />

– Close the engine housing hatch and swing up the pump cover behind the climbing<br />

ladder.<br />

– Watch the connection MP on the valve manifold through the opening.<br />

– Have the engine started by a second, reliable and instructed person and run for so<br />

long (at maximum 15 seconds), until the gear oil emits from the opening at the valve<br />

manifold without bubbles.<br />

– Immediately screw on the closure plug again, when the oil emits free of bubbles, and<br />

tighten it using a torque of 16 Nm.<br />

If the oil does not emit within 15 seconds, then screw in the closure plug again and<br />

call the customer service.<br />

– Wait at least 10 minutes and then again test the oil level, as described above.<br />

– If needed, fill up oil.<br />

Danger!.The pressure reservoir of the hydraulics system is permanently under high<br />

internal pressure, even if the remaining hydraulics system is already pressureless. Work<br />

on the pressure reservoirs may only be performed by especially trained people familiar<br />

with handling of pressure reservoirs. The system must first be rendered pressureless for<br />

all work on the hydraulics system or on the pressure reservoirs. Work on the hydraulics<br />

system may only be performed by people having been instructed about the specific risks<br />

and hazards of working on hydraulics systems.<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

Regularly check the hoses of the hydraulics system for aging and damage! Immediately<br />

exchange damaged or aged hoses. Only use hoses as replacements corresponding to<br />

the technical specifications of the original hose!<br />

When using a vacuum pump, do not set vacuum of less than 0.2 bar.<br />

Observe, that a soiled cooler will achieve a clearly reduced cooling performance. This<br />

substantially reduces the load bearing capacity of the machine. If the hydraulic fluid is<br />

heated up too much, then shut off the engine and try to determine the cause. Usually,<br />

the hydraulic fluid cooler is soiled; possibly, the heating system for the hydraulic fluid<br />

tank has not been shut off.<br />

Warning! Burning hazard! Every cooler is heated up during operation. Wear protective<br />

gloves! Before all work performed on cooling system, let the machine cool down<br />

sufficiently!<br />

7.4.1 Hydraulic fluid tank<br />

Hydraulic fluid cooler<br />

The tank for hydraulic fluid is located on the cabin platform behind the handrail. The<br />

hydraulic fluid level must be checked daily before starting the machine. Fluid level and<br />

fluid temperature may be read at the inspection glass on the front side of the hydraulic<br />

fluid tank. The hydraulic fluid level should always remain in the range between the center<br />

of the inspection glass and the upper edge of the inspection glass. Always make sure<br />

of correct fluid level in the hydraulic fluid tank. During all work on the hydraulics system,<br />

make sure of the utmost cleanliness!<br />

Take note that different types of hydraulic fluid may not be mixed.<br />

212


213<br />

7 Maintenance and Service<br />

Unscrew the black filler lid (bleeding head) from the cover of the fluid tank for refilling<br />

hydraulic fluid.<br />

When you open the filler lid for hydraulic fluid, it is possible that you will hear a „hissing“<br />

noise. This noise is normal.<br />

The filling and bleeding filter ensures the required air equalization for fluctuating fluid<br />

level (for instance due to oil temperature). Replace it when it is soiled, but at the latest<br />

every 2 years (<strong>ROPA</strong> item no.: 270389).<br />

7.4.1.1 Hydraulic fluid change<br />

The hydraulic fluid must be changed annually, best shortly before start of the season.<br />

For this purpose, provide a vessel of sufficient size. Use the fluid drain hose supplied for<br />

changing the hydraulic fluid. Screw the oil drain hose onto the valve on the bottom of the<br />

hydraulic fluid tank. The valve opens and the old fluid drains.<br />

Drain valve<br />

Hydraulic fluid<br />

Filling lid incl.<br />

bleeding filter<br />

Inspection glass<br />

fluid level + fluid<br />

temperature<br />

Approved fluid types: Hydraulik fluid HVLP 46 as per DIN 51524, part 3.<br />

Filling volume: about 190 Liter<br />

In no case use common HLP fluids.<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

7.4.1.2 Check intake strainers<br />

The intake strainers inside of the hydraulic fluid tank must be checked every two years<br />

before filling up with fresh hydraulic fluid, by means of visual inspection, for soiling. If the<br />

intake strainers are soiled, then clean them.<br />

– For this purpose, take off the metal lid of the hydraulic fluid container. Flush the<br />

intake strainers from inside to the outside using sufficient cleaning agent .<br />

– Reinsert the intake strainers.<br />

Intake strainer inside the hydraulic fluid tank<br />

– Place the gasket and the metal lid on them.<br />

– Coat the bolts for fastening the metal lid with sealing compound (<strong>ROPA</strong> item no.<br />

017026) before inserting them and tighten the bolts.<br />

214<br />

Metal lid<br />

Intake return filter


7.4.1.3 Replacing the hydraulic fluid filter<br />

215<br />

7 Maintenance and Service<br />

Before filling up fresh hydraulic fluid, replace both filters of the hydraulics system. These<br />

filters are one-way products. They may not be cleaned. Cleaning destroys the filters and<br />

the hydraulics system may sustain severe damage.<br />

An intake return filter is located on the hydraulic fluid tank. When replacing the filter<br />

element – as during all work on the hydraulics system – make sure of the utmost<br />

cleanliness. Make sure that hte O ring seals in the filter housing are neither damaged<br />

nor soiled. Before opening the filter housing, make sure that the hydraulics system is<br />

rendered absolutely pressureless and the fluid filler lid is open.<br />

Filter lid<br />

O ring (164.47 x 5.33 NBR contained<br />

in item no. 270483<br />

Separating plate<br />

Filter element <strong>ROPA</strong> item no 270483<br />

Dirt catch basket<br />

(fastened to the filter element using a<br />

bayonet catch)<br />

Initial replacement of the filter element is required after the first 50 operating hours, then<br />

annually.<br />

For replacing the filter element in the intake return filter, proceed as follows:<br />

– four lid fastening bolts and keep these in a safe place.<br />

– Take off the lid of the intake return filter.<br />

– Using a slight rotating movement, pull the filter separating plate including the<br />

attached filter element out.<br />

– Disassemble the pulled-out unit into the filter separating plate, filter element and dirt<br />

catch basket.<br />

– Clean the housing, lid, filter separating plate and dirt catch basket.<br />

– Examine the filter for mechanical damage. Damaged parts may not be reinstalled<br />

any more (these must be replaced immediately).<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

– Check the O rings and replace possibly damaged parts.<br />

– Before installation, wet sealing surfaces, threads and O rings using fresh hydraulic<br />

fluid.<br />

– Use ONLY a new filter element (<strong>ROPA</strong> item no. 270483) for installation.<br />

– Use the O ring supplied when inserting the new filter element.<br />

– Install the filter separating plate, filter element and dirt catch basket into one unit.<br />

– Insert the filter separating plate with the attached filter element and dirt catch basket<br />

into the filter head using a light rotating movement.<br />

– Place the lid on again and screw in the fastening bolts. The tightening torque of the<br />

fastening bolts is 40 Nm.<br />

7.4.2 Replacing the pressure filter element<br />

A large pressure filter for operating hydraulics is located above the right front wheel<br />

behind the cabin. The filter element must be replaced annually.<br />

Pressure filter operating hydraulics<br />

Replacing the pressure filter element<br />

– Switch off the engine.<br />

– Unscrew the filter bowl (SW 32) and catch the emitting hydraulic fluid using<br />

a suitable vessel. Dispose of the hydraulic fuel in compliance with the locally<br />

applicable environment protection regulations.<br />

– Pull the filter element from the element stud. Inspect the surface of the uninstalled<br />

filter elements for dirt residue and larger particles. These may point to damage to the<br />

components.<br />

– Dispose of the filter element in compliance with the regionally applicable<br />

environment protection regulations.<br />

– Clean the filter bowl.<br />

– Check the new filter for mechanical damage, especially the sealing surfaces and<br />

threads.<br />

– Replace the O ring on the filter bowl (dirt or incomplete pressure relief during<br />

disassembly may lead to sticking of the bowl thread).<br />

216


Element installation<br />

217<br />

7 Maintenance and Service<br />

– Wet the thread and sealing surfaces of the filter bowl and head as well as the O ring<br />

of the bowl and element using fresh and clean hydraulic fluid.<br />

– Install the new element (<strong>ROPA</strong> item no. 270430 incl. O ring). For this purpose,<br />

carefully place the filter element onto the element stud.<br />

– Screw in the filter bowl to the stop.<br />

– Unscrew the filter bowl by one sixth of a revolution.<br />

– Start the engine and lock the tank (run against pressure) (check filter for leaks).<br />

Remark!.Dispose of hydraulic fluid, filter elements and cleaning rag, etc. in compliance<br />

with the locally applicable environment protection regulations!<br />

7.5 Mechanical drive of the two steering axles<br />

7.5.1 Cardan shafts from the transfer gear to the steering axles<br />

Both jointed shafts of <strong>euro</strong>-Maus3 must be lubricated after each 200 operating hours.<br />

Danger! Hazard to life due to rotating machine parts. When the engine is running,<br />

body parts or pieces of clothing may be caught by rotating jointed shafts and pulled into<br />

the machine. Before lubricating, immobilize <strong>euro</strong>-Maus3 and shut off the engine. The<br />

machine must be secured against inadvertent starting of the engine.<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

Example illustration: one lubricating nipple<br />

One lubricating nipple each is installed in each joint. This must be lubricated after each<br />

200 operating hours.<br />

7.5.2 Maintenance cardan joints of the axles<br />

The cardan joints of the double-joint shafts in the steering knuckles of the two steering<br />

axles must be lubricated each 200 operating hours. Each cardan joint has two lubricating<br />

nipples. Both lubricating nipples must be lubricated.<br />

7.6 <strong>Manual</strong> transmission<br />

The manual transmission is used for switching the operating modes „turtle“ and „rabbit“<br />

as well as speeds I and II and all wheel drive.<br />

218


219<br />

7 Maintenance and Service<br />

The oil level of the manual transmission must be checked weekly. Control is performed<br />

using the inspection glass. The oil level is correct if the oil level is in the central range of<br />

the inspection glass. The inspection glass is located at the rear of the transmission next<br />

to the cardan shaft.<br />

The first oil change is due after 50 operating hours; further oil changes are required<br />

annually.<br />

7.7 Axles<br />

Remark!.The complete transmission consists of two units connected by a narrow duct<br />

and therefore having a joint oil circuit. For the oil change, the machine must be standing<br />

completely level. After filling up, wait for at least one hour until final control. Only if after<br />

this waiting period the oil level is on the same level in both inspection glasses and at the<br />

center of the inspection glasses has enough oil been filled up in the transmission.<br />

Attention! Burning hazard. Danger from hot oil! The oil in the manual transmission may<br />

be very hot under certain circumstances. During oil change at the manual transmission,<br />

always wear gloves and suitable protective clothing.<br />

Proceed as follows for oil change:<br />

– Place a catching pan of sufficient size underneath.<br />

– Screw out the two oil drain screws (these are located at the lower corner of the<br />

transmission housing and at the bottom of the reduction gear); the old oil is drained.<br />

– Clean the magnetic oil drain screws of metal filings. Then reinsert the screws and<br />

tighten them.<br />

– Screw out the oil filler screw (it is located on the rear cardan shaft drive) and fill<br />

up fresh oil at the oil filler opening, until the oil level is in the upper range of the<br />

inspection glass.<br />

– Screw in the oil filler screw again.<br />

Prescribed oil type:<br />

Synthetic transmission oil: Mobil Mobilube SHC-LS SAE 75W-90<br />

Other oil brands are not allowed!<br />

Filling volume: about 12 Liter<br />

7.7.1 Planetary gear (applies to both axles)<br />

The first oil change must be performed after the first 50 operating hours. Thereafter, an<br />

oil change is required annually.<br />

Park <strong>euro</strong>-Maus3 so that the respective wheel is standing as shown in the illustration.<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

Attention!.Injury hazard! Immobilize <strong>euro</strong>-Maus3 each time and shut off the engine<br />

before performing an oil change on the individual planetary gears. The machine must be<br />

secured against inadvertent starting of the engine. All maintenance and repair work may<br />

only be peformed by trained specialist personnel. Danger.from.hot.oil.emitting.under.<br />

pressure! The oil in the planetary gears may become very hot and – due to heating up<br />

– be under a certain pressure. When perfoming an oil change on the planetary gears,<br />

always wear gloves and suitable protective clothing. Always, at first, screw out the oil<br />

filler screw very slowly and with due care, so that the pressure, which may have built up<br />

in the planetary gears, can be relieved without hazard.<br />

1<br />

Oil level<br />

Proceed as follows for performing an oil change:<br />

– Change the oil only with transmission at operating temperature. Park the machine on<br />

level ground. The oil level control screw („Oil Level“) (1) is level (see illustration).<br />

– Place a catching pan of sufficient size underneath.<br />

– Open the oil drain screw (2) and the oil level control screw and let the old oil drain.<br />

– Screw in the oil drain screw again.<br />

– Fill up the planetary gears using the <strong>ROPA</strong> planetary oil filler supplied, until the oil<br />

level reaches the lower edge of the opening for oil level control.<br />

– Screw in the oil level control screw again.<br />

– Wait for about 15 minutes and then check the oil level again. If needed, fill up a little<br />

oil.<br />

Remark! The <strong>ROPA</strong> planetary oil filler should be used for filling up oil (<strong>ROPA</strong> special tool<br />

item no. 018143). You can exactly and easily fill up the corresponding oil volume using<br />

this special tool.<br />

Prescribed gear oil: Hypoid gear oil as per API GL 5 SAE 85W-90<br />

Filling volume: each planetary gears at the front and rear axle<br />

220<br />

about 3.5 Liter<br />

Bleeding when<br />

filling oil up<br />

Planetary gears<br />

front and rear axles<br />

2


Front axle<br />

7.7.2 Differential gears on the front and rear axles<br />

221<br />

7 Maintenance and Service<br />

The first oil change is required after the first 50 operating hours. Thereafter, an oil<br />

change must be performed annually.<br />

Attention!.Injury hazard. Immobilize <strong>euro</strong>-Maus3 before the oil change and shut off the<br />

engine. The machine must be secured against inadvertent starting of the engine. All<br />

maintenance and repair work may only be performed by trained personnel.<br />

Differential gears on both axles:<br />

Proceed as follows when performing an oil change:<br />

– Change oil only with gears at operating temperature.<br />

– Place a catching pan of sufficient size underneath.<br />

– Screw out the oil drain screw of the differential gears. It is located at the bottom, at<br />

the lowest position of the axle body.<br />

– Open the oil level control screw and wait until the oil has completely drained.<br />

– Screw in the oil drain screw again.<br />

– Fill up oil in the oil filler opening for so long until the oil level reaches the lower edge<br />

of the oil filler opening.<br />

– Screw in the oil level control screw again.<br />

Prescribed gear oil: Hypoid gear oil as per API GL 5 SAE 85W-90<br />

Filling volume: Differential gears of the front axle about 22 Liter<br />

Differential gears of the rear axle about 20 Liter<br />

Differential gears<br />

Oil filler opening<br />

and oil level<br />

control screw<br />

Rear axle<br />

Oil drain screw<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

7.8 Pneumatics System – Maintenance and Service<br />

Air drier cartridge<br />

Maintenance work on the pneumatics system is only required on the air drier and the<br />

compressed air reservoirs. The compressor is maintenance-free.<br />

The air drier and the three compressed air reservoirs are located under the right lateral<br />

hatch. The drier cartridge of the air drier must be replaced after each 2000 operating<br />

hours.<br />

Condensed water must be drained from the compressed air reservoirs after each<br />

100 operating hours. If the machine is to be immobilized for a longer period of time (more<br />

than one week), then condensed water must also be drained from the compressed<br />

air reservoirs.<br />

222<br />

Drain valve for<br />

condensed water


7.9 Brake System – Maintenance and Service<br />

223<br />

7 Maintenance and Service<br />

The front axle and, if existing, the additional axle are braked by a compressed-air<br />

operated drum brake. Two independent brake circuits guarantee maximum safety, even<br />

if one brake circuit should fail.<br />

After washing the machine, „drive dry“ the brake. If the machine is started up with brakes<br />

frozen tight (ice formation by ingress of water), then this may lead to severe damage to<br />

the brake system!<br />

7.10 Pickup<br />

Check functioning of the brakes before each drive!<br />

Setting and repair work on the brakes may only be performed by specialist<br />

personnel familiar with maintenance and repair of compressed air brakes due to<br />

vocational training.<br />

Danger! If errors are made during maintenance, repair or setting work, there is extreme<br />

hazard to life for the driver and for other road users.<br />

7.10.1 Stop switch of the pickup<br />

Take off cover<br />

Occasionally clean the stop switch of the pickup. The switches are located to the right<br />

and left behind the hinged plate at the central part of the pickup. If the switches are<br />

blocked by dirt, then the pickup cannot be lowered, and the respective hinged plate<br />

cannot be swung up.<br />

Clean switch<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

7.10.2 Central mark<br />

After opening the front closing lid, the bearing for the central mark is accessible. The<br />

bearing must be relubricated after each 200 operating hours using the lubricating nipple.<br />

After opening the rear closing lid, the shaft of the eccentric drive is accessible. The<br />

eccentric drive must be relubricated weekly using the lubricating nipple.<br />

Check the lower side of the central mark daily for soiling (visual inspection) with lateral<br />

pickup parts retracted. Strong soiling should indispensably be immediately removed.<br />

Loosen the four bolts under the front closing lid for uninstalling the cover of the central<br />

mark.<br />

Pickup rollers<br />

224<br />

Lubricating nipple pickup roller<br />

Verschlussdeckel<br />

Power transmission from the pickup roller gears to the pickup roller is performed using<br />

an externally toothed shaft at the transmission and internal toothing on the roller. This<br />

toothing must be lubricated weekly using a grease gun.


7.10.3 Pickup roller gears<br />

225<br />

7 Maintenance and Service<br />

<strong>euro</strong>-Maus3 is fitted to the right and left outside on the lateral pickup parts with one<br />

set of pickup roller gears each. The oil level of these two gear units must be checked<br />

daily with pickup swung out and lowered. The inspection is performed at the inspection<br />

glasses. If the oil level is above the center of the inspection glass, then no oil has to be<br />

filled up.<br />

Pickup roller gears<br />

An oil change is required after the first 50 operating hours, then annually.<br />

Proceed as follows for performing an oil change:<br />

– Swing in the clearing plates.<br />

– Change the oil only with the gear units at operating temperature.<br />

– Place a catching pan of sufficient size underneath.<br />

– Open the oil drain screw and let the old oil drain.<br />

– Retighten the oil drain screw.<br />

Oil filler screw<br />

Inspection glass<br />

Oil drain screw<br />

– Fill up so much fresh oil at the filler opening (simultaneously bleeding plug), until the<br />

oil level with pickup lowered is in the upper range of the inspection glass.<br />

Prescribed gear oil: Hypoid gear oil as per API GL 5 SAE 85W-90<br />

Filling volume per gear unit: about 12.9 Liter<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

7.10.4 4-fold pinch roller gears<br />

An oil change must be performed after the first 50 operating hours, then annually.<br />

Proceed as follows for performing an oil change:<br />

– - Change the oil only with the gear unit at operating temperature.<br />

- Place a catching pan of sufficient size underneath.<br />

- Open the oil drain screw and let the old oil drain.<br />

- Retighten the oil drain screw.<br />

- Fill up so much fresh oil at the filler opening (simultaneously bleeding plug), until the<br />

oil level with pickup lowered is within the upper range of the inspection glass.<br />

Prescribed gear oil: Hypoid gear oil as per API GL 5 SAE 85W-90<br />

Filling volume per gear unit: about 2.7 Liter<br />

226<br />

4-fold pinch roller gears<br />

<strong>euro</strong>-Maus3 is fitted with one 4-fold pinch roller gear unit each to the right and left<br />

outside on the lateral pickup parts.<br />

Oil motor tapered roller Inspection glass<br />

Oil drain screw<br />

Oil filler<br />

screw<br />

Gears 4-fold pinch rollers


7.11 Uninstalling and Installing Rollers<br />

227<br />

7 Maintenance and Service<br />

Danger! When uninstalling and installing rollers, there is the danger that the lateral<br />

pickup parts suddingly swing down and that people staying in this sector may be<br />

severely injured. Before starting work, the respective lateral pickup part must be<br />

securely supported or suspended from a crane with sufficient load bearing capacity and<br />

additionally secured. Comply with the applicable accident prevention regulations when<br />

working under raised loads.<br />

Protective cap<br />

Hexagonal recess bolt M12 for<br />

anti-twist protection<br />

Pipe of the central<br />

lubricating system<br />

Perform a weekly check of the pipes of the central lubricating system leading to the<br />

rollers (visual inspection of the pipes, below the protective caps).<br />

Anti-twist protection<br />

M24 fine thread bolt<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

7.11.1 Uninstallation and installation of the pickup roller and the cleaning roller<br />

Pickup roller and cleaning roller (1 st and 2 nd roller) may only be jointly uninstalled,<br />

because the „pig tails“ of the pickup roller reach between the discs of the cleaning roller.<br />

The cleaning roller is plugged onto the gear unit. After releasing the thrust bearing, it<br />

may be pulled off at the center of the pickup (pedestal bearing with setting ring). There is<br />

no safeguard at the gear unit for the cleaning roller.<br />

The pickup roller is plugged onto a toothed shaft and additionally axially secured at<br />

the gear unit using a bolt (M20 x 350). The gear oil does not have to be drained for<br />

deinstallation. The closure lid of the bearing flange (on the outside of the gear unit) must<br />

be taken off before deinstallation of the pickup roller:<br />

– For this purpose, unscrew the four hexagonal bolts (SW 13) at the closure lid and<br />

remove the lid.<br />

– Remove the two securing screws (grub screws), which are located beside the large<br />

hexagonal bolt (M20 x 350).<br />

– Screw out the hexagonal bolt (M20 x 350).<br />

– Pull the pickup roller from the gear unit.<br />

– During installation of the pickup roller, screw in the hexagonal bolt (M20 x 350)<br />

again.<br />

Lid bearing flange<br />

– Only lightly tighten the bolt and then unscrew it by 1/8 th of a revolution.<br />

– Secure the hexagonal bolt against twisting using the two grub screws.<br />

– Both hexagonal bolts (M20 x 350 <strong>ROPA</strong> item no. 414725) must be replaced annually.<br />

228<br />

Grub<br />

screw<br />

Bearing flange<br />

Grub screw<br />

Hexagonal bolt M20 x 350


229<br />

7 Maintenance and Service<br />

7.11.2 Exchanging the pig tails of the pickup rollers/build-up welding<br />

The pickup rollers are fitted with turnover plates (<strong>ROPA</strong> item no. 101677) at the pickup<br />

pig tails.<br />

When the wear limit has been reached, these turnover plates must be rotated.<br />

This ensures long service life. Due to fastening using a bolted connection, each<br />

individual turnover plate being worn may be turned or replaced without problems and<br />

without large installation effort in case of need.<br />

Pig tail with turnover plate<br />

In case of very sandy soil (abrasive ground conditions), we recommend the use of<br />

hard-coatet wear plates (<strong>ROPA</strong> item no. 102080 incl. mounting bolt). These wear plates<br />

cannot be rotated.<br />

Warning!.Danger of severest contusion injuries in case of improper work on the pig tails<br />

of the pickup rollers. Work in this sector may only be performed when the machine is<br />

completely shut off and has been reliably secured against inadvertent startup (ignition<br />

key pulled off, securely kept by a responsible person and the driver‘s cabin locked).<br />

Only perform build-up welding. When repairing worn pig tails, the welding material may<br />

only be built up to a height of 70 mm (see drawing). In any case, make sure that the<br />

welding material is not built up too high, since the distance to the cleaning roller may not<br />

become too small.<br />

For the cleaning roller, at the corners of the individual disks, build-up welding should be<br />

performed in the form of a lateral seam to extend the service life.<br />

29.06.2007 17:21:23, Wast<br />

70 mm<br />

Wear limit<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

On the spirals of the feed and pinch rollers, the welding material may only be applied<br />

to the feed sides of the pinch rollers. In no case manually apply a build-up weld bead<br />

directly to the roller shaft. This will warp the complete roller due to the heating effect and<br />

it becomes useless. Make sure that the built-up beads are not higher than 20 mm. If the<br />

surface of your weld beads is rough, then you should smoothen the weld beads using an<br />

angle grinder and a fan disk. By this, you avoid surface damage to the beets at the start<br />

of the season.<br />

In case of especially high wear, build-up welding should be performed on the inner<br />

section of the four feed rollers (two each on the left and right) as well.<br />

The same holds true for the section below the central mark. In case of corresponding<br />

wear effects, we recommend, only here, to weld in laterally oriented pieces of steel bars<br />

(Ø ca. 12 mm) between the coils of the feed rollers.<br />

In case of need, four small hard-coated lateral beads should be applied to the inside<br />

ends of the cleaning rollers and the pickup rollers (directly next to the pedestal bearings).<br />

These must be distributed over the roller surface at the roller ends at 90° angle, so that<br />

two weld beads each are on opposite sides.<br />

A specific welding rod for build-up welding under inert protective gas (Ø 1.2 mm,<br />

15 kg/drum) may be obtained from <strong>ROPA</strong> with the order number 017014.<br />

For heavy wear ground, we recommend a much greater quality welding rod (containing<br />

tungsten carbide) – with longer service life – for build-up welds. This filler wire with a<br />

diameter of 1.6 mm may be obtained on 15 kg/drum from <strong>ROPA</strong>, with the order number<br />

017136.<br />

230


Please observe in any case:<br />

231<br />

7 Maintenance and Service<br />

– All retaining collars of the front roller bearings are tighted to the right (clockwise).<br />

– All polyamide plug-in couplings must be greased before sliding them onto the clutch<br />

dogs.<br />

– Insert a new O ring in the clutch dogs before installation.<br />

– The four M12 x 80 hexagonal recess bolts, by which the polyamide plug-in couplings<br />

are fastened to the rollers, must be coated with Loctite 270 bolt retention.<br />

7.11.3 Deinstallation and installation feed rollers<br />

The feed rollers (3 rd and 4 th roller) are plugged onto the gear unit. They may be pulled<br />

off after loosening the thrust bearing at the center of the pickup (pedestal bearing with<br />

retaining collar). There is no further locking device at the gears for the feed rollers.<br />

When installing the feed rollers, make sure that the turns of the rollers are not aligned.<br />

The turns of the rollers should be centrally offset to each other.<br />

– All retaining collars of the front roller bearings are tightened counter to the roller<br />

rotating direction.<br />

– All polyamide plug-in couplings must be greased for sliding them onto the clutch<br />

dogs.<br />

– Before assembly, a new O ring must be inserted in the clutch dogs.<br />

– The four M12 x80 hexagonal recess bolts, by which the polyamide plug-in couplings<br />

are fastened to the rollers, must be coated with Loctite 270 bolt retention.<br />

7.11.4 Deinstallation and installation tapered roller and pinch rollers<br />

The tapered rollers are directly plugged onto the respective drive motors on the outside<br />

(plug-in coupling). The pinch rollers are plugged onto the 4-fold pinch roller gears<br />

(plug-in coupling). To uninstall the tapered roller or pinch rollers, take off the protective<br />

cap above the central lubricating line and first screw out the fine thread bolt M24 below<br />

(inside, at the roller bearing), then the hexagonal recess bolt M12.<br />

All M24 fine thread bolts are fitted with right-handed thread (!) The tightening torque<br />

amounts to 1000 Nm. They are not.secured using liquid bolt retention (Loctite).<br />

Remark!.Before installation, apply a thin coat of copper paste (<strong>ROPA</strong> order no. 017159<br />

tube containing 100 g) to the thread.<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

Hinweis! Vor dem Einbau ist das Gewinde der Feingewindeschrauben dünn mit Kupferpaste<br />

For installation, the fine thread bolts M24 must be tightened using a torque of 1000 Nm.<br />

(<strong>ROPA</strong> Bestell-Nummer 017159) einzustreichen.<br />

The fine thread bolt M24 fastens the roller to the bearing plate using a bushing. The<br />

hexagonal recess bolt Beim M12 Einbau passes sind through die Feingewindeschrauben a bore in the bearing plate M24 into mit the einem twist Drehmoment von<br />

protection of the roller 1000 bearing. Nm festzuziehen. Die Sechskantschraube M24 hält mit einer Buchse die<br />

Walze an der Lagerhalteplatte fest. Die Innensechskantschraube M12 geht durch<br />

eine Bohrung der Lagerhalteplatte in die Verdrehsicherung des Walzenlagers.<br />

Twist protection pinch roller bearing<br />

Verdrehsicherung Zwickwalzenlagerung<br />

Keep at least Hier 0.2–0.5 mindestens mm radial 0,2 clearance – 0,5 here! mm<br />

The bushing Spiel must einhalten!<br />

have clearance in the bore! In<br />

no case should Keinesfalls it have a tight spielfrei fit !!! einbauen !!!<br />

The wear flange is required in two versions: 169<br />

wear flange <strong>ROPA</strong> item no. 101235 for rollers with right-handed thread<br />

232<br />

(without specific marking)<br />

wear flange <strong>ROPA</strong> item no. 101230 for rollers with left-handed thread<br />

7.11.5 Replacing the wear flange<br />

(marking: 2 grooves)<br />

The distance between two wear flanges amounts to about 0.5 mm for a new machine.<br />

When this distance becomes too great, more gass, weeds, beet leaves, etc. get caught<br />

at the transition to the next conveyor.<br />

Die Konuswalzen sind außen direkt auf den jeweiligen Antriebsmotor aufgesteckt<br />

(Steckkupplung). Die Zwickwalzen sind auf das 4-fach-Zwickwalzengetriebe aufgesteckt<br />

(Steckkupplung). Um Konuswalze oder Zwickwalzen auszubauen, nehmen<br />

Sie die Schutzkappe über der Zentralschmierleitung ab und drehen zuerst<br />

die darunterliegende Feingewindeschraube M24 heraus (innen an der Walzenlagerung),<br />

abschließend die Innensechskantschraube M12.<br />

Alle M24-Feingewindeschrauben sind mit einem Rechtsgewinde (!) versehen.<br />

Das Anziehdrehmoment beträgt 1000 Nm. Sie sind nicht mit flüssiger Schraubensicherung<br />

(Loctite) gesichert.<br />

Twist Verdrehsicherung<br />

protection item<br />

no. Art.Nr. 101231 101231<br />

Grub screw<br />

<strong>ROPA</strong> recommends replacing the wear flanges when the distance amounts to 2-3 mm.<br />

This exchange is easy to perform. The settings of the tapered roller bearings are left<br />

untouched, since they are behind the wear flange.<br />

Wear flange<br />

Konuswalze oder<br />

Tapered roller or pinch roller<br />

Zwickwalzen<br />

Fastening bolt wear flange<br />

Safety Sicherheitsscheibe disk S 12 Zn item S 12 no. Zn Art.Nr. 418105<br />

418105<br />

M12*16 hexagonal recess screw D912 steel 10.9<br />

item M 12*16 no. 414436; Inbusschraube use Loctite D912 270 Stahl 10.9 Art.Nr. 414436<br />

tighten Loctite using 270 und 145mit Nm145<br />

Nm festziehen<br />

Fine<br />

Schraube<br />

thread bolt<br />

M 24*1.5*90<br />

M24 with<br />

(Schmierbohrung)<br />

lubrication bore, item<br />

Art.Nr.<br />

no.<br />

101004<br />

101004,<br />

mit<br />

tighten<br />

1000<br />

using Nm 1000 festziehen Nm<br />

Only the fastening bolts of the wear flange must be removed to replace it. If the grub<br />

screw is screwed into the thread, then simultaneously the wear flange is pressed out.<br />

Kapitel 9<br />

Wartung und Pflege


233<br />

7 Maintenance and Service<br />

When uninstalling respectively installing rollers, comply with the following assembly<br />

information applying to all rollers:<br />

– All M12 hexagonal recess bolts of twist protection are fitted with a specific retaining<br />

washer (S12). This retaining washer (<strong>ROPA</strong> item no. 418105) must be replaced<br />

each time when the hexagonal recess bolt is loosened or screwed out. In addition,<br />

this hexagonal recess bolt must be coated with liquid bolt retention, for<br />

instance Loctite 270. This hexagonal recess bolt (M12) must be tightened using a<br />

torque of 145 Nm.<br />

– All polyamide plug-in couplings must be greased before they are slid onto the clutch<br />

dogs. Besides this, a new O ring must be inserted in the clutch dog before assembly.<br />

– The four M12 x 80 hexagonal recess bolts fastening the polyamide plug-in coupling<br />

to the rollers must be coated with Loctite 270 bolt retention.<br />

To ensure even wear of the rollers, the pinch rollers should, if needed, be installed on the<br />

respective other lateral pickup part; the pinch rollers must be exchanged across for this<br />

purpose.<br />

7.11.6 Assembling/setting bearing of pinch rollers or tapered roller<br />

You indispensably require a special tool for assembly respectively setting of bearings<br />

(adjustable taper roller bearings), which are located at the ends of the pinch rollers<br />

respectively the tapered roller. This tool may be obtained from <strong>ROPA</strong> under the item<br />

number 018156. But such work is required extremely rarely.<br />

Hint on deinstallation of the tapered roller:<br />

To be able to sufficiently lift up the tapered roller, so that it may be pulled from the plug-in<br />

coupling, it is necessary to tip over the drive motor a little. The drive motor may be tipped<br />

when the 4 fastening bolts of the engine are unscrewed and the three hydraulic lines are<br />

loosened.<br />

Hint on deinstallation of a pinch roller:<br />

To be able to lift a pinch roller from its support, it must be lifted up above the bearing<br />

plate. This is easiest performed using a self-made lifting hook gripping below the roller.<br />

The weight of each roller is about 118 kg. The lifted roller will slightly tilt on the clutch<br />

dog. The pinch roller may knocked off the clutch dog by light axial blows on the roller<br />

turns.<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

7.12 Pile Pickup With Residual Beet Pickup<br />

The pile pickup withz residual beet pickup (rubber shield) requires low maintenance<br />

effort. Clean the hydraulically moved parts of coarse dirt and occasionally coat the<br />

telescopic tube with lubricating grease.<br />

For machines from model year 2007, the clearance between outside and inside tube of<br />

the telescopic tube may be set as follows, if needed:<br />

– Loosen the 4 locknuts each of the grub screws from the right and below.<br />

– Screw the grub screws into the thread for so long until the clearance corresponds to<br />

your desire.<br />

– Retighten the locknuts.<br />

Grub screws<br />

234<br />

Pile pickup<br />

Residual beet pickup


7.13 Infeed Conveyor<br />

235<br />

7 Maintenance and Service<br />

The deflecting rollers of the infeed conveyor (at the far front at the infeed conveyor inlet)<br />

are fitted with scrapers. They scrape off sticking soil. The bolts in the scrapers must be<br />

checked weekly and when the bolt heads are largely ground off, they must be replaced.<br />

If the bolt heads are worn too much, then the scraper may loosen and swing into the<br />

infeed conveyor. This destroys the infeed conveyor. Such damage is excluded from any<br />

guarantee, warranty or accommodation.<br />

If needed, and depending on wear, the scrapers must be reset or replaced. Depending<br />

on ground condition, the sector of infeed conveyor deflection must be checked several<br />

times a day to weekly and cleaned in case of strong soiling. The strainer chain of the<br />

infeed conveyor must be retightened in case of need.<br />

It may never be tightened too much.<br />

Scraper<br />

Deflecting roller<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

7.13.1 Tightening the infeed conveyor<br />

Warning!.Danger of severe injuries. Retightening of the infeed conveyor may only be<br />

performed with drive switched off and engine shut down. Pull off the ignition key and<br />

switch off the electric system using the main battery switch.<br />

Only check tension of the infeed conveyor if the pickup is swung out and lowered to<br />

operating height.<br />

Perform a daily check whether all bearing rollers in the infeed conveyor duct are in<br />

proper condition. If rollers are broken, very worn or missing near the front axle, then<br />

the conveyor will slide across the axle. This causes substantial damage to the axle<br />

suspension.<br />

If the infeed conveyor has to be retightened, then loosen the fastening bolt of the<br />

tightening roller (to the right and left behind the front wheel, on the bottom of the frame<br />

tube) and pull the tightening roller down using the tightening screw. Make sure that the<br />

tightening rollers are moved by the same distance on both sides.<br />

236<br />

Tightening screw


7.13.2 Replacing the infeed conveyor drive wheels (finger disk)<br />

The wear limit of the finger disks is reached<br />

7.14 Recleaner<br />

237<br />

7 Maintenance and Service<br />

Replace the drive wheels in due time; do not wait until the strainer chain skips!<br />

Depending on equipment, your <strong>euro</strong>-Maus3 hat a strainer chain cleaner or an 8-fold<br />

pinch roller cleaner.<br />

7.14.1 Strainer chain cleaner – maintenance<br />

The cleaning conveyor may not be firmly tightened. When beets are transported on<br />

the conveyor, the conveyor must be suspended on the supporting rollers left and right<br />

installed lower.<br />

Supporting roller<br />

installed lower<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

Warning!.Danger of severest injurites due to the starting cleaning conveyor!<br />

Retightening of the cleaning conveyor may only be performed if the machine drive and<br />

the engine are switched off. Pull off the ignition key and keep it in a safe place (carry it<br />

on your body!) and switch off the electric system using the main battery switch.<br />

– First, remove the short counter support of the rubber cover. For this purpose, remove<br />

the two hexagonal bolts.<br />

– To retighten the conveyor, loosen the locknuts on the two tightening bars right and<br />

left.<br />

– Screw in the tightening bars as far as necessary and retighten the locknuts.<br />

– Make sure that you adjust the tightening bars on both sides by the same length, so<br />

that the conveyor is evenly tightened.<br />

Experience has shown that retightening of the conveyor is required about annually.<br />

<strong>euro</strong>-maus3 version with strainer chain cleaner<br />

238<br />

tensioning screw<br />

lock nut


7.14.2 8-fold pinch roller cleaner – maintenance<br />

The 8-fold pinch roller cleaner is driven by a hydraulic motor.<br />

The oil level of the spur gear unit must be checked weekly.<br />

239<br />

7 Maintenance and Service<br />

Danger!.Hazard of severest injuries by starting pinch rollers! Work on the 8-fold pinch<br />

roller cleaner may only be performed after the machine drive and the engine have been<br />

shut off. Pull off the ignition key and keep it in a safe place (carry it on your body!) Switch<br />

off the electric system using the main battery switch.<br />

Falling hazard! When working on the pinch roller cleaner, always use ladders safe to<br />

step on or an approved working platform.<br />

Checking the oil level is performed using the inspection glass. If the oil level is above the<br />

center of the inspection glass, then no oil has to be filled up.<br />

The first oil change is required after the first 50 operating hours, then annually.<br />

Oil drain screw<br />

Proceed as follows for performing an oil change:<br />

– - Change the oil only with the gear unit at operating temperature.<br />

- Place a catching pan of sufficient size underneath.<br />

- Open the oil drain screw and let the old oil drain.<br />

- When the oil has drained, insert the oil drain screw and tighten it.<br />

- Fill up with so much fresh oil through the oil filler opening until the oil level is in the<br />

upper range of the inspection glass.<br />

Prescribed gear oil: Hypoid gear oil as per API GL 5 SAE 85W-90<br />

Filling volume: about 4.5 Liter<br />

There are a total of six lubricating nipples at the upper and lower suspension of the<br />

8-fold pinch roller cleaner. These must be lubricated weekly using the grease gun.<br />

Deinstallation and installation of the pinch rollers is identical to deinstallation and<br />

installation of the pinch rollers of the pickup (see page 233, pickup).<br />

Oil filler<br />

opening<br />

Inspection<br />

glass<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

7.15 Truck Conveyor – Maintenance<br />

7.15.1 Tightening of the truck conveyor<br />

The truck conveyor must be retightened if needed. The conveyor tenseness is correctly<br />

set, if with the truck conveyor completely lowered and with totally straight articulation<br />

(truck conveyor almost completely straight), the lower, empty returning side of the<br />

conveyor sags by about 2-3 cm between the supporting rollers.<br />

1<br />

Proceed as follows for retightening the truck conveyor:<br />

– Loosen the two fastening bolts (1) on the deflection rollers left/right.<br />

– Screw the nuts (2) on the tightening bars (3) left/right so far until the deflecting<br />

rollers left/right have been pushed back far enough.<br />

– Lock the nuts (2) on the tightening bars (3) left/right.<br />

– Retighten the fastening screws (1) of the deflection rollers left/right.<br />

– In any case, make sure that you evenly retighten both sides of the conveyor, so that<br />

the conveyor does not touch on the side and is damaged.<br />

240<br />

2 3


7.15.2 Rotating drives of the swivel arm and truck conveyor<br />

241<br />

7 Maintenance and Service<br />

The drive for rotating the swivel arm and the truck conveyor is made hydraulically using<br />

two hydraulic motors. These motors are flanged to one gear unit each. Each drives its<br />

own rotating assembly using a pinion gear.<br />

Attention!.Hazard of severest injuries due to starting crown gears! Work on the drives<br />

of swivel arm and truck conveyor may only be performed after the engine has been shut<br />

off. Pull off the ignition key and keep it in a safe place (carry it on your body!). Switch off<br />

the electric system using the main battery switch.<br />

Falling.hazard!.During all work performed on the drives of the swivel arm and the<br />

truck conveyor, generally use ladders and climbing aids safe to step on or an approved<br />

working platform. In no case climb around on the machine.<br />

Rotating drive swivel arm Rotating drive truck conveyor<br />

Oil filler screw<br />

Oil control screw<br />

Oil drain screw<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

The tooth flanks of the rotating assemblies for rotating the swivel arm and truck conveyor<br />

must be sprayed with rotating assembly spray if needed. The oil in the gear units must<br />

be changed annually.<br />

– Proceed as follows to perform an oil change:<br />

- Only change the oil with the gear units at operating temperature.<br />

- Place a catching pan of sufficient size and oil resistant underneath.<br />

- Screw out the oil drain screw and let the old oil drain.<br />

- Also screw out the oil filler screw respectively open the lid of the expansion vessel,<br />

so that the oil can drain quicker.<br />

- When the oil has drained, screw in the oil drain screw again.<br />

- Fill up the expansion vessel of the swivel arm with fresh oil for so long until the oil<br />

almost reaches the upper edge of the expansion vessel.<br />

- Fill up the truck conveyor with fresh oil until the oil reaches the lower edge of the oil<br />

level control opening.<br />

- Reinsert all screws you have removed and close the expansion vessel.<br />

The expansion vessel must always be filled up with oil! If needed, fill up oil in due time.<br />

Prescribed oil type: gear oil of the quality EP,<br />

242<br />

viscosity ISO VG 150 for instance MOBIL Mobilgear 629<br />

as per DIN 51517 part 3<br />

Filling volume swivel arm: about 2.5 Liter<br />

Filling volume truck conveyor: about 3.5 Liter<br />

Further maintenance and repair work on the rotating assembly and swivel drive may only<br />

be performed by <strong>ROPA</strong> or specialist personnel, which has been expressly authorized for<br />

this work by Ropa.


7.16 Printer (Option)<br />

243<br />

7 Maintenance and Service<br />

After larger printing jobs, depending on the paper quality and disadvantageous<br />

environmental effects, it may be necessary to clean the print head, the sensor and the<br />

drive roller. Especially if some places are no longer properly printed.<br />

– Open the paper hopper lid and remove the paper roll.<br />

– Using a small brush, remove soiling on the paper, sensor as well as the ripping<br />

edge.<br />

– Blow strong into the paper hopper bowl to remove coarse dust.<br />

– Saturate a cotton swab with pure isopropanol alcohol (IPA) and clean the pressure<br />

strip or use the print head cleaning pen/cleaning card.<br />

– Remove further heavy soiling also using a cotton swab (IPA).<br />

Never use sharp objects for cleaning. This might damage the print head.<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

7.17 Heating and Ventilation System<br />

If the heating and ventilation system should not work at full power, even if the circulating<br />

air grid is fully opened, then the cause for this is usually found in blocked filters.<br />

Therefore, always clean both filters.<br />

7.17.1 Fresh air intake filter<br />

The fresh air intake filter for the cabin is located to the right, outside on the rear cabin<br />

wall.<br />

This filter must be cleaned as follows, if needed:<br />

– Open the cover.<br />

– Unscrew the knurled head screw and take the filter from the bracket.<br />

– Clean the filter element using compressed air.<br />

– Reinsert the cleaned filter element in the bracket and fasten it using the knurled<br />

head screw.<br />

– Reclose the cover.<br />

This filter element should be replaced annually in any case.<br />

244<br />

Fresh air intake filter


7.17.2 Circulating air filter<br />

245<br />

7 Maintenance and Service<br />

The circulating air filter is located in the fan unit below the cover behind the driver‘s seat.<br />

Filter mat circulating air filter<br />

This filter should be cleaned at least annually using compressed air as follows:<br />

– Take off the cover.<br />

– Open bayonet closures.<br />

– Pull out the filter mat upward.<br />

– Blow out the filter mat using compressed air.<br />

– Reinsert the cleaned filter mat.<br />

– Reinstall the cover.<br />

7.17.3 Draining condensed water from the air conditioning system<br />

The condensed water drain of the air conditioning system is located at the cabin floor<br />

below the driver‘s cabin. Regularly check if condensed water is emitting here. If you<br />

should not detect emitting water, then the condensed water drain must be cleaned.<br />

Chapter.7.<br />

Maintenance and Service


7 Maintenance and Service<br />

Chapter.7.<br />

Maintenance and Service<br />

7.18 Immobilization for a longer period of time<br />

If <strong>euro</strong>-Maus3 is to be immobilized for a period of one to four weeks, then in any case<br />

switch off the main battery switch. In addition, in the central electric system, pull out the<br />

sliding switch S86, since the timer of the independent heating system is supplied with<br />

power from the battery even if the main battery switch is switched off.<br />

If <strong>euro</strong>-Maus3 is to be immobilized for a period of more than four weeks, then in any<br />

case perform the following additional work:<br />

– Thoroughly wash the machine. Avoid directly spraying bearings and supporting<br />

rollers.<br />

– Drain the condensed water from the three compressed air reservoirs.<br />

– Lubricate the lubricating points of the machine which must be manually lubricated.<br />

– Let the central lubricating system run for at least 30 minutes with machine drive<br />

switched on.<br />

– Grease the geared rims and pinions.<br />

– Spray the whole machine using corrosion protection oil.<br />

– Make sure that no oil or grease touches the tires.<br />

– Grease all piston rods and the collars of the hydraulics cylinders.<br />

– Park the machine in a dry place, protected from weather, if possible, in a hall.<br />

246


247<br />

7 Maintenance and Service<br />

Attention!.Danger of chemical burns. Battery acid may cause dangerous burns on the<br />

skin and the respiratory system. Therefore, when handling acid batteries, always wear<br />

sufficient protective clothing (protective goggles, acid-resistant gloves, apron). Avoid<br />

skin contact with battery acid. Avoid inhaling acid fumes. When handling batteries, make<br />

sure of sufficient ventilation of the workplace. In case of skin contact to battery acid,<br />

immediately flush the skin surface with ample water. Then, immediately consult a doctor.<br />

– Uninstall the batteries. The batteries should be stored cool and dry, but protected<br />

against frost. Before storing, check the acid level and fill up with distilled water, if<br />

needed. Completely charge the batteries before storing them. During storage, check<br />

the battery voltage monthly and recharge the batteries, if needed. Grease the battery<br />

terminals using a specific terminal grease.<br />

Danger!.If acid batteries are improperly charged using unsuitable charging devices<br />

or too high charging voltage, then this may lead to generation of oxyhydrogen gas.<br />

Oxyhydrogen gas is very easily combustible and may explode. Always make sure of the<br />

correct charging voltage. Make sure, that the batteries are charged only in well ventilated<br />

places. Smoking, fire or open flame are strictly prohibited.<br />

Service life of the batteries<br />

In the interest of a long service life of the batteries, exactly comply with the following<br />

hints:<br />

– Check the liquid level. If it is too low, then exclusively fill up with distilled water up to<br />

the maximum acid level mark.<br />

– The self-discharge rate amounts to about 0.2 % of the nominal capacity/day at<br />

20 °C.<br />

– The acid density must be checked at regular intervals to avoid deep discharge.<br />

If the acid density is below 1.21 kg/l, then the batteries must be recharged. The<br />

recommended charging current is 1/10 th of the capacity.<br />

– Deep discharged batteries form lead sulphate. Regeneration by recharging is no<br />

longer possible.<br />

– There are neither guarantee nor warranty claims in case of batteries with sulphate<br />

formation, detectable from the silver plate coating and from turbid battery acid. They<br />

are also excluded from any accommodation, since this damage is due to gross<br />

negligence during maintenance.<br />

Chapter.7.<br />

Maintenance and Service


249<br />

8 Fault and Remedy<br />

Chapter 8<br />

Fault and Remedy<br />

Chapter.8.<br />

Fault and Remedy


8 Fault and Remedy<br />

251<br />

8 Fault and Remedy<br />

Your attention is visually drawn to faults or hazardous situations by warning indications<br />

on the color terminal and acoustically by warning sounds. Individual functions may be<br />

blocked in dangerous situations.<br />

8.1 Safety Circuits<br />

The machine offers the utmost safety for operator and material. Safety switches in the<br />

cabin block individual functions of the machine when the operator leaves the cabin. If<br />

any function cannot be executed from the cabin, or if switches are blocked, at first check<br />

if the left joystick console has been swung down, the rear platform wall has been swung<br />

up and the engine housing lid is closed.<br />

If the fault cannot be remedied in this manner, then read the corresponding sections of<br />

this operating manual about the components concerned respectively without function.<br />

There, you will find hints on safety circuits and possible reasons for a fault.<br />

Warning!.Hazard of severest injuries or damage to the machine. Never defeat safety<br />

installations, safety locks or safety circuits. This may cause severest injuries. Never<br />

perform functional tests if you are not fully informed about all of the consequences<br />

of such a test. Make sure taht during search for faults respectively when remedying<br />

faults a second reliable person is present in case of need, which is familiar with the<br />

machine to the extent that it may immediately shut down the machine as soon as<br />

danger is imminent. Even in case of the slightest doubt, call in specialist personnel<br />

with corresponding training or enquire with service personnel of <strong>ROPA</strong>. Do not perform<br />

any repairs on the machine if you do not have the required specialist knowledge and<br />

experience.<br />

If you should be able to contact your dealer or the manufacturer by radio or cell phone,<br />

then further fault diagnostics is possible using specific diagnostics menus on the color<br />

terminal. For safety reasons, individual menus are locked for the operator. In case of<br />

improper handling, people could be injured with hazard to life or heavy damage could be<br />

caused to the machine, which would have the consequence of costly repairs.<br />

Chapter.8.<br />

Fault and Remedy


8 Fault and Remedy<br />

Chapter.8.<br />

Fault and Remedy<br />

8.2 Electric System<br />

8.2.1 Fuses<br />

The electric fuses are located on the radio console, the seat console in the driver‘s cabin<br />

and in the switching cabinet of the central electric system, to the right outside on the<br />

cabin platform.<br />

Mainly, <strong>euro</strong>-Maus3 employs commercially available flat plug-in fuses.<br />

Labels on the inside of the sheet-metal cover designate the fuses.<br />

In addition, in the central electric system, in the plug-in sockets of the reserve fuse<br />

holder, there are three electronic cutouts.<br />

These electronic cutouts are not integrated in the electric circuits and may therefore be<br />

used by you in searching for faults. For this purpose, insert a suitable electronic cutout<br />

in place of the burned-out fuse. In case of overload (for instance short circuit), the<br />

automatic cutout is triggered. By pressing the reset button, the electronic cutout may be<br />

reactivated.<br />

Switching cabinet of the central electric system Lid of the switching cabinet of the central electric<br />

252<br />

system<br />

Fuses F03 to F29 in the switching cabinet of the central electric<br />

system<br />

Electronic cutouts for fault search


Fuses F30 to F45 in the radio console<br />

Fuses F50 to F59 in the seat console<br />

Fuse F47 in the battery box<br />

253<br />

8 Fault and Remedy<br />

Chapter.8.<br />

Fault and Remedy


8 Fault and Remedy<br />

8.2.2 Schedule of Fuses (Fuses)<br />

Schedule of fuses from model year 2005<br />

Version 23.06.2006<br />

Chapter.8.<br />

Fault and Remedy<br />

The battery box contains the main fuses (Mega Fuse fuses). F01 supplies the central<br />

electric system and the seat console of the cabin, F02 the radio console and the working<br />

spotlights. Whether these two fuses are in working condition may only be detected using<br />

a measuring device (circuit indicator).<br />

No. Ampere Function Pos. in the machine<br />

Main power supply, screwed-in Littlefuse MEGA fuses<br />

F01 125 Supply central electric system X1 Battery box<br />

F02 125 Supply lighting radio console Battery box<br />

In the central electric cabinet<br />

F03 20 Kl. 30 MR Daimler Chrysler (A435) in central electric cabinet<br />

F04 10 Kl. 30 ADM2 Daimler Chrysler (A403) in central electric cabinet<br />

F05 15 Kl. 30 computer B (A02) in central electric cabinet<br />

F06 15 Kl. 30 computer B (A02) in central electric cabinet<br />

F07 15 Kl. 30 computer C (A03) in central electric cabinet<br />

F08 15 Kl. 30 computer C (A03) in central electric cabinet<br />

F09 15 Power supply PWM outputs A21 in central electric cabinet<br />

F10 15 Power supply PWM outputs A22 in central electric cabinet<br />

F11 15 Power supply PWM outputs A23 in central electric cabinet<br />

F12 15 Power supply PWM outputs A24 in central electric cabinet<br />

F13 15 Socket rear/tool box in central electric cabinet<br />

F14 15<br />

Heating ventilator for operation of the<br />

independent heating system<br />

254<br />

in central electric cabinet<br />

F15 15 Independent heating system Kl 30 in central electric cabinet<br />

F16 3<br />

Control device air conditioning system during<br />

operation of the independent heating system<br />

in central electric cabinet<br />

F17 15 Engine housing lighting, socket 24 V, lamp ZE in central electric cabinet<br />

Terminal 30<br />

of X1


255<br />

8 Fault and Remedy<br />

Nr. Ampere Funktion Pos. in der Maschine<br />

F20 15 Front window wiper in central electric cabinet<br />

F21 15 Heating ventilator Kl 15 in central electric cabinet<br />

F22 15 Air conditioning compressor, clutch, water pump in central electric cabinet<br />

F23 15 Central lubrication, air dryer, backup lamp in central electric cabinet<br />

F24 3 Kl 15 generators in central electric cabinet<br />

F25 3 Control device air conditioning system Kl 15 in central electric cabinet<br />

F26 3 15 V voltage transformer for sensors in central electric cabinet<br />

F28 7,5 Parking light right in central electric cabinet<br />

F29 7,5 Parking light left dashboard lighting in central electric cabinet<br />

Cabin radio console<br />

F30 10 ASW (= working spotlight) camera, Central mark in radio console, top<br />

F31 15 ASW roof bottom in radio console, top<br />

F32 15 ASW roof center in radio console, top<br />

F33 15 ASW roof outside in radio console, top<br />

F34 15 ASW roof rear in radio console, top<br />

F35 15 ASW cleaning, truck conveyor in radio console, top<br />

F36 7.5 ASW right left in radio console, top<br />

F37 7.5 Rotating beacons in radio console, top<br />

F38 7.5 Mirror heating/mirror adjustment right/left in radio console, bottom<br />

F39 15 Internal lamps, socket 24 V, voltage transformer in radio console, bottom<br />

F40 7.5<br />

Kl 15 RK, video system, timer independent<br />

heating system<br />

in radio console, bottom<br />

F41 7.5 Window wiper left in radio console, bottom<br />

F42 10 Window wiper right and rear in radio console, bottom<br />

F43 7.5 Kl 30 timer independent heating system in radio console, bottom<br />

F44 5<br />

Public address system, 12 V for central electric<br />

system<br />

in radio console, bottom<br />

F45 5 12 V sockets in radio console, bottom<br />

Console driver‘s seat<br />

F50 10 Hazard warning system Kl 30 in seat console<br />

F51 7.5 Terminal Kl 30 in seat console<br />

F52 frei Reserve Kl 30 in seat console<br />

F53 10 Dimmed headlight in seat console<br />

F54 10 Driving light in seat console<br />

F55 10 Air seat, compressor in seat console<br />

F56 10 Rear axle steering, main switch in seat console<br />

F57 10<br />

Steering column switch, horn, direction<br />

indicator, window wiper control, window washer<br />

pump, hazard warning system Kl 15<br />

in seat console<br />

F58 frei Reserve Kl 15 in seat console<br />

F59 7.5<br />

Others<br />

Kl. 15 overall electronics, ESTs, terminal,<br />

joystick, operating section, engine electronics<br />

in seat console<br />

F47 8 Ground, timer, independent heating system in battery box<br />

Terminal<br />

15<br />

of<br />

light<br />

Terminal<br />

30 of F01<br />

Terminal<br />

15<br />

Chapter.8.<br />

Fault and Remedy


8 Fault and Remedy<br />

Chapter.8.<br />

Fault and Remedy<br />

8.2.3 Electronic Cutouts<br />

red LED<br />

8.2.4 Schedule of Electronic Cutouts<br />

The cutouts (F70r to F116r) are implemented as self-resetting electronic cutouts. If the<br />

red light emitting diode (LED) of a cutout is lit, then the cutout is overloaded and power<br />

supply to the component connected is interrupted.<br />

No. For component Function Position in the machine<br />

Sensors operating at 15 Volt<br />

F70r<br />

F71r<br />

F72r<br />

F73r<br />

F74r<br />

B26 DS driving power<br />

B61 DS braking pressure service brake<br />

B20 DS pickup rollers<br />

B21 DS pinch rollers 4-fold<br />

B22 DS cleaner<br />

B27 DS additional axle<br />

B68 DS relief pickup right<br />

B69 DS relief pickup left<br />

B377 Fuel pressure pickup<br />

B60 Reservoir pressure compressed air reservoir<br />

256<br />

in central electric cabinet 15 V<br />

in central electric cabinet 15 V<br />

in central electric cabinet 15 V<br />

in central electric cabinet 15 V<br />

in central electric cabinet 15 V<br />

F75r B51 PVG lubrication in central electric cabinet 15 V<br />

F76r B47 Driving speed sensor in central electric cabinet 15 V<br />

F77r<br />

B46 Fuel tank pickup fuel level<br />

B67 DS relief pickup center<br />

in central electric cabinet 15 V


257<br />

8 Fault and Remedy<br />

No. For component Function Position in the machine<br />

Sensors operating at 8.5 Volt, supply from A02<br />

F80r B01 Sensor wheel angle front axle in central electric cabinet 8.5 V<br />

F81r B02 Sensor wheel angle rear axle in central electric cabinet 8.5 V<br />

F82r<br />

B08 Sensor lateral pile pickup<br />

B10 Sensor pickup depth<br />

(DS = abbreviation for pressure sensor)<br />

in central electric cabinet 8.5 V<br />

F83r B32 Sensor driving pedal 2 in central electric cabinet 8.5 V<br />

F84r<br />

B70 Sensor pile pickup height<br />

B71 Speed sensor truck conveyor<br />

Sensors working at 8.5 Volt, supply by A03<br />

in central electric cabinet 8.5 V<br />

F85r B09 Sensor driving pedal 1 in central electric cabinet 8.5 V<br />

F86r B62 Speed sensor pickup rollers right in central electric cabinet 8.5 V<br />

F87r B63 Speed sensor pickup rollers left in central electric cabinet 8.5 V<br />

F88r B64 Speed sensor 4 pinch rollers right in central electric cabinet 8.5 V<br />

F89r B65 Speed sensor 4 pinch rollers left in central electric cabinet 8.5 V<br />

F90r B66 Speed sensor 8 pinch rollers/infeed conveyor in central electric cabinet 8.5 V<br />

F100r 8.5 V for driver‘s seat signal generation in console 8.5 V<br />

8.3 Schedule of Relays<br />

Nr. Bezeichnung Position in der Maschine Bemerkung Art-Nr.<br />

K01<br />

K03<br />

K04<br />

Relay main load<br />

Kl 15<br />

Relay direction<br />

indicator<br />

Relay fan module/<br />

independent<br />

heating system<br />

in central electrics<br />

rating 70 A, load relay<br />

electrics<br />

320099<br />

seat console flasher relay 320021<br />

in central electrics<br />

only in case of<br />

independent heating<br />

system<br />

320154<br />

K06 Relay window wiper in central electrics switches the front wiper motor 320573<br />

K07<br />

K15<br />

Relay central<br />

lubricating system<br />

Relay reversing<br />

lights<br />

K16 Relay water valve<br />

K17<br />

K19<br />

Relay air<br />

conditioning control/<br />

independent heating<br />

devicesystem<br />

Relay air<br />

conditioning<br />

compressor<br />

in central electrics<br />

in central electrics<br />

in central electrics, only in case of<br />

water spraying system<br />

in central electrics<br />

in central electrics<br />

switches the central<br />

lubricating pump<br />

for reversing beeper and<br />

-reversing lights<br />

for automatic operation of<br />

the water system<br />

for switching the air<br />

conditioning control device<br />

from Kl.15 to Kl.30<br />

for switching the air<br />

conditioning compressor<br />

320154<br />

320154<br />

320154<br />

320154<br />

320154<br />

Chapter.8.<br />

Fault and Remedy


8 Fault and Remedy<br />

Chapter.8.<br />

Fault and Remedy<br />

K01<br />

8.4 Color Code for Electrical Wiring<br />

brown ground<br />

Color code for electrical wiring<br />

red terminal 30<br />

pink terminal 15<br />

yellow 8.5 Volt<br />

violett 12 Volt<br />

red/yellow 15 Volt<br />

K04<br />

K06<br />

K07<br />

blue signal lines digital (ON/OFF)<br />

green signal lines analog (changing sensor values)<br />

grew all lamps (load = light bulbs and warning device (beeper „H“ + „E“))<br />

K15<br />

white electric motors and internal wiring, others<br />

orange control lines to all valves and solenoids (all „Y“)<br />

258<br />

K16<br />

Relay in the switching cabinet of central electrics<br />

K17 K19


8.5 Fault Search Using the Color Terminal<br />

259<br />

8 Fault and Remedy<br />

Malfunctions are partially signaled on the color terminal by warning icons. In case of<br />

electrical or electronic problems, the components concerned are shown, naming the<br />

component.<br />

Example:<br />

= Communication problem to control device<br />

A03 = computer EST C (refer to the table below).<br />

= Analog signal in forbidden range.<br />

On the color terminal, to the right, next to the warning icon, the text field shows which<br />

sensor signal is in an illegal range.<br />

= Line break or short circuit was determined.<br />

To the right, next to the warning icon, the color terminal shows whether this concerns a<br />

line break or a short circuit.<br />

You are also informed about which component is concerned.<br />

= IInternal memory fault EEPROM.<br />

Fault during reading of parameters.<br />

Chapter.8.<br />

Fault and Remedy


8 Fault and Remedy<br />

Chapter.8.<br />

Fault and Remedy<br />

DIN Component Position in the machine Remarks Item no.<br />

A02 EST B<br />

in central electrics box,<br />

center top at the lid<br />

computer B, steering,<br />

positioning truck<br />

conveyor<br />

320615<br />

A03 EST C<br />

in central electrics box,<br />

outside top at the lid<br />

computer C, driving<br />

power, operating drives<br />

320615<br />

A07 Terminal in the seat console top color terminal 320669<br />

A10 Joystick right in the seat console, on CAN 320663<br />

A16<br />

Operating section<br />

machine setting<br />

in the console right with 12 stage switch 320682<br />

A19<br />

Air conditioning<br />

control device<br />

in central electrics on base<br />

plate<br />

for temperature control in<br />

the cabin<br />

320659<br />

A20 Joystick left<br />

in the console left, may be<br />

swung up, on CAN<br />

320712<br />

A21 Computer,<br />

I/O-Modul<br />

in central electrics at the lid,<br />

on the hinge side, internal<br />

module<br />

for pile pickup 320716<br />

A22 Computer,<br />

I/O-Modul<br />

in central electrics at the lid,<br />

on the hinge side, external<br />

module<br />

for transmission and<br />

block switching<br />

320716<br />

A23 Computer,<br />

I/O-Modul<br />

in central electrics at the lid,<br />

for diverse functions<br />

closure side, internal module<br />

320716<br />

A24 Computer,<br />

I/O-Modul<br />

in central electrics at the<br />

lid, closure side, external<br />

module<br />

for feed valve, rabbit<br />

speeds, axle support<br />

320716<br />

8.5.1 Overview of Diagnostic Menus<br />

Below, we are showing illustrations of the available diagnostic menus of the color<br />

terminal. They facilitate fault diagnostics for service personnel, if you call up the<br />

corresponding menu items after being requested to by service personnel and<br />

communicate the values or icons shown to service personnel.<br />

260


261<br />

8 Fault and Remedy<br />

Chapter.8.<br />

Fault and Remedy


8 Fault and Remedy<br />

Chapter.8.<br />

Fault and Remedy<br />

262


263<br />

8 Fault and Remedy<br />

Chapter.8.<br />

Fault and Remedy


8 Fault and Remedy<br />

Chapter.8.<br />

Fault and Remedy<br />

264


265<br />

8 Fault and Remedy<br />

The meaning of error codes<br />

for the Diesel engine is<br />

explained from page 270.<br />

Chapter.8.<br />

Fault and Remedy


8 Fault and Remedy<br />

Chapter.8.<br />

Fault and Remedy<br />

266


267<br />

8 Fault and Remedy<br />

Chapter.8.<br />

Fault and Remedy


8 Fault and Remedy<br />

Chapter.8.<br />

Fault and Remedy<br />

8.6 Error Codes Diesel Engine Mercedes-Benz<br />

The Mercedes-Benz error codes are sent by the ADM2 computer to the color terminal<br />

and may be read there.<br />

The error code is broken down for the following sectors:<br />

SPN number/FMI number<br />

The meaning of SPN/FMI may be found using the following code list.<br />

8.6.1 Error Codes of Diagnostic Version 202<br />

Error codes<br />

SAE J 1939<br />

SPN/FMI<br />

Error<br />

codes<br />

ADM2<br />

45/3 10003 Constant throttle<br />

MBR_KD<br />

45/4 10004 Constant throttle<br />

MBR_KD<br />

Meaning Remedy<br />

cable breakage – Check wiring.<br />

short circuit – Check wiring.<br />

– Check unit for constant throttle for fault.<br />

– Check unit for constant throttle for fault.<br />

98/0 10400 Oil level excess filling – Drain oil in case of high excess filling.<br />

98/1 10401 Oil level low oil level – Fill up oil.<br />

98/14 10414 Oil level very low oil level – Fill up oil.<br />

100/1 10501 Oil pressure low oil pressure – Check pump and oil circuit.<br />

100/14 10514 Oil pressure very low oil pressure – Check pump and oil circuit.<br />

110/0 10900 Engine<br />

temperature<br />

110/14 10914 Engine<br />

temperature<br />

111/1 11001 Cooling water<br />

level KW_SE<br />

111/3 11003 Cooling water<br />

level KW_SE<br />

111/4 11004 Cooling water<br />

level KW_SE<br />

– Remarks: this problem may also occur if the wrong oil pan type has been set<br />

as parameter in PLD-MR.<br />

– Remarks: this problem may also occur if the wrong oil pan type has been set<br />

as parameter in PLD-MR.<br />

coolant temp. too high – Check cooling water level and cooling circuit.<br />

coolant temp. much<br />

too high<br />

low cooling water level – Refill cooling water<br />

cable breakage – Check wiring.<br />

short circuit – Check wiring.<br />

– Check cooling water level and cooling circuit.<br />

– Check wiring, if inspite of refilled cooling water the fault remains active.<br />

– voltage must be greater than 2.0 V.<br />

158/0 11100 Terminal 30 excess voltage – Check system voltage.<br />

158/1 11101 Terminal 30 low voltage – Check system voltage<br />

625/2 12202 CAN zu PLD-MR no connection to<br />

PLD-MR<br />

625/14 12214 CAN zu PLD-MR single wire operation<br />

(MCAN faulty)<br />

629/12 12312 VCU-Intern internal VCU fault –<br />

– parameter 2/08 : check 24/12 V insert for match with system voltage.<br />

– parameter 2/08 : check 24/12 V insert for match with system voltage.<br />

– Check wiring engine CAN.<br />

– Check wiring PLD-MR.<br />

– Check PLD-MR parameter for single wire ability and parameter 1/01 of ADM2<br />

(single wire ability) for identical setting.<br />

– Check PLD-MR parameter for single wire ability and parameter 1/01 of ADM2<br />

(single wire ability) for identical setting.<br />

268


8.6.2 Error Codes of Diagnostics Version 203<br />

Error codes<br />

SAE J 1939<br />

SPN/FMI<br />

Error<br />

codes<br />

ADM2<br />

45/3 10003 Constant throttle<br />

MBR_KD<br />

45/4 10004 Constant throttle<br />

MBR_KD<br />

Meaning Remedy<br />

cable breakage – Check wiring.<br />

short circuit nach<br />

Masse<br />

– Check unit for constant throttle for fault.<br />

– Check wiring.<br />

– Check unit for constant throttle for fault.<br />

98/0 10400 Oil level excess filling – Öl ablassen bei zu starker excess filling.<br />

98/1 10401 Oil level low oil level – Fill up oil.<br />

98/14 10414 Oil level very low oil level – Fill up oil.<br />

100/1 10501 Oil pressure low oil pressure – Check pump and oil circuit.<br />

100/14 10514 Oil pressure very low oil pressure – Check pump and oil circuit.<br />

110/0 10900 Engine<br />

temperature<br />

110/14 10914 Engine<br />

temperature<br />

111/1 11001 Cooling water<br />

level KW_SE<br />

111/3 11003 Cooling water<br />

level KW_SE<br />

111/4 11004 Cooling water<br />

level KW_SE<br />

269<br />

8 Fault and Remedy<br />

– Remarks: this problem may also occur if the wrong oil pan type has been set<br />

as parameter in PLD-MR.<br />

– Remarks: this problem may also occur if the wrong oil pan type has been set<br />

as parameter in PLD-MR.<br />

coolant temp. too high – Check cooling water level and cooling circuit.<br />

coolant temp. much<br />

too high<br />

low cooling water level – Refill cooling water.<br />

cable breakage – Check wiring.<br />

short circuit – Check wiring.<br />

– Check cooling water level and cooling circuit.<br />

– Check wiring, if inspite of refilled cooling water the fault remains active.<br />

– voltage must be greater than 2.0 V.<br />

158/0 11100 Terminal 15 excess voltage – Check system voltage<br />

158/1 11101 Terminal 15 low voltage – Check system voltage<br />

625/2 12202 CAN to PLD-MR no connection to<br />

PLD-MR<br />

625/14 12214 CAN to PLD-MR single wire operation<br />

(MCAN faulty)<br />

629/12 12312 VCU internal internal VCU fault –<br />

– parameter 2/08 : check 24/12 V insert for match with system voltage.<br />

– parameter 2/08 : check 24/12 V insert for match with system voltage.<br />

– Check wiring engine.<br />

– Check wiring PLD-MR.<br />

– Check PLD-MR parameter for single wire ability and parameter 1/01 of ADM2<br />

(single wire ability) for identical setting.<br />

– Check PLD-MR parameter for single wire ability and parameter 1/01 of ADM2<br />

(single wire ability) for identical setting.<br />

Chapter.8.<br />

Fault and Remedy


8 Fault and Remedy<br />

8.6.3 Error Codes of Engine Cont rol (PLD-MR)<br />

Error codes<br />

SAE J 1939<br />

SPN/FMI<br />

Chapter.8.<br />

Fault and Remedy<br />

Error<br />

codes<br />

ADM2<br />

98/2 02517 Engine oil level<br />

sensor<br />

98/3 02515 Engine oil level<br />

sensor<br />

98/4 02516 Engine oil level<br />

sensor<br />

98/5 02509 Engine oil level<br />

sensor<br />

100/2 11617 Engine oil<br />

pressure sensor<br />

100/3 11615 Engine oil<br />

pressure sensor<br />

100/4 11616 Engine oil<br />

pressure sensor<br />

102/2 11417 Charge-air<br />

pressure sensor<br />

102/3 11415 Charge-air<br />

pressure sensor<br />

102/4 11416 Charge-air<br />

pressure sensor<br />

105/3 11215 Charge-air<br />

temperature<br />

sensor<br />

105/4 11216 Charge-air<br />

temperature<br />

sensor<br />

110/3 11515 Coolant<br />

temperature<br />

sensor<br />

110/4 11516 Coolant<br />

temperature<br />

sensor<br />

Meaning Remedy<br />

measuring range<br />

implausible<br />

measuring range<br />

exceeded<br />

measuring range<br />

undercut<br />

– Check oil level.<br />

– Check electrical connections.<br />

– Check sensor, if needed, replace.<br />

– Set point 22 Ohm with full oil pan.<br />

– Check oil level.<br />

– Check line for cable breakage or short circuit to U B .<br />

– Check sensor, if needed, replace.<br />

– Set point 22-25 Ohm.<br />

– Check oil level .<br />

– Check line for short circuit to ground.<br />

– Check sensor, if needed, replace.<br />

– Set point 22-25 Ohm.<br />

cable breakage – Check oil level.<br />

measuring range<br />

implausible<br />

measuring range<br />

exceeded<br />

measuring range<br />

undercut<br />

– Check line for cable breakage.<br />

– Check sensor, if needed, replace.<br />

– Check line for cable breakage.<br />

– Check sensor, if needed, replace.<br />

– Check line for cable breakage or short circuit to UB .<br />

– Check sensor, if needed, replace.<br />

– Check line for short circuit to ground.<br />

Messert unplausibel – Check sensor, if needed, replace.<br />

measuring range<br />

exceeded<br />

measuring range<br />

undercut<br />

measuring range<br />

exceeded<br />

measuring range<br />

undercut<br />

measuring range<br />

exceeded<br />

measuring range<br />

undercut<br />

158/2 12219 Terminal 15 term. 15 detection of<br />

discrepancy of PLD-<br />

MR to ADM2<br />

– Check line for cable breakage.<br />

– Check sensor, if needed, replace.<br />

– Check line for cable breakage or short circuit to U B .<br />

– Check sensor, if needed, replace.<br />

– Check line for short circuit to ground.<br />

– Check line for cable breakage or short circuit to UB.<br />

– Check line for short circuit to ground.<br />

– Check sensor, if needed, replace.<br />

– Set point : 2,4 kOhm (21°C).<br />

– Check line for cable breakage or short circuit to UB .<br />

– Check sensor, if needed, replace.<br />

– Set point : 2,4 kOhm (21°C)<br />

– Check line for short circuit to ground.<br />

– Check fuse 30.<br />

– Check line for cable breakage.<br />

168/3 07542 Terminal 30 excess voltage – Generator or control module broken.<br />

168/4 07543 Terminal 30 low voltage – Battery discharged too much or broken.<br />

174/3 11115 Fuel temp.<br />

sensor<br />

measuring range<br />

exceeded<br />

– Generator/control module/fuse broken.<br />

– Check line for cable breakage or short circuit to UB .<br />

270


Error codes<br />

SAE J 1939<br />

SPN/FMI<br />

Error<br />

codes<br />

ADM2<br />

174/4 11116 Fuel temp.<br />

sensor<br />

175/3 01015 Engine oil temp.<br />

sensor<br />

175/4 01016 Engine oil temp.<br />

sensor<br />

Meaning Remedy<br />

measuring range<br />

undercut<br />

measuring range<br />

exceeded<br />

measuring range<br />

undercut<br />

190/0 10530 Engine speed measuring range<br />

exceeded<br />

609/12 01315 PLD fault,<br />

atmospheric<br />

pressure sensor<br />

609/12 01316 PLD fault,<br />

atmospheric<br />

pressure sensor<br />

measuring range<br />

exceeded<br />

measuring range<br />

undercut<br />

609/12 04024 Internal fault Dry-running computer<br />

failure<br />

609/12 14034 D) Internal fault Highside transistor<br />

prop. valve bank1<br />

(PVB 1) high<br />

resistance<br />

609/12 14035 D) Internal fault Highside transistor<br />

prop. valve bank2<br />

(PVB 2) high<br />

resistance<br />

609/12 14036 D) Internal fault Highside transistor<br />

prop. valve 5 (PV 5)<br />

high resistance<br />

609/12 14038 Internal fault Starter output stage<br />

high resistance (main<br />

branch)<br />

609/12 14039 Internal fault Starter output stage<br />

low resistance (main<br />

branch or emergency<br />

branch)<br />

609/12 14041 Internal fault Prop.valve Highside<br />

transistor burnt<br />

through<br />

609/12 04038 Internal fault Starter output stage<br />

high resistance<br />

(redundant/emergency<br />

branch)<br />

609/12 04040 Internal fault Level detection Starter<br />

faulty<br />

609/14 04037 Internal fault Number of cylinders<br />

implausible<br />

609/14 04047 Internal fault Ignition mapping set<br />

faulty<br />

609/14 04048 Internal fault Number of cylinders<br />

implausible<br />

– Check line for short circuit to ground.<br />

– Check sensor, if needed, replace.<br />

– Set point : 2,4 kOhm (21°C).<br />

– Check line for cable breakage or short circuit to U B .<br />

– Check sensor, if needed, replace.<br />

– Set point : 2,4 kOhm (21°C).<br />

– Check line for short circuit2 to ground.<br />

– Obtain information about allowed max. speed .<br />

– Delete fault memory.<br />

– In case of faults 11415 or 11416 check there.<br />

271<br />

8 Fault and Remedy<br />

– Otherwise check actual values with engine standing still for +/-10 %<br />

– In case of faults 11415 or 11416 check there.<br />

– Otherwise check actual values with engine standing still for +/-10 %<br />

– Check plug-in connections/electric components.<br />

D) = only applies to D models of the PLD-MR control devices.<br />

D) = only applies to D models of the PLD-MR control devices.<br />

D) = only applies to D models of the PLD-MR control devices.<br />

– Check plug-in connections/electric components.<br />

– Check plug-in connections/electric components.<br />

– wenn Fehler 07543, dann dort nachschauen.<br />

– Check plug-in connections/electric components.<br />

– Check plug-in connections/electric components.<br />

– Check plug-in connections/electric components.<br />

– Check plug-in connections/electric components.<br />

– Check plug-in connections/electric components.<br />

609/14 14049 Internal fault Parameter fault – Check plug-in connections/electric components.<br />

609/14 04050 Internal fault False hardware<br />

detection<br />

609/14 04051 Internal fault EEPROM: fault<br />

checksum 1 (CKS1):<br />

all other blocks<br />

– Check plug-in connections/electric components.<br />

– Check plug-in connections/electric components.<br />

Chapter.8.<br />

Fault and Remedy


8 Fault and Remedy<br />

Error codes<br />

SAE J 1939<br />

SPN/FMI<br />

Chapter.8.<br />

Fault and Remedy<br />

Error<br />

codes<br />

ADM2<br />

Meaning Remedy<br />

609/14 14052 Internal fault EEPROM: fault<br />

checksum 2 (CKS2):<br />

blocks vehicle<br />

parameters<br />

609/14 24053 Internal fault EEPROM: fault<br />

checksum 3 (CKS3):<br />

block series or<br />

immobilizer<br />

609/12 14054 Internal fault CAN Datenbereich<br />

defekt<br />

625/2 10104 CAN connection keine Verbindung zu<br />

CAN<br />

625/2 10102 CAN connection CAN Daten<br />

unplausibel<br />

625/14 10100 CAN connection CAN_High Leitung<br />

unterbrochen/<br />

kurzgeschlossen<br />

625/14 10101 CAN connection CAN_Low Leitung<br />

unterbrochen/<br />

kurzgeschlossen<br />

– Check plug-in connections/electric components.<br />

– Check plug-in connections/electric components.<br />

– Check plug-in connections/electric components.<br />

– Check CAN connection to the control device.<br />

– Perform function control.<br />

– Check CAN for line break.<br />

– Check CAN for line break.<br />

625/14 10149 CAN connection Parametrierfehler CAN – Check parameters, correct if needed.<br />

636/1 10310 Crankshaft<br />

sensor<br />

636/3 10309 Crankshaft<br />

sensor<br />

636/4 10308 Crankshaft<br />

sensor<br />

636/7 10311 Crankshaft<br />

sensor<br />

636/8 10312 Crankshaft<br />

sensor<br />

636/14 10313 Crankshaft<br />

sensor<br />

651/5 15027 Injection<br />

cylinder 1<br />

651/6 25028 Injection<br />

cylinder 1<br />

651/7 15026 Injection<br />

cylinder 1<br />

651/12 09044 Injection<br />

cylinder 1<br />

651/14 09045 Injection<br />

cylinder 1<br />

652/5 15127 Injection<br />

cylinder 2<br />

652/6 25128 Injection<br />

cylinder 2<br />

Pegel zu gering – First, pull out the sensor with the engine standing still and perform visual<br />

inspection, then push in sensor with engine standing still to the mechanical<br />

stop.<br />

cable breakage – Check line and sensor for cable breakage with the setpoint 1,2 kOhm.<br />

short circuit nach<br />

Masse<br />

KW/NW-Signal<br />

Zuordnung unplausibel<br />

Timeout (kein<br />

Kurbelwellensignal)<br />

– Check line and sensor for short circuit to ground with the setpoint 1,2 kOhm.<br />

– With engine standing still, pull out both sensors and perform visual inspection,<br />

then push in both to the mechanical stop. Check KW sensor and NW sensor<br />

at the plug N3 for permutation.<br />

– First, pull out the sensor with the engine standing still and perform visual<br />

inspection, then push in sensor with engine standing still to the mechanical<br />

stop.<br />

Sensor verpolt – Correctly connect sensor in the plug of PLD-MR.<br />

control fault plug-in<br />

pumps solenoid valve<br />

cylinder 1 disturbed<br />

short circuit plug-in<br />

pumps solenoid valve<br />

cylinder 2<br />

impact detection plugin<br />

pumps solenoid<br />

valve no impact<br />

cylinder 1<br />

air tranquility controller<br />

limiter cylinder 1<br />

individual cylinder<br />

tuning limiter cylinder 1<br />

control fault plug-in<br />

pumps solenoid valve<br />

cylinder 2 disturbed<br />

short circuit plug-in<br />

pumps solenoid valve<br />

cylinder 2<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– Check electrical supply lines for interconnecting short circuits, short circuit to<br />

ground, short circuit to U B .<br />

– Unscrew electrical bolted connection of the plug-in pump concerned.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– Check electrical supply lines for interconnecting short circuits, short circuit to<br />

ground, short circuit to U B .<br />

– Unscrew electrical bolted connection of the plug-in pump concerned.<br />

272


Error codes<br />

SAE J 1939<br />

SPN/FMI<br />

Error<br />

codes<br />

ADM2<br />

652/7 15126 Injection<br />

cylinder 2<br />

652/12 09144 Injection cylinder<br />

2<br />

652/14 09145 Injection<br />

cylinder 2<br />

653/5 15227 Injection<br />

cylinder 3<br />

653/6 25228 Injection<br />

cylinder 3<br />

653/7 15226 Injection<br />

cylinder 3<br />

653/12 09244 Injection<br />

cylinder 3<br />

653/14 09245 Injection<br />

cylinder 3<br />

654/5 15327 Injection<br />

cylinder 4<br />

654/6 255328 Injection<br />

cylinder 4<br />

654/7 15326 Injection<br />

cylinder 4<br />

655/12 09344 Injection<br />

cylinder 4<br />

655/14 09345 Injection<br />

cylinder 4<br />

655/5 15427 Injection<br />

cylinder 5<br />

655/6 25428 Injection<br />

cylinder 5<br />

655/7 15426 Injection<br />

cylinder 5<br />

655/12 09444 Injection<br />

cylinder 5<br />

655/14 09445 Injection<br />

cylinder 5<br />

656/5 15527 Injection<br />

cylinder 6<br />

656/6 25528 Injection<br />

cylinder 6<br />

Meaning Remedy<br />

impact detection plugin<br />

pumps solenoid<br />

valve no impact<br />

cylinder 2<br />

air tranquility controller<br />

limiter cylinder 2<br />

individual cylinder<br />

tuning limiter cylinder 2<br />

control fault plug-in<br />

pumps solenoid valve<br />

cylinder 3 disturbed<br />

short circuit plug-in<br />

pumps solenoid valve<br />

cylinder 3<br />

impact detection plugin<br />

pumps solenoid<br />

valve no impact<br />

cylinder 3<br />

air tranquility controller<br />

limiter cylinder 3<br />

individual cylinder<br />

tuning limiter cylinder 3<br />

control fault plug-in<br />

pumps solenoid valve<br />

cylinder 4 disturbed<br />

short circuit plug-in<br />

pumps solenoid valve<br />

cylinder 4<br />

impact detection plugin<br />

pumps solenoid<br />

valve no impact<br />

cylinder 4<br />

air tranquility controller<br />

limiter cylinder 4<br />

individual cylinder<br />

tuning limiter cylinder 4<br />

control fault plug-in<br />

pumps solenoid valve<br />

cylinder 5 disturbed<br />

short circuit plug-in<br />

pumps solenoid valve<br />

cylinder 5<br />

impact detection plugin<br />

pumps solenoid<br />

valve no impact<br />

cylinder 5<br />

air tranquility controller<br />

limiter cylinder 5<br />

individual cylinder<br />

tuning limiter cylinder 5<br />

control fault plug-in<br />

pumps solenoid valve<br />

cylinder 6 disturbed<br />

short circuit plug-in<br />

pumps solenoid valve<br />

cylinder 6<br />

273<br />

8 Fault and Remedy<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– Check electrical supply lines for interconnecting short circuits, short circuit to<br />

ground, short circuit to U B .<br />

– Unscrew electrical bolted connection of the plug-in pump concerned.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– Check electrical supply lines for interconnecting short circuits, short circuit to<br />

ground, short circuit to U B .<br />

– Unscrew electrical bolted connection of the plug-in pump concerned.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– Check electrical supply lines for interconnecting short circuits, short circuit to<br />

ground, short circuit to U B .<br />

– Unscrew electrical bolted connection of the plug-in pump concerned.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– Check electrical supply lines for interconnecting short circuits, short circuit to<br />

ground, short circuit to U B .<br />

– Unscrew electrical bolted connection of the plug-in pump concerned.<br />

Chapter.8.<br />

Fault and Remedy


8 Fault and Remedy<br />

Error codes<br />

SAE J 1939<br />

SPN/FMI<br />

Chapter.8.<br />

Fault and Remedy<br />

Error<br />

codes<br />

ADM2<br />

656/7 15526 Injection<br />

cylinder 6<br />

656/12 09544 Injection<br />

cylinder 6<br />

656/14 09545 Injection<br />

cylinder 6<br />

657/5 15627 Injection<br />

cylinder 7<br />

657/6 25628 Injection<br />

cylinder 7<br />

657/7 15626 Injection<br />

cylinder 7<br />

657/12 09644 Injection<br />

cylinder 7<br />

657/14 09645 Injection<br />

cylinder 7<br />

658/5 15727 Injection<br />

cylinder 8<br />

658/6 25728 Injection<br />

cylinder 8<br />

658/7 15726 Injection<br />

cylinder 8<br />

658/12 09744 Injection<br />

cylinder 8<br />

658/14 09745 Injection<br />

cylinder 8<br />

677/3 18005 Starter relay<br />

(from PLD-MR)<br />

677/5 18009 Starter relay<br />

(from PLD-MR)<br />

677/6 18008 Starter relay<br />

(from PLD-MR)<br />

677/7 18086 Starter relay<br />

(from PLD-MR)<br />

677/14 18033 Starter relay<br />

(from PLD-MR)<br />

698/5 17309 PWM driver 2:<br />

proportional valve<br />

2: control engine<br />

brake constant<br />

throttle (MBR-KD)<br />

Meaning Remedy<br />

impact detection plugin<br />

pumps solenoid<br />

valve no impact<br />

cylinder 6<br />

air tranquility controller<br />

limiter cylinder 6<br />

individual cylinder<br />

tuning limiter cylinder 6<br />

control fault plug-in<br />

pumps solenoid valve<br />

cylinder 7 disturbed<br />

short circuit plug-in<br />

pumps solenoid valve<br />

cylinder 7<br />

impact detection plugin<br />

pumps solenoid<br />

valve no impact<br />

cylinder 7<br />

air tranquility controller<br />

limiter cylinder 7<br />

individual cylinder<br />

tuning limiter cylinder 7<br />

control fault plug-in<br />

pumps solenoid valve<br />

cylinder 8 disturbed<br />

short circuit plug-in<br />

pumps solenoid valve<br />

cylinder 8<br />

impact detection plugin<br />

pumps solenoid<br />

valve no impact<br />

cylinder 8<br />

air tranquility controller<br />

limiter cylinder 8<br />

individual cylinder<br />

tuning limiter cylinder 8<br />

starter control: starter<br />

relay external flow<br />

starter control: cable<br />

breakage<br />

starter control: short<br />

circuit to ground<br />

starter control: starter<br />

does not engage<br />

starter control: starter<br />

relay is sticking<br />

Low Side with short<br />

circuit to ground<br />

Remarks: control device<br />

PLD-MR has wrong<br />

parameters/short circuit<br />

to ground<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– Check electrical supply lines for interconnecting short circuits, short circuit to<br />

ground, short circuit to U B .<br />

– Unscrew electrical bolted connection of the plug-in pump concerned.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– Check electrical supply lines for interconnecting short circuits, short circuit to<br />

ground, short circuit to U B .<br />

– Unscrew electrical bolted connection of the plug-in pump concerned.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– After repair of mechanical and electrical faults, set smoothness control to<br />

zero.<br />

– Check the line to the starter relay for short circuit to U B .<br />

– Check starter relay, replace if needed.<br />

– Reinstall electrical connections.<br />

– Disconnect battery .<br />

– Check line to the starter relay for cable breakage.<br />

– Check starter relay, replace if needed.<br />

– Check line to the starter relay for short circuit to ground.<br />

– Check starter relay, replace if needed.<br />

– Check starter electrically and mechanically.<br />

– Perform functional control.<br />

– Check starter relay, replace if needed.<br />

– Perform functional control.<br />

– Check parameters: parameter 7 must be set to NOT ACTIVE, otherwise data<br />

set false.<br />

– If parameters are correct, then check line for cable breakage.<br />

– If parameters false, then set new parameters for the control device.<br />

274


Error codes<br />

SAE J 1939<br />

SPN/FMI<br />

Error<br />

codes<br />

ADM2<br />

698/6 17306 PWM driver 2:<br />

proportional valve<br />

2: control engine<br />

brake constant<br />

throttle (MBR-KD)<br />

Meaning Remedy<br />

Low Side with short<br />

circuit to ground<br />

Remarks: control device<br />

PLD-MR has wrong<br />

parameters/short circuit<br />

to ground<br />

275<br />

8 Fault and Remedy<br />

– Check parameters: parameter 7 must be set to NOT ACTIVE, otherwise data<br />

set false.<br />

– If parameters are correct, then check line for cable breakage.<br />

– If parameters false, then set new parameters for the control device.<br />

723/3 10409 Camshaft sensor cable breakage – Check line and sensor for cable breakage with the setpoint 1,2 kOhm.<br />

723/4 10408 Camshaft sensor short circuit to ground – Check line and sensor for short circuit to ground with the setpoint 1,2 kOhm.<br />

723/8 10412 Camshaft sensor timeout (no camshaft<br />

signal)<br />

723/14 10413 Camshaft sensor sensor wrongly<br />

connected<br />

– Pull out sensor with engine standing still and perform visual inspection.<br />

– Push in sensor with engine standing still to the mechanical stop.<br />

– Correctly connect sensor in the plug of PLD-MR.<br />

Chapter.8.<br />

Fault and Remedy


8 Fault and Remedy<br />

Chapter.8.<br />

Fault and Remedy<br />

8.7 Main Battery Switch<br />

The electrical system may be completely separated from the batteries using the main<br />

battery switch. This is only the case, if additionally the sliding switch F47 in central<br />

electrics is pulled. The main battery switch is located on the left vehicle side in the<br />

opening of the cover between stepladder and battery box.<br />

Attention! Danger of damage to electrics and electronics of the machine. The main<br />

battery switch may not be switched off as long as the machine is running and the ignition<br />

is switched on.<br />

8.8 Jumpstarting and Charging the Battery<br />

Should it be necessary to jumpstart <strong>euro</strong>-Maus3, then in no case may a charging or<br />

jumpstart device connected to the mains or to a generator be used, since the use of<br />

these devices would lead to irrepairable damage to electronics of <strong>euro</strong>-Maus3.<br />

Only other motor vehicles with a system voltage of 24 V or vehicle batteries with a<br />

battery voltage of 24 V and sufficient capacity may be used for jumpstarting.<br />

We expressly want to point out, that quick charge devices and mains-connected<br />

jumpstart devices are expressly prohibited for starting of <strong>euro</strong>-Maus3. Excess voltage<br />

damage caused by use of unapproved charging devices or jumpstart devices are neither<br />

covered by the guarantee nor by the statutory warranty. No accommodation is granted in<br />

case of such damage.<br />

276<br />

main battery switch


Charging the battery/jumpstarting<br />

277<br />

8 Fault and Remedy<br />

Generally, the plus poles must be disconnected and the main battery switch must be<br />

switched off to charge the batteries. Only normal battery charging devices may be used<br />

to charge the battery. Quick charge devices are expressly prohibited!<br />

The charging current may at max. amount to one tenth of the nominal capacity of the<br />

battery.<br />

II䔠<br />

II䔠<br />

2<br />

4V+<br />

0<br />

2<br />

4V+<br />

0<br />

2<br />

0<br />

2<br />

0<br />

2<br />

0<br />

0 2<br />

04V+<br />

Since damage has been incurred several times in the past due to improper charging of<br />

the battery or jumpstarting, we expressly want to point out, that <strong>euro</strong>-Maus3 may only<br />

be jumpstarted using the following method:<br />

Attention! Injury hazard. In any case, observe the hints on safety of the battery<br />

manufacturer when handling acid batteries.<br />

Chapter.8.<br />

Fault and Remedy


8 Fault and Remedy<br />

Chapter.8.<br />

Fault and Remedy<br />

Jumpstarting<br />

– Exclusively use standardized jumpstarting cables with really sufficient cross-section<br />

of the electric conductors.<br />

– Only use batteries with the same nominal voltage (24 V).<br />

– Make sure of sufficient battery capacity of the assisting vehicle.<br />

– Shut off the engines of both vehicles and switch off the ignition.<br />

– Shut off the main battery switch of <strong>euro</strong>-Maus3.<br />

– Make sure, that the vehicles do not touch anywhere.<br />

– First connect the minus pole of the battery of the assisting vehicle to the minus pole<br />

of the battery of <strong>euro</strong>-Maus3. Alternately, a blank metal and electrically conductive<br />

place (for instance ground strap or engine block) of the assisting vehicle may be<br />

connected to a similar place (ground strap or engine block) of the <strong>euro</strong>-Maus3 to be<br />

started.<br />

– Connect the plus pole of the battery of the assisting vehicle to the plus pole of the<br />

battery of <strong>euro</strong>-Maus3.<br />

– Switch on the main battery switch of <strong>euro</strong>-Maus3.<br />

– Start the engine of the assisting vehicle and accelerate this engine to a medium<br />

speed.<br />

– Start the engine of <strong>euro</strong>-Maus3 and make sure, that any try at starting does not last<br />

for more than 15 seconds.<br />

– Before removing the jumpstart cable, in any case shut down the engine of the<br />

assisting vehicle, since otherwise the electronics of the assisting vehicle may be<br />

damaged.<br />

– Remove the jumpstart cables from both vehicles in reverse order (first plus cable,<br />

then minus cable).<br />

assisting vehicle<br />

278<br />

main battery switch<br />

<strong>euro</strong>-Maus3


8.9 Welding Work on the Machine<br />

8.10 Towing<br />

279<br />

8 Fault and Remedy<br />

In case of welding work on the machine, the main battery switch must always be<br />

switched off. The ground cable of the welding transformer must be connected as close to<br />

the welding position as possible.<br />

Attention! Welding work on the machine may only be performed by people sufficiently<br />

qualified for the respective work under regional regulations. Welding work on structural<br />

parts or parts with safety function may only be performed after enquiry with <strong>ROPA</strong>, to<br />

the extent as this is admissible under the respective applicable regulations. All welding<br />

work may only be performed in compliance with applicable standards and recognized<br />

engineering principles. In any case, observe the increase fire hazard when welding near<br />

combustible parts or liquids (fuel, oils, greases, tires, etc.). We expressly want to point<br />

out that <strong>ROPA</strong> does not assume any warranty for damage to the machine caused by<br />

improper welding work.<br />

If it should be necessary to tow the machine, then always comply with the regionally<br />

applicable regulations for the towing vehicle and for securing the vehicle combination<br />

on public roads and paths. In any case, move the transmission into neutral position. For<br />

this purpose, shut down the machine. Engage the parking brake and additionally secure<br />

the machine against inadvertent rolling away using the two wheel chocks in the engine<br />

housing in front of the fuel tank.<br />

1. Shut off compressed air supply of working pneumatics. For this purpose, turn the red<br />

plastic stopcock (1) above the transmission crosswise to the course of the line.<br />

1<br />

Stopcock open, turn by 90° to close.<br />

2. Push respectively pull the shift rod (to the right outside on the front side of the<br />

transmission) into central position. Neither of the two gears may be engaged.<br />

Chapter.8.<br />

Fault and Remedy


8 Fault and Remedy<br />

Chapter.8.<br />

Fault and Remedy<br />

Warning!.The vehicle is very difficult to steer with the engine standing still! Take care, if<br />

the brake is not in operating condition! Only use vehicles with sufficient braking power to<br />

tow <strong>euro</strong>-Maus3. For towing, exclusively use load-securing devices with sufficient<br />

load-bearing capacity. No other vehicles may be towed or trailers pulled by <strong>euro</strong>-Maus3.<br />

It is impossible to start up the engine of <strong>euro</strong>-Maus3 by tow starting or rolling.<br />

8.11 Coupling of Salvaging Aids<br />

Proceed as follows for coupling of salvaging aids (steel wires, chains, ropes, salvaging<br />

nooses, belts, etc.):<br />

Couple salvaging aid to the rear of the machine:<br />

– Swing tank aside.<br />

– Fasten salvaging aids to to the rear towing lugs, that the machine cannot be<br />

damaged.<br />

280<br />

Shift rod<br />

Rear towing lug


Fastening salvaging aids to the front of the machine:<br />

281<br />

8 Fault and Remedy<br />

– Swing up both lateral parts and secure using the securing chains available.<br />

– Push a shaft with sufficient load-bearing capacity (diameter about 50 mm) through<br />

the connecting pipe of the central pickup frame (about 300 mm above the infeed-<br />

conveyor deflecting rollers) and connect the salvaging aids to both ends of this shaft.<br />

Remark! Always make sure of sufficient stability of the salvaging aids. Consider<br />

that the load caused by salvaging a vehicle may amount to several times the normal<br />

vehicle weight. When salvaging the machine, call in experts with as much experience<br />

as possible and always use devices with sufficient load bearing capacity and suitable<br />

vehicles.<br />

8.12 <strong>Manual</strong> Release of the Parking Brake<br />

Sufficient pressure must be available in the compressed air system to release the<br />

parking brake.<br />

In emergencies, the parking brake may even be manually released if there is not<br />

sufficient pressure available for the braking system. For this purpose, the spring-loaded<br />

cylinder must be manually deactivated.<br />

slide shaft through here<br />

Danger!.Hazard to life from the machine rolling away. Before releasing the spring-<br />

loaded cylinder, the machine must be secured against rolling away using both chocks.<br />

Work on vehicle brakes may only be performed by specialist personnel (for instance car<br />

mechanics, mechanics for agricultural machinery, brake service, etc.) with corresponding<br />

training, in compliance with the applicable safety regulations.<br />

To deactivate the spring-loaded cylinder, screw out the releasing bolt (1) to the left and<br />

right on the front axle to the stop. The releasing bolt is located on the rear of the cylinder.<br />

Chapter.8.<br />

Fault and Remedy


8 Fault and Remedy<br />

Chapter.8.<br />

Fault and Remedy<br />

Deactivation spring-loaded cylinder right/left:<br />

– Shut off engine and secure against inadvertent start.<br />

– Secure vehicle against rolling away using both chocks.<br />

– Using a box wrench SW24, turn the emergency release bolt (hexagonal bolt at<br />

the center of the cylinder) counter-clockwise for so long (maximum torque 35 Nm,<br />

distance about 70 mm), until a fixed stop can be felt.<br />

– The spring-loaded cylinders are released, the vehicle is completely without brakes.<br />

– The vehicle may, under observance of the corresponding safety regulations, be<br />

towed to the next workshop or a safe parking place.<br />

Danger! Never park the vehicle unsecured when the spring-loaded cylinders are<br />

released. Secure the vehicle against rolling away using chocks of sufficient size. In the<br />

field of vision of the driver, fasten a conspicuous sign bearing the text: „Danger! Vehicle<br />

is without brakes! Spring-loaded cylinders are released“. Keep the ignition key in a safe<br />

place.<br />

Work on the spring-loaded cylinders is dangerous and may only be performed by people<br />

trained for this work and familiar with work on preloaded spring packages.<br />

Warning! Danger of severe injuries from parts flung away with great force. In no case,<br />

open the spring-loaded cylinders forcibly or improperly. The parts inside of the spring-<br />

loaded cylinder are preloaded with great spring force and may be flung away in case of<br />

improper opening and severely injure people. Maximum admissible releasing pressure<br />

8 bar!<br />

When the repairs are complete, the spring-loaded cylinders must be reactivated as<br />

follows:<br />

Releasing bolt<br />

Using the box wrench SW24, screw in the emergency release bolts (hexagonal bolt<br />

at the center of the cylinder) clockwise into the housing to the stop an tighten using a<br />

torque of 30 Nm.<br />

282


8.13 Adjust Brake<br />

283<br />

8 Fault and Remedy<br />

Work on the vehicle brakes may only be performed by specialist personnel (for<br />

instance car mechanics, mechanics for agricultural machinery, brake service, etc.)<br />

with corresponding training, in compliance with the applicable safety regulations.<br />

The wedge brake is fitted with an automated readjusting device. Readjusting the brake is<br />

therefore not required.<br />

8.14 Hydraulics Valves<br />

All hydraulics valves are electrically controlled. Problems on solenoid valves may be<br />

located using specific test cables, which are supplied with each machine. These test<br />

cables may only be connected to the solenoid valves by trained and instructed specialist<br />

personnel.<br />

If an electrically controlled valve should not work, then in every case, without exception,<br />

a specialist must be called in. In no case may a try be made to remedy possible contact<br />

problems or a line breakage by shaking the solenoids concerned. If, during such tries,<br />

the valve is suddenly opened, then the person concerned may sustain deadly injuries.<br />

Warning!.Troubleshooting and fault repairs on all components of the hydraulics system<br />

is exclusively the task of trained specialists. We expressly warn against tries to repair or<br />

arbitrary tests on electromagnetically operated hydraulics valves. If, during such tests<br />

or tries to repair, parts of the hydraulics system are suddenly pressurized, then this may<br />

lead to unwanted machine movements. This may squeeze or even crush people or body<br />

parts.<br />

Chapter.8.<br />

Fault and Remedy


8 Fault and Remedy<br />

Chapter.8.<br />

Fault and Remedy<br />

8.15 Central Lubricating System – Bleeding and Removal of Blocks<br />

Lubrication pump Main distributor<br />

During all work on the central lubricating system, make sure of the utmost cleanliness. In<br />

no case may dirt ingress into the lubricating system.<br />

If the reservoir should, by accident, have been driven empty, then the lubricating pump<br />

must be bled. For this purpose, remove the main line from the main distributor and<br />

switch on the pump for so long until air-free grease emits from the main line. Screw a<br />

lubricating nipple into the input of the main distributor and pump grease into the main<br />

distributor for so long until the grease emits at the bearings. Then, reconnect all line<br />

connections again.<br />

Should the line system be blocked, then the grease is emitted at the pressure relief valve<br />

(directly at the line output of the pump). To remove this block, proceed as follows:<br />

284<br />

Subdistributor<br />

Pressure relief valve<br />

Lubrication point


285<br />

8 Fault and Remedy<br />

– Search for the blocked place in the line system. Follow the stiffer grease line from<br />

the lubricating pump to the main distributor (the blocked line is stiffer, because it<br />

is under pressure) and on to the corresponding subdistributor and from there to<br />

the blocked lubricating point. Please find the organization of the central lubricating<br />

system in the diagram below. You will find a detailed plan in Chapter 9.<br />

– Unscrew the line from the load and screw a lubricating nipple into the corresponding<br />

(sub) distributor.<br />

– Try to loosen the block by strongly pumping grease into the distributor using the<br />

grease gun.<br />

– Proceed systematically: from the grease pump to the main distributor, from there to<br />

the subdistributor, etc.<br />

– When you notice that the line is free again, reconnect the line to the load. Test free<br />

passage by performing intermediate lubrication.<br />

– If you should not be successful using the method described here, then contact your<br />

<strong>ROPA</strong> service location.<br />

Function of outputs at the lubricating pump<br />

Lubricating circuit 3<br />

8-fold pinch roller cleaner<br />

(option)<br />

Lubricating pump under the cabinet of the central electric system.<br />

Lubricating circuit 2<br />

pickup<br />

Lubricating circuit 1<br />

chassis<br />

Chapter.8.<br />

Fault and Remedy


8 Fault and Remedy<br />

Chapter.8.<br />

Fault and Remedy<br />

8.16 Emergency <strong>Operation</strong> Fan Drive<br />

To check if the fan wheel of the radiator system is really running at maximum speed, the<br />

plug designated (Y99) may testwise be pulled from the hydraulics pump. Then, the fan<br />

should be running at maximum speed. If the cooling performance does not improve from<br />

this measure, then the machine may only be operated at reduced load.<br />

286<br />

Y 99


287<br />

8 Fault and Remedy<br />

8.17 Independent Heating System (Optional) – Measures in Case of Faults<br />

When faults occur, the fuses and plug-in connections must be checked for perfect<br />

condition and tight fit.<br />

If these measures do not serve to remedy the fault, then please contact a Webasto<br />

service point (www.webasto.com) stating the model of your independent heating system<br />

(Thermo 90 ST.25.D 24V).