Operation Manual euro ... - ROPA Fahrzeug

ropamaschinenbau

Operation Manual euro ... - ROPA Fahrzeug

Mercedes-Benz engine OM 926 LA

Software version: 2007M0112

Printed in Germany 27.09.2007

Innovative technology

for harvesting beets

Translation of the Original

Operating Manual

euro-Maus3 from 2006


Imprint

All rights reserved

© Copyright 2006 by

ROPA Fahrzeug- und Maschinenbau GmbH

Sittelsdorf 24

D-84097 Herrngiersdorf

Telephon + 49 – 87 85 – 96 01 0

Telefax + 49 – 87 85 – 56 6

Internet www.ropa-maschinenbau.de

E-mail kundendienst@ropa-maschinenbau.de

These operating instructions may only be reprinted or otherwise reproduced

– even in excerpts – with the express approval of ROPA GmbH.

Any type of reproduction, distribution or storage on data medium in any form and

of any type not authorized by ROPA GmbH forms a violation of current domestic and international copyright law

and will be judicially prosecuted.

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

effect on function or operation.

Publisher responsible for content: ROPA Fahrzeug- und Maschinenbau GmbH

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

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

Printed in Germany 27.09.2007


EC Declaration of Conformity

In confirmation of conformity with the machine directive

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

The company ROPA Fahrzeug- und Maschinenbau GmbH

Sittelsdorf 24

84097 Herrngiersdorf

Deutschland

hereby declares, as manufacturer, that the machine designated below:

Self-propelled beet loading and cleaning machinet

Designation: euro-Maus3

Machine model: e-M

from serial number: 8**550

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

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

Directives and standards additionally applied: 89/336 EWG

This declaration becomes invalid in case of any modification to the machine not directly agreed

with ROPA Fahrzeug- und Maschinenbau GmbH.

Date: 31.07.2006

Signature manufacturer: Ottl Georg

Function of the signer: Leiter Produktion


Table of contents

5

Table of contents

0 Preface ............................................................................. 15

0.1 Name plate and important data ...............................................................17

0.2 Serial number Diesel engine....................................................................18

1 Safety ............................................................................... 21

1.1 General ....................................................................................................21

1.2 Obligations of the entrepreneur ...............................................................21

1.3 General symbols and instructions............................................................22

1.4 Proper use ...............................................................................................22

1.5 Hazard zone ............................................................................................23

1.6 Safety stickers on the machine ................................................................26

1.7 Safety and accident protection ................................................................27

1.8 Requirements for operating and maintenance personnel ........................27

1.9 In the event of accidents ..........................................................................28

1.10 Handling old parts, process materials......................................................28

1.11 Residual risks ..........................................................................................28

1.12 Hazards caused by mechanical influences..............................................29

1.13 Hazards caused by process materials .....................................................29

1.14 Hazards caused by noise ........................................................................30

1.15 Hazards caused by the hydraulics system ..............................................30

1.16 Hazard From the Pneumatic System .......................................................31

1.17 General hints on safety when handling acid batteries .............................31

1.18 General Hints on Safety for the Independent Heating System (Optional) 32

2 Road Traffic ..................................................................... 35

3 General View And Specifications .................................. 41

3.1 General view euro-Maus3.......................................................................41

3.2 Specifications ...........................................................................................43

3.3 Transport draft for low-loader transport euro-Maus3 ..............................45

3.4 Load-securing points ...............................................................................46

3.5 Transport draft for loading euro-Maus3 on a ship ....................................47

3.6 Supporting Points for Wheel Replacement ..............................................48

4 General Description ....................................................... 51

4.1 Function ...................................................................................................51

4.2 Scope of delivery .....................................................................................51

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5 Operating Components .................................................. 55

5.1 Steering column .......................................................................................55

5.1.1 Steering Column Switch ..........................................................................56

5.2 Driver‘s Seat ............................................................................................57

5.2.1 Rotate Cockpit .........................................................................................57

5.2.2 Adjusting the Driver‘s Seat ......................................................................58

5.3 Operating Components on the Floor of the Driver‘s Cabin ......................62

5.4 Operating Console Right .........................................................................63

5.4.1 Switch section 1 .......................................................................................63

5.4.2 Operating Section ....................................................................................64

5.4.3 Switch section 2 .......................................................................................66

5.4.4 Switch section 3 .......................................................................................66

5.4.5 Switch section 4 .......................................................................................67

5.4.6 Right joystick with multi-functional handle ..............................................68

5.4.7 Joystick movements (right joystick) .........................................................71

5.4.7.1 Only in operating mode rabbit..................................................................71

5.4.7.2 Only in operating mode turtle...................................................................72

5.4.8 Left Joystick .............................................................................................73

5.5 Operating Components in the Radio Console on the Cabin Ceiling...............74

5.6 Air Conditioning .......................................................................................76

5.7 Operating Components Outside of the Cabin ..........................................77

6 Operation ......................................................................... 81

6.1 Initial Commissioning ...............................................................................81

6.2 Safety Regulations for Operation of euro-Maus3 ....................................82

6.2.1 Working in the vicinity of power lines .......................................................84

6.2.2 Behaviour during or after contact to an electric power line: .....................85

6.3 Color Terminal ..........................................................................................86

6.3.1 Keyboard and display sectors..................................................................86

6.3.2 Main screen driving on roads...................................................................88

6.3.3 Select function section .............................................................................89

6.3.4 Main menu ...............................................................................................89

6.3.4.1 Loading settings (menu code 1) ..............................................................89

6.3.4.2 System menu (menu code 2)...................................................................90

6.3.4.3 Service menu (menu code 3)...................................................................91

6.3.4.4 Menu basic settings (menu code 4) .........................................................91

6.3.4.5 Submenu special functions (menu code 5)..............................................92

6.3.4.6 Empty menu (menu code 6) ....................................................................92

6.3.5 Operating data .........................................................................................93

6.3.6 Adjusting warning limits ...........................................................................94

6.3.7 Warning and status indications on the color terminal ..............................95

6.4 Air Conditioning .......................................................................................98

6.5 Independent Heating System (Optional)..................................................100

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6.5.1 Operation timer ........................................................................................100

6.5.2 Operation independent heating system ...................................................100

6.6 Heating Hydraulics Fluid Tank

(only jointly with the independent heating system) ..................................102

6.7 Diesel Engine ...........................................................................................103

6.7.1 Starting the engine...................................................................................103

6.7.2 Starting the engine without booting up the terminal.................................104

6.7.3 Engine speed adjustment ........................................................................104

6.7.3.1 Operating mode „rabbit“...........................................................................104

6.7.3.2 Operating mode „turtle“ ............................................................................105

6.8 Switching Driving Power ..........................................................................105

6.8.1 Switching gears .......................................................................................106

6.8.2 Switching process differential lock ...........................................................107

6.9 Driving ......................................................................................................109

6.9.1 Driving on roads (operating mode rabbit) ................................................110

6.9.1.1 Switching driving direction .......................................................................110

6.9.1.2 Cruise control ...........................................................................................111

6.9.2 Quick description: operating cruise control ..............................................113

6.9.3 Driving in operating mode turtle (loading) ................................................114

6.10 Braking System ........................................................................................115

6.10.1 Operating brake .......................................................................................115

6.10.2 Parking brake ...........................................................................................116

6.10.3 Automatic parking brake (only in operating mode rabbit) ........................116

6.11 Steering ...................................................................................................117

6.11.1 Main steering switch ................................................................................117

6.11.2 Rear axle steering in operating mode Rabbit ..........................................118

6.11.2.1 Manual rear axle steering ........................................................................118

6.11.2.2 All-wheel steering ....................................................................................118

6.11.2.3 Setting the rear axle to straight position ..................................................119

6.11.2.4 Quick description: steering in operating mode „rabbit“ ............................120

6.11.3 Steering in operating mode „turtle“ (loading operation) .......................121

6.12 Loading Operation ...................................................................................121

6.12.1 Safety circuit for loading operation of euro-Maus3 ..................................121

6.12.2 Preparations for loading...........................................................................123

6.12.3 Switching on swing axle support rear axle...............................................124

6.12.4 Swing out pickup......................................................................................124

6.12.4.1 Move pickup to operating depth...............................................................127

6.12.5 Swing out truck conveyor.........................................................................127

6.12.5.1 Loading direction to the right or left .........................................................129

6.12.6 Switching on machine drive .....................................................................131

6.12.7 Relieving pickup/depth setting ................................................................133

6.12.8 Clearing shields .......................................................................................135

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6.12.9 Beet stretch ..............................................................................................136

6.12.9.1 Truck conveyor (in the drawing drive A) ..................................................137

6.12.10 Recleaner (in the drawing drive B) ..........................................................138

6.12.10.1 Beet brake (only for 8-fold pinch roller cleaner) .......................................141

6.12.11 Infeed conveyor (in the drawing drive C) .................................................142

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

6.12.13 Pickup rollers (in the drawing drive E) .....................................................144

6.12.14 Automatic reversing function for all roller drives ......................................145

6.12.15 Loading transporting vehicle ....................................................................147

6.12.16 Continued loading function ......................................................................147

6.12.17 Pile pickup/picking up residual beets ......................................................148

6.12.18 Change from working to transporting position .........................................149

6.12.19 Special conditions during loading ............................................................155

6.12.19.1 Frozen beet pile .......................................................................................155

6.12.19.2 Extremely narrob beet pile .......................................................................156

6.12.19.3 Very strongly soiled beets and sticky ground conditions/

water spraying system (option) ...................................................................156

6.13 Diesel Enginer .........................................................................................160

6.13.1 Modifications respectively amendments of the engine operating

manual of Mercedes-Benz .......................................................................162

6.14 Pump Distributor Gears (PVG) ................................................................163

6.15 Hydraulics System ...................................................................................164

6.16 Compressed Air System ..........................................................................167

6.16.1 Compressor .............................................................................................169

6.16.2 Air drier ....................................................................................................169

6.16.3 Compressed air reservoir ........................................................................169

6.17 Central Lubricating System......................................................................170

6.17.1 Filling up the grease gun .........................................................................171

6.17.2 Intermediate lubrication ...........................................................................171

6.18 Printer ......................................................................................................173

6.18.1 Description of the keyboard functions......................................................173

6.18.2 Which thermally-sensitive paper is suitable ............................................174

6.19 Video Monitoring ......................................................................................175

6.20 Electrics ...................................................................................................175

6.20.1 Sockets ....................................................................................................175

6.20.2 Main battery switch ..................................................................................176

6.20.3 Voltage monitoring ...................................................................................177

6.20.4 Fuses .......................................................................................................177

6.21 Tire Pressures .........................................................................................178

6.22 Immobilizing up to One Week ..................................................................179

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Table of contents

7 Maintenance and Service ............................................... 183

7.1 Engine ......................................................................................................183

7.1.1 Dry Air Filter .............................................................................................184

7.1.2 Oil change for the engine.........................................................................188

7.1.3 Fuel Supply ..............................................................................................190

7.1.3.1 Fuel Prefilter Separ ..................................................................................192

7.1.3.2 Replace Standard Prefilter Element/Drain Water ...................................194

7.1.3.3 Microorganisms in the fuel system ..........................................................196

7.1.3.4 Fuel fine filter at the engine .....................................................................197

7.1.3.5 Other maintenace work on the Diesel engine ..........................................198

7.1.4 Radiator System ......................................................................................199

7.1.4.1 Reversing fan drive ..................................................................................199

7.1.4.2 Cleaning the radiator system ...................................................................199

7.1.4.3 Checking coolant .....................................................................................202

7.1.4.4 Replacing coolant ....................................................................................205

7.2 Air Conditioning System ..........................................................................206

7.3 Pump distributor gears .............................................................................208

7.4 Hydraulics system ....................................................................................211

7.4.1 Hydraulic fluid tank ..................................................................................212

7.4.1.1 Hydraulic fluid change .............................................................................213

7.4.1.2 Check intake strainers .............................................................................214

7.4.1.3 Replacing the hydraulic fluid filter ...........................................................215

7.4.2 Replacing the pressure filter element .....................................................216

7.5 Mechanical drive of the two steering axles ..............................................217

7.5.1 Cardan shafts from the transfer gear to the steering axles......................217

7.5.2 Maintenance cardan joints of the axles ...................................................218

7.6 Manual transmission ................................................................................218

7.7 Axles ........................................................................................................219

7.7.1 Planetary gear (applies to both axles) .....................................................219

7.7.2 Differential gears on the front and rear axles ...........................................221

7.8 Pneumatics System – Maintenance and Service ....................................222

7.9 Brake System – Maintenance and Service ..............................................223

7.10 Pickup ......................................................................................................223

7.10.1 Stop switch of the pickup .........................................................................223

7.10.2 Central mark ..................................................................................................224

7.10.3 Pickup roller gears ...................................................................................225

7.10.4 4-fold pinch roller gears ..........................................................................226

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7.11 Uninstalling and Installing Rollers ............................................................227

7.11.1 Uninstallation and installation of the pickup roller and

the cleaning roller ....................................................................................228

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

7.11.3 Deinstallation and installation feed rollers ...............................................231

7.11.4 Deinstallation and installation tapered roller and pinch rollers.................231

7.11.5 Replacing the wear flange .......................................................................232

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

7.12 Pile Pickup With Residual Beet Pickup ...................................................234

7.13 Infeed Conveyor ......................................................................................235

7.13.1 Tightening the infeed conveyor ................................................................236

7.13.2 Replacing the infeed conveyor drive wheels (finger disk)........................237

7.14 Recleaner ................................................................................................237

7.14.1 Strainer chain cleaner – maintenance .....................................................237

7.14.2 8-fold pinch roller cleaner – maintenance ...............................................239

7.15 Truck Conveyor – Maintenance ...............................................................240

7.15.1 Tightening of the truck conveyor ..............................................................240

7.15.2 Rotating drives of the swivel arm and truck conveyor .............................241

7.16 Printer (Option) ........................................................................................243

7.17 Heating and Ventilation System ...............................................................244

7.17.1 Fresh air intake filter ................................................................................244

7.17.2 Circulating air filter ...................................................................................245

7.17.3 Draining condensed water from the air conditioning system ...................245

7.18 Immobilization for a longer period of time ................................................246

8 Fault and Remedy ........................................................... 251

8.1 Safety Circuits ..........................................................................................251

8.2 Electric System ........................................................................................252

8.2.1 Fuses .......................................................................................................252

8.2.2 Schedule of Fuses (Fuses) .....................................................................254

8.2.3 Electronic Cutouts ....................................................................................256

8.2.4 Schedule of Electronic Cutouts................................................................256

8.3 Schedule of Relays ..................................................................................257

8.4 Color Code for Electrical Wiring ...............................................................258

8.5 Fault Search Using the Color Terminal ....................................................259

8.5.1 Overview of Diagnostic Menus ...............................................................260

8.6 Error Codes Diesel Engine Mercedes-Benz ............................................268

8.6.1 Error Codes of Diagnostic Version 202....................................................268

8.6.2 Error Codes of Diagnostics Version 203 ..................................................269

8.6.3 Error Codes of Engine Cont rol (PLD-MR) ..............................................270

8.7 Main Battery Switch .................................................................................276

8.8 Jumpstarting and Charging the Battery ...................................................276

8.9 Welding Work on the Machine .................................................................279

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8.10 Towing ......................................................................................................279

8.11 Coupling of Salvaging Aids ......................................................................280

8.12 Manual Release of the Parking Brake .....................................................281

8.13 Adjust Brake ............................................................................................283

8.14 Hydraulics Valves ....................................................................................283

8.15 Central Lubricating System – Bleeding and Removal of Blocks ..............284

8.16 Emergency Operation Fan Drive .............................................................286

8.17 Independent Heating System (Optional) – Measures in Case of Faults .................287

9 Schedules and Tables/Plans and Diagrams/

Maintenance Slips .............................................................. 291

9.1 Lubricants and Operating Supplies euro-Maus3 .....................................291

9.2 Wartungstabelle euro-Maus3 ...................................................................292

9.3 Lubricating Plan euro-Maus3 (Lubrication Using Grease Gun) ...............296

9.4 Filter Cartridges, V-Belts euro-Maus3 with Mercedes OM926 LA ..........297

9.5 Maintenance Slips ...................................................................................298

9.5.1 Software updates .....................................................................................298

9.5.2 Maintenance Certificate ...........................................................................298

9.5.3 Maintenance Slip Oil Change + Filter Change (only Disel engine) ..........299

Maintenance Slip Oil Change + Filter Change ........................................300

9.6 Torque Table for Bolts and Nuts (Nm) ......................................................301

9.7 Lubricating Plans .....................................................................................302

9.7.1 Machine Recleaner With Version Infeed Conveyor .................................302

9.7.2 Machine With Recleaner Version 8-Fold Pinch Roller ............................303

9.8 Lubricant Translation Table for ROPA Machines .....................................304

9.9 Excerpt From the Mercedes-Benz Works Standard

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

9.9.1 Multigrade Engine Oils (Specification 228.5) ...........................................305

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

9.10 Approved Lubricating Greases ................................................................312

9.10.1 Recommended Greases for the Central Lubricating System ..................312

9.10.2 Recommended Biologically Degradable Greases for

the Central Lubricating System................................................................312

9.11 Safety Information ....................................................................................313

9.12 Confirmation of Driver Instructions ..........................................................314

Driver Instructions Loading Mouse ..........................................................315

Safety Instructions for Farmers for Loading Beets ..................................315

9.13 Remarks on Beet Harvest ........................................................................316

9.13.1 Practical Hints ..........................................................................................316

9.13.2 Erection Plan for a Beet Pile ....................................................................317

Index ................................................................................ 323

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Table of contents


13

0 Preface

Chapter 0

Preface

Chapter.0.

Preface


0 Preface

15

0 Preface

We congratulate you to your new ROPA machine. Please take the time and thoroughly

read the operating manual. The operating manual is mainly directed at the machine

operator. It contains all information required for safe operation of this machine, informs

about safe handling and gives hints on practical use as well as for self-help and

servicing. The respective safety hints are based on the safety, accident prevention and

health protection regulations applicable at print of this operating manual. In case of

questions about the machine, on operation of the machine or on ordering of spare parts,

please contact the dealer in your vicinity or the manufacturer directly:

ROPA Fahrzeug- und Maschinenbau GmbH

Sittelsdorf 24

D-84097 Herrngiersdorf

Telephone + 49 – 87 85 – 96 010

Telefax + 49 – 87 85 – 566

Internet www.ropa-maschinenbau.de

E-Mail Kundendienst@ropa-maschinenbau.de

Important information

– Original ROPA parts have been especially developed for your machine. They

conform to the high ROPA standards for safety and reliability. We would like to point

out that parts and accessories not approved by ROPA may not be used on ROPA

machines, because otherwise the safety and operability of the machine may be

impaired. We cannot assume any responsibility for such installations, additions or

reconstructions. In case of unauthorized modifications to the machine, any warranty

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

removed.

Warning!.In rare cases, massive interference of vehicle electronics or malfunctions of

the machine may occur due to operation of improperly installed electronic appliances

(for instance radios or other appliances emitting electromagnetic radiation). In case

of such interference, the complete machine may suddenly stop operating or execute

unwanted functions. In such cases, immediately shut off the sources for interference and

immediately shut down the machine. In case of need, notify the company ROPA or the

nearest authorized customer service of ROPA.

Chapter.0.

Preface


0 Preface

Chapter.0.

Preface

– Servicing and specific maintenance work on the engine may only be performed by

companies or persons expressly authorized for this purpose by DaimlerChrysler.

This work must be acknowledged accordingly in maintenance vouchers of

DaimlerChrysler by these persons or companies. Without these maintenance

vouchers properly completed, any warranty or statutory warranty of the engine

manufacturer lapses.

– Technical modifications serving improvement of our machines or increasing the

safety standards are expressly reserved by us – even without specific notification.

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

refer to the driving direction forward.

– Please always state the chassis number of the machine for any orders for spare

parts and technical enquiries. You will find the chassis number on the name plate

and on the vehicle chassis above the name plate.

– Please have the machine serviced according to regulations. Comply with the

information given in this operatings manual and have parts subject to wear replaced

in due time respectively ensure timely repairs.

– Have the machine services respectively repaired according to regulations.

Employ the decades of experience collected by ROPA in sugar beet lifting and

loading technology and implemented in this machine, by correct operation of this

machine. Remember that any neglect in maintenance and servicing inevitably leads

to loss of performance and therefore to loss of time.

– Listen for suddenly occurring unusual noises and have their cause remedied before

the machine is operated further, since otherwise heavy damage or costly repairs to

the machine may be caused.

– Generally comply with the respective applicable regulations for road traffic and the

applicable regulations on employment safety and health protection.

We expressly point out that any damage caused by the fact that this operating manual is

not or not completely complied with is in no case covered by the guarantee respectively

statutory warranty of ROPA. Even though this operating manual is comprehensive, in

your own interest you should completely and carefully read it and slowly attain familiarity

with the machine using this operating manual.

16


0.1 Name plate and important data

17

0 Preface

The name plate (2) of euro-Maus3 is located on the right side of the vehicle, on the

vehicle frame near the front wheel below the factory number (1).

1

2

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

need this data for ordering spare parts.

Chapter.0.

Preface


0 Preface

Chapter.0.

Preface

0.2 Serial number Diesel engine

The serial number of the engine is located at the top of the engine block below the

exhaust manifold.

Serial number

18


19

1 Safety

Chapter 1

Safety

Chapter.1.

Safety


1 Safety

1.1 General

21

1 Safety

euro-Maus3 has been manufactured according to the current state of technology and

been tested for safety.

The machine is CE compliant and therefore conforms to the respective European

regulations for free movement of goods within the European Union respectively the

European economic region.

Modifications to this machine may only be performed with the express approval of the

manufacturer, since otherwise the manufacturers‘ warranty lapses.

In addition, the road traffic registration may lapse and other registrations of the machine

may become invalid. The operating manual supplied must be strictly observed. The

manufacturer shall not be liable for damage caused by incorrect handling, inappropriate

application or incorrect repairs respectively missing maintenance and service carried out

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

for its intended purpose and with due consideration of the risks involved

1.2 Obligations of the entrepreneur

The entrepreneur employing the machine respectively his agent are obliged:

– to observe the applicable European employment safety regulations.

– to instruct the machine operators about their special obligation for safe driving of the

machine. These instructions must be given anew before the start of each season.

Records must be prepared about giving of these instructions, which must be signed

by the entrepreneur and the instructed machine operator. These records must be

kept for at least one year by the entrepreneur.

– before first use of the machine, to instruct the machine operators about operation

respectively about safe handling of the machine.

Forms for these instructions may be found in Chapter 9 of this operating manual

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

forms before completing them.

Chapter.1.

Safety


1 Safety

Chapter.1.

Safety

1.3 General symbols and instructions

The following symbols are used for safety instructions in this operating manual. They

serve as a warning against possible personal injury or material damage, or provide help

in facilitating work.

Danger! This symbol warns of imminent danger of fatal accident or serious injury. This

hazard may always occur if the operating or work instructions are not complied with or

only complied with unprecisely.

Warning! This symbol warns you of a possibly dangerous situation which may lead

to grave injury or to death. These hazards may occur if the operating or working

instructions are not or only unprecisely observed.

Attention! This symbol warns of possible hazardous situations which may lead to

heavy injuries and of damage to the machine or other heavy damage. Non-observance

of these remarks may lead to loss of warranty. This hazard may always occur if the

operating or working instructions are not or only unprecisely observed.

Information! This icon warns you of damage to materials or draws your attention to

specific characteristics. This makes your work easier.

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

will work more comfortably or contribute to a longer service life of the machine.

1.4 Proper use

This machine is exclusively meant for loading and cleaning of sugar beets or similar

crops.

Included in proper use is that the machine is driven under compliance with the applicable

road traffic regulations on public roads. This includes driving forward and backward.

Any other use of the machine is deemed improper and is therefore prohibited. We would

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

towing or salvaging other vehicles or for pulling respectively pushing or transport of any

loads or any goods.

22


1.5 Hazard zone

23

1 Safety

Nobody may be present within the hazard zone during operation of the machine. In case

of danger, the operator must immediately shut down the machine and ask the people

concerned to immediately leave the hazard zone. He may only restart the machine when

no people are located within the hazard zone anymore.

People wanting to close on the machine during operation must clearly communicate their

intentions to the operator (for instance by calling or by agreed hand signals) to avoid

misunderstanding.

The hazard zone shown in the following drawing applies as soon as the machine is

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

down and the corresponding person asked to immediately exit the hazard zone. The

machine may only be restarted when there are no longer any people located in the

hazard zone.

Only specifically authorized people may enter the hazard zones for discharging

maintenance and monitoring tasks after precise agreement with the operator. These

people must be informed precisely about hazards possibly occurring before entering

the hazard zones. All activities made between the operator and these people must be

precisely agreed on before starting these activities. All maintenance, adjusting and

monitoring work on this machine must – to the extent as technically possible – be

always performed with the machine standing totally still and engine shut off. In this

case, the operator of the machine is responsible for the fact that the machine may not

be, by unauthorized people, be put into operation inadvertently or in contrary to prior

agreements.

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

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

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

and fragmented. Objects may be pulled in by the shafts and destroyed or cause severe

damage to the pickup of the machine. The operator is obliged to immediately shut down

the machine as soon as people or animals enter the hazard zone or reach into the

hazard zone with objects.

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

into the pickup is expressly prohibited while the machine is running. The engine must be

shut off and the ignition key pulled off before any maintenance and repair work. Please,

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

these activities have lead to the severest accidents. Staying under lifted machine parts

or within the swiveling perimeter of machine parts is hazardous and therefore prohibited.

Chapter.1.

Safety


1 Safety

Chapter.1.

Safety

We recommend that the operator of the macine informs all people present during lifting

about the possible hazards. You will find an information sheet for this purpose in the

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

concerned. For your own safety and as protection against possible recourse (liability)

claims, you should obtain written confirmation about receipt of this sheet in the space

provided.

All parts of the machine which may cause specific hazards are additionally marked

using warning labels (pictographs). These pictographs point out possible hazards.

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

legible condition. Damaged or illegible safety stickers must immediately be replaced.

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

number is given for each pictograph. This is the ROPA order number. Stating this

number, you may reorder the respective pictograph from ROPA. The number stated

in brackets is printed on the respective sticker. This enables simple allocation of the

pictograph to the order number and the explanation.

24


355070 (34)

Shut down the engine before

performing maintenance and repair

work and pull off the ignition key.

Read the operating manual and

comply with remarks on safety.

355069 (41)

Burning hazard due to hot surfaces!

Keep sufficient distance to hot

surfaces!

355071 (1)

Before starting up, read the operating

manual respectively the maintenance

manual and observe all remarks on

safety.

355073 (50)

Hazard due to machine parts

swinging down. Never step into the

hazard zone of raised and unsecured

machine parts.

355065 (37)

Falling hazard! Riding on steps or

platforms is prohibited.

355064 (52)

Hazard due to the machine

inadvertently rolling away. Secure

machine against inadvertently

rolling away using a wedge before

uncoupling or parking it.

25

1 Safety

355068 (39)

Hazard due to electrical current! Observe

a sufficiently safe distance to high-voltage

power lines.

355078 (11)

Hazard of lowering machine parts! Staying in

the hazard zone is only admissible when the

safety lock for the lifting cylinder is engaged.

355081 (40)

The hazard of discharge of liquids under high

pressure. Before performing maintenance

and repair work, read the operating manual

and comply with remarks on safety.

355063 (33)

Hazard from parts being flung away with

the engine running. Keep a sufficient safety

distance!

355072 (15)

Hazard from rotating

parts. Never reach into the

operating auger or pinching

rollers. Hazard of clothing

or body parts being pulled

in. Do not open or remove

protective equipment

during operation.

Chapter.1.

Safety


1 Safety

15

Chapter.1.

Safety

25

4 6

355080 (42)

Explosion hazard. The

pressure reservoir is under

very high pressure. Perform

removal and repair only

following instructions from

the manual.

355075 (9)

Chain drive! Hazard of body

parts or clothing being pulled

in with running drive. Before

opening the cover, shut down

the machine and secure it

against inadvertent startup!

1.6 Safety stickers on the machine

1 34 39 40 33

25

355067 (44)

Never step in

the hazard area

between attached

device and

machine.

26

41

42

11

15

37

41

15 33

on the rear wall

6 50

41

15

42 on the rear wall

In case of numbers highlighted in grey, you will find the corresponding stickers at the

opposite position on the machine on the rear wall as well.

355076 (24)

Only touch machine

parts after they have

come to a complete

stop.

355066 (9)

Avoid serious bodily injury from

rotating machine parts.

Do not enter this area until rotating

parts have completey stopped.

Stop engine and remove key.

6

37

4 50


1.7 Safety and accident protection

The stipulations and regulations listed below must be rigorously observed in order

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

regionally applicable regulations and instructions on safety at work and for safe

27

1 Safety

handling of self-propelled processing machines must be observed in any case. For

safety reasons, anyone working with the machine must have read and understood the

operating instructions at hand. He must also be familiar with the relevant labor protection

and health protection regulations. For safe operation of the machine, the applicable

health protection regulations, the relevant national labor protection regulations, or

equivalent relevant national labor protection and health protection regulations of other

member states of the European Union or other states which have signed the agreement

on the European Economic Area, must be rigorously applied.

The operator is obliged to provide the applicable regulations in their current versions free

of charge to the machine operator.

– The machine may only be used for its intendend purpose and in compliance with

these operating instructions.

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

guaranteed at any time.

– The machine may not be operated in enclosures.

– The effectiveness of operating and adjusting elements may not be influenced or

nullified in an impermissible manner.

1.8 Requirements for operating and maintenance personnel

The independent operation and maintenance of the machine is restricted exclusively to

persons who are of age and:

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

– are physically and mentally suitable,

– are not under the influence of drugs, alcohol or medicine, which may impair the

reactions of the machine operator in any manner,

– have been instructed about operation and maintenance of the machine and have

proven their ability to the entrepreneur,

– have been instructed by the entrepreneur about their special obligation for safe

driving of the machine,

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

the tasks bestowed on them, and

– who are specifically authorized by the entrepreneur.

Operating personnel must have read and understood the operating instructions of the

machine.

Chapter.1.

Safety


1 Safety

Chapter.1.

Safety

All maintenance work which is not specifically the responsibility of the operator may only

be carried out by instructed or trained maintenance personnel.

Some activities may only be performed by people expressly authorized by ROPA for

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

specific activitiy yourself without hazard.

Remark! Forms for proof of proficiency and instruction on safety given for operating and

maintenance personnel are included in this operating manual. In case of need, please

copy these forms before completing them.

1.9 In the event of accidents

In the event of accidents involving personal injury, the machine must be shut down

immediately. To the extent required, immediately necessary first aid measures must be

initiated, medical assistance called in and possibly the next accessible superior should

be informed.

1.10 Handling old parts, process materials

– When handling process materials the appropriate protective clothing must always be

worn to prevent or reduce skin contact with these materials.

– Defective, dismantled parts shall be sorted according to material type and passed on

for proper recycling.

– Residues of oil, grease, solvents or cleaning agents must be reliably and

1.11 Residual risks

environmentally compatibly collected in suitable and prescribed containers and

stored before being disposed of in an environmentally compatible manner in

accordance with the local regulations.

Residual risks are special hazards involved in the use of the machine which cannot be

fully eliminated despite of safety conscious design. These residual risks are not evidently

recognizable and may result in injury or damage to health.

In the event of such unforeseen residual risks becoming apparent, the machine must be

shut down immediately and possibly the responsible supervisor informed accordingly.

The supervisor then makes any further decisions and initiates the necessary measures

for elimination of the hazard. If required, the machine manufacturer must be informed.

28


1.12 Hazards caused by mechanical influences

Attention! Hazard of damage to the environment by leaking fuel or oil! Hazard of

pollution of ground or water bodies.

29

1 Safety

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

parts jutting out. Rotating machine parts and breaking attached parts may lead to

severest injuries like contusions, detachment of body parts and broken bones. These

injuries may be deadly in especially severe cases. During loading, there is extreme

hazard to life in the sector of pickup due to rotating pickup shafts.

You can protect yourself against these hazards by keeping a sufficient safety distance,

by constant attention and by wearing suitable protective clothing.

1.13 Hazards caused by process materials

Warning!.Oil, fuel and grease can cause the following damage:

– Poisoning by inhalation of fuel vapors,

– Allergies due to skin contact with fuel, oil or grease,

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

handling fuel, oil or grease.

Protective measures

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

forbidden. Oil and fuel may only be kept in suitable, approved containers.

– Do not expose fuel containers to direct sunlight.

– Always keep fuel containers in the shade.

– Great caution must be exercised when handling fuel. The relevant safety regulations

for handling of fuel must be strictly observed.

– Clothing soaked in fuel must be removed immediately and ventilated in a suitable

place.

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

disposed of in an environmentally compatible manner. Always use a suitable funnel

for filling fuel or oil.

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

– In case of need, wear suitable protective gloves.

– Only decant fuel oil or oil in the open or in well ventilated rooms.

Chapter.1.

Safety


1 Safety

Chapter.1.

Safety

Prevention

– Always close containers containing fuel or oil carefully.

– Dispose of empty containers in accordance with regulations and in an

environmentally compatible manner.

– Keep a supply of a suitable binding agent and use immediately as required.

1.14 Hazards caused by noise

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

such as loss of balance or consciousness disorders, as well as disorders of the heart

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

may interfere with verbal communications among operating personnel as well as to the

outside world. Perception of acoustic warning signals may be impaired or blocked.

Possible causes:

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

Machine noise in excess of 90 dB (A)

Protection

Wear ear protection (cotton wool, earplugs, capsules or helmets); keep sufficient

distance to operating machines.

1.15 Hazards caused by the hydraulics system

Warning!.Hydraulics fluid may cause irritation of the skin; emitting hydraulics fluid

may damage the environment. High pressure and partially high temperatures exist

within hydraulics systems. Hydraulics fluid emitting at high pressure may enter the

body through the skin and cause the heaviest tissue damage and scalding. In case of

improper working on the hydraulics system, tools or machine parts may be flung away

with great power and cause heavy injuries.

Protection

Regularly check all hydraulics hoses for their condition and immediately have damaged

hoses exchanged by trained specialist personnel. Have work on the hydraulics system

performed only by especially trained personnel. When working on the hydraulics system,

first render it pressureless! Avoid skin contact to hydraulics fluid. Have hydraulics

hoses regularly checked following the recognized rules of technology and the regionally

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

the hydraulics system only performed by especially trained personnel. When working on

the hydraulics system, first render it pressureless! Avoid skin contact to hydraulics fluid.

30


1.16 Hazard From the Pneumatic System

31

1 Safety

In case of damage to the pneumatic system, the lifted warning signs on the pile pickup

may suddenly come down and cause severe injury to people being in this sector.

In case of faults of the pneumatic system, shut down the machine as quickly as possible

and then have the cause for this damage repaired by specialist personnel being familiar

with handling pneumatic systems.

1.17 General hints on safety when handling acid batteries

– Fire, sparks, smoking and open flames prohibited. Avoid generation of sparks

formed by connecting and disconnecting electrical loads or measuring devices

directly to battery terminals. Before connecting and disconnecting batteries, switch

off the main battery switch. First remove the ground connection. Avoid short circuits

by connecting false polarity and working with spanners. When connecting, connect

the ground cable last.

– Wear eye/face protection!

– Keep children away from acids and batteries!

– Batteries contain corrosive acid. Wear appropriate protective clothing and acid-

resistant rubber gloves. Do not tilt the battery, acid may emit from the ventilation

opening.

– Comply with instructions from the battery manufacturer.

Explosion.hazard!.Increased care is required after longer operation respectively

charging the battery using a charging device. Charging may create highly explosive

oxyhydrogen gas. Make sure of good ventilation. Make sure that acid batteries are only

charged using the admissible charging current.

Chapter.1.

Safety


1 Safety

Chapter.1.

Safety

1.18 General Hints on Safety for the Independent Heating System

(Optional)

– The heating appliance may not be operated in enclosed rooms, not even under

timer control or „Telestart“ (for instance garage or workshops without exhaust-gas

extraction).

– Due to the explosion hazard, the heating system must be switched off at gas

stations and fuel dispensing systems.

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

combustible fumes or dust can form (for instance near fuel, coal, wood dust or grain

storage or similar).

– The heating system must be checked by a specialist at the latest at start of the

heating season.

– In case of lasting, strong generation of smoke, unusual combustion sounds or smell

of fuel fumes, the heating system must be shut down by removal of the fuse and

may only be recommissioned after inspection by personnel trained by Webasto for

this work.

– Suitable fuel is the fuel prescribed by the vehicle manufacturer. Only Diesel fuel may

be used.

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

exceeded. Excess temperature may cause permanent damage to the electronics.

32


33

2 Road Traffic

Chapter 2

Road Traffic

Chapter.2.

Road Traffic


2 Road Traffic

35

2 Road Traffic

euro-Maus3 is regarded to be a self-propellant processing machine within the territory

of the European Union. This type of vehicle is subject to very specific regulations and

conditions which may differ between countries. Differences are also possible within a

country in the individual conditions established by the respective competent road traffic

authorities. Upon individual request, euro-Maus3 may also be registered as a motor

vehicle. In this case, partially regulations apply, which are different from those listed

here. In any case, the operator must make sure that euro-Maus3 is furnished with

the regionally required equipment and aids for securing, for instance warning triangle,

warning lamp, etc. and that these devices are always carried in functional condition.

Remark!.ROPA expressly wants to point out that the driver and owner of euro-Maus3

are always alone responsible for compliance with the respective regulations and

conditions of the competent road traffic authorities.

euro-Maus3 in Stellung Straßenfahrt

The following generally applies before driving on public roads in the territory of

the Federal Republic of Germany:

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

swivel arm to the stop).

– Move pickup up to the stop.

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

each.

– The supporting feet must be completely swung into the vehicle profile.

– The pile pickup must be swung into central position, set to horizontal position and

pulled in up to the central mark.

– The residual beet pickup must be turned laterally to the driving direction.

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

– Axle support for the rear axle must be released.

Chapter.2.

Road Traffic


2 Road Traffic

Chapter.2.

Road Traffic

– The operating mode must be set to rabbit II.

– The driver‘s seat must be locked in driving direction.

– The wheels of the rear axle must be aligned in straight position.

– Rear axle steering must be locked (switch off main steering switch).

– All work lights must be switched off.

– The machine must be cleaned until:

- the admissible total weight is not exceeded,

- all warning signs can be easily recognized,

- all turn indicators and lighting fixtures are clean and in operating condition.

– The safety of the vehicle during operation and in traffic, especially that of steering

and lighting, must be reviewed and reinstated, if necessary;

– The additional axle (this ONLY applies, if your euro-Maus3 is fitted with an

additional axle) must be lowered for driving on public roads and paths.

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

staying within range of the additional axle!

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

off roads. When you switch from operating mode Rabbit to operating mode Turtle, while

the additional axle is lowered, the color terminal displays the following warning icon .

To raise or lower the additional axle, select position 9 on the rotating selector switch on

the operating console.

If the additional axle is lowered, then the color terminal displays the icon . Ist die If

the additional axle is raised, then the color terminal displays the icon .

key = rise

key = lower

36


37

2 Road Traffic

When driving on public roads and paths, the yellow rotating beacons must be switched

on independent of the time of day.

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

euro-Maus3 is not subject to the registration and license plate duty. But a sign must

be fastened to the machine on its left side which contains the following information

unobliterable and clearly legible:

– First and last name of the owner as well as town of residence and the full address of

the owner.

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

registration and license plate duty. Furthermore, the vehicle must be insured against

damage from vehicle owners’ liability according to the locally applicable regulations.

For both variants, the following conditions must always be fulfilled:

– A guide giving the directions required for safe driving of the vehicle to the driver must

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

and road junctions, when backing up, or in case of unfavorable weather conditions)

cannot be ensured.

– Rear wheel steering may only be switched on for a short time for passing narrow

turns at low vehicle speed.

– Only persons familiar with the vicinity, experienced and reliable may be used as

driver and accompanying personnel.

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

required and valid drivers‘ license. Besides the valid drivers‘ license, the driver also

has to carry the general type approval of euro-Maus3 and the existing and valid

exceptional permit.

– No people may ride on the platform in front of the drivers‘ cabin.

– Case before beginning a working period about his special obligation for safe driving

of the vehicle. The instructions given must be acknowledged by the drivers with their

signature. The vehicle owner must keep these acknowledgements for at least one

year.

A form for these instructions is included in Chapter 9. ROPA reccommends copying

this form before completing it.

– As already mentioned, the regionally competent road traffic authorities may establish

additional conditions or conditions deviating from the regulations listed. It is the

sole responsibility of the vehicle owner and the driver to gain knowledge of these

regulations and to comply with them.

– If parts or functions of the vehicle are subsequently modified, whose condition

respectively sequence has been prescribed, then „general type approval“ lapses

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

each country.

Chapter.2.

Road Traffic


39

3 General View And Specifications

Chapter 3

General View And

Specifications

Chapter.3.

General View And Specifications


3 General View And Specifications

3.1 General view euro-Maus3

5 6

3 4

2

1

7

8

41

3 General View And Specifications

(1) Central electric system

(2) Rear wall of the platform

(3) Air filter

(4) Intake grid for cooling air

(5) Swivel arm

(6) Small rotating assembly

(7) Articulation of the truck conveyor

(8) Truck conveyor

(9) Fuel tank

(10) Storage compartment

(11) Recleaning wire mesh or

8-fold-pinch roller (option)

(12) Large rotating assembly

(13) Engine housing

(14) Battery box

(15) Compensating tank for coolant

(16) Hydraulic fluid tank

(17) Stepladder

(18) Cabin platform

(19) 4-fold pinch rollers

(20) Swivel plates

(21) Supporting foot

(22) Clearing shield

(23) Pickup rollers

(24) Central mark

(25) Residual beet pickup

(26) Central belt

(27) Stack remover (telescopic tube)

9

11

10

27

26

12

13

15

14

16

18

25

17

19

23

20

23

21

22

Chapter.3.

General View And Specifications


3 General View And Specifications

Chapter.3.

General View And Specifications

42


3.2 Specifications

Vehicle model: e-M3

Valid from series: 2006

Daimler Chrysler engine model: Mercedes Benz OM926LA E3A/2

Certificate: E 3A/2

Exhaus emission stage: Euromot 3a

Exhaus emission standard: 97/68/EG Stage 3a

Power: 220 kW at 2200 min -1

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

Nominal speed: 2200 min -1

43

3 General View And Specifications

Drive type: Diesel engine 4-stroke, direct fuel injection

Displacement: 7.201 cm³

Driving power: Continuously variable, hydrostatic in three operating

Operating mode „turtle I“:

Operating mode „rabbit I“:

„rabbit II“:

modes

0 - 0.7 km/h

0 - 10.3 km/h

0 - 20 km/h (respectively 25 km/h)

Two mechanically driven axles with differential lock swing axle support rear. One additional axle

(series in FRG; optional in all other countries).

Curb weight, depending on

equipment variant:

24700 kg to 26550 kg

Maximum permitted weight: refer to type label

Tank content: 1340 l

Fuel consumption: 0.12 - 0.20 l/loaded ton

season average max. 20 l/h

Tires front and rear: 710/75 R34 178A8

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

Chapter.3.

General View And Specifications


3 General View And Specifications

Chapter.3.

General View And Specifications

Vehicle model: e-M3

Loading performance: on average 200 t/h

Generators: 2 x 100 A

Voltage electric system: 24 V

Battery capacity: 2 x 143 Ah

Length (setting driving on roads): 13350 mm

Width: 3000 mm

Height (setting driving on roads): 4000 mm

Driving noise (driving by): 88.7 dB (A)

Refrigerant air conditioning system: R134a

Refrigerant content about: 1.7 kg

44


45

3 General View And Specifications

3.3 Transport draft for low-loader transport euro-Maus3

roller cleaner

3 rd axle

rear axle

Remark: For transportation on a deep-loading semitrailer, the max.

Fur Tiefladertransport max. zul. Kraftstoffmenge im Tank: 990 Liter

admissible fuel quantity in the tank: 990 liters

heaviest equipment: total weight 26.5 t

(=fuel tank full (1320 l) and roller cleaner)

- without roller cleaner: about –1.0 t

- without additional axle: -0.45 t

Chapter.3.

General View And Specifications

07.08.2007 11:53:23, Hermann


3 General View And Specifications

Chapter.3.

General View And Specifications

3.4 Load-securing points

Front axle from the front Front axle from the rear

Tie-down using a tension chain

46

Rear axle

Front axle from the rear

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


47

3 General View And Specifications

3.5 Transport draft for loading euro-Maus3 on a ship

container tie-down

max. 8° aslant

max. 8° aslant

roller cleaner

max. 200 l Diesel

fuel in the tank

tires: min. 2.0 bar

1x

centrally

Remark

lLading by crane only using the cargo gear shown.

Ropa order number: 018306 allowed!

The scope of delivery includes the top shackle on the supporting tube.

Cargo gear not included in the scope of delivery of the machine.

Chapter.3.

General View And Specifications

08.08.2007 10:33:00, Hermann


3 General View And Specifications

3.6 Supporting Points for Wheel Replacement

Chapter.3.

General View And Specifications

Wheel replacement

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

secured against rolling away (wheel chocks).

– Work on tires and wheels may only be performed by specialists and using suitable

mounting tools!

– Check wheel nuts for tight fit after every wheel replacement!

Tighten using torque as per table.

48


Chapter 4

General Description


4 General Description

4.1 Function

51

4 General Description

euro-Maus3 is a self-propellant processing machine for picking up, cleaning and

loading of sugar beets in stacks at the side of the field.

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

roller, works several centimeters in the ground, picks up the sugar beets and lifts them

over a cleaning roller onto two conveyor rollers. The conveyor rollers perform transport

of the beets to the outside. Fingers are attached top the feed rollers. These preclean

the sugar beets and move the beets to the four contrarotating worm rollers. The front

and rear rollers may be individually adjusted in their speed. he rotating direction is

reversible. Operating trouble due to pinched stones are largely automatically detected

and remedied by the machine.

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

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

required.

Main cleaning action is on the rollers at the front of the machine. The contrarotating

rollers pull out soil, weeds and other material. Further cleaning is then performed,

depending on furnishings, using a wire mesh or a roller cleaner transporting the sugar

beets to the loader. The loader moves the sugar beets to the transport vehicle.

Picking up and loading of the sugar beets is controlled and monitored from the cabin by

a single operator.

4.2 Scope of delivery

The scope of delivery of euro-Maus includes a fire extinguisher, a medical kit, two

wedges and a set of tools including small parts package.

The medical kit is located in the cabin; the fire extinguisher is located on the cabinet of

the central electric system.

The tool box containing the tool set is located in the lateral storage compartment in front

of the Diesel fuel tank; the spare parts package as well.

Chapter.4.

General Description


5 Operating Components

Chapter 5

Operating Components

53

Chapter.5.

Operating Components


5 Operating Components

5.1 Steering column

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

may lose control of the machine and cause severest damage. Therefore, NEVER adjust

the steering column while driving!

Clamp screw (1) inclination adjustment

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

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

desired position.

55

5 Operating Components

1

Chapter.5.

Operating Components


5 Operating Components

Chapter.5.

Operating Components

5.1.1 Steering Column Switch

– Push lever to the right: Turn indicator right (R)

– Push lever to the left: Turn indicator left (L)

– Lever up/down:

driving light/high beam/headlight flasher (F)

– Pressure switch at the end: horn (H)

– Slider below the horn:

– Washing system (W)

– Turning the slider to the first register position:

interval wiping

– Wiper front (S). The duration of the wiping interval

may be set at the color terminal, menu „basic settings“,

line „interval period wiper“.

– Turning the slider to the second register position:

continuous operation wiper front (S).

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

dry windows.

56


5.2 Driver‘s Seat

5.2.1 Rotate Cockpit

The rotating driver‘s seat hat a pneumatic seat brake. This seat brake is operated using

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

favorable for you.

An additional mechanical lock always locks the seat in the position prescribed by law

when driving on roads.

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

rotation by using the mechanical seat lock on the bottom of the driver‘s seat. The seat

may not be adjusted while driving, because otherwise there is increased accident hazard

and danger to your health.

Mechanical seat lock for driving on roads

Using the large pushbutton (20) (ratchet button) at the front of the left joystick locks the

seat (press 1 x) or release lock (seat brake) (press again).

57

20

5 Operating Components

Chapter.5.

Operating Components


5 Operating Components

Chapter.5.

Operating Components

5.2.2 Adjusting the Driver‘s Seat

Safety instructions:

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

weight before use and before every change of driver.

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

seat.

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

correctly engaged before the vehicle is driven.

– Adjustments must not be made while driving.

– When the backrest upholstery has been removed, the backrest frame must be

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

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

injury.

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

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

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

structural change to the driver‘s seat must be approved by Grammer.

– Fasteners must be checked regularly for tightness. If the seat wobbles there may be

loose bolts or other faults.

If the seat does not function correctly (for example the seat suspension), contact a

specialist workshop immediately to arrange for repairs to be carried out.

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

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

Weight adjustment

The seat should be adjusted for the driver’s weight by briefly

pulling the actuator lever of the automatic weight and height

adjuster (arrow) with the vehicle at a standstill and the driver

sitting on the seat.

The driver must sit absolutely still during adjustment.

To prevent damage to the health, the setting for the driver’s

weight must be checked and adjusted as necessary before

the vehicle is driven.

58


Height adjustment

The seat height can be set pneumatically and is infinitely

adjustable.

The seat height can be altered by pulling or pressing the

actuator lever fully out or in (arrow). If the adjustment

reaches the top or bottom end stop, the height is adjusted

automatically in order to guarantee a minimum spring travel.

In order to avoid damage, do not operate compressor for

more than 1 minute.

Seat depth adjustment

The depth of the seat pan can be individually adjusted.

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

(see arrow). By moving the seat cushion backwards or

forwards the desired seating position can be reached.

Seat pan angle adjustment

The angle of the seat pan can be individually adjusted.

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

arrow). By exerting pressure on or off the seat pan it can be

moved to the desired angle position.

Longitudinal adjustment without control lever handle

Lateral adjustment of the seat is released by pressing the

locking lever upward.

The locking lever must latch into the desired position. It

should not be possible to move the driver’s seat into another

position when it is locked.

59

5 Operating Components

Chapter.5.

Operating Components


5 Operating Components

Chapter.5.

Operating Components

Longitudinal adjustment with control lever handle

Moving the locking lever upward releases lateral

adjustment.

The locking lever must latch into the desired position.

It should not be possible to move the driver’s seat into

another position when it is locked.

Headrest

The headrest can be individually adjusted for height by

pulling it upward over the various increments up the end

stop.

By pushing forward or rearward the angle of the headrest

can be adjusted individually.

To remove the headrest, pull it over the end stop.

Lumbar support

By turning the adjustment knob to the left or right, both

the height and curvature of the backrest cushion can be

individually adjusted.

This increases both the seating comfort and the

performance of the driver.

Armrests

The armrests can be folded up if required and the height

individually adjusted.

To adjust the armrests for height, separate the round cap

(see arrow) from the cover, loosen the hexagon nut (size

13mm) and adjust the armrest to the desired position and

tighten the nut again.

60


Armrest adjustment

The inclination of the armrests can be modified by turning the

adjustment knob (arrow).

Backrest adjustment

The backrest is adjusted using the locking lever (arrow).

The locking lever must latch into the desired position. It

should not be possible to move the backrest into another

position when it is locked.

Front/rear attenuation

Under certain driving conditions, it is useful to activate the

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

driving direction can be better absorbed by the driver seat.

Position 1 = front/rear attenuation on

Position 2 = front/rear attenuation off

Cleaning

Dirt can impair the function of the seat, so make sure you

keep your seat clean!

Upholstery can be quickly and simply removed from the

seat frame for easy cleaning, or replacement. To remove the

upholstery, turn the clips (arrow) and remove the upholstery.

Attention!.Take care with the backrest frame – it may jerk forward and cause injury!

Hold onto the backrest before adjusting.

61

5 Operating Components

Chapter.5.

Operating Components


5 Operating Components

Chapter.5.

Operating Components

5.3 Operating Components on the Floor of the Driver‘s Cabin

Opener for the

cleaning flap

Foot switch

looking forward

62

Foot switch

driving direction

Gas pedal

Brake pedal


5.4 Operating Console Right

1

You will find comprehensive explanations in Chapter 6 „Operation“. The console is

divided into different operating sections:

(1) Switch section 1

(2) Operating part

(3) Ignition lock (see page 103)

(4) Switch section 2

(5) Switch section 3

(6) Switch section 4

(7) Joystick with multi-functional handle

(8) Color terminal

5.4.1 Switch section 1

8

7

2 3 4

6

63

5 Operating Components

1 Main steering switch

5

– Main steering switch flipped

downward = unlocked:

steering of rear axle possible.

– Main steering switch flipped

upward = locked:

steering of the rear axle

blocked (see page 117).

2 Flasher indicator

3 High beam indicator

Chapter.5.

Operating Components


5 Operating Components

Chapter.5.

Operating Components

5.4.2 Operating Section

(1) Switching operating mode turtle/rabbit: see page 106

(2) Switching I st /II nd gear: see page 106

(3) Differential lock front axle ON/OFF: see page 107

(4) Differential lock rear axle ON/OFF: see page 107

(5) Water spraying system (option) ON/OFF/AUTOMATIC: see page158.

(6) Air conditioning system ON/OFF: see page 98

(7) key:

This executes functions or increases speeds selected using the rotating selector

switch.

(8) key:

This executes functions or decreases speeds selected using the rotating selector

switch.

1

6

5

8

64

2

3

4

7

9


(9) Rotating selector switch with 12 selectable positions:

Pos. 6: Swivel fuel tank:

see pages 130, 151.

key pressed = left,

key pressed = right.

Pos. 5: Not used

Pos. 4: Adjust beet brake (only in case of option roller recleaner):

see page 141.

key pressed = brake beets more,

key pressed = brake beets less.

Pos. 3: Speed recleaning: see page 139

key pressed = more caring,

key pressed = more aggressive.

Pos. 2: speed 4-fold pinching rollers pickup: see page 143

key pressed = slower,

key pressed = faster.

Pos. 1: Speed pickup rollers see page 144.

key pressed = slower,

key pressed = faster.

Pos. 7: Fuel tank lock: see page 130

key pressed = lock tank,

key pressed = unlock tank.

Pos. 8: Swivel plate: see page 152.

key pressed = swing down,

key pressed = swing up.

Pos. 9: Additional axle (option) up/down: see page 36.

key pressed = additional axle down,

key pressed = additional axle up.

Pos. 10: Set speed cruise-control: see page 112.

key pressed = slower,

key pressed = faster.

Pos. 11: Set desired temperature air conditioning: see page 98.

key pressed = lower desired temperature,

key pressed = increase desired temperature.

Pos. 12: Fan speed of ventilation control: see page 98

set using the / keys.

65

5 Operating Components

Chapter.5.

Operating Components


5 Operating Components

Chapter.5.

Operating Components

5.4.3 Switch section 2

5.4.4 Switch section 3

(1) Switch fast speed truck conveyor/in-feed conveyor see page 138

(2) Switch reverse fan drive see page 199

(3) Connector for USB stick

(4) Switch swing axle support on/off see page 124

(5) Switch swing axle load to right/left see page 131

The following message must apper on the screen after inserting a USB stick: „ the

USB stick is ready for operation“. This message must be acknowledged by the driver

by pressing on the rotating switch. If this message is not displayed, then the USB stick

must be removed immediately. This USB stick is incompatible and may not be used on

this machine. You can obtain compatible USB sticks from ROPA under the item number

320706.

5

1 2

4

66

Switch parking light/low beam

up: off

center: parking light

down: parking light and low beam

Hazard warning system

3


5.4.5 Switch section 4

(1) EMERGENCY-OFF

This is used to switch off all drives – with the exception of the Diesel engine.

Applies from chassis number 8**561: turn the emergency off switch by about one

quarter rotation clockwise for unlocking.

(2) Steer rear axle right/left (only in operating mode turtle).

(3) Parking brake

1 2

3

67

5 Operating Components

Chapter.5.

Operating Components


5 Operating Components

1

Chapter.5.

Operating Components

5.4.6 Right joystick with multi-functional handle

You can comfortably control a number of functions of euro-Maus3 with one hand using

the right joystick, without distracting the attention of the driver. For improved orientation,

there are stickers on the side window of the cabin containing a schematic diagram of all

functions of the left joystick.

X-Y switch (1) forward/backward

X-Y switch (1) left/right

FORWARD Lower pickup

BACKWARD Raise pickup

ONLY in operating mode rabbit

On the right joystick, it is possible to switch by sliding the X-Y switch (1) to the

right/left between driving with manual engine speed control (to the left) and

automotive driving (to the right). To switch, the X-Y switch (1) must be slid in the

corresponding direction and shortly held in the end position (see page 104).

68


1

2

3

X-Y switch (1) left/right

ONLY in operating mode turtle

Preselect loading direction left/right. For this purpose, slide the switch in the

corresponding direction and shortly hold it in the end position (see page 128).

LEFT Loading direction to the left (the truck is located on

the left side of euro-Maus3)

RIGHT Loading direction to the right (the truck is located on

the right side of euro-Maus3)

If the X-Y switch (1) is pressed to the left/right and shortly held there, then the

rotating direction of the large rotating assembly changes in each instance.

Key (2) driving forward

Tipping on this key, you switch on driving power forward in operating mode turtle.

Pressing this key again stops driving power (see page 114).

Key (3) driving backward

Using this key, you switch on driving power backward in operating mode turtle for as

long as you keep the key pressed. If euro-Maus3 is driving forward during loading,

then you stop forward movement by tipping on this key (see page 114).

X-Y switch (4) supporting feet

FRONT LEFT raise supporting foot left

FRONT RIGHT raise supporting foot right

X-Y switch (5) swing pickup

4

5 Operating Components

(= pickup rollers operate deeper in the ground)

(= pickup rollers operate deeper in the ground)

FRONT LEFT Swing out pickup side part left.

FRONT RIGHT Swing out pickup side part right.

REAR LEFT Swing in pickup side part left.

REAR RIGHT Swing in pickup side part right.

69

Chapter.5.

Operating Components


5 Operating Components

Chapter.5.

Operating Components

14

With this, you also change the release pressure of the pickup side parts

(see page 125).

7 8 5 6

Key (6) machine drive On/off (see page 131).

Key (7) drive pickup rollers On/off/reverse (see page 144)

Key (8) drive 4-fold pinch rollers On/off/reverse (see page 143)

Key (9) drive recleaner On/off/reverse (see page 138)

Key (10) drive in-feed conveyor On/off (see page 142)

Multi-key (11) ONLY in operating mode rabbit

Move rear axle to central position (see page 120)

Multi-key (11) ONLY in operating mode turtle AND in combination with

X-Y switch (4) bzw (5)

4

Adjust both supporting feet simultaneously or

9

10

11

12

13

swing both pickup side parts simultaneously (see page 125)

Keys (12) and (13) ONLY in operating mode rabbit

Shortly press both keys simultaneously

Activate all wheel steering

(see page 120)

Handpoti (14) ONLY in operating mode rabbit

Engine speed adjustment with manual speed control

Handpoti (14) ONLY in operating mode turtle

Change driving speed when loading.

70

14


5.4.7 Joystick movements (right joystick)

5.4.7.1 Only in operating mode rabbit

FORWARD Cruise-control on

BACKWARD Cruise-control off (see page 115)

LEFT Steer rear axle to the left

RIGHT Steer rear axle to the right (see page 118)

71

5 Operating Components

Chapter.5.

Operating Components

.e-M3/e-BM3 Rop.Art. 355250


5 Operating Components

Chapter.5.

Operating Components

5.4.7.2 Only in operating mode turtle

Multi-key (11) NOT pressed

Press Multi-key (11) and keep it pressed

.e-M3/e-BM3 Rop.Art. 355250

This is exclusively used to turn the two rotating assemblies!

Joystick FORWARD turn swivel arm (large rotating assembly)

Joystick BACKWARD turn swivel arm (large rotating assembly)

The rotating direction of the swivel arm always depends on the selected

loading direction!

.e-M3/e-BM3 Rop.Art. 355250

Joystick LEFT turn truck conveyor to the left

(small rotating assembly)

Joystick RIGHT turn truck conveyor to the right

(small rotating assembly)

(see page 129)

This is used to raise or lower the truck conveyor or articulation

Joystick FORWARD lower truck conveyor

Joystick BACKWARD raise truck conveyor

Joystick LEFT

.e-M3/e-BM3 Rop.Art. 355250

swing down truck conveyor articulation

Joystick RIGHT swing up truck conveyor articulation

72

(See page 127)


5.4.8 Left Joystick

When the left joystick console has been swung up, machine drive and driving power are

automatically stopped.

Joystick movements

FORWARD extend pile pickup (telescopic tube)

BACKWARD retract pile pickup (telescopic tube)

RIGHT swing pile pickup (completely) to the right

LEFT swing pile pickup (completely) to the left

Turn grip molding of the joystick

to the RIGHT Turn residual beet pickup to the right

(same function as using the keys (18) and (19))

to the LEFT Turn residual beet pickup to the left

(15) push-button potentiometer (red)

DOWN lower pile pickup

UP raise pile pickup

(same function as using the keys (18) and (19))

(16) gas key reduce speed Diesel engine (see page 105)

(17) Gas key increase speed Diesel engine (see page 105)

(18) turn residual beet pickup to the right

(19) turn residual beet pickup to the left

.e-M3 Rop.Art. 355251

All functions may only be executed with the joystick if the seat console is swung down

all the way and the machine is operated in operating mode turtle I or turtle II. Or if the

main steering switch is released.

(20) set/release ratchet button rotating seat brake (see page 57)

73

5 Operating Components

17

16

18

19

15

20

Chapter.5.

Operating Components


5 Operating Components

Chapter.5.

Operating Components

5.5 Operating Components in the Radio Console on the Cabin Ceiling

All loads switched using the switches on the radio console are operational even with the

ignition switched off. Please do not forget to switch off these loads in due time, when the

engine is not running.

(1) Microphone for public address system (optional)

(2) Radio (for operation, refer to separate operating manual)

(3) Rotating switch for swinging the left rear view mirror in/out

(4) Rotating beacons

(5) Mirror heating system

(6) Side window wiper/washer left

(7) Power outlet 24 V/8 A max. (for small automobile plug)

8

9

1 2 3

4

10

11

(8) Switch work light central mark

(9) Switch work light ROOF bottom

12 13 14 15 16 17

(10) Switch work light ROOF top center

(11) Switch work light ROOF top outside

(12) Switch work light ROOF rear left

(13) Switch work light ROOF rear right

(14) Switch work light cleaning and truck conveyor

(15) Switch work lights bottom left and right on the vehicle frame

(16) Fuse box with flat-type fuses F30 - F37

(17) Fuse box with flat-type fuses F38 - F45

74

7

6

5


23

22

21

20

(18) Video display (refer to the operating manual enclosed)

(19) 12 V power outlet 5 A max (for small automobile plug)

(20) Rotating switch for swinging the right rear view mirror in/out

(21) Switch central mark camera/truck conveyor camera (only in case of optional truck

conveyor camera)

(22) Side window wiper/washer right.

(23) Four-way switch for electrical adjustment of the external rear view mirrors (option).

Remark!.If the 12 V power outlets are overloaded, then this may lead to damage to the

voltage transformer.

(24) Internal lights

(25) Wiper/washer rear window

(26) Storage compartment

Warning! Do not place any heavy or sharp-edged objects in the storage compartment.

In case of jerky movement of the machine or driving curves, these may fall out and

severely injure the driver. If possible, place such objects in the storage compartment on

the rear cabin wall.

(27) 12 V power outlet 5 A max (for large automobile plug)

(28) Installation space for radio set

24 25 26 27 28 29

(29) Timer for independent vehicle heater (optional)

75

5 Operating Components

18

19

Chapter.5.

Operating Components


5 Operating Components

Chapter.5.

Operating Components

5.6 Air Conditioning

Air vents in the radio console

Rotating switch circulating air

grid open/closed

Circulating air grid in the rear wall

Air vent in the footwell

76

Temperature sensor for the air conditioning system

By example: air vents in the right

A column of the driver‘s cabin


5.7 Operating Components Outside of the Cabin

The main battery switch (1) is located on the left vehicle side, below the cover between

stepladder and battery box. The vehicle electric system is separate from the batteries as

soon as you switch off this switch.

Remark! To avoid damage to the vehicle electric system or vehicle electronics system,

the main battery switch may NEVER be switched off with the engine running or the

ignition switched on.

Main battery switch (1)

2

1

The motor housing contains the switch (2) for motor housing lighting and a power outlet

24 V (3).

77

5 Operating Components

3

Chapter.5.

Operating Components


79

6 Operation

Chapter 6

Operation

Chapter.6.

Operation


6 Operation

81

6 Operation

In this chapter, you will receive all information for safe operation of euro-Maus3. For

most work in the agricultural sector, the mode of working and the work results are

affected by many individual and diverse factors. It would exceed the scope of this

operation manual if we were to address all conceivable situations (ground conditions,

sugar beet varieties, weather, local landscape, etc.). This operation manual cannot be

a complete instruction manual on loading sugar beets or replace driving instructions for

driving on roads. Precondition for operation of this machine and for optimum harvesting

results are, besides driving training offered by the manufacturer, solid basic agricultural

knowledge and some experience with sugar beets and the associated work processes.

This chapter will inform you about operation processes and the context in operation of

the machine and gives hints on setting of the machine.

Remark! Before any operation of euro-Maus3, obtain in-depth information about

safety measures for operating this machine. If any people should be present who are

not informed about the hazard zones and safety distances applying, then inform these

people about safety distances and hazard zones. In any case, instruct these people that

you will immediately put the machine out of operation if anybody unauthorized closes on

the hazard zones.

6.1 Initial Commissioning

For the sake of safety, check all oil levels, the level of coolant and the available fuel

quantity. Otherwise, all work and measures are required for initial commissioning which

also have to be performed for daily commissioning.

All bolted connections must be checked for tight fit after the first 10 operating hours

and retightened in case of need. In addition, the complete hydraulics system must be

checked for leaks. Possible leaks must be repaired immediately. Furthermore, all hose

clamps on coolant lines, charge air lines and air intake lines must be checked for tight fit

(visual inspection).

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.2 Safety Regulations for Operation of euro-Maus3

– Before starting work, make yourself familiar with the machine and the operating

components. In case of need, obtain instructions from a person already having

sufficient experience in handling of the machine.

– Before every startup of the machine, check the machine for traffic and operating

safety.

– Inform all people staying near the machine about the hazard zones and the

applicable safety regulations for handling of the machine. Strictly prohibit all people

from entering the hazard zones when the machine is running. In the appendix to this

operation manual, you will find a drawing showing the hazard zones of the machine.

If needed, copy this sheet and hand it out to all people present during operation of

the machine. Obtain a confirmation of receipt of this sheet by signature from each

person.

– Generally, transporting people on the cabin platform is not allowed, neither when

driving on roads nor when loading. If deviation from this regulation is made for

training purposes, then this is at own risk and responsibility of the participants.

– The effectiveness of operating or setting components may in no case be impaired

or defeated. Safety attachments may not be circumvented nor bridged or otherwise

rendered ineffective.

– When working with and on the machine, always wear tightly fitting and suitable

protective clothing respectively approved personal protective equipment. Depending

on the activities, the following personal protective equipment is required: warning

vest, protective helmet, safety shoes, hand protection, ear protection, face

protection.

– Rollers and conveyors may never be stepped on when the engine is running.

– Staying under raised machine parts is prohibited, even if the machine is shut off.

These parts may suddenly come down and severely injure people.

– Staying in the swivel range of machine parts is prohibited.

– Only especially authorized people after exact agreement with the operator may

enter the hazard zones for maintenance or monitoring work. These people must

be precisely informed about possibly occurring hazards before entering the hazard

zones. All activities between the operator and these people must be exactly agreed

before beginning these activities. All maintenance, adjustment and monitoring work

on this machine must – to the extent technically possible – always be performed

with the machine standing totally still and engine shut off. The operator of the

machine is responsible for the fact, that the machine cannot be put into operation by

unauthorized people, inadvertently or in contrary to prior agreements.

82


83

6 Operation

Danger!.There is a hazard of severest or even deadly injuries for people staying in the

hazard zone. Especially near the pickup, objects or people may be drawn into rollers

by body parts or pieces of clothing. In this case, body parts may be ripped off and

fragmented. Objects may be drawn in by the rollers and destroyed or cause severe

damage to the pickup of the machine. The operator is obliged to immediately shut down

the machine, as soon as people enter the hazard zone or ingress into it with objects. It is

expressly prohibited to place sugar beets not having been lifted by the machine into the

machine manually or using tools, as long as the machine is running. The engine must

be shut off before maintenance and repair work and the ignition key must be removed.

Read the operating manual and observe safety information. In the past, these activities

have lead to severest accidents.

– Shut off the engine when refuelling. Smoking, fire and naked flame are strictly

prohibited when handling fuel. Explosion hazard! Do not use wireless telephones or

radios while refuelling.

– Always shortly sound then horn before starting up the engine. By this, you draw the

attention of all people in the vicinity to the necessity of leaving the hazard zones.

Assure yourself that no people are staying within the hazard zones anymore at

startup of the machine.

– Always make sure of sufficient fire protection by keeping the machine free of dirt,

grease residue and other combustible items.

– Immediately remove spilt fuel or spilt oil using suitable binding materials.

– Do not operate the machine in enclosed rooms. There is a poisoning hazard from

poisonous engine exhaust gases. If the engine is to be run in an enclosed room

for maintenance or tuning work, then the exhaust gases must be routed into the

environment using suitable measures (exhaust device, exhaust gas hoses, exhaust

pipe extensions, etc.).

– In your own interest, when driving on public roads and paths, comply with applicable

laws and regulations.

– Safe operation of the machine requires the full concentration and attention of the

driver. Do not wear headsets for listening to the radio and for monitoring radio sets,

etc.

– While driving, do not use radio sets, wireless telephones (cell phones), etc.

– Should there be operational reasons for having to use such devices while driving,

then please always use a suitable hands-free unit for this purpose.

– Set the external rear view mirrors before starting up the machine.

– Before starting to drive, always check if people are staying in the immediate vicinity

of the machine. Inform these people about your plans and instruct these people

to stay at a safe distance. The individual driving behaviour of the machine always

depends on the road conditions respectively depends on the ground conditions.

Always match your driving style to the respective environmental and ground

conditions. Never leave the driver‘s seat when the machine is running.

– When working in sloped terrain and working on slopes, always make sure of

sufficient stability of the machine.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.2.1 Working in the vicinity of power lines

Danger! Hazard to life due to electrical current! Due to the dimensions of the machine,

the landscape and the construction of power lines, the prescribed safety distance may

be violated when passing under power lines or while working in the vicinity of power

lines. This causes the greatest hazard to life for the driver and bystanders.

– When working in the vicinity of power lines, indispensably comply with the applicable

minimum distances. These minimum distances between the outside edge of the

machine and the power line may amount to up to 8.5 m. The size of this minimum

distance always depends on the voltage of the power line. The greater the voltage,

the greater the prescribed minimum distance. Obtain information from the power

company responsible about the technical situation in due time before starting loading

work. If needed, agree a voltage shut down with the power company for the power

line for the time in which you perform work using the machine.

– Precisely observe the agreements closed with the power company for possible

voltage shutdown. Only start work after you have assured yourself, if needed by

calling the power company, that voltage has actually been shut off.

– Especially when working at night or in dreary weather, exactly inform yourself about

the routing of power lines. In case of need, have warning and safety sentries set up,

which will warn you in due time using suitable signals (visual or acoustical signals) of

hazardous closing on power lines.

– During work, make sure that you do not fall below the prescribed minimum

distances.

– When installing antennas or other attachments, always make sure that the total

height of the machine does not exceed the dimension of 4 m.

Memorize the following behavioural rules well, if you work near electric power lines.

Exact compliance with these rules may save your life.

84


6.2.2 Behaviour during or after contact to an electric power line:

– Immediately try to interrupt contact to the electric power line by backing up.

– Try to swing down the truck conveyor.

85

6 Operation

– Stay calmly seated on the driver‘s seat – no matter what happens around you!

– Do not walk around in the cabin.

– In case of electric shock or after contact to an electric power line, in no case leave

the driver‘s cabin. There is extreme hazard to life outside of the cabin.

– Wait until help arrives.

– In no case use a cell phone or radio connected to an external antenna.

– Warn people closing on the machine by hand signals and loud shouting of the

danger.

– Only leave the driver‘s cabin after you have been asked to by rescuers.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.3 Color Terminal

The color terminal is the information and command center of euro-Maus3. You can

monitor the complete machine from here, obtain information about operating status and

performance data and set parts of the machine.

Before working with euro-Maus3, you should indispensably familiarize yourself with the

color terminal and the different warning and status indications on the color terminal to be

able to safely and effectively use the machine.

6.3.1 Keyboard and display sectors

The terminal is operated using the keyboard and the potentiometer (1). You can move up

and down in all menus by rotating the potentiometer. A blue bar or a field highlighted in blue

(cursor) in a menu or in a function selection shows your current position.

You confirm the current position of the cursor by lightly pressing on the middle of the

potentiometer (Enter function).

You can move laterally in the menu or in the line using the keys „left arrow“ (3) or

„right arrow“ (4). In some menus, you can comfortably modify the values shown using the

potentiometer without having to input individual characters.

You can exit the current menu or the line selected by pressing the ESC key (5)

(up by one level).

You can interrupt input by pressing the key C (6).

You input numbers, characters or letters using the number keys – as on the numbers

pad of your telephone.

Different functions are stored for the F1 key (7), depending on the respective display on

the screen. The respective function of this key is either stated directly on the screen or is

explained at the corresponding function within this manual, if needed.

86

7

3

4

1

6

5


A Display section steering status (see page 117)

B Display section operating parameters

Engine cooling water temp.

G H I

Hydraulics fluid temp.

F

E

C Display section scales and order management (option from 2008)

D Dialog field operating section (see page 64)

87

J

6 Operation

Compressed air system pressure reservoir

Battery voltage

E Fields for status displays (see page 97)

K

F Display section beet section (see page 136)

A

B

C

D

E D

Engine oil level

Pressure driving power

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

G Display section driving speed (see page 103)

H Display section Diesel engine (see page 160)

I Display section function selection

J Quick overview loading parameters

Stage speed pickup rollers

Drive pressure pickup rollers

Stage speed 4-fold pinch rollers

Drive pressure 4-fold pinch rollers

Stage speed 8-fold pinch roller cleaner

Drive pressure 8-fold pinch roller cleaner

Stage speed recleaner strainer chain

Drive pressure recleaner strainer chain

K Display section for warning indications and hints (see page 95)

6.3.2 Main screen driving on roads

When driving on roads, the main screen shows the machine in setting driving on roads in

the display section F (beet section). If the tank should be shown swung out to the left or

right in this display, then the tank lock is not engaged.

88


6.3.3 Select function section

6.3.4 Main menu

89

6 Operation

Place the blue field on the desired function section using the potentiometer and confirm

by pressing on the center of the potentiometer.

Main menu

selected

All submenus of the main menu may be directly called up by entering the respective

menu code.

6.3.4.1 Loading settings (menu code 1)

Operating data

selected

Menu code 1

Menu code 2

Menu code 3

Menu code 4

Menu code 5

Menu code 6

After confirmation of the selection, the following menu is displayed:

Warning limits

selected

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

The desired menu item is navigated using the potentiometer and selected by pressing

on the potentiometer. This activates the associated bar graph.

The recommendation of the manufacturer is always the value of 0. Deviations may be

set by the driver, if desired, from -10 to +10.

- values = the hydraulics circuit reacts more sluggishly

+ values = the hydraulics circuit reacts more aggressively

You may comfortably store your personal loading settings (those are all settings

displayed on the color terminal) on your specific USB stick using the function „export“.

This way, your settings are not lost in case of possible change of drivers. When starting

your next work shift, you can transfer these settings from the USB stick to the machine

using the function „import“.

6.3.4.2 System menu (menu code 2)

The submenus are largely self-explaining.

It is possible to switch between the standard display and the expert mode in the

submenu display type. We generally recommend standard display, since this is much

clearer. The export mode does not offer any additional functions or advantages for

everyday work; it is mainly meant for maintenance personnel or development purposes,

to show specific operating conditions in detail.

90


6.3.4.3 Service menu (menu code 3)

91

6 Operation

Of meaning to the operator in the service menu are only the submenus version and

diagnostics (see chapter faults and remedies (from page 313 and after). The submenus:

tuning and teach in are only accessible after input of a service code.

Danger! Access to these menus is locked using a specific code for safety reasons. If

wrong settings are mad ein these menus, or if the applicable safety regulations are not

or not sufficiently complied with, then this may lead to severest accidents with deadly

injuries. In many cases, severe damage may be caused to the machine, which lead to

expensive repairs or long stand-still periods. Access to these menus is therefore only

allowed during direct contact by telephone to the manufacturer or to people expressly

authorized for this purpose by the manufacturer.

6.3.4.4 Menu basic settings (menu code 4)

Most submenus are comprehensively described at the respective function.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.3.4.5 Submenu special functions (menu code 5)

Central lubrication (see page 171)

Engine oil change (see page 188)

6.3.4.6 Empty menu (menu code 6)

This menu only serves to inform people who are working on continued development of

the control program. No input is possible for the operator here. The information displayed

cannot be sensibly used by the operator.

You can exit this menu respectively the function section using the ESC key.

92


6.3.5 Operating data

93

6 Operation

Operating data may be selected using the potentiometer and the selection confirmed by

pressing on the center of the potentiometer.

Operating data

selected

The following menu is displayed after calling up the function section operating data:

Operating data engine = Total engine service hours

Oper. hrs Loading = Total active period machine drive

Distance = Driven distance in km in operating modes „turtle“

and „rabbit“.

Time = Total time in hours in operating modes „turtle“

and „rabbit“.

Consumption = Total fuel consumption in Liters

in operating modes „turtle“ and „rabbit“.

Recording of operating data is performed per season (values may be deleted) as well

as over the whole service life of the machine (values may not be deleted). The values

recorded are generally evaluated differentiated for the operating modes „turtle“ and

„rabbit“.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

The „season statistics“ may only be deleted if the keys and are pressed one

after the other before deletion. This avoids inadvertent deletion.

No input may be made nor values deleted or modified in „machine statistics“.

The functions „scales“ and „order management“ are available from model year 2008.

The description is contained in a separate operating manual.

6.3.6 Adjusting warning limits

Select the function section warning limits using the potentiometer and confirm the

selection by pressing on the center of the potentiometer.

Warning limits

selected

This function section may be used to modify the warning limits for drives of pickup

rollers, 4-fold pinch rollers and recleaner.

Warning limit

Value warning limit in %

Select the display bar for the desired drive by rotating the potentiometer and confirm

selection by pressing on the center of the potentiometer. Then, by rotating the

potentiometer, scroll the red mark for the warning limit and confirm the setting by

pressing on the center of the potentiometer.

Exit the menu respectively the function section using the ESC key.

94


6.3.7 Warning and status indications on the color terminal

Warning indications

95

6 Operation

Engine oil pressure too low Recleaner rollers blocked

Engine oil level too low

Drive central mark/truck

conveyor blocked

Cooling water level too low Pickup rollers overloaded

Cooling water temperature too

high

Grave engine problems,

immediately shut off engine

4-fold pinch rollers overloaded

Recleaner rollers overloaded

Engine starting block Recleaner conveyor overloaded

Lubrication pump distributor

gears failed

Clutch pressure pump distributor

gears

Hydraulics fluid level too low

Hydraulics fluid too hot

Releasing pressure parking

brake too low

Battery voltage too low or too

high (below 24 V/higher than

30 V)

Drive cental mark/truck

conveyor overloaded

Generator 1 (upper generator)

defective

Generator 2 (lower generator)

defective

Fault in Mercedes engine

control

Fuel prefilter soiled

Fuel fine filter soiled

WARNING! Injury hazard Air filter soiled

Pickup rollers blocked (stone

jammed)

4-fold pinch rollers blocked

Recleaner conveyor blocked

Differential lock front axle not

released

Differential lock rear axle not

released

Reservoir pressure

compressed air system too low

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

Remarks on operation

Please close engine

compartment hatch

96

Please swing fuel tank to central

position and lock

Please close rear platform wall Please unlock fuel tank

Start engine respectively let go of

the ignition key

Please swing down left joystick

console

Please lock main steering switch

Please unlock main steering

switch

Please press foot switch „line of

vision front“

Please release foot switch „line

of vision front“

Please press foot switch „line of

vision front“ or lift pile pickup

Please swing out truck conveyor

further

Please set rear axle straight Please switch off axle support

Please set pile pickup to central

position

Please raise pickup further

Please release parking brake

Please release driving pedal for

switching on the differential lock

Please lower pickup further Please release foot brake

Please swing out pickup

Please release driving pedal to

change gears

Please press driving pedal Please change gears

Please release driving pedal

Please driver more slowly

Please switch to operating mode

turtle 1. Change gears

Please switch to operating mode

rabbit 2. Change gears

Please drive faster Please raise additional axle

EMERGENCY-OFF pressed,

please reset

Please turn in front axle less

Please set rear axle straight Please turn in rear axle less

Please activate driving power

forward


Status indications

Cruise control activated Additional axle raised

Machine drive switched on Additional axle lowered

Driving power loading forward

activated

Driving power loading backward

activated

All-wheel steering active

Automatically set rear axle

straight active

Operating mode rabbit active

(driving on roads)

Operating mode turtle active

(loading operation)

97

6 Operation

Central lubrication operating

Automotive driving active

Manual engine speed control

active

Loading direction left active

Loading direction right active

Differential lock front engaged

1 st gear active Differential lock rear engaged

2 nd gear active Parking brake engaged

Water spray system in

automated mode

Water spray system in

permanent mode

Please refill fuel tank

Axle support switched on

Hints on electronics problems

Automatic parking brake active

Please, when switching on the

machine drive, press the „foot

switch line of sight front“

Height indicator pile pickup in

percent

Fault driving pedal sensors Fault data backup

Analog signal in prohibited range Wrong machine configuration

Line break or short circuit

detected

Internal memory fault in

EEPROM

Speed signal in prohibited range

Communications problem with

control device

No connection to operating

section

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.4 Air Conditioning

The air conditioning system provides optimum climatic conditions in the driver‘s cabin, if

possible. For setting the desired temperature, select position 11 on the rotating selector

switch.

The setting range is between 15 and 30 °C. The desired temperature is lowered by

pressing the key; the desired temperature is increased by pressing the key. You

can read the respective set temperature on the color temperature.

Setting the fan speed is performed using the and keys in the operating section. For

this purpose, select position 12 on the rotating selector switch.

Fan stage 0: STOP

Fan stage 1: Cooling switched off

Fan stage 2-5: Cooling possible depending on setting of the ECO key

Fan stage AUTO: Automated air conditioning with infinitely variable

control of fan speed. The cabin temperature is adjusted

to the preset desired temperature.

98


EC key = air conditioning system ON/OFF

99

6 Operation

Press key 1 x: LED is lit, no cooling, only fresh air respectively heating. Keep key

pressed for several seconds: LED is flashing, defroster function for freeing windows. Fan

and heater run at maximum power, simultaneously, the air is dried at maximum power.

1

Circulating air grid in the rear wall

Temperature sensor for air conditioning

Air jet in the foot well

To reach the desired cabin temperature as quickly as possible, open the circulating air

grid on the right side in the rear wall using the rotating switch (1).

In case of cold weather, open the ventilation jet of the fan cover for heating up the foot

well. When you have opened this jet, the air volume of the other ventilation openings

substantially decreases.

Observe that fogged windows are only freed quickly if you keep the jet in the foot well

closed until the windows are free.

Make sure that the temperature sensor (1) on the rear cabin wall is always unobstructed

and is not covered by pieces of clothing or other objects, because otherwise, the air

conditioning system will not work correctly.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.5 Independent Heating System (Optional)

6.5.1 Operation timer

Time display

Alarm display

Memory

Time of day

The time of start of heating may be preselected using the timer within a period of up to

7 days. Programming of 3 startup times is possible, of which only one may be activated.

The timer has an alarm function.

With the ignition switch on, the clock shows the current time of day and the day of the

week. If the heating system is operating, then the display and the keys are lit. After

connecting up power supply, all icons of the display flash. The time of day and the day of

the week must be set.

6.5.2 Operation independent heating system

Operation of the clock is designed so that all flashing icons may be set using the keys

and . If no key is pressed for 5 seconds, then the time displayed is stored. If the

keys and are pressed for more than 2 seconds, then fast mode is activated.

If the ignition is switched off, while the heating system is in permanent heating mode,

then the display shows a residual operating time of 15 minutes and the heating system

remains in operation.

Day of the week Operation indication

Program selection

Return

Immediate

Feed heating

Switching on

Manually: by pressing the key (permanent heating mode)

Automatic: by programming of the start of heating

Ausschalten

Manually: by pressing the key

Automatic: by programming the operating time

With the heating system operating: by setting the residual operating time

Setting the time of day/day of the week

Press key for more than 2 seconds – time of day flashes – set time of day using the

keys and – day of the week flashes – set day of the week.

100

Timer

Forward

Return


Query time of day

When ignition is switched off: press key .

Program start of heating

101

6 Operation

Press key – flashes – set start of heating using the keys and dday of the week

flashes – set day of the week.

The memories 2 and 3 may be programmed or a switch may be made to the time of day

mode by pressing the key several times.

Query/delete the preselect times

Press key several times, until the desired memory is displayed. Deleting of the

preselect time – press the key several times, until the time of day and no memory is

displayed.

Program operating period

The heating device must be switched off. Press the key for 3 seconds – operating

period flashes – set the desired operating time using the keys and

(10 to 120 minutes).

Set remaining operating time

Set the desired remaining operating time using the keys and B (1 to 120 minutes).

The remaining operating time is the time the heating device remains in operation. It may

only be modified while the heating device is operating and the ignition is switched off.

Set alarm time

The alarm time is not tied to a day of the week. Press the key several times, until the bell

icon appears on the display. Set the desired alarm time using the keys and .

The alarm switches off after 5 minutes or when one of the keys is pressed.

Query / delete alarm time

Press the key several times, until the bell icon appears on the display– read alarm

time. Deleting the alarm time – press key , until the bell icon no longer appears on

the display.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.6 Heating Hydraulics Fluid Tank (only jointly with the

independent heating system)

If your euro-Maus3 is fitted with the optional independent heating system, then the

fluid in the hydraulics fluid tank may be preheated using the fluid tank heater. A heat

exchanger is located in the hydraulics fluid tank, which is connected to the cooling water

circuit of the Diesel engine.

The heater of the hydraulics fluid tank should be switched on for each cold start.

1

For this purpose, move the lever of the ball cock (1) on the outside wall of the hydraulics

fluid tank up. To switch off the fluid tank heater, move this lever to the front.

Remark! Use the fluid tank heater. Preheated hydraulics fluid reduces wear of the

hydraulics system.

For as long as the independent heating system is operating, the main battery switch

may only be switched off in emergencies, because in this case, the heating system is

switched off without running on (danger of overheating!).

Switch off the fluid tank heater before starting the Diesel engine, but at the latest as soon

as the color terminal displays a hydraulics fluid temperature of 40° C or more. Otherwise,

the hydraulics fluid is constantly heated up by the cooling water of the Diesel engine and

unnecessarily heated up.

102

Art. Nr. 355172


6.7 Diesel Engine

6.7.1 Starting the engine

103

6 Operation

If the driving pedal is not in resting position during starting, then for safety reasons,

driving power is blocked. The block is upheld for so longe until the driving pedal is

completely released and pressed again.

The engine is started and shut off using the ignition lock.

The ignition lock has four switching positions:

Position 0: Switch off engine/ignition off – key may be pulled off

Let the engine idle for a short time before shutting off the engine.

If the engine is shut off at too high speed, then the turbocharger will

run on after the oil pressure has already dropped.

This leads to lack of lubricant and therefore to unnecessary bearing

wear at the quickly rotating turbocharger.

Position I: Ignition on, engine is ready for starting

Position II: Not connected

Position III: Starting the engine

The green color in the display field for the Diesel engine indicates the starting process.

After each start of the engine, the fan of the radiator system is automatically reversed for

a short time. This frees the radiator system of loose dirt (leaves, etc.).

Attention! The use of chemical starting aids (for instance Startpilot, etc.) is expressly

prohibited, since this may lead to injuries and to damage to the engine.

If the engine should not start immediately, then the electronic system switches off the

starter after a certain period of time. Then, wait at least 2 minutes until the next try to

start, so that the starter can sufficiently cool down.

If the engine cannot be started due to a starting block, then the following warning icon is

displayed on the color terminal: .

This warning icon and one of the following alternately flash on the color terminal:

Close engine Swing up rear

housing cover platform wall

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.7.2 Starting the engine without booting up the terminal

When the parking brake is engaged (toggle switch pressed to the rear), then the engine

may also be shut off by pressing the EMERGENCY-OFF switch. For this method, the

color terminal continues to operate. After resetting the „EMERGENCY-OFF“ switch, the

engine may be started new.

6.7.3 Engine speed adjustment

6.7.3.1 Operating mode „rabbit“

On the right joystick, it is possible to switch, by sliding the X-Y switch (1) to

the right/left, between driving with manual engine speed control (to the

left)

and automotive driving (to the right). To switch, the X-Y switch (1) must

be slid into the respective direction and shortly held in this position.

1

14

Automatic engine speed adjustment (automotive driving)

During automotive driving (display on the color terminal: ), adjustment of the engine

speed is exclusively performed using the driving pedal = gas pedal.

Manual adjustment of the engine speed

In the operating mode rabbit, with manual engine speed adjustment,

adjusting of the engine speed is only performed using the manual

potentiometer (14). The highest engine speed is at about 1500 min -1 . This

variant is best suited for driving on uneven track.

104


6.7.3.2 Operating mode „turtle“

16

17

Engine speed control is manually performed using the gas (17) / gas key

(16) on the left joystick.

Shortly press the gas key: The engine speed increases by 25 min -1 each

time it is pressed.

Shortly press the gas key: The engine speed reduces by 25 min -1 each

time it is pressed.

Press the gas / gas key and keep it pressed: the speed changes for so

long until you release the key.

Operating mode „turtle“ machine drive On/Off

After switching off the machine drive, the speed of the Diesel engine is

automatically set to the value, which had been set before last switching off

of the machine drive. After switching off of the machine drive, the engine

speed is automatically reduced to idling speed (exception „recharging“ see

page 147).

Actual

engine

speed

6.8 Switching Driving Power

euro-Maus3 may be operated in the following operating modes:

„Turtle I“ = loading operation

„Turtle II“ = This operating mode may be switched on,

but it does not make sense in practical operation,

since all-wheel drive is switched off.

„Rabbit I“ = Slow driving on roads with all-wheel drive

„Rabbit II“ = Quick driving on roads witout all-wheel drive

105

Set engine speed

6 Operation

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.8.1 Switching gears

The manual transmission is used to switch between the operating modes „turtle“ and

„rabbit“ as well as between gear I and gear II. The color terminal displays the icon of the

currently active combination of operating mode and gear. In the operating mode turtle,

the climbing ladder is swung out and the warning signs on the pile pickup swing up.

Driving speeds:

Operating mode „turtle I“: 0 - 0.7 km/h

Operating mode „rabbit I“: 0 - 10.3 km/h

Operating mode „rabbit II“: 0 - 20.0 km/h (respectively 25 km/h)

Switching process

– Engage the parking brake.

– Set the engine to idling speed.

– Select the desired combination of operating mode and gear using the keys (1) and

(2) of the operating section:

Key (1) „turtle“/„rabbit“);

Key (2) gear I/II.

LED 1 2 LED

– When switching to a different operating mode, a sound may be heard („clack“).

– If one of the two key LEDs and the icon on the color terminal are flashing after

switching, then the transmission is under tension. Release the parking brake and

drive very carefully (!) and very slowly forward or backward. The transmission

will now audibly switch. Inspite of this, check if the icon for the selected operating

mode is visible on the color terminal and if the key LED of the operating section is

constantly lit.

Remark! Danger of severe damage to the transmission.

In any case, observe the hints given above! Transmission damage caused by non-

compliance or imprecise compliance is excluded from any guarantee or warranty!

The keys for switching between the operating modes may ONLY be used if the machine

is standing completely still (0.0 km/h). In addition, sufficient pressure must be available

in the compressed air system. This is the case, when the icon is no longer displayed

on the color terminal. If you do not observe this hint, then the manual transmission may

be destroyed.

106


107

6 Operation

If it should not be possible to move the vehicle, then the cause for this is displayed on

the color terminal:

Ignition key is in the position „start engine ”.

Please release the parking brake by pressing the toggle switch

„parking brake“.

Please release the foot brake.

Reservoir pressure of the compressed

air brake too low!

Release pressure of the parking brake

too low!!

Fault of the driving pedal sensors!

6.8.2 Switching process differential lock

A lit LED (light emitting diode) within the respective key and an icon on the color terminal

show which differential lock is switched on.

LED

3

LED

call in customer service!

A flashing LED shows that the corresponding switching process cannot be executed,

either because the axle is locked up or the engaging position has not been reached.

Remedy: move steering back and forth in the central range or drive forward and

backward for a short stretch.

It is not possible to lock the rear axle alone. The lock of the rear axle can only take

effect, if the differential lock of the front axle has been switched on. If, on the other hand,

the differential lock for the front axle is switched off, then automatically the differential

lock for the rear axle is switched off as well.

Only switch the differential locks when the machine is standing still (0.0 km/h) and the

wheels on the axles are approximately aligned straight!

Only switch on the differential locks if they are actually needed. For normal pile ground

as well as correctly set pickup depth and pickup relief, no use of the differential locks is

required.

4

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

Remark! If traction of the machine should be insufficient under extreme conditions, then

at first, only switch on the differential lock of the front axle. The rear axle lock may only

be used if continuation of work would otherwise be impossible. To avoid damage to the

axle, the wheels must in any case be steered to about straight alignment.

The rear axle is subject to uneven loads during the loading process. The wheel on the

side of the truck conveyor swung out has to bear up to 80 % of the rear axle load during

loading. The greatest share of the overall feed pressure is assumed by this one rear

wheel with the large wheel load. The power transmitting components (differential drive,

jointed shaft, planetary gears, etc.) are subject to very heavy strain. Never steer the

wheels with a too great angle with the differential lock engaged! When you increase

the steering angle too much, one of the following warning icons is displayed on the

color terminal. In addition, a warning signal sounds. Before switching on, always set the

wheels straight!

If the front or rear axle has a too great steering angle, then the differential lock cannot be

engaged.

Remark!.The rear axle is only able to perform limited steering tasks with the differential

lock engaged. If larger steering movements of the rear axle are required, then first shut

off the differential lock of the rear axle.

When switching to operating mode rabbit II, the differential locks are automatically

switched off.

If the differential lock should be accidentally switched on while driving, the following

warning icon is displayed on the color terminal: .

To switch on the differential lock, completely release the driving pedal and stop the

machine.

108


6.9 Driving

109

6 Operation

Hydrostatic drives are deemed very safe. The following measure additionally increases

this safety, if there should be any operating faults of the drive. If, when releasing the

driving pedal, the machine should neither reduce driving speed nor stand still, then a

safety circuit is activated by engaging the parking brake.

2.

This safety circuit defeats the standard control behaviour of the hydraulics system and

opens a safety valve quickly shutting off driving power.

If, in the extremely improbable case of failure of all safety devices, the machine should

still not stop, then shut off the Diesel engine as quickly as possible.

Danger!.Danger of severe rear-end collisions with injuries hazardous to life or even

deadly when engaging the parking brake or shutting off the Diesel engine, while the

machine is driving. Therefore, take this EMERGENCY-STOP measure only in extreme

emergencies and try to warn following traffic by pressing the foot brake pedal several

times and switching on the hazard warning system.

1.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.9.1 Driving on roads (operating mode rabbit)

In the operating mode rabbit, the electronic control relieves the driver as well as the

environment by means of automotive driving.

Automotive driving means that the driving speed is set by pressing on the driving pedal.

The electronics controls the hydrostatic drive and the Diesel engine so that the set

speed is always driven at the lowest possible engine speed, independent of the fact,

whether you are driving uphill or downhill.

You control the driving speed of the machine using the driving pedal. The further you

push down on the pedal, the faster the machine drives. When you completely release

the pedal, the machine strongly brakes down due to the hydrostatic drive. If the vehicle,

after switching to operating mode „rabbit II“, should only be moving very slowly, then the

color terminal will display the following icon .

At this time, at the latest, swing the fuel tank in central position and lock it in this position.

6.9.1.1 Switching driving direction

Foot switch driving direction::

NOT PRESSED Driving direction „forward“

PRESSED Driving direction „reverse“

Foot switch driving

direction

110

Driving pedal


111

6 Operation

Only in operatin gmode „rabbit II“, the driving pedal must be released completely for

switching to driving in reverse. Wait, until the machine is standing completely still

(0.0 km/h). Only then may the „foot switch driving direction“ be pressed and held in this

position. When the driving pedal is now pressed, the machine will drive in reverse.

In operating mode „rabbit I“, the driving direction may be changed at low driving speed.

A warning signal always sounds when driving backward, which draws the attention

of other people to backward movement. Simultaneously, both backup lamps are

automatically switched on.

6.9.1.2 Cruise control

euro-Maus3 is fitted with cruise control to relieve the driver. This enables control of the

driving speed, only in operating mode „rabbit II“, either by pressing the driving pedal or

by switching on cruise control. Especially when driving for longer stretches, this relieves

the driver.

Switching on cruise control

Cruise control may only be switched on if the following conditions are met:

– Operating mode „rabbit II“ switched on

– Left joystick console swung down

– Driving speed greater than 10 km/h.

.e-M3/e-BM3 Rop.Art. 355250

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

Input the desired speed using the driving pedal. When this speed has been reached,

press the right joystick all the way forward and hold it in this position, until the display

field for the driving speed turns green on the color terminal.

Cruise control takes over the speed set by the driving pedal at the time at which the

joystick has been moved forward.

This speed is not necessarily the currently driven speed.

Example: the currently driven speed amounts to 11 km/h. The driver quickly presses the

driving pedal to the stop – the driving pedal sets maximum speed for the machine.

The machine begins to accelerate. In this moment, cruise control is switched on.

Cruise control takes over the speed set by the driving pedal (= maximum speed).

If you want to increase speed for a short time while driving, you can override

cruise control at any time by pressing on the driving pedal. If you drive faster than

set for cruise control, then cruise control is switched on, but the effect can only

be found when you reduce pressure on the driving pedal. When you release the

driving pedal, the machine again drives on at the speed set for cruise control.

Adjusting cruise control speed

When cruise control is switched on and the driving pedal is released, then driving speed

of euro-Maus3 may be changed as follows:

– Turn the rotating selector switch to position 10.

– The driving speed may be modified in steps of about 1.0 km/h by pressing the or

key.

112


Switching off cruise control

113

6 Operation

Before switching off cruise control, you should always press down the driving pedal

so far until you take over the speed driven under cruise control using the pedal. This

prevents sudden braking of the machine when switching off cruise control.

To switch off cruise control, shortly pull the right joystick completely back. Further options

for switching off cruise control are:

Pressing the footbrake pedal or pressing the footswitch driving direction.

6.9.2 Quick description: operating cruise control

Start engine.

Select operating mode „rabbit II“ .

Drive faster than 10 km/h.

Push right joystick forward all the way until

the field for display of the driving speed

turns green .

Cruise control is switched off by pulling back the right joystick,

pressing the footbrake pedal, pressing on the „footswitch driving direction“, pressing

the EMERGENCY-OFF button, engaging the parking brake or raising the left joystick

console.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.9.3 Driving in operating mode turtle (loading)

In operating mode turtle, driving power is operated almost exclusively using the keys (2)

and (3) and the potentiometer (14) on the right joystick.

If driving forward is activated using key (2), then the terminal displays the icon .

This key is used to switch on driving forward. Pressing this key again stops driving

power.

Switching off machine drive also switches off driving power.

The driving speed (= feed speed) for loading operation is set using the manual

potentiometer (14).

The speed set may be overridden up to maximum speed using the driving pedal. This

function enables quicker driving to the beet pile.

If reverse driving is active using the key (3), then the terminal displays the icon .

This key is used to switch on driving power reverse for so long as the key is kept

pressed. If euro-Maus3 is driving forward during loading, then you can stop this

movement by pressing this key. While driving in reverse, speed control using the manual

potentiometer is not possible. The machine always drives backwards at the maximum

possible speed.

In addition, driving power may be stopped as follows:

– Pressing the EMERGENCY-OFF button

– Shortly pressing the footswitch driving direction

2

3

14

– Engaging of the parking brake.

114


6.10 Braking System

6.10.1 Operating brake

115

6 Operation

The braking system of euro-Maus3 is designed as a pneumatically operated dry drum

brake. For safety reasons, it consists of two independent braking circuits:

The operating brake operated using the brake pedal on the cabin floor, and the parking

brake, which is operated using the toggle switch.

Danger! Hazard to life in case of defective brakes. Check functioning of the brakes

before each drive! The braking systems must regularly be thoroughly checked! Setting

and repair work on the brakes may only be performed by trained specialist personnel.

The operating brake is activated using the left pedal (1) on the cabin floor. It takes

effect on the front wheels and only works if there is enough pressure in the compressed

air system. If an optional additional axle is present, then this is also braked down. If

the operating brake should not be working well enough (for instance too low reservoir

pressure), then the following warning icon is displayed on the color terminal .

Driving pedal

Brake pedal (1)

Danger! When a warning icon is displayed on the color terminal referring to problems

with the braking system, there is the greatest hazard to life for the driver and people

standing by as well as other participants in traffic. Operation of euro-Maus3.must

ceased immediately in this case. The machine must be parked in such a manner that

nobody is endangered or impaired. The machine must be secured against rolling away

by engaging the parking brake. It may only be moved when the cause for the fault of the

brake has been remedied by specialist personnel and the machine has been released

for operation by the corresponding specialist personnel.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

Constant throttle brake

The operating brake is needed only in exceptional cases. Normally, braking using the

hydrostatic drive is sufficient. The Diesel engine is fitted with a constant throttle brake.

This brake automatically activates itself when releasing the driving pedal or when

driving downhill on steep slopes – when the set engine speed is greatly exceeded – and

increases the braking effect of the hydrostatic drive.

The color orange iin the display zone for the Diesel engine indicates the active constant

throttle brake.

6.10.2 Parking brake

Operation of the parking brake is performed using the toggle switch on the console. The

parking brake only takes effect on the front wheels. Even if the ignition is switched off

and the pneumatics system is pressureless, the parking brake is automatically engaged

and takes effect.

For safety reasons, the parking brake is only released if there is sufficient pressure in the

pneumatics system. If the releasepressure of the parking brake is too low, then the color

terminal displays the following warning icon .

If the parking brake is engaged, then the color terminal displays the following icon

. For as long as the parking brake is engaged, pressure on the driving pedal remains

without effect. In emergencies, the spring-loaded cylinders of the parking brake may be

manually mechanically released. You can find instructions for this in Chapter 8 „Faults

and Remedies“.

6.10.3 Automatic parking brake (only in operating mode rabbit)

116

3

When the machine is standing still (driving pedal released for several seconds), then

the parking brake is automatically engaged. As soon as the automatic parking brake is

active, the color terminal displays the following icon: .

This avoids inadvertent rolling away of the machine, especially on sloped ground.

If the driving pedal is pressed again, then the automatic parking brake is released.


6.11 Steering

The front axle is generally steered using the steering wheel.

active

steering mode

6.11.1 Main steering switch

117

6 Operation

Position indication

front axle steering

Position indication

rear axle steering

The main steering switch (1) is used to block steering of the rear axle. If the main

steering switch is unlocked, then the rear axle may be steered.

Danger! Hazard of deadly injuries when driving with unlocked main steering switch

and driving speeds of in excess of 8 km/h. This may lead to uncontrolled swinging

movements of the vehicle. This may seriously endanger or even cause deadly injuries

to people. The main steering switch may therefore only be unlocked for driving through

very tight curves, at low speed (below 8 km/h) and only as long as indispensably

required.

If operating faults occur at higher speeds than 8 km/h, or if hydraulics or electrical

components fail, then driving safety is no longer ensured. Severe accidents would be the

consequence.

1

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

12

6.11.2 Rear axle steering in operating mode Rabbit

6.11.2.1 Manual rear axle steering

In operating mode „rabbit“, the rear axle may be steered independent of the

front axle by moving the right joystick right/left. For this purpose, the main

steering switch must be unlocked. When driving in operating mode rabbit

at a speed of more than 8 km/h, the main steering switch must generally be

locked.

6.11.2.2 All-wheel steering

13

All-wheel steering may be used to be able to simultaneously steer the rear and front

axles without further activities of the driver. For this purpose, the rear axle steers in

contrary to the front axle. This steering type facilitates navigating of the machine for

drivers with less experience.

The following conditions must be met for switching on all-wheel steering:

– Operating mode rabbit switched on

– Main steering switch unlocked

– Speed at least 0.5 km/h and at maximum 8.0 km/h

For activating, press the keys (12) and (13) on the right joystick simultaneously, until the

color terminal displays the following icon .

118

.e-M3/e-BM3 Rop.Art. 355250

When all-wheel steering is activated, then the speed of euro-Maus3 is limited to about

8.0 km/h. All-wheel steering may be switched off either by moving the right joystick

right/left, by activating straight setting of the rear axle, or by locking the main steering

switch.


11

6.11.2.3 Setting the rear axle to straight position

– Switch on operating mode „rabbit“.

– Drive slowly (below 8 km/h).

– Unlock main steering switch.

– Drive at least 0.5 km/h and shortly press the multi-key (11) on the joystick.

119

6 Operation

Then, the rear axle steers in straight position. The color terminal displays the following

icon .

Then, the main steering switch must IMMEDIATELY locked again.

If the rear axle is not locked in straight position, then during driving in operating mode

„rabbit II“, the color terminal displays the following warning icon .

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.11.2.4 Quick description: steering in operating mode „rabbit“

11

12

13

The rear axle may be steered to

the left (L) or right (R) using the

joystick.

Drive at least 0.5 km/h.

Press multi-key (11).

Rear wheels are set straight and

remain in this position.

Drive slowly (below 8 km/h).

Unlock main steering switch.

Important: lock main steering switch.

120

Start engine.

Select operating mode „rabbit“ .

L R

If the rear axle is not in straight position or the main steering switch is not locked,

then corresponding warning messages are displayed on the color terminal:

or

Activate all-wheel steering. For this

purose, press keys (12) and (13)

simultaneously while driving, until the color

terminal displays the icon .


6.11.3 Steering in operating mode „turtle“ (loading operation)

121

6 Operation

During loading operation, the rear axle is steered using the toggle switch (2) in switch

section 4. Condition for this is that the main steering switch is unlocked. There are the

following limitations for this type of steering:

– The steering angle is very limited, when the differential lock is activated.

– The rear axle should be steered as little as possible, to avoid excess wear of the

cardan joints.

6.12 Loading Operation

2

Danger! There is an acute hazard to life for all people staying in the hazard zone during

the loading process! No people may be staying in the hazard zone during loading. When

people close on the hazard zone, the machine must be immediately immobilized and the

loading process must be interrupted. The people must be strictly instructed to leave the

hazard zone. The loading process may only be continued when all people are located

outside of the hazard zone. If these people do not leave inspite of being requested to do

so, then the loading process may neither be begun nor continued.

6.12.1 Safety circuit for loading operation of euro-Maus3

euro-Maus3 is fitted with a protective safety circuit. This may neither be bridged nor

defeated. The circuit is the result of accident analyses and is to contribute to further

increasing the safety for people in especially critical phases of the loading process.

Simultaneously, the driver is always reminded of his personal responsibility.

Anyone who tries to manipulate this circuit in any manner is completely

responsible for his activities, knowingly violates safety requirements and is acting

gross negligently. He is fully responsible for all consequences and also liable!

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

Safety circuit when switching on the machine drive

The „foot switch line of sight forward“ must indispensably be pressed, when you switch

on the machine drive. This forces you, when switching on the machine drive, to look

forward and to convince yourself, that there are really no people staying in the hazard

zone of the pickup.

This circuit has a cooling off period. If you shut down the machine drive only for a short

time (less than 30 seconds for truck change without waiting period), then you may restart

the machine drive without pressing the „foot switch line of sight forward“ again.

If the cooling off period has expired, then the following indication is displayed on the

color terminal:

Safety circuit for residual beet pickup

Pile pickup up

As long as the pile pickup is lifted up sufficiently high, the indication for the pile pickup

on the color terminal is displayed highlighted in green. The green color indicates, that

the safety circuit has no effect during loading. As long as a certain minimum height is not

undercut, the pile pickup may be used without restrictions (for instance in a half-frozen

pile).

Pile pickup down

If the height indication for the pile pickup is displayed highlighted in orange, because

the pile pickup is lowered, then the telescopic arm may only be moved left/right and

up/down without additional measures. When the telescopic arm is to be extended or

retracted, the driver‘s seat must be turned to the front and the „foot switch line of sight

forward“ on the cabin floor must be pressed.

This „foot switch line of sight forward“ must always be pressed and held, when residual

beets are picked up. When this foot switch is released, all rollers of the pickup stop.

They can only be switched on using the right joystick if the driver‘s seat is rotated fully

forward and the „foot switch line of sight forward“ is pressed.

122

Height indication pile pickup

Foot switch

line of sight forward


123

6 Operation

If the rollers of pickup are rotating and the pile pickup is lowered below the height limit

already mentioned, then you have a little time to rotate the driver‘s seat forward and

press the „foot switch line of sight forward“. The safety circuit only takes effect after a

couple of seconds. You are informed about expiry of this cooling-off period by a visual

indication on the color terminal and an acoustic warning signal.

If the „foot switch line of sight forward“ is permanently pressed (for instance electrically

bridged or constantly loaded mechanically), then the machine drive cannot be switched

on any more.

6.12.2 Preparations for loading

Before starting work, familiarize yourself with the local ground and landscape conditions.

Even before loading, check whether the pile conforms to the requirements of the pile

design plan in the appendix. Especially make sure that the pile is not wider than 8.5 m

in any place. If this should be the case, make sure that the pile is as evenly as possible

brought to a maximum width of 8 m.

Ideal pile width Beet losses by exceeding the max. admissible

pile width

IInform people present before starting to work about the most important safety

regulations, especially about the hazard zones and about the required safety distances.

Have these instructions given confirmed by signature on the form in the appendix (make

a copy before completing the form!).

Indispensably point out to all people present that you are obliged to immediately stop the

machine and immediately cease work if a person enters the hazard zones or does not

exit them upon request.

Drive to a distance of about 1 meter to the beet pile.

Switch on operating mode turtle I (see page 106).

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.12.3 Switching on swing axle support rear axle

– Swing switch (3) down and thereby switch on swing axle support for the rear axle.

Indication swing axle support on

6.12.4 Swing out pickup

– Remove securing chains for the pickup and insert them into the hooks on the vehicle

frame provided for this purpose.

Attention! Danger of severe injuries due to chain links flung away. Do not forget, before

swinging out pickup, to remove the safety chains on the lateral parts of pickup. During

hydraulic lowering of the pickup, the links of the safety chains are busted with great

force. Chain lings flung away may cause severest injuries to bystanders.

– Slightly extend the telescopic tube of the pile pickup and raise the pile pickup as

much as possible.

124

3


5

– Swing out both lateral pickup parts horizontally.

For this purpose: move X-Y key (5) to the

FRONT LEFT swing out lateral pickup part left

FRONT RIGHT swing out lateral pickup part right

125

6 Operation

For swinging out faster, press the multi-key (11) and keep it pressed. If you then

slide the X-Y key (5) to the front left or right, then both lateral pickup parts are

simultaneously swung out. When both lateral pickup parts are completely swung out

and this is not displayed on the color terminal, please check the control rods of the

limit switches (see page 223).

11

– Turn rotating selector switch to position 8 and swing up the swivel plates all the way

by pressing the key. When swinging up the swivel plates, the supporting feet are

simultaneously extended all the way.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

Swinging up the swivel plates is only possible, when the color terminal shows that

both lateral pickup parts are swung out. This is indicated as follows on the color

terminal:

Both lateral parts completely swung out

Only the left lateral part is swung out

Only the right lateral part is swung out

The relief pressure of the lateral pickup parts is displayed even if the lateral part is not

completely swung out.

126


6.12.4.1 Move pickup to operating depth

127

6 Operation

– Slide the X-Y key (4) diagonally to forward right and retract the right supporting foot

to the estimated operating height of the pickup.

– Slide the X-Y key (4) diagonally to forward left and retract the left supporting foot to

the estimated operating height of the pickup.

1

For retracting quicker, press the multi-key (11) and keep it pressed. If you now

slide the X-Y key (4) forward to the left or right, then both supporting feet are

simultaneously retracted.

– Check again, whether both safety chains have been removed.

– Press X-Y key (1) forward and lower the complete pickup to the ground. This makes

it almost impossible to get the machine to tip over during swing out of the truck

conveyor.

Remark! Danger of damage to the pickup. In any case, avoid pressing pickup so much

into the ground when lowering it, so that the front axle is unloaded. This may damage

the pickup.

Lowering of the pickup is only possible when the color terminal indicates that both

lateral pickup parts are swung out.

6.12.5 Swing out truck conveyor

4

Danger!.Staying under the truck conveyor swung out is strictly prohibited. There is

hazard to life! The machine operator must make sure that no people are staying within

the swiveling range of the truck conveyor.

In any case, take care of power lines within the swiveling range of the truck conveyor.

Always keep a sufficient safety distance to these lines. This is always determined by the

type of power line and must be enquired with the competent power company.

All people staying in the sector of the transporting vehicle have the duty of wearing an

approved hard hat. In case of operating error of the truck conveyor, sugar beets may fall

off the transporting vehicle and severely injure bystanders.

11

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

The recleaner is pneumatically swung into the truck conveyor when swinging out the

truck conveyor. Swinging out the truck conveyor may only be begun when the icon for

reservoir pressure warning is no longer displayed on the color terminal. As long as

this warning is displayed on the color terminal, the truck conveyor may not be rotated,

because otherwise the recleaner may be damaged!

When rotating the truck conveyor from the position „driving on roads“ to the position

„loading operation“, make sure that the recleaner moves and also swings out. If this is

not the case, then immediately stop swinging out and remedy the malfunction.

Remark!.For loading, the truck conveyor must be swung out at least so far that the

recleaner may completely swing into the truck conveyor.

– Press the multi-key (11) on the right joystick and keep it pressed; simultaneously,

lightly pull back on the right joystick, to slightly (about 3 cm) lift the truck conveyor

above the transport support.

11

– Release the multi-key (11). Then, carefully push the right joystick a little to the right,

and by this, rotate the truck conveyor out of the vehicle profile.

– Press the multi-key (11) on the right joystick and keep it pressed, simultaneously

press the right joystick to the right and thereby swing up the truck conveyor

articulation so far, until sufficient distance to the ground is reached.

– Determine loading direction:

– Preselect loading direction left/right. For this purpose, slide the X-Y key (1) in the

corresponding direction and shortly hold it in the end position.

Loading direction to the right The truck is standing on the right side of the machine.

Loading direction to the left The truck is standing on the left side of the machine.

If the X-Y key (1) is pressed to the left/right and shortly held, then the rotating

direction of the large rotating assembly is reversed.

128

1


6.12.5.1 Loading direction to the right or left

Loading direction left Loading direction right

Pickup

Joystick

Driver‘s

Pickup

Driver‘s

seat

seat

Joystick

Infeed

conveyor

Swivel arm

Truck conveyor Truck conveyor

.e-M3/e-BM3 Rop.Art. 355250 .e-M3/e-BM3 Rop.Art. 355250

129

Infeed

conveyor

Swivel arm

6 Operation

Danger! Assure yourself before any swivelling of the fuel tank, that there are no people

staying in the swivel range of the tank. If a person is seized during swivelling of the tank

and penned in, then this person may sustain deadly injuries!

Hazard of deadly injuries, if the machine tips over. NEVER swing the fuel tank into the

direction of the truck conveyor.

When rotating the truck conveyor, make sure that you neither damage nor destroy the

driver‘s cabin with the truck conveyor!

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

Loading direction to the right

Unlock fuel tank/lock fuel tank

Swivel fuel tank

– Unlock fuel tank. For this purpose, move the rotating selector switch on the

operating section to position 7 and unlock the fuel tank by pressing the key.

– Move rotating selector switch on the operating section to position 6 and swivel the

fuel tank so fahr to the left, until the weight of the truck conveyor is balanced out, by

pressing the key.

– Raise the truck conveyor so far using the right joystick and rotate it, until the drop

point is positioned above the loading space of the transporting vehicle.

– Set the height of the truck conveyor so, using the right joystick, that the articulation

reaches level to lightly sloped upward over the loading space of the transporting

vehicle.

The fuel tank is always pointing in the direction opposite to the selected loading direction. The truck

conveyor is always pointing in the selected loading direction.

130


Loading direction to the left

131

6 Operation

– First, swivel the truck conveyor across the center of the vehicle to the left vehicle

side.

– Unlock the fuel tank, as described for the loading direction to the right, and then

swing the fuel tank to the right.

– Align the machine – if required – in parallel to the ground. For this purpose, set the

4

swing axle support for the rear axle accordingly using switch (4).

Remark!.Always operate swing axle support carefully and „sensitively“. Make sure,

that the tire tread of both rear wheels is always completely touching the ground, since

one-sided load on the machine may cause severe damage to the tires or the rear axle.

In addition, the forward feed force of the machine cannot be sufficiently used, inspite of

engaged differential lock.

6.12.6 Switching on machine drive

Danger! There is acute hazard to life for all people staying in the hazard zone during

the loading process! Before switching on the machine drive, therefore perform a diligent

visual inspection to make sure that no people are staying in the hazard zone of the

machine – especially within range of the pickup. No people may be staying in the hazard

zone during loading. When people close on the hazard zone, the machine must be

immediately immobilized and the loading operation must be interrupted. The people

must be strictly instructed to leave the hazard zone. The loading process may only be

begun or continued, when all people are at a sufficient distance to the machine. If these

people do not leave inspite of being requested to do so, then the loading process may

not be begun or continued.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

Foot switch line of

sight forward

Turn the driver‘s seat forward. First, emit a short but clear horn signal to point out to all

bystanders that you are starting the machine drive and that sufficient distance to the

machine must be observed immediately. Only switch on the machine drive, if there are

no people staying in the hazard zones.

– Shortly press the yellow button (6) on the right joystick. After expiry of the cooling-

off period, the machine will only react if you simultaneously press the „foot switch

line of sight forward“ using your foot and therefore confirm, that you have convinced

yourself by visual inspection, that nobody is staying within the hazard zone.

– Set the speed of the truck conveyor using the keys (16) Gas and (17) Gas as

desired (recommendation: engine speed between 1200 and 1500 min -1 ).

The cooling-off period has expired. To switch

on the machine drive, please turn the driver‘s

seat forward and press the foot switch line of

sight forward.

132

16 17

6

Machine drive is switched on.


6.12.7 Relieving pickup/depth setting

133

6 Operation

– Depth guide of the pickup is assumed by the two supporting feet adjustable in

height (except for external side of the two lateral parts of pickup) and the central part

(central mark).

– Drive into the beet pile (see pagees 148 and 316).

– Set the pickup depth.

The pickup should be set to such a height that the fingers of the pickup roller enter

the ground for their whole length. This pickup depth is the optimum for preserving,

power saving work.

1 4 5

The X-Y key (1) on the right joystick is used to set the height of the central pickup

section and therefore also the height of the inside section of the lateral pickup parts.

The X-Y key (4) is used to set the height of the supporting feet and therefore the

height of the lateral pickup parts outside right and left.

The pickup must be relieved so that it does not sink into the ground too deeply

during loading. This means that the supporting feet are only required to partially

carry the weight of the lateral pickup parts. The greatest share of the load is to be

transferred to the chassis.

Used for this are the hydraulics cylinders swing the lateral pickup parts in and out (X-

Y key (5) on the right joystick). The lateral parts must be relieved so much by raising

them until the support feet only apply little weight to the ground.

left

Pickup height in %

relief pressure

center

right

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

To relieve the pickup, press the X-Y key (5) only shortly, until the desired relief pressure

is achieved. The relief pressure is indicated on the color terminal. As a non-binding

recommendation, it should be at least 80-100 bar. The relief pressure of the central part

should be as high as possible, to put as much weight as possible on the front axle. This

improves traction of the front tires and the drive train is more evenly loaded.

If the pickup is correctly relieved, then you will see only shallow dragging tracks behind

the two supporting feet in case of normal ground conditions.

There is no guide value for the relief pressure of the central part. The display on the

video display is decisive. You should see here that all beets are picked up and that no

beet losses occur.

The pickup height is displayed on the color terminal. This indication only serves as a

rough orientation.

Working too deep in the ground increases the power requirements of the pickup drive

and substantially increases roller wear!

The depth setting must constantly be adjusted to the ground profile and the load on the

pickup by the beet weight.

134


6.12.8 Clearing shields

Extension plate

135

6 Operation

The clearing shields limit the pickup width and guide the beets on the side onto the

pickup roller.

During first operation of the machine, set the extension plates and wear rails to the

correct height, so that the extension plates are just above the ground. The wear rails

should just be touching the ground for their full length.

During loading, especially watch out for frozen ground and built-up bulging soil in the

course of the clearing shield. Do not drive through obstacles with the clearing shields!

The swinging mechanism could be damaged.

In case of overload, the piston rod of the swivel plate cylinder will break at the beginning

of the thread. Such damage is excluded from any guarantee or warranty.

Predetermined

breaking point at the

swivel plate cylinder

Wear rail

Clearing shield

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.12.9 Beet stretch

This section of the color terminal symbolizes the flow of beets through the machine. This

clearly presents all important operational parameters to you.

A A

B B

C

D

The following general meaning is allocated to the individual colors and icons:

white = section is switched off

green = section is active, but not moving

green with black arrows = section is moving in working direction

grün with orange arrows = section is overloaded

red = section is blocked

orange with arrows = section is being reversed; it is moving

136

against working direction

– Set the speed of the complete beet path as optimally as possible. Match the speeds

of the pickup rollers to the 4-fold pinch rollers. Set the speeds of the pickup rollers

and 4-fold pinch rollers to such a high speed, that the beets picked up are moved to

the infeed conveyor without buildup. When selecting the speed, consider the degree

of soiling of the beets. In case of very soiled beets and wet ground, you should

select a higher speed. This means that the rollers should be running faster than

under „good“ conditions.

E


137

6 Operation

– The feed speed is used to additionally take effect on the degree of cleaning:

Low feed speed means thin beet cover on the rollers means all beets pass through a

double cleaning path = greater cleaning effect.

High feed speed means a thick beet cover on the rollers means only some of the

beets pass through the double cleaning path = lower cleaning effect and more caring

treatment of the beets.

The greater your experience with euro-Maus3, the greater your precision at

estimating the optimum speeds.

6.12.9.1 Truck conveyor (in the drawing drive A)

The truck conveyor moves the beets from the recleaner to the transporting vehicle. The

beets should be treated as carefully as possible during this process.

6

This drive is switched on or off jointly with the machine drive using the key (6) on the

right joystick. The speed depends on the speed of the Diesel engine. If this drive is

stopped, then the drives B through E (see drawing) are also stopped. This drive cannot

be reversed. For machines from model year 2007, the color terminal displays the

following icon , if this drive is overloaded. If the truck conveyor is blocked, then the

color terminal displays the following icon .

If the truck conveyor is blocked, then the cause for this is either found in the section of

the truck conveyor or in the section of the central mark. The oil motors for drive of the

central mark and drive of the truck conveyor are connected „in series“. Therefore, if the

central mark is blocked, then the oil motor for the truck conveyor is also not running.

Usually, you will find the cause for blocks in the central mark.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

Fast speed truck conveyor

Sometimes, a larger quantity of soil sticks to the conveyor – for instance when loading

under unfavorable conditions. To be able to fling this soil off the conveyor, the truck

conveyor is fitted with a fast speed. Then, the truck conveyor runs at double speed.

You can switch on the fast speed using the toggle switch (1). For this purpose, move this

switch upward and hold it for so long, until soiling is removed.

To avoid unnecessary jerking loads on the strainer chain, the speed of the Diesel engine

is shortly automatically reduced when switching on fast speed.

Only switch on fast speed when the conveyor is empty and no beets are on the truck

conveyor any more. The infeed conveyor is automatically stopped for as long as the

truck conveyor is switched to fast speed.

For as long as the truck conveyor runs at fast speed, the central mark is also running at

double speed. If large quantities of dirt are sticking to the top of the central mark, then

you should use fast speed only for a short time, because otherwise, the drive for the

central mark may be damaged.

6.12.10 Recleaner (in the drawing drive B)

9

1

Depending on equipment, your euro-Maus3 has a strainer chain cleaner or an 8-fold

pinch roller cleaner. This performs recleaning of the beets. The recleaner is located

between the infeed conveyor and the truck conveyor. The drive for the recleaner is only

operating when the machine drive has already been switched on. Press the key (9) on

the right joystick once shortly to switch on the recleaner.

If this key is pressed shortly again, then the drive for the recleaner is switched off. When

this key is pressed and held pressed, then the rotating direction of the recleaner is

reversed. Reversing of the recleaner is only possible for the version with a pinch roller

cleaner.

138


The speed of the strainer chain cleaner may be set to one of 10 stages.

For this purpose, set the rotating selector switch to position 3.

You can change the speed of the recleaner by pressing the / key.

key = more agressive recleaning

key = more caring recleaning

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6 Operation

If the recleaner is designed as an 8-fold pinch roller cleaner, then the speed may be set

in 11 stages (0-10 and additionally „MAX“).

To treat the beets as caringly as possible, the speed of the recleaner should not be

selected higher than necessary.

The stage „MAX“ should only be used in case of extremely sticky soil. In this stage,

the speed of the pinch roller cleaner is exclusively dependent on the speed of the

Diesel engine. To switch on the stage „MAX“, press the key for so long until the color

terminal displays the stage „MAX“.

Strainer chain cleaner

Warning!.Never climb onto the machine, as long as the drive is running. When the

strainer chain is running, there is the hazard, that people are caught by the strainer

chain on body parts or pieces of clothing. This can lead to severest injuries. Never touch

the running strainer chain with your hands, with tools or objects, they could be dragged

along by the strainer chain. This could lead to injuries to people and heavy damage to

the machine. Before all work on the strainer chain, switch off the machine and secure it

against starting (pull off the ignition key and carry it on your body).

For the strainer chain cleaner, the cleaning effect is mainly achieved by the fact that the

conveyor is moving faster forward than the beet flow. The beets start to roll and are so

cleaned.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

If the warning limit of the strainer chain cleaner is exceeded, then the following icon is

displayed on the color terminal .

If the strainer chain is blocked, then the following icon is displayed on the color terminal

.

In case of blocks of the recleaner, the drives C / D / E are switched off.

If the strainer chain is blocked by a foreign object, then this foreign object must be

manually removed. For this purpose, always shut off the engine and secure it against

inadvertent restarting (carry the ignition key on your body).

8-fold pinch roller cleaner

Danger!.Never climb onto the machine as long as the machine is running. When the

pinch rollers are rotating, there is the hazard that people are caught on body parts or

pieces of clothing and drawn in. This may lead to severest or deadly injuries. Body parts

may be ripped off or crushed. Never touch the running pinch rollers with your hands, with

tools or objects; these may be drawn in by the pinch rollers and destroyed. You could

be severely injured and the machine heavily damaged. Switch off the machine before

all work on the pinch roller cleaner and secure it against starting (pull off the ignition key

and carry it on your body).

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141

6 Operation

If the warning limit is exceeded at the pinch roller cleaner, then the following icon is

displayed on the color terminal .

If the pinch roller cleaner is blocked, then the following icon is displayed on the color

terminal .

In case of blocking of the pinch roller cleaner, the drives C / D / E are switched off.

Blocking foreign objects may usually be removed from the pinch roller cleaner by

reversing.

6.12.10.1 Beet brake (only for 8-fold pinch roller cleaner)

Beet brake

For the roller cleaner, the cleaning effect is mainly achieved by the fact, that the rollers

pull dirt and trimmings off downward.

In addition, a swiveling beet brake is mounted. Braking bars mounted to the frame of the

roller cleaner, pile up the beets. Due to this, the beets additional rub against each other

and the cleaning effect is increased.

Submersion of the braking bars into the beet flow and therefore the intensity of

recleaning may be set at the operating section.

For this purpose, set the rotating selector switch to position 4.

You change the braking effect of the beet brake by pressing the / keys:

key = The beet flow is braked more (more intense cleaning).

key = The beet flow braked less (more caring cleaning).

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.12.11 Infeed conveyor (in the drawing drive C)

The infeed conveyor moves the beets from the pickup to the recleaner. This drive is

switched on or off using the key (10) on the right joystick.

1

You can switch on fast speed using the toggle switch (1). For this purpose, tip this switch

downward and hold it for so long, until soiling is removed. The infeed conveyor then runs

at double speed.

To avoid unnecessary jerking loads on the infeed conveyor, when switching on the fast

speed, the speed of the Diesel engine is shortly reduced.

Only switch on fast speed, when the infeed conveyor is empty and no beets are on the

infeed conveyor any more.

10

The infeed conveyor only runs when the recleaner is already running. The speed

exclusively depends on the speed of the Diesel engine. If this drive is stopped, then the

drives D and E also stop. This drive may not be reversed.

Fast speed infeed conveyor

Sometimes, a larger quantity of dirt sticks mainly in the section of the infeed and the

deflection rollers of the infeed conveyor. This usually happens when loading under very

unfavorable conditions. Therefore, the infeed conveyor is fitted with the fast speed

gear 1 to be able to fling away this dirt from the strainer chain.

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143

6 Operation

Shortly switch on fast speed, when in the section behind the deflecting roller a „roll“

made of soil and dirt builds up. Fest speed removes this roll of dirt, as long as it does not

exceed a specific size. Otherwise, the dirt must be manually removed.

If the recleaner is blocked, then the infeed conveyor automatically shuts off. When the

block of the recleaner is removed, then the infeed conveyor may be started again by

shortly pressing on the key (10) on the right joystick.

6.12.12 4-fold pinch rollers in the pickup (in the drawing drive D)

8

The 4-fold pinch rollers in the pickup move the beets to the center of the pickup

onto the infeed conveyor. They are only then moving in feed direction, when the

machine drive is switched on and the infeed conveyor is running.

These pinch roller may also be reversed when the infeed conveyors stops.

To switch on the 4-fold pinch rollers, shortly once press the key (8) on the right

joystick.

If this key is shortly pressed again, then the 4-fold pinch rollers stop.

If this key is pressed and held pressed, then the rotating direction of the 4-fold pinch

rollers is reversed.

Move the rotating selector switch to position 2 to adjust the speed of the 4-fold

pinch rollers.

You can change the speed of the 4-fold pinch rollers by pressing the / keys.

key = Increase speed (more agressive cleaning and transport).

key = Reduce speed (more caring cleaning and transport).

The speed of the 4-fold pinch rollers may be adjusted in 11 stages (0-10 and additionally

„MAX“).

To treat the beets are carefully as possilbe, the speed of the 4-fold pinch rollers should

not be selected higher than necessary.

The stage „MAX“ should be used only for extremely sticky soil. In this stage, the speed

of the 4-fold pinch rollers only depends on the speed of the Diesel engine. To switch on

the stage „MAX“, press the key for so long until the color terminal indicates the stage

„MAX“.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

If the warning limit is exceeded for the 4-fold pinch rollers, then the following warning

icon is displayed on the color terminal .

If the 4-fold pinch rollers are blocked, then the color terminal displays the following

warning icon .

In case the 4-fold pinch rollers are blocked, drive E is switched off.

6.12.13 Pickup rollers (in the drawing drive E)

7

The pickup rollers have different tasks. They pick up the beets from the ground and

transfer them to the cleaner rollers. These forward the beets to the feed rollers and

simultaneously clean the pig tails of the pickup rollers.

The feed rollers preclean the beets and guide them to the outside, to achieve a

greater cleaning effect due to the longer route.

The pickup rollers always move in operating direction, when the 4-fold pinch rollers

also move in operating direction.

To switch on the pickup rollers, press the key (7) on the right joystick once shortly.

When this key is shortly pressed again, the pickup rollers stop.

If this key is pressed and held pressed, then the rotating direction of the pickup

rollers is reversed.

Move the rotating selector switch to position 1 to adjust the speed of the pickup

rollers.

You change the speed of the pickup rollers by pressing the / keys:

key = Increase speed (pickup rollers rotate quicker).

key = Decrease speed (pickup rollers rotate slower).

The speed of the pickup rollers may be set in 11 stages (0-10 and additionally „MAX“).

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145

6 Operation

To treat the beets as caringly as possibly, the speed of the pickup rollers should not be

selected higher than necessary.

The stage „MAX“ should only be used for extremely sticky soil. At this stage, the speed

of the pickup rollers only depends on the speed of the Diesel engine. To switch on the

stage „MAX“, press the key for so long until the color terminal indicates the stage

„MAX“.

If the warning limit is exceeded for the pickup rollers, then the color terminal displays the

icon .

If the pickup rollers are blocked, then the color terminal displays the icon .

When the pickup rollers stop or are reversed, the driving power is also automatically

stopped.

6.12.14 Automatic reversing function for all roller drives

You can set the automatic reversing function in the menu „basic settings“ (menu

code 45) to „ON“ or „OFF“ for all roller drives. The automatic reversing function

detects blocks on all roller drives of the beet route.

When the system detects a block, then the automatic reversing function immediately

stops all drives located in front of the blocked drive. Simultaneously, driving power is

stopped. The automatic reversing function now several times reverses the rotating

direction of the blocked drive (at maximum 5 times), until the block is overcome.

Then, all drives – including driving power – are automatically switched on again.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

7

8 9

If it should not be possible, using the five tries by reversing, to release the block,

then all drives are switched off.

You can manually start additional tries by reversing using the keys (7), (8) or (9) on

the right joystick. If this is also unsuccessful, then the cause for the block must be

manually removed.

For this purpose, switch off the machine and secure it against inadvertent starting.

Warning! Danger of severe injuries when removing blocks of drives. In any case, before

removing blocks, completely shut down the machine and secure it against starting by

third parties. For this purpose, pull off the ignition key and lock the driver‘s cabin. Secure

the ignition key against access by third parties!

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6.12.15 Loading transporting vehicle

147

6 Operation

When loading on transporting vehicles, in any case complay with the following hints for

treating the beets as caringly as possible during loading.

– In any case, avoid a change of direction of the beet flow of 90° or more between

infeed conveyor, recleaner and truck conveyor!

– Set up the overall beet cleaning system as caring as possible (lowest possible

speeds).

– Work at the lowest possible Diesel engine speed to save fuel and to protect the

environment.

– Avoid letting the beets fall into the loading compartment of the transporting vehicle

deeper than indispensably required. For this purpose, lower the truck conveyor as

far as possible and at start of loading, let the articulation go as deep as possible

between the walls of the transporting vehicle.

The function described below only exists if your machine is fitted with an 8-fold pinch

roller cleaner, because it is substantially wider than a strainer chain cleaner.

The truck conveyor is turned too far forward, if the color terminal displays the following

icon . Due to this, the recleaner swings out of the input section of the truck conveyor,

and part of the beets fall to the ground. To avoid these beet losses, the machine drive is

completely shut off. In this case, swing the truck conveyor back a little and switch on the

machine drive again.

6.12.16 Continued loading function

6

If, after switching off the machine, you would like to place a slight quantity on the

transportation vehicle,well dosed, then you may comfortably do this using the continued

loading function.

Continued loading is always performed using a low engine speed programmed fixed,

which the driver cannot take influence on.

For this purpose, press the key (6) machine drive ON/OFF on the right joystick and

keep it pressed, until the desired beet volume has been loaded using continued loading.

When you release the key, the drive stops.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.12.17 Pile pickup/picking up residual beets

The pile pickup can be used to clear the end of a beet pile to the outsides of the pickup.

The residual beet pickup (rubber shield) is fitted to the pile pickup. It is used to pull the

last beets of a pile into the pickup. The pile pickup is controlled using the left joystick.

Picking up residual beets

Before picking up residual beets, we recommend lowering the pickup, at very slow

speed, by a few centimeters, and picking up the residual beets as follows:

– Always pull the residual beets onto the pickup rollers near the central mark.

For this purpose, move the residual beet pickup in parallel to the tapered roller and

wait for so long, until the beets have been transported to the infeed conveyor.

– Then, also pull the beets lying on the outside across the tapered roller.

With a little experience, you should have the residual beets picked up in four passes.

Tip! When picking up residual beets, always work near the central mark and always from

the center of the pickup to the outside.

Remark! When loading, always make sure tha t no lumps of frozen beets reach the

infeed conveyor, because this may lead to blocks of the beet flow and to damage on the

strainer chains during loading.

148

.e-M3 Rop.Art. 355251


149

6 Operation

If the color terminal displays the following icon , then the pile pickup must be turned

to the center and raised before raising the pickup.

If the pile pickup is to be swung far to the right or left, then the pickup must first be

lowered. If the pickup is not lowered far enough, then the color terminal displays the

following icon .

Warning signs with limit lamps are fitted to the pile pickup. When you switch to operating

mode turtle, these warning signs are automatically swung up.

6.12.18 Change from working to transporting position

When changing from working to transporting position, do not forget to first swing in the

truck conveyor and only then swing in the pickup.

Swinging in the truck conveyor

When swinging in the truck conveyor, work very diligently and concentrated, since

otherwise, you could severely damage the machine. ROPA therefore urgently

recommends to call in a second, reliable person as flagman for the first tries. This

person may in no case be staying in the rotating and swivelling range of the truck

conveyor or the fuel tank.

Danger! While swivelling the truck conveyor or the fuel tank, no people may be

staying in the rotating and swivelling range of the machine. During all work with the

truck conveyor, all people being near the machine must wear a suitable and approved

hardhat.

Perform the individual machine movements only in little steps and constantly convince

yourself, that

– no people are entering the hazard zone.

– you do not damage the machine by uncontrolled or imprudent switching or steering

actions.

Proceed as follows for swinging in the truck conveyor:

– In any case, swing in the articulation to the stop. For the standard truck conveyor,

the apron only completely swings in, when the articulation has already reached the

stop.

- Raise the truck conveyor so far until it is just above the height of the lateral transport

support.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

– Rotate the swivel arm so far, until, when looking back from the driver‘s cabin, the

wall thickness (1) of the large rectangular tube is aligned to the center of

the sight (2).

2

– Rotate the truck conveyor so far, until the stop screw (3) touches the impact plate

of the swivel arm (the rotating movement automatically stops, when the stop screw

reaches the impact plate provided). Check by visual control, whether the recleaner

after contact to the incoming truck conveyor evenly moves out of the profile of the

truck conveyor.

1

3

Careful! During swivelling, always make sure that the truck conveyor is raised only as

slightly as required above the lateral transport support and that the articulation is not

able to damage the machine. The truck conveyor may in no case be lifted too high.

150


– Lower the truck conveyor so far, until it rests on the support.

– Swing the fuel tank to the center and lock it

Fuel tank

151

6 Operation

Warning!.The tank must always be locked when driving on public roads. The machine

may not be moved on roads or moved to another place, if the tank is not locked. Do not

climb onto the fuel tank! No people may be staying in the swivel range of the tank during

operation of the machine.

– Set the rotating selector switch on the operating section to position 6 . You swivel the

fuel tank by pressing the or key.

key pressed = swivel tank to the left,

key pressed = swivel tank to the right.

Chapter.6.

Operation


6 Operation

1

Chapter.6.

Operation

– Set the rotating selector switch on the operating section to position 7. Now, press the

key and keep it pressed for several seconds, so that the locking cam is pressed

against the locking profile. Swivel the tank as exactly in the center as possible

(visual control in the rearview mirrors).

– Set the rotating selector switch to position 6 again and swivel the fuel tank slightly

to the left and right by pressing the or key, until the locking cam discernably

engages the groove in the locking profile. Then, the fuel tank can no longer be

moved.

Swing in pickup

– Swing the pile pickup to the center and raise it as far as possible.

– Raise the central part of the pickup as far as possible. For this purpose, pull the

X-Y key (1) on the right joystick backwards.

– Set the rotating selector switch to position 8.

Press the key for so long, until the swivel plates are fully swung down and the

supporting feet are fully retracted.

Remark! You may only swing in or out the lateral pickup parts, when the central section

of the pickup has been raised to the stop! If the central part of the pickup is not at the

upper stop, then the lateral parts can only be swung in for two thirds.

152


11

5

Relief pressure

153

6 Operation

– Completely swing in the lateral pickup parts. For this purpose, pull the X-Y key (5)

on the right joystick back diagonally.

To swing in faster, press the multi-key (11) and keep it pressed. If you then pull the

X-Y key (5) diagonally to the rear left or right, then both lateral pickup parts are

simultaneously swung in.

After swinging in, hold the X-Y key (5) for so long, until the pressure indication on

the color terminal shows at least 120 bar relief pressure for the lateral parts, so that

they are pressed against the stop.

If, for a machine standing on a slope to the side, a very soiled pickup should not be able

to be swung in, then at first park the machine with the front slope up or slope down.

Then, swing in the pickup.

Relief pressure

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

Inserting the safety chains and securing the pickup

The is one safety chain each on the right and left front of the chassis. These chains must

be fastened to the two lateral parts for driving on public roads.

Danger! Staying under the raised and unsecured pickup is prohibited! There is hazard

to life if the pickup parts suddenly swing down. Make sure that no people are staying in

the hazard zone during swinging in and out of the lateral pickup parts. Additionally, no

people may be staying on the cabin platform.

Fasten the chains on the central part of the pickup, when you have swung in the pickup

and are leaving the machine. In case of a malfunction of the hydraulics system, the

pickup then cannot unexpectedly come down. Otherwise, severe damage to the cabin

will be the consequence! Such damage is excluded from any guarantee or warranty.

The safety chain fastened to the central part of the

pickup

154

Safety chain fastened to the

lateral part


6.12.19 Special conditions during loading

6.12.19.1 Frozen beet pile

155

6 Operation

A lightly frozen beet pile may be broken up or loosened using the pile pickup. A tightly

frozen beet pile may never be broken up using the pile pickup. Always use suitable

heavy-duty equipment for this purpose (for instance excavator, wheel loader, etc.).

The telescopic tube of the pile pickup may only be pressed into the pile using its own

force. Additionally driving the vehicle forward invariably leads to destruction of the

telescopic tube.

Remark!.A frozen beet pile may not be loosened by raising the complete pickup. This

may lead to severe damage to the pickup.

When loading lightly frozen beet piles, always place the frost breakers in the infeed

conveyor intake and the lateral pickup parts. When the machine is delivered, the frost

breakers are located in the tool box in front of the fuel tank. The frost breakers help to

break up frozen lumps of beets, and so make sure of largely uninterrupted flow of beets

through the machine.

Without frost breaker Frost breaker lateral part and center

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.12.19.2 Extremely narrob beet pile

Even in case of a very narrow beet pile, for which, from its appearance, half of the

pickup width would be sufficient for loading, the pickup must be completely swung out

and used for loading.

6.12.19.3 Very strongly soiled beets and sticky ground conditions/water spraying

system (option)

Composition and function

The water spraying system serves to moisten the pinch rollers in case of especially

sticky ground conditions.

The water needed for moistening is filled from above into the tank, which is at first

pressureless. The pressure required for moistening is generated by the compressed air

compressor of euro-Maus3.

Switching the water spraying system on and off is comfortably performed from the

driver‘s seat.

Attention!.Injury hazard by dirt particles and water spraying out. Before filling up the

water tank, slowly and carefully open the stopcock to relieve any pressure existing in the

water tank. Do not bend over the filling opening for so long until the pressure has been

completely relieved.

Filling up the water tank

Before filling up, close the ball cock 1

(position OFF).

Before filling up the water tank, slowly open the ball cock (7) on the filler neck to relieve

possibly existing pressure.

Fill up only clean water without pollutants into the vessel.

Close the ball cock (7), when the vessel is filled up.

.

156

7


Position of the four ball cocks in the four operating modes

157

6 Operation

Whenever filling up, check the strainer filter in the filter bowl (6) for dirt and clean the

strainer if needed.

To open the filter, first close the ball cock 2 , then the ball cock 4 . Then, open the ball

cock 3 so that the pressure can escape. Only unscrew the filter bowl, when the ball

cocks are closed. If the strainer filter is damaged, you can obtain a new strainer filter

under the item number 208032.

6

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

Operation

A lit LED indicates that the water valve has been

opened and the system is spraying.

The water spraying system is switched ON and OFF using the key (5) on the operating

section. Move the four ball cocks to the operating mode desired.

Operating mode I OFF Close ball cock 1 for as long as the water spraying

system is not needed.

Operating mode II ON If you need the water spraying system, set the four

ball cocks as required for operating mode II.

Press key (5) for so long, until the color Water spraying system on. The

terminal displays the following icon system constantly sprays, when the

158

machine drive is switched on.

Press key (5) for so long, until the color The water spraying system runs in

terminal displays the following icon automatic mode. When exceeding

a pressure limit preset by the works

for the 4-fold pinch rollers or the

8-fold pinch rollers, the water spraying

system begins to spray. If the pressure

falls below this pressure limit, then

spraying is stopped.

Press key (5) again, until the icon is no Water spraying system switched off.

longer displayed on the color terminal.

5

The water pressure is set as required (max. 5 bar) at the pressure reducer of the water

spraying system.

Pressure reducer for the water spraying system


3

8

Operating mode III Draining water and emptying tank

In case of frost hazard or before longer periods of standstill, we

recommend, to avoid damage to the water spraying system, to

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6 Operation

Attention!.The response pressure for the safety relief valve (8) has been preset fixed to

6 bar by the works. The setting for this safety component may in no case be changed,

since this may lead to severe injuries or damage to materials. When replacing it, only a

corresponding equal spare part may be installed, which must be obtained directly from

the manufacturer of euro-Maus3.

completely drain water from the system in due time. For quicker

emptying of the tank, the engine of euro-Maus3 should be running

(for compressed air supply).

Operating mode IV Blowing out spraying jets and pressure lines

Blowing out of pressure lines and spraying jets is required in case of

frost hazard. The machine drive must be switched on for blowing out the

spraying jets. Set the ball cocks to the positions as for operating mode

IV and switch on the water spraying system using the key (5)

(permenant operation). Leave the system switched on for so long, until

all spraying jets only emit air without water mist. Then, open the water

filter and empty the filter bowl. Screw the filter bowl including strainer

filter to the filter head again.

2

1

Spray jet

Spray jet

Shutoff cocks for the spray jets, if not all are needed

simultaneously::

1 = recleaner;

2 = pickup left;

3 = pickup right;

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.13 Diesel Enginer

A summary of the required maintenance work on the engine is found in Chapter 7, in the

original operating instructions and the original maintenance booklet of Mercedes-Benz.

You will find information about measures to take in case of malfunctions in Chapter 8

„Faults and Remedies“ and in the original operating manual from Mercedes-Benz.

The contents of the fuel tank is displayed on the color terminal in percent. When the

engine has been shut off for at least one minute, then the color terminal displays the

approximate engine oil level in percent of the filling volume. This indication also serves

as a rough orientation. Decisive is always the oil level determined using the oil dipstick.

This indication is not displayed with the engine running, since for technical reasons, oil

level monitoring is not possible with the engine running.

Actual speed

Set speed

Contents fuel tank

160

Constant throttle intervention (orange)

Starter control (green)

Current fuel consumption in l/h

Cooling water temperature

Engine oil level


161

6 Operation

The following warning indications are displayed on the color terminal in case of engine

trouble:

Engine oil pressure too low. IMMEDIATELY SHUT OFF and fill up engine oil.

Engine oil level too low. IMMEDIATELY fill up engine oil.

Coolant temperature too high. Shut off engine, determine and remedy cause

(for instance clean radiator).

Coolant level too low. Shut off engine and immediately fill up coolant.

Severe engine problems!

IMMEDIATELY shut off engine and call in Mercedes-Benz customer service.

Remark! Danger of severe engine damage. When one of the above warning icons

is displayed on the color terminal, immediately shut off the engine and determine the

cause for the warning. The engine may be started again only after the cause has been

removed.

Fault in Mercedes-Benz engine control.

Air filter soiled! Immediately perform maintenance on the air filter!!

Fuel prefilter soiled! Replace filter, since soon loss of engine power

is to be expected.

Fuel fine filter blocked! Replace filter, since soon loss of engine power

is to be expected.

Reserve fuel quantity reached!

The fuel reserve set by you has been reached,

when this warning icon is displayed on the color terminal.

You can set the warning limit for fuel

reserve in the menu „Basic settings“,

line „Fuel reserve warning at (%)“.

Input this figure in percent of the

overall tank content.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.13.1 Modifications respectively amendments of the engine operating manual of

Mercedes-Benz

In case of engines from Mercedes-Benz, which are installed in ROPA machines, the

items listed below must also be considered:

– Currently, only engine model OM 926 LA euroMOT 3a

(Variante 220 kW at 2200 -1/min) are installed. Therefore, only those parts of the

operating manual from Mercedes-Benz referring to this engine model and those

parts generally applying to all engine models apply.

– All engines are supplied without flame starting system, but with constant throttle

brake. Control is performed using the ADM2 control device via the CAN bus. This

control device is located in the switching cabinet of the central electric system.

– The „warning lamp electronics“ mentioned in the operating manual from Mercedes-

Benz and the „stop lamp“ are replaced by warning indications on the color terminal

for ROPA machines. The meaning of these indications is identical to the lamps

described in the operating manual from Mercedes-Benz.

When the STOP indication is displayed on the color terminal, then the engine must

be IMMEDIATELY shut off, because a severe engine fault has occurred, which could

lead to total loss of the engine in case of continued operation.

The control lamp „charging current“ is also replaced by a warning indication on the

color terminal for ROPA machines.

– The diagnostics socket (X-340) for engine electronics is located at the rear side of

the switching cabinet for central electrics on the cabin platform.

– The START button and the STOP button on the engine are defeated by securing of

the hatch on the engine compartment.

– On the engine, instead of the original oil drain screw, there is a specific oil drain

valve. This serves to make work easier for engine oil change.

ROPA machines are fitted with two generators with a power of 100 A each.

– If the engine is to be operated using Biodiesel fuel, then exclusively the following

quality may be used:

FAME (= fatty acid methyl ester) as per DIN EN 14214.

When operating using Biodiesel fuel, immediately before ending the sugar beet

campaign, at least two complete tank fillings of pure, unmixed Diesel fuel must be

consumed. If, during the standstill period, Biodiesel remains in the fuel lines respectively

in the injectors, then this may lead to substantial damage to the whole fueling system

and to the engine.

– Please have confirmation for maintenance work of Mercedes-Benz customer service

made on the enclosed original documentation from Mercedes-Benz.

The operating manual from Mercedes-Benz is absolutely binding and was supplied as

an original with the machine.

162


6.14 Pump Distributor Gears (PVG)

6

If the machine drive is switched on and the oil pressure of the multi-disk clutch

163

6 Operation

The pump distributor gears are directly connected to the Diesel engine and transfers

engine power to the hydraulics pumps. Those hydraulics pumps are switched in, which

are needed for loading, using a multi-disk clutch. This clutch and therefore the machine

is drive is switched on or off by shortly pressing the yellow key (6) on the right joystick.

The pump distributor gears are fitted with pressure circulation lubrication. If lubrication is

insufficient, then a warning signal sounds. The following warning icon is displayed on the

color terminal .

Remark! Hazard of severe damage to the machine. Immediately shut off the engine,

when the warning signal sounds.

is too low, then the the color terminal displays following warning icon (clutch

pressure pump distributor gears). In this case, the machine drive must be switched off

immediately and the cause for low oil pressure must be determined and removed. If

the drive continues to operate inspite of low oil pressure, then the multi-disk clutch is

invariably destroyed.

Multi-disk clutch

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.15 Hydraulics System

Warning!.The hydraulics system is under high pressure. Hot hydraulics fluid may

emit from leaks and cause severe injuries! Work on the pressure reservoirs of the

machine may only be performed by specialist personnel. When working on the pressure

reservoirs, the system must therefore be rendered completely pressureless. The

pressure reservoirs may in no case be damaged or opened, because the constant

preloading pressure may severely injure people. The preloading pressure in the

pressure reservoirs exists even then, due to their design, when the remaining hydraulics

system is already rendered pressureless. During all work on the hydraulics system, the

utmost cleanlyness must be ensured. When dirt – and even if only minute quantities

– enter the hydraulics system, this may lead to severe damage to the overall hydraulics

system.

The hydraulics system is ready for operation after the Diesel engine has been started. To

spare the hydraulics system, the engine speed should not exceed the figure of

1300 min -1 during the first minutes (about 5 min.) after starting the cold engine.

Even shortly higher speeds should be avoided. If your euro-Maus3 is fitted with an

independent heating system, then use it for preheating the hydraulics fluid

(see page 100). In case of environmental temperatures of below +10 °C, at the start of

work, for first starting of the machine drive, proceed as follows:

Before switching on the machine drive, switch off the drives of the recleaner and pickup.

For this purpose, press the keys (9) (8) and (7) on the right joystick one after the other.

These drives are then displayed in white on the color terminal. Switch on the machine

drive by shortly pressing key (6) on the right joystick. The hydraulics system is operating,

the rollers are standing still. Wait for two to three minutes, before you switch on the

drives again, one at a time, one after the other.

7 8 6

9

Hydraulics fluid temperature

The temperature of the hydraulics fluid may be read on the terminal.

After starting the cold engine, the temperature is only correctly displayed on the color

terminal if it is greater than 45 °C.

Only then, the thermal valve in the hydraulics fluid circuit is opened and the hot

hydraulics fluid flows around the temperature sensor in the output of the hydraulics fluid

cooler.

164


165

6 Operation

If the temperature of the hydraulics fluid should be 70 °C or more, then clean the

hydraulics fluid cooler. The color terminal displays the following warning icon .

If the temperature displayed should be lower and still the above warning icon is

displayed on the color terminal, then this may be caused by a fault of the thermal valve.

In this case, please contact the service of ROPA.

If the hydraulics fluid level is too low, then the color terminal displays the following

warning icon .

IMMEDIATELY shut down the engine!

Determine the cause for the lack of fluid and fill up hydraulics fluid, if needed. In case of

a ruptured hydraulics hose, under unfavorable conditions, the system will run dry within

30 sec.

Regularly check the hoses of the hydraulics system! Immediately replace damaged

or aged hoses. Only use original hoses from ROPA or hoses fully complying with the

technical specifications of the original hoses! Comply with the regional safety regulations

on the service life of hydraulics hoses.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

Hydraulics pumps:

Item Function

101 Driving power

102 Working hydraulics + front axle steering

103 Fan drive radiator/charged air/oil coolers

104 Drive pickup rollers

105 Drive 4-fold pinch rollers

106 Drive recleaner

107 Drive for central mark/truck conveyor/infeed conveyor

108 Lubrication PVG + shifting multi-disk clutch

euro-Maus3 has 8 hydraulics circuits serviced by six axial-piston pumps, one tandem

pump and one gear pump. Pump number 108 only serves the clutch and transmission

lubrication. It is not connected to the hydraulics system.

The pumps 101/102/103/108 are always operating when the Diesel engine is running.

The pumps 104/105/106/107 only operate when the Diesel engine is running, the

machine drive is switched on and the flow of power is engaged using the multi-disk

clutch.

166


6.16 Compressed Air System

167

6 Operation

The compressed air system supplies the braking system and the working pneumatics

system with compressed air. The following processes of euro-Maus3 are performed by

the working pneumatics system:

– Switching of operating modes „turtle“/„rabbit“ for the manual transmission.

– Switching between the gears „I“ und „II“.

– Switching off all-wheel drive.

– Switching on differential locks.

– Fixing of the rotating seat.

– Swivelling of the recleaner.

– Swinging of the two rearview mirrors.

– Swinging the warning signs UP/DOWN.

– Swinging of the climbing ladder.

Besides the working pneumatics system, the compressed air compressor also supplies:

– the compressed air tap on the machine.

– the blowing out gun in the driver‘s cabin (from model year 2007).

In any case, make sure that the stopcock (1) of the working pneumatics system is

always open, since otherwise a large share of the working pneumatics system is out of

operation.

Compressed air coupling

In the position shown, the stopcock is

open. Turn by 90° for closing.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

The exact reservoir pressure of the compressed air system may be read on the color

terminal. All shifting processes under pneumatic control may only be performed reliably if

there is enough pressure available in the compressed air system.

If the pressure of the compressed air system is insufficient, then the color terminal

displays the following warning icon .

As long as this icon is displayed on the color termin, the machine may not be moved at

all.

Indication reservoir pressure

Attention! Injury hazard from parts flung away. When working on the compressed

air system, it must be rendered pressureless before starting work. For as long as

the system is under pressure, people may be injured from parts flung away. Work

on the compressed air system may only be performed by people knowing about the

specific hazards and risks when handling pneumatics systems and who have received

corresponding training.

168


6.16.1 Compressor

6.16.2 Air drier

169

6 Operation

The overall pneumatic system of the machine is supplied with compressed air by a

compressor. The compressor is directly connected to the engine. The air is sucked

in by the compressor through the air filter of the engine. If the set maximum pressure

is reached, then the pressure regulator automatically blows off. The compressor is

maintenance-free.

The air drier is located below the right lateral hatch. It separates condensed water,

before the air reaches the compressed air reservoir. The air drier contains a heating

element, which prevents freezing in case of low temperatures. The heating element of

the air drier is automatically switched on, if needed.

6.16.3 Compressed air reservoir

Compressed air coupling on the rear compressed air

reservoir (only for the version without water spraying system)

euro-Maus3 has three compressed air reservoirs. The two large compressed air

reservoirs supply the braking system and the working pneumatics with compressed air.

The small compressed air reservoir serves to regenerate the air drier. Depending on

equipment, a compressed air jack is located either directly at the rear compressed air

reservoir or below the hatch of the water spraying system.

Compressed air coupling of the water spraying system

Air drier

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.17 Central Lubricating System

euro-Maus3 is fitted with a central lubricating system and in the variant with strainer

chain cleaner has two or in the variant with 8-fold pinch roller cleaner has three

lubricating circuits.

One lubricating circuit supplies the pickup, a second the chassis and a third the

optionally present recleaner rollers with lubricating grease.

All lubricating points connected (about 58 respectively 65 pieces) are automatically

supplied with lubricating grease. The lubricating pump supplies the grease to the main

distributors. The main distributors distribute the grease to the subdistributors and from

there, the individual lubricating points are supplied. With every switching on of the

machine drive, the lubricating pump is switched on for the period of time entered by the

operator in the menu „basic settings“. For as long as the lubricating pump is running, a

stirring blade rotates in the grease reservoir, and the color terminal displays the following

icon . When this period of time has expired, the lubricating pump stops.

This period of time is set to 150 seconds by the works. It may be extended by the driver

to up to 300 seconds. When loading up to 20 tons per transporting unit, we recommend

the standard setting of 150 seconds lubricating period (pump operating period). When

loading transporting units of about 28 tons, we recommend a pump operating period of

about 200 seconds, for larger transporting units corresponding longer pump operating

periods.

In any case, make sure that there is always a sufficient supply of grease in the reservoir.

In no case may the grease supply be used up so much that air ingresses the line

system!

170


171

6 Operation

The 2 kg supply reservoir of the grease pump is filled up using the lever on the large

grease bucket. Never completely fill up the 2 kg supply reservoir of the grease pump.

Only fill up the supply reservoir of the grease pump for 90 %. By this, you avoid

blockage of the bleeding pipe on the 2 kg supply reservoir. If the bleeding pipe is filled

up with grease, then the system is no longer able to supply grease to the grease points

anymore.

6.17.1 Filling up the grease gun

Shutoff cock

There is a shutoff cock with a plug-in coupling in the supply hose to the grease pump.

By this, the grease gun from vehicle tools may be filled up directly from the grease

bucket. For this purpose, press the grease gun into the connecting nipple and close the

shutoff cock. When you press the lever on the grease bucket, the grease gun is filled up

with lubricating grease.

6.17.2 Intermediate lubrication

Nipple for filling up the

grease gun

The lubricating system may at any time be manually activated. For this purpose, call

up the menu „special functions“ on the color terminal. In the line „central lubrication“,

change the selection from „Auto“ to „On“.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

After an operating period of 20 minutes, the central lubricating system switches back to

„Auto“ (automatic).

Regularly check the lubricating pipe system. Perform a daily check whether the

lubricating system works without faults. One possibility is controlling the two respectively

three main distributors. An indicator pin is installed there as functional control. This

indicator pin moves slowly, when grease flows through the main distributor. This

indicates whether the pump element of this lubricating circuit works.

Main distributor chassis front

Subdistributor

chassis front

Main distributor pickup

172

Indicator pin

Main distributor recleaner rollers


ïì Ì¿­¬»²º«²µ¬·±²»² 6 Operation

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kóÐóÚ´¿­¸ ­¬»¸¬ ·² ¼»® Þ¿¬½¸¼¿¬»· Ìî ¼»® Þ»º»¸´ ºÅ® бó

6.18 Printer

©»® Ѻ º ø²¿½¸ »·²»® Í»µ«²¼»÷ò Ü¿³·¬ ©·®¼ ¼·»­» Ì¿­¬»

ÚÛÛÜ ñ ÛÒÌÛÎ øï÷

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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

¼»²ò

The keyboard functions differ depending on the status – normal operation or setup

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

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.

´–²¹»® ¿´­ FEED/ENTER(1)

î Í»µ«²¼»² ¹»¼®Å½µ¬ ©·®¼ ó °»®³¿²»²¬ ª±®ó

¹»­½¸±¾»²ò

Í»´¾­¬¬»­¬ This key may be used to wake the printer from sleep

Ü»® Ü®«½µ»® mode ©·®¼ and ¼«® to ½¸ feed ͬ¿®¬»² paper. »·²»­ ß«­¼®«½µ»­ ·³

Í»´¾­¬¬»­¬ ¿«º ­»·²» ·²²»®» Ú«²µ¬·±² ¸·² ¹»°®Åº¬ò Ü¿¦«

©·®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

ª±®­½¸«¾¬¿­¬» currently ¥ÚÛÛÜ£ set font øï÷ ¼·»­» is fed ºÅ® and ³·²¼»­¬»²­ – if it is pressed í for more

Í»µ«²¼»² ¹»¼®Å½µ¬ ¹»¸¿´¬»²ò Ü·» ͽ¸²·¬¬­¬»´´»² ©»®¼»²

than 2 sec. – then feeding is performed constantly.

¼¿¾»· ²·½¸¬ ¹»°®Åº¬ò ͱº¬©¿®»ª»®­·±² «²¼ Æ»·½¸»²­¿¬¦

©»®¼»² ¹»¼®«½µ¬ò ÚÅ® ÑÛÓ µ†²²»² ¾»·³ Í»´¾­¬¬»­¬ ó íò

¿«½¸ ͱ²¼»®¿«­¼®«½µ»

Self-test:

¿µ¬·ª·»®¬ ©»®¼»²ò

The printer is tested for functioning by starting a

printout in self-test. For this purpose, when waking

the printer from power OFF, the feed key {FEED} (1)

is pressed for at least 3 sec.

Ì¿­¬» ÚÛÛ ÜñÛÒÌÛÎ Ì¿­¬» ÑÚÚ ñÒÛÈÌ ßµ¬·±²

¹»¼®Å½µ¬

²·½¸¬ ¹»¼ ®Å½µ¬

п°·»®ª±®­½¸«¾ «³ »·²» Æ»·´ »

Key ¹»¼®Å½µ¬ FEED/ENTER â î­

²·½¸¬ Key ¹»¼ OFF/NEXT ®Å½µ¬

µ±²¬·²«·»®´·½¸»® Activityп°

·»®ª±®­½¸«¾

pressed Ù»¼®Å½µ¬ ¾»· Û·²­ ½¸¿´¬»² ä ï­ not ²·½¸¬ pressed ¹»¼ ®Å½µ¬

Paper ß«º©»½µ»²ô feed by one µ»·² line п° ·»®ª±®­½¸«¾

pressed ¹»¼®Å½µ¬ > 2 s ¾»· Û·²­½¸¿´¬»² not ²·½¸¬ pressed ¹»¼ ®Å½µ¬

Continuous Ìð ¿«º®«º»² paper øÍ» ´¾­¬¬»­¬÷ feed

Gedrückt п°·»® bei »·²¹ Einschalten »´»¹¬ â î­ < 1 s not pressed Wake up, no paper feed

pressed ¹»¼®Å½µ¬ on power ¾»· Û·²­½¸¿´¬»² on

±¸²» п° ·»® â î­

paper inserted > 2 s

¹»¼®Å½µ¬ ·³ Ø»¨ ¼«²°óÓ±¼»

not ²·½¸¬ pressed ¹»¼ ®Å½µ¬

²·½¸¬ ¹»¼ ®Å½µ¬

Call up ß«º®«º TO Ø»¨ (self-test) ¼«³°óÓ±¼»

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pressed ±¸²» on п° power ·»® on

not pressed Call up hexdump mode

without ²·½¸¬ paper ¹»¼ ®Å½µ¬ > 2 s

Ì¿­¬» ´±­´ ¿­­»² ²¿½ ¸ ä ï­ ·³ Ò±®ó Ìï ¿«º®«º»²

pressed in hexdunp mode

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not pressed

øã ¼»º¿ «´¬ Ú±® ³º»»¼ ï Ô·²· »÷

End hexdump mode

²·½¸¬ ¹»¼ ®Å½µ¬

without paper

Ì¿­¬» â í­ ¹»¼ ®Å½µ¬

Ìî ¿«º®«º»² ø¼»º ¿«´¬ ã ß«­­½¸¿´¬»² ²¿½ ¸ »·ó

²»® Í»µ «²¼»÷

not pressed ¹»¼®Å½µ¬

Release ¹»¼®Å½µ¬ key after < 1 s Call up Û·²­¬»´´³»²Å T1 ¿«º ®«º»²

in normal paper mode (= default form feed 1 line)

not pressed Key pressed > 3 s Call up T2 (default = shutdown

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

173

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after one second)

pressed pressed Call up setup menu

ïò

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Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

è Þ »¼·»²«²¹ «² ¼ É¿®¬«²¹

èòï É»´½¸»­ ̸»®³±°¿°·»® ·­¬ ¹»»·¹²»¬á

6.18.2 Which thermally-sensitive paper is suitable

The printer is designed for a paper width of 57.5 ± 0.5 mm,

at 60 g/m 2 . ROPA offers the suitable paper roll as standard

equipment ¹»»·¹²»¬»² (ROPA ̸»®³±°¿°·»®­ item no. 206068). ¹»® ²» ¾»¸·´º´·½¸ò Other paper may cause

malfunctions. Thermally-sensitive paper is available for

specific tasks, which is water, grease and alcohol-resistant.

We will gladly assist you in the selection of suitable

thermally-sensitive paper.

Which side ͬ¿²¼¿®¼æ of the ÙÐÎóÌðïóðëéóðíïóððéóð thermally-sensitive êðß paper can be printed

on? On the paper roll, almost always the outside is the

printable side. If you should still have doubts, make the

finger nail test: quickly run over the paper with the tip of a

finger nail, exerting pressure. The thermally-sensitive side is

blackened ¾»¼®«½µ»²ò due to the frictional heat.

Þ»¼·»²«²¹ «² ¼ É¿®¬«²¹

Ü»® Ü®«½µ»® ·­¬ ºÅ® »·²» п°·»®¾® »·¬» ª±² ëéôë o ðòë ³³ô ³·¬ êð ¹ñ³îô ­°»ó

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íò Ô»¹»² Í·» ¼·» п°·»®®±´´» ­± ·² ¼·» п°·»®ª±®®¿¬­³«´¼»ô ¼¿­­ ¼·» ß«­ó

­»²­»·¬» ¦«³ Ü®«½µ©»®µ ¦»·¹¬ò Ò«® ¼·»­» ß«y»²­»·¬» ´–­­¬ ­·½¸ ·³ Ü®«½µ»®

ìò ͽ¸´·»y»² Í·» ¼»² Ü»½µ»´ ³·¬ »·²»³ µ®–º¬·¹»² Ü®«½µò Û® ­½¸²¿°°¬ ¼¿²²

¸†®¾¿® »·²ô ­± ¼¿­­ Í·» »¬¦¬ ¼¿­ п°·»® ¿² ¼»® ß¾®»·yµ¿²¬» ¿¾®»·­­»² µ†²ó

²»²ô ±¸²» ¼¿­­ ­·½¸ ¼»® Ü»½µ»´ ©·»¼»® †º º²»¬ «²¼ ±¸²» ¼¿­ п°·»® ¼«® ½¸

How is the ¼»² paper Ü®«½µµ±°º inserted? ®«¬­½¸¬ò

1. Unwind about 10 cm of paper from the roll. Keep the

paper wound tight.

2. Open the cover of the printer by lightly pressing the ìò

LEVER in the lid upward. The platen is levered out of the

printing mechanism together with the lid. The lid may now

be easily èòî É¿®¬«²¹ô opened. λ·²·¹«²¹

Ò¿½¸ ¹®†y»® »² Ü®«½µ´»·­¬«²¹»²ô ¿¾¸–²¹·¹ ª±² ¼»® п°·»® ¯«¿´·¬–¬ «²¼

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

µ±°ºô Í»²­±® «²¼ ¼·» ß²¬®·»¾­©¿´¦» ¦« ®»·²·¹»²ô ·²­¾»­±²¼»® » ¼¿²² ©»²²

manner, ͬ»´´»² that ²·½¸ the ³»¸® outside ±®¼»²¬´·½¸ shows ¹»¼®«½µ¬ in ©»® direction ¼»²ò of the printing

{ п°·»®ª±®®¿¬­óÜ»½µ»´ †º º²»² «²¼ п°·»®® ±´´» »²¬º»® ²»²ò

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.

ß¾® »·­­µ¿²¬» ´†­»²ò

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

º»® ²»²ò

off paper { É¿¬¬»­¬–¾½¸»² at the cutting ³·¬ ×­±°® edge, ±°¿²±´ ß´µ±¸±´ the lid ø×Ðß÷ opens again and slides through the printing

¬®–²µ»² «²¼ ¼·» Ü®«½µ´»·­¬» ® »·²·¹»² ±¼»® Ü®«½µµ±°ºóλ·²·¹«²¹­­¬·º ¬ ñ

head without the paper.

λ·²·¹«²¹­µ¿®¬» ª»®©»²¼»²ò

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174

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6.19 Video Monitoring

175

6 Operation

euro-Maus3 is fitted with a video camera as standard equipment. This camera is

located at the front, below the central mark, and serves to determine the correct working

depth. When loading, always switch on lighting for the camera in the central mark using

switch (8) in the radio console.

Optionally, euro-Maus3 may be fitted with a further video camera on the truck conveyor

to monitor the loading process.

Switching between the two cameras is performed manually using the switch (19) in the

radio console.

This can be used to switch between the cameras at any time.

The cameras are maintenance-free. When the image quality deteriorates, you should

clean the lens cover of the camera using a soft, clean and slightly moist cloth. When

cleaning, make sure that the lens cover is not scratched.

6.20 Electrics

6.20.1 Sockets

Socket 24 V

19

To connect external loads, the machine is fitted with two further 24 V sockets for

automobile plugs small on the outside.

Socket 24 V

One socket is located in the engine compartment on the engine frame. The second

socket is located at the rear right in front of the tank above the stopcock for the fuel line.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.20.2 Main battery switch

The electrical system (with the exception of the timer for the independent heating

system) may be completely separated from the batteries using the main battery switch.

The main battery switch is located in the cover between the climbing ladder and the

battery box.

Main battery switch

Remark! To avoid damage to the vehicle electrics or vehicle electronics, the main

battery switch may NEVER be switched off with the engine running or the ignition

switched on.

If the timer for the independent heating system should also be separated from power

supply, then the sliding switch S86 next to the fuse F03 in the switch box of central

electrics must be pulled.

S 86

176


6.20.3 Voltage monitoring

177

6 Operation

The battery voltage is monitored by the system. In case of too high or too low voltage,

the color terminal displays the following warning icon .

The battery voltage may not exceed 30 V and may not fall below 23 V. In case of a

battery voltage of below 23 V, experience has shown that the machine cannot be started

anymore.

6.20.4 Fuses

Indication battery voltage

When a generator fails, the color terminal displays the following icon for generator 1

(upper generator) and for generator 2 (lower generator).

Most fuses are located in the switching cabinet of the central electric system.

Further fuses are located at the radio console and in the seat console. The main fuses

are located in the battery box. Details on this are found in the Chapter Faults and

Remedies from page 251.

In case of problems with the electric or electronic system, please contact service of

ROPA.

Chapter.6.

Operation


6 Operation

Chapter.6.

Operation

6.21 Tire Pressures

Regularly check it using the tire pressure meter supplied during the campaign!

Tire model independent

of the manufacturer min. Recommendation max.

1 Front axle

710/75R34 TL 178A8

2 Rear axle

710/75R34 TL 178A8

3 Additional axle (option)

235/75R17.5 TL143J

1

178

3

2

2.2 2.2 3.2

2.2 2.2 3.2

– 7.5 –


6.22 Immobilizing up to One Week

Park euro-Maus3 so that nobody is impaired or endangered. Also make sure of

sufficient safety distance to power lines routed above ground.

– Engage the parking brake.

– Raise the pickup all the way up.

– Switch off the engine.

– Fasten the safety chains to the central part of the pickup.

– Switch off all electrical loads.

– Pull off the ignition key.

– Leave the machine and lock the driver‘s cabin.

179

6 Operation

Remark!.Due to lowering pressure in the hydraulics system, the pickup may come down

during langer standstill periods and severely damage the driver‘s cabin. Therefore, when

parking the machine, always fasten the safety chains on the left and right of the central

pickup part.

– Do NOT switch off the main battery switch, so that the independent heating system

remains operations.

– Secure the machine against rolling away using the chocks.

Remark! In case of need, consider an additional child safety catch.

Chapter.6.

Operation


181

7 Maintenance and Service

Kapitel 7

Maintenance and Service

Chapter.7.

Maintenance and Service


7 Maintenance and Service

183

7 Maintenance and Service

Warning! There is the hazard of severe or severest injuries and the hazard of damage

to the machine during all maintenance work. Never climb over the rear wall of the

platform.

7.1 Engine

During all maintenance work, make sure that nobody is able to inadvertently start up

the machine (pull off the ignition key, lock the driver‘s cabin, always carry the ignition

key on your body and to the extent possible, switch off the main battery switch, pull it off

and also carry it on your body). Only perform maintenance work you have been trained

for and for which you have the required knowledge and tools. During all maintenance

work, strictly comply with all regionally applicable regulations on safety for protection of

health and the environment. Never forget: when you do not comply with the applicable

regulations on safety, protection of health or the environment, you endanger yourself,

other people and the environment. In addition, you may lose insurance coverage. Always

use approved and safe ladders and climbing aids.

Perform a daily check, with the machine standing on level ground and cold engine not

running, of the engine oil level using the oil dipstick. You engine contains sufficient oil if

the oil level is in the middle between the minimum and maximum mark. In case of need,

fill up with a corresponding quantity of approved engine oil. Always make sure that you

do not fill up too much oil.

Below, you will find excerpts of a maintenance manual of Mercedes-Benz. To wholly

preserve guarantee and warranty claims concerning Mercedes-Benz, the operator of

the engine must ensure, that the maintenance work prescribed by Mercedes-Benz

are performed in due time and completely by people expressly authorized for this by

Mercedes-Benz. These people are obliged to confirm correct and timely performance of

maintenance work on the original maintenance slips.

Chapter.7.

Maintenance and Service


7 Maintenance and Service

Chapter.7.

Maintenance and Service

7.1.1 Dry Air Filter

The engine is fitted with a dry air filter, consisting of the main filter element and the

safety cartridge.

The main element must be replaced:

– Once annually (urgently recommended).

– When the icon is displayed on the terminal.

– When the cartridge shows signs of damage.

The safety cartridge is accessible after uninstalling the main element. It protects

engine from dirt during maintenance of the main element or when the main element is

damaged. The safety cartridge cannot be cleaned. It must be replaced if needed, but at

the latest every two years.

Remark!.Danger of damage to the engine. When replacing filters, always ensure

the utmost cleanliness. Furthermore, the engine may never be operated without filter

elements.

The dry air filter is located above the hydraulics fluid tank and is accessible from the

climbing platform. When uninstalling and installing, make sure of the utmost cleanliness

and correct fit of the cartridge. A damaged air filter cartridge must be immediately

replaced by a new, undamaged filter cartridge.

The filter cartridge may only be uninstalled when the engine is standing still.

The safest, quickest and cleanest method of performing maintenance on a filter cartridge

is to replace it with a new cartridge.

The main element may, as described below, be cleaned. Since slight damage is only

difficult or even impossible to detect, we recommend to always use a new filter cartridge

to protect the engine. We do not assume warranty for cleaned elements and the

consequences caused by them.

184


45 XXX XX XXX

ent warten

ng des Hauptelements nur bei

rechen des Wartungsigers/-schalters

bzw. nach

tung des Geräte- oder

renherstellers durchführen.

ment ausbauen

verschlüsse entriegeln und

rteil abnehmen (siehe Bild 3).

äuseunterteil abnehmen

nt unter leichten Drehbewetändig

vom inneren Stützrohr

n (siehe Bild 4).

185

7 Maintenance and Service

- Zur Reinigung Bild ein 4: Rohr Hauptelement auf eine Druckluft- entnehmen Bild 5: Hauptelement reinigen

pistole – aufsetzen, Carefully and dessen diligently Ende clean um ca. the 90° inside of the housing, especially at the sealing

gebogen surface ist. Das for Rohr the filter muss cartridge. so lang Diligently sein, ensure that no dirt can reach the clean air

dass es side bis zum of the Boden filter. des Hauptelementes

reicht. Hauptelement mit trockener

– Never rinse or brush out the main element. When blowing it out, strictly make sure

Druckluft (maximal 5 bar) vorsichtig durch

Auf- und that Abbewegen no dust reaches des Rohres the inside im Haupt- of the main element.

element – Blow so lange out using von a innen compressed-air nach außen gun. Install a pipe on this gun, which is angled by

ausblasen, bis keine Staubentwicklung

90° at the lower end (see illustration).

mehr auftritt (siehe Bild 5).

MANN+HUMMEL Industriefilter 7

uptelement entnehmen Bild 5: Hauptelement reinigen

– This pipe is not commercially available, but it may be made by yourself without any

problem. It should be so long that it reaches the cartridge bottom.

oft sehr schwer oder gar nicht

erkennbar sind, empfehlen wir zum

Schutz der Motoren oder Geräte

stets neue Elemente zu verwenden.

Für gereinigte Elemente können wir

keine Gewährleistung übernehmen.

- Zur Reinigung ein Rohr auf eine Druckluftpistole

aufsetzen, dessen Ende um ca. 90°

gebogen ist. Das Rohr muss so lang sein,

Gehäuseinnenseite mit einem

dass es bis zum Boden des Hauptelemen-

feuchten Tuch sorgfältig auswites

reicht. Hauptelement mit trockener

schen. Dabei darauf achten, dass

Druckluft (maximal 5 bar) vorsichtig durch

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-

applicable Reinluftseite regulations des Filters for protection gelangt. of the environment: element so lange von innen nach außen

Bild 3: Gehäuseunterteil abnehmen

ausblasen, bis keine Staubentwicklung

– Open the filter housing.

mehr auftritt (siehe Bild 5).

5.2.2 Hauptelement – Carefully pull reinigen the main element from the bracket, slightly turning it, and place it so

Hauptelement

- Hauptelement unter leichten Drehbewe-

that gungen it cannot vollständig be damaged. keinesfalls aus-

vom inneren Stützrohr

waschen oder ausbürsten.Beim

herunterziehen (siehe Bild 4).

Ausblasen darf kein Staub auf die

Innenseite des Hauptelementes

gelangen.

Das Hauptelement kann wie nachfolgend

beschrieben gereinigt

werden. Da kleine Beschädigungen

oft sehr schwer oder gar nicht

erkennbar sind, empfehlen wir zum

Schutz der Motoren oder Geräte

stets neue Elemente zu verwenden.

Für gereinigte Elemente können wir

keine Gewährleistung übernehmen.

dustriefilter 7

– Set the pressure reducer to at max. 5 Bar and blow out the filter cartridge using

dry compressed air for so long until no dust develops anymore. When blowing out,

constantly move the compressed-air gun up and down and constantly turn the filter

Chapter.7.

Maintenance and Service


Europiclon Baureihe 45 XXX XX XXX

Vor dem Wiedereinbau muss das

gereinigte Hauptelement sorgfältig

7 Maintenance and Service auf Beschädigungen am Papierbalg

und an den Gummidichtungen

geprüft werden.

n Baureihe 45 XXX XX XXX

bau

r in die Halterung einsetzen und in die

ünschte Einbaulage drehen/verschiedarauf

achten, dass der Filter in der

rung einrastet (siehe Bild 1).

nnfeder zuklappen und auf der

chlussseite einrasten.

Die Spannfeder muss sich ohne

Werkzeug mit der Hand einrasten

lassen. Andernfalls nochmals Lage

des Filters kontrollieren.

Zum Öffnen der Spannfeder einen

Schraubendreher auf der Verschlussseite

zwischen Spannfeder

und Halter einstecken und Spannfeder

aushebeln (siehe Bild 2).

Bei Ausführung mit Staubaustragsventil

und waagrechter

MANN+HUMMEL Industriefilter

Einbaulage

Chapter.7.

muss das Staubaustragsventil

Maintenance nach and unten Servicezeigen

(± 15° Abweichung der „OBEN/

TOP“-Markierung ist zulässig, siehe

Bild 1); ggf. Gehäuseunterteil

Jede Falte des Papierbalges mit

Hilfe einer geeigneten Stablampe

auf Risse und Löcher untersuchen

(siehe Bild 6). Damit auch kleinere

Beschädigungen erkennbar sind,

sollte die Untersuchung nicht bei

direkter Sonneneinstrahlung,

sondern z.B. in einem abgedunkelten

Raum durchgeführt werden.

Bild 6: Hauptelement kontrollieren

Examine each fold individually and carefully using a suitable flashlight. Damaged filter

cartridges may not be reused in any case. Use the secondary element only independent

Unabhängig von der Einsatzdauer,

müssen Hauptelemente spätestens

nach 2 Jahren ausgewechselt werden.

Beschädigte Hauptelemente

auf keinen Fall weiterverwenden. Im

Zweifelsfall immer ein neues Hauptelement

einbauen.

of the term of use, original MANN + Hummel filter cartridges (main element ROPA item

no. 301225; safety cartridge ROPA item no. 3012226). In no case install filter elements

with metal sheathing.

– Slide the main element with the open side into the housing.Install lid and observe the

position of the just ejection valve (see illustration). The dust ejection valve must point

downward (±15° deviation of the „OBEN/TOP“ mark is allowable); if needed, take off

the lower part of the housing and reinstall after turning it.

5.2.3 Hauptelement einbauen

– - Reclose the wire snap-fastener.

Nur Original MANN+HUMMEL

Elemente verwenden! Auf keinen

Fall Elemente mit Metallaußenmantel

einbauen!

- Hauptelement mit der offenen Seite zuerst

vorsichtig in das Gehäuseoberteil einschieben.

- Bei Vakuumausführung Dichtung zwischen

Gehäuseober- und Gehäuseunterteil auf

Beschädigungen kontrollieren, ggfs.

austauschen.

186

- Gehäuseunterteil aufsetzen (La

Staubaustragventils beachten, sie

Abschnitt 4).

- Drahtspannverschlüsse in die Nut d

sches am Gehäuseoberteil ansetz

spannen (sinngemäß umgekehrt B

– Then, check the cartridge for damage to the paper bellows and to the rubber seals.

5.3. Sekundärelement wechseln

In case of damage (cracks, buckling, dents, etc.), a new cartridge must be used.

Cracks or holes in the paper bellows may be very easily detected by testing using

a hand lamp (see illustration). So that smaller damage becomes visible as well, this

examination should not be performed in direct sunlight or bright daylight, but in a

darkened room, if available.

Bild 1: Filter einsetzen

Das Sekundärelement ist b

5. Wartung des Haupteleme

nach spätestens 2 Jahren z

seln.

5.3.1 Hauptelement ausbauen

(siehe Abschnitt 5.2.1)

5.3.2 Sekundärelement wechseln

Das Sekundärelement da

gereinigt und nach Ausba

wiederverwendet werden.

Je nach Ausführung Sekundärelem

folgt ausbauen:

Ausführung A:

Siegel (Schwimmhaut) des Sek

elements mit einem geeigneten W

(z. B. Schraubendreher) von inne

außen durchstoßen und die

Laschen hochziehen (siehe Bild 7)

(Schwimmhaut) nur öffnen, u

Sekundärelement auszuwechsel

Bild 7: Siegel öffnen (Ausführung


Replacing the safety cartridge

Storing of filter cartridges

187

7 Maintenance and Service

The safety cartridge must be exchanged at every fifth maintenance of the main element

or at the latest after two years for a new safety cartridge. The safety cartridge may not

be cleaned or reused after deinstallation.

– Uninstall main element as just described.

– Grip the safety cartridge at the recessed grip and pull it out.

– Slide in the new safety cartridge.

Filter elements must be stored standing upright, protected from dust and moisture in

original packaging, so that they cannot be damaged. We recommend having at least one

replacement filter element in stock for each filter element being used.

Dust ejection valve

Dust ejection valves are largely maintenance-free. Possible dust deposits are easily

removed by compressing the rubber valve several times. The valve must be installed

so that it is always unobstructed and does not abut anywhere. A damaged dust ejection

valve must be exchanged immediately.

Chapter.7.

Maintenance and Service


7 Maintenance and Service

Chapter.7.

Maintenance and Service

7.1.2 Oil change for the engine

Remark! VExclusively use approvel high-performance engine oils complying with the

DaimlerChrysler works standard 228.5.

hen using bio Diesel (FAME), the oil change intervals must be reduced from 400 hours to

150 hours.

The first oil change for the engine is required after 400 operating hours – when using

FAME (RME bio Diesel), after 150 operating hours. Further oil changes are required

after every 400 operating hours – when using FAME (RME bio Diesel), after every

150 operating hours. The engine oil filter must be replaced at each oil change.

The oil change should only be performed with the engine at operating temperature.

Before performing the oil change, park the machine on level ground and secure it

against rolling away.

Attention! Scalding hazard! When changing the engine oil, do not touch hot

components of the engine. Wear suitable and closely fitting protective clothing.

To drain the old oil, place a catch pan of sufficient size, oil-resistant and temperature-

resistant underneath. Screw off the closure cap of the oil drain valve.

Oil filler neck Oil dipstick

Oil drain valve engine

188

Engine oil filter


189

7 Maintenance and Service

The valve opens when you have screwed the oil drain hose supplied onto the valve.

When the old oil has completely drained, reclose the oil drain valve by unscrewing the oil

drain hose from the valve.

Replacing the oil filter inser

– Unscrew oil filter lid using ratchet and hexagonal box wrench insert SW36.

– When the oil has drained from the oil filter bowl, pull out the oil filter lid including the

oil filter insert.

– Release the oil filter insert by lateral pressure on the lower edge and dispose of

compatible with the environment.

– Replace the sealing ring on the screw-on lid. Wet the new sealing ring with engine oil

before inserting it.

– Insert the new oil filter insert in the oil filter lid and fit it into the lid by pressing it

laterally.

– Place the oil filter lid including oil filter insert onto the oil filter bowl and screw tight

(tightening torque 25 Nm).

Filling up engine oil

– Fill up fresh engine oil through the oil filler neck.

Filling volume about 23-28 Liter (Min-Max mark).

– Switch on the ignition from the driver‘s seat and call up the submenu „special

functions“ from the main menu of the color terminal. Here, in the line „engine oil

change Start/Stop active“ select the option „yes“.

Chapter.7.

Maintenance and Service


7 Maintenance and Service

Chapter.7.

Maintenance and Service

190

Start button

Stop button

Climb onto the open lid of the battery box and reach across the engine. Simultaneously

press the START and the STOP button on the engine for about 10 seconds. During

this time, the engine is turned over without load and without starting. Close the engine

housing. When the ignition is switched off or the engine is started, the setting „oil change

START/STOP active“ is automatically reset. Then, start the engine from the driver‘s seat

and let it idle for about one minute. Then, switch off the engine.

About 5 minutes, after the engine has been shut off, check the oil level using the oil

dipstick. When the oil has collected in the oil pan, the oil level should have levelled off in

the middle between the min. and max. mark on the oil dipstick. Do not fill up too much

engine oil.

Check engine and oil filter for leaks (visual inspection).

7.1.3 Fuel Supply

Remark!.Danger of damage to the environment due to leaking fuel. When working on

the filter, first place a catching pan underneath and properly dispose of caught fuel.

Attention! Fire hazard when handling Diesel fuel. Smoking, fire and open flames are

prohibited when handling Diesel fuel, since fuels and fuel fumes are easily combustible

and explosive. Always make sure of sufficient supply of fresh air when handling fuels.

Danger of skin injuries and poisoning hazard. Diesel fuel may cause damage to the skin

in case of direct contact. When handling Diesel fuel, always wear suitable protective

gloves, avoid inhaling fuel fumes, since this may lead to symptoms of poisoning.


Shutoff cock

Standard prefilter

Separ filter: is only installed in machines for CIS states

191

7 Maintenance and Service

The Diesel fuel is drawn in by the fuel pump through a rough prefilter (Separ filter is

only installed in machines for CIS states) and a standard prefilter (with integrated water

separator and manual pump) and fed to the fine fuel filter at the engine. The Separ filter

is fitted with an extra large water separator.

The filter cartridges must be cleaned respectively exchanged as per maintenance plan.

The fine fuel filter at the engine must be immediately replaced, independent of the

service life, when the following icon is displayed on the color terminal.

On the other hand, if the following icon is displayed on the color terminal, then the

Separ filter must be cleaned respectively the filter cartridge of the standard prefilter must

be replaced.

Before all work on the fuel system respectively on teh fuel filters, the tank lid must

be shortly opened and immediately closed again. This serves to reduce any possibly

existing pressure in the fuel system. Only use original fuel filters approved by

Mercedes-Benz respectively ROPA.

After all work on the fuel prefilters, bleed these using the manual pump at the standard

prefilter.

Separ filter

Chapter.7.

Maintenance and Service


7 Maintenance and Service

Chapter.7.

Maintenance and Service

7.1.3.1 Fuel Prefilter Separ

Maintenance Separ filter (drain water and flush)

Draining of the water collected is required when the water collection vessel is full,

freezing threatens or the exchange filter is replaced. For this purpose:

– Shut off the engine.

– Close the shutoff cock at the input of the filter.

– Open the bleeding screw on top of the filter.

– Open the drain cock at the bottom of the filter.

– Let the water and dirt drain from the transparent bowl and properly dispose of it. The

filter strainer is flushed and cleaned by draining of the water.

– Close the drain cock.

– Close the bleeding screw.

– Open the shutoff cock.

– Start the engine. The air in the filter is moved off into the tank.

Shutoff cock

Lid

Drain cock for

water

192

Bleeding screw

Cap screw


Cleaning the filter insert

193

7 Maintenance and Service

Cleaning of the filter insert (metal strainer with 60 Mikron filter mesh; ROPA item no.

301231) in the Separ filter is required once annually or when the intake resistance is too

high. The following icon is displayed on the color terminal .

Clean the filter insert as follows:

– Shut off the engine.

– Close the shutoff cock to the filter.

– Unscrew the lid screws (4 pieces).

– Take off the lid.

– Take off the spring housing and then take out the filter insert.

– Clean the filter insert using clean Diesel fuel. Do not use any other cleaning agents,

since otherwise damage to the filter may occur.

– Insert the cleaned filter insert and clip the spring housing onto the filter insert.

– Check the lid gasket and replace it if needed.

– Fill up the filter as far as possible using clean Diesel fuel (shorter bleeding time).

– Put on the lid and make sure of correct fit.

– Retighten the lid screws.

– Open the shutoff cock.

– Start the engine.

Chapter.7.

Maintenance and Service


7 Maintenance and Service

Chapter.7.

Maintenance and Service

7.1.3.2 Replace Standard Prefilter Element/Drain Water

Exchange of the filter insert is required annually or when the intake resistance is too high

(the following icon is displayed on the color terminal ) and the engine shows loss of

power.

Manual feed pump

(diaphragm pump)

Replace the filter cartridge as follows:

– Shut off the engine.

– Close the shutoff cock before the fuel prefilter.

– Uninstall the old filter cartridge. The old filter cartridge may stick to the filter head.

– Loosen the old filter cartridge using suitable tools.

– Unscrew the water collection vessel.

– Dispose of the old filter cartridge in compliance with the local disposal regulations.

– Oil the gasket.

– Screw on the filter by hand, until the gasket is touching.

– Keep turning by hand, until the filter has tight fit (about 3/4 revolution).

– Open the shutoff cock before the fuel prefilter.

– Bleed for so long using the manual pump, until no air bubbles are visible any more.

– Check the filter unit for leaks (visual inspection).

194

Standard prefilter with diaphragm

pump until model year 2007

Standard prefilter with piston pump from model year 2008


Draining water from the water collecting vessel

195

7 Maintenance and Service

Draining of water collected is required when the water collecting vessel is full, freezing

threatens or the exchange filter is replaced.

– Open drain screw (2) at the bottom

of the water collecting vessel (1).

– Let the water drain.

– Retighten the drain screw.

Bleed prefilter using the manual pump

Bleeding of the filter is necessary when work has been performed on the fuel system

near the prefilter or the fuel tank has been run completely dry.

– Switch off the engine.

Only applies to prefilters with diaphragm pump:

– Pump for so long until a noticeable counterpressure can be felt.

– Immediately start the engine.

Only applies to prefilters with piston pump:

– Unlock the bayonet cap of the piston pump on the fuel prefilter.

– The pump piston is pushed outward by the spiral spring. Fuel supply from the tank is

interrupted then.

– Pump using the piston pump. For this purpose, push the piston into the filter head

up to at maximum 15 mm before reaching the suspension point. In this manner, you

achieve the best pumping performance.

– Pump for so long until a noticeable counterpressure is felt (maybe up to

200 strokes).

– To start the engine, completely press the pump piston into the filter head and let the

bayonet engage by about one quarter of a revolution to the right.

– Immediately start the engine.

opening

closing

Chapter.7.

Maintenance and Service


7 Maintenance and Service

Chapter.7.

Maintenance and Service

7.1.3.3 Microorganisms in the fuel system

Occasionally, at first inexplicable obstructions in the fuel system filled with Diesel or bio

Diesel fuels will be found. These obstructions are often caused by microorganisms.

These microorganisms (bacteria, mushrooms, yeast) may multiply very much under

favorable conditions: needed for growth are water, which is found in every storage or

vehicle (fuel) tank as condensing water, and vital elements in chemically bound form,

like sulfur, phosphor, nitrogen, oxygen and trace elements. Fuel additives may also

contribute to microorganism growth.

Depending on the temperature, growth is stronger or less strong, which leads to the

formation of fiberous mushroom meshes and sludge.

The consequences: obstruction of the fuel prefilter by rust and fibers (mushroom mesh)

and frequent filter exchange. This leads a loss of power of the engine and in extreme

cases to breakdown of the vehicle.

Remedial measures

If infestation with microorganisms is found for storage or vehicle (fuel) tanks, then we

recommend the following disinfecting agents to fight it:

Product: GrotaMar 71 or:.

Manufacture: Schülke & Mayr

D-22840 Norderstedt

0 40 / 5 21 00 - 0

Fax: 0 40 / 5 21 00 - 244

In case of need, please contact the manufacturers

(for instance to enquire about sources abroad).

196

Product: BAKZID

Manufacture: Bode Chemie Hamburg

Melanchthonstr. 27

D-22525 Hamburg

0 40 / 5 40 06 - 0

Fax: 0 40 / 5 40 06 - 200


7.1.3.4 Fuel fine filter at the engine

1

197

7 Maintenance and Service

The fuel fine filter at the engine must be replaced after the first 400 operating hours,

thereafter at least annually.

When the warning icon is displayed on the color terminal, the fuel fine filter must

also be replaced.

To exchange the fuel fine filter, proceed as follows:

– Park vehicle and shut off engine.

– Close the shutoff cock before the fuel prefilter.

– Place a vessel of sufficient size and being fuel-resistant under the filter bowl to

catch emitting fuel.

– Swing the tommy bar of the 3-way cock (1) upward (this blocks fuel supply and

the content of the filter bowl can drain into the vessel placed underneath).

– Unscrew the screw-on lid (2) of the fuel fine filter using a ratchet and a box

wrench insert (SW 36).

– Slightly pull the screw-on lid (2) including the filter cartridge from the filter housing

and let the fuel drain.

– Take off the screw-on lid including filter insert.

– Remove the filter insert by lateral pressure on the lower edge.

In any case, make sure that no foreign objects ingress the filter housing. Do not wipe the

inside of the filter housing. Avoid any ingress of water into the filter housing.

– Replace the gasket for the fuel fine filter (slightly grease it).

– Clip the new filter insert into the screw-on lid (2).

– Screw on the screw-on lid (2) including filter insert on the filter bowl and tighten

using a tightening torque of 25 Nm.

2

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7 Maintenance and Service

Chapter.7.

Maintenance and Service

– Swing the tommy bar of the 3-way cock (1) to the front (this reopens fuel supply and

drain of the filter bowl is closed.

– Open the shutoff cock before the fuel prefilter).

– Bleed the fuel system by activating the manual pump at the fuel prefilter.

There must be sufficient battery capacity available during the starting process for

bleeding of the fuel line at the engine.

Let the engine run for about 1 minute, so that the fuel system can be bled. Then:

– Check the fuel filter for leaks (visual inspection).

7.1.3.5 Other maintenace work on the Diesel engine

During each maintenance service on the Diesel engine, the following work must be

carefully additionally performed in compliance with the Mercedes-Benz maintenance

regulations (see maintenance booklet for the engine):

– Leak and condition examination of all pipes and hoses of the engine.

– Checking the intake lines between the air filter and engine, and the lines for the

cooling and heating system for condition and leaks.

– Checking all lines and hoses for undamaged condition as well as chafe-free and

proper routing and fastening.

– Checking all hose clamping collars, flanged connections and air intake manifolds for

tight fit.

Checking respectively adjusting of valve clearance is required after the first 400

operating hours and then once annually respectively every 1200 operating hours. This

work may only be performed by people expressly authorized for this work by

Mercedes-Benz. The work process is described in the Mercedes-Benz maintenance

instructions.

Valve-clearance for cold engine:

– Inlet valves 0.40 mm

– Outlet valves 0.60 mm

198


7.1.4 Radiator System

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7 Maintenance and Service

The radiator system must be regularly checked for cleanliness and cleaned if needed.

If the admissible maximum temperature of the coolant or the hydraulics fluid is

repeatedly exceeded during very high environmental temperature, then the complete

cooling system must be checked for cleanliness and, in case of need, be immediately

cleaned.

7.1.4.1 Reversing fan drive

Always make sure that the air intake grids are free of dirt or adherent leaves, etc.

To clean the intake grid of loose pollutants, the fan drive for the radiator system is

automatically reversed at each start of the engine. The fan largely blows the intake grid

free.

If automatic reversing should not be sufficient to keep the intake grid free, then the fan

drive may be manually reversed during operation.

For this purpose, press seitch (2). You achieve the best cleaning effect if you increase

the engine speed to maximum speed during reversed fan drive.

7.1.4.2 Cleaning the radiator system

2

The radiator system is located above the Diesel engine. After swing down the rear

platform wall, the radiator system is easily accessible from the climbing platform. Always

shut off the engine for cleaning work on the air intake girds or the radiators and secure it

against inadvertent starting (pull off the ignition key and carry it on your body).

Warning! Burning hazard. Each radiator is heated up during operation. Wear protective

gloves! Before all work on the radiator systems, let the machine cool down sufficiently!

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7 Maintenance and Service

Chapter.7.

Maintenance and Service

Charge air cooler

Proceed as follows for cleaning the radiator system:

– Switch off the engine and secure the machine against inadvertent starting (pull off

the ignition key and carry it on your body).

– Swing down the rear platform wall.

– Clean the air intake grid using a brush and – if necessary – using the water jet from

a water hose of possibly sticking dirt.

– Swing up the air intake grid.

Hydraulics fluid cooler

200

Water cooler

Rear platform wall

Air intake grid


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7 Maintenance and Service

– Swing up the rear platform wall, close the cabin door and start the engine.

Attention!.Hazard of eye and skin injuries due to foreign objects blown out. Nobody may

be staying on the climing platform during manual reversal. Due to the strong air current

of the fan, eye and skin injuries can be caused by dirt particles flung away by the air

current.

– Reverse the fan manually for about one minute. You achieve the best cleaning effect

if you let the Diesel engine run at maximum speed.

– Switch off the Diesel engine and secure the machine against inadvertent starting

(pull off the igntion key and carry it on your body).

– Pull the locking lever for the engine air box and swing it up.

Locking lever

engine air box

Attention! Hazard of skin injuries due to sharp edges on the air conditioning condenser.

When working on the open fan housing, always wear suitable protective clothing

(protective gloves, hard helmet, closely fitting working clothing).

Engine air box

swung up

Air conditioning

condenser

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7 Maintenance and Service

Chapter.7.

Maintenance and Service

– Check the radiator system for soiling. Remove coarse dirt by manual collection, by

7.1.4.3 Checking coolant

cleaning the radiator system using a water hose (NOT high pressure cleaner) or

by blowing out using compressed air. You will find a plug-in coupling for connecting

a blow gun – depending on the equipment of your machine – on the right, at the

compressed air reservoir, or below a cover for the ball cocks of the water spraying

system. During all work on the radiator system, make sure that you do not damage

the fins of the air conditioning condenser.

– After completion of cleaning work, close the fan housing and the intake grid. Swing

up the rear platform wall again.

Warning! Poisoning hazard and hazard of damage to the skin. Corrosion protection

and antifreeze agents contain hazardous materials. There is an acute poisoning hazard

when swallowing. In case of contact to the skin, irritation or cauterization/burns may

occur. Never fill corrosion protection/antifreeze agents into drinking vessels or beverage

bottles. Always store these agents so that children do not have access to the agents.

In any case, comply with the hints on safety of the manufacturer of these agents. Hazard

of damage to the environment. Corrosion protection/antifreeze agents are hazardous for

the environment. When handling these materials, always make sure that the corrosion

protection/antifreeze agents do not enter the environment, but are disposed of in a

manner compatible to the environment.

Always make sure of sufficient antifreeze and only use corrosion protection/antifreeze

agents expressly approved in the Mercedes-Benz company standards 325.0 or 326.0

(see page 298).

If the liquid level in the cooling-water expansion tank is too low, then the warning icon

is displayed on the color terminal.

The cooling-water expansion tank with the filler neck for coolant is located on the

climbing platform behind the hydraulics liquid tank.

202


Filler lid

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7 Maintenance and Service

Warning! As long as the engine is hot, the cooling system is under high pressure. There

is a scalding hazard due to emitting steam or hot cooling liquid spraying out! Wear

protective gloves and protective goggles. Carefully open the radiator lid when the engine

has cooled down.

Expansion tank for coolant for euro-Maus3

Check cooling liquid level and corrosion protection/antifreeze agent, if needed,

correct

Only check the coolant level at a coolant temperature of below 50 °C. Before correcting

the coolant level, check corrosion protection/antifreeze.

Checking of the coolant level is performed by visual control at the expansion vessel. The

coolant level is correct if the cold coolant reaches the lower edge of the filler opening.

The correct share of 50 Vol.% corrosion protection/antifreeze agents in the coolant is

warranted if it is frost-proof up to -37 °C. If less antifreeze is indicated, then correct the

mixture ratio.

If the concentration is too low, there is the hazard of damage to the engine due to

corrosion/cavitation in the cooling system!

Avoid concentrations of more than 55 Vol.-% corrosion protection/antifreeze agents,

because otherwise the maximum frost protection of up to -45 °C is not achieved.

For refilling, only use prepared coolant with 50 Vol.-% corrosion protection/antifreeze

agents, which are expressly approved by Mercedes-Benz.

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7 Maintenance and Service

Chapter.7.

Maintenance and Service

Remarks of Mercedes-Benz on the cooling agent (general information):

Normally, coolant consists of water and corrosion protection/antifreeze agent. The

corrosion protection/antifreeze agents (ethylene glycol with corrosion inhibitors) have

the following tasks in the cooling system:

– Sufficient corrosion and caviation protection for all components of the cooling system

– Lowering of the freezing point (frost protection)

– Raising of the boiling point.

For reasons of corrosion protection, the cooling liquid must be added about

50 Vol.-% corrosion protection/ antifreeze agents, if the environmental temperatures to

be expected do not require an even higher concentration. This concentration (50 Vol.-%)

offers antifreeze protection up to about -37 °C. A higher concentration is only sensible for

even lower environmental temperatures. Even in case of extremely low environmental

temperatures, do not use more than 55 Vol.-% of corrosion protection/antifreeze agents,

since the maximum frost protection is achieved then, and an even greater share in

the mixture again reduces frost protection and worsens heat dissipation (55 Vol.-%

corresponds to frost protection up to about -45 °C). If these coolant regulations are not

complied with, then corrosion and damage to the cooling system are inevitable. Adding

of corrosion protection/antifreeze agents raises the boiling point. Increased pressure

further increases the boiling temperature. Both physics coherences are used in modern

cooling systems – the maximum coolant temperature is increasedwithout increasing

the hazard of boiling. Corresponding to the higher temperature level, the cooling

performance increases. Only approved products (sheet 325.0/326.0) offer reliable

protection of the cooling system.

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7.1.4.4 Replacing coolant

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7 Maintenance and Service

Only use corrosion protection/antifreeze agents approved by Mercedes-Benz. The

coolant must be exchanged every three years. In any case, comply with the regionally

applicable regulations on environmentally compatible disposal of coolant.

– Before renewal of coolant, check the cooling and heating system for leaks and

condition.

– Slowly open the closure cap of the engine cooling system; relieve excess pressure

and take off the closure cap.

Drain valve for

coolant

The valve for draining the cooling liquid is located above the starter motor behind the

exhaust pipe of the Diesel engine.

Attention!.Burning hazard on the hot engine block and the hot exhaust pipe. Wait for

so long for changing the cooling liquid until the engine has sufficiently cooled down. To

protect against burns, wear suitable protective clothing (working clothing and protective

gloves).

– Screw the drain hose onto the coolant drain valve on the engine block.

– Drain the coolant and catch it in a suitable vessel.

– Fill up with premixed and approvel coolant

(filling volume about 25 Liter).

– Set the desired temperature of the air conditioning system to the maximum

temperature, so that the control valve of the heating system is opened.

– Switch on the heating system of the hydraulics fluid tank (lever up).

– If you machine is fitted with an independent heating system, then switch it on.

– Fill up coolant in the prescribed composition to the lower edge of the filler neck.

– Start the engine and let it run for about 1 minute at different speeds.

– Check the coolant liquid level and fill up coolant liquid, if required.

– Close the cooling system (this process may have to be repeated several times).

– Have replacing of the coolant confirmed on the maintenance slip.

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7 Maintenance and Service

Chapter.7.

Maintenance and Service

7.2 Air Conditioning System

Attention!.Hazard of damage to health and hazard of damage to the environment.

Maintenance work on the air conditioning system requiring opening of the coolant

circuit (for instance refilling of coolant, exchange of the collector dryer, etc.) may only be

performed by an authorized specialist workshop.

The air conditioner condenser is located in the ventilator air box. It is attached in front

of the radiator. Use compressed air or a water hose for cleaning (in no case a high-

pressure cleaner!). The air conditioner condenser is swung up with the air box for

cleaning.

Warning! Burning hazard! Every radiator is heated up during operation. Wear protective

gloves! Let the machine cool down sufficiently before all work on the cooling systems!

206

condenser

air conditioning

If the air conditioning system has a too low cooling performance, then the following

causes may apply:

– Air conditioning condenser dirty.

Remedy: blow out the air conditioning condenser using compressed air

(max. 5 bar). During blowing out, make sure that the fins of the condenser are not

damaged.


– Coolant circuit insufficiently filled.

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7 Maintenance and Service

Remedy: Possible only by specialist personnel using the required specialist tools.

Filling is sufficient, if at the inspection glass of the collector drier coolant without

bubbles is visible. The collector drier is located in the engine compartment behind

the engine and in front of the vehicle frame. It is accessible by a housing hatch in the

segment of the infeed conveyor.

Danger!.Hazard to life when opening the hatch while the machine is running. Before

opening the hatch, switch off the engine and secure the machine against switching on.

For this purpose, pull off the ignition key and carry it on your body. Additionally, switch off

the main battery switch.

Maintenance hatch

Inspection glass of the collector drier

If the air conditioning system has a too low cooling performance, then the following

causes may apply:

– Circulating air grid in the cabin not open

Remedy: Open circulating air grid.

– Circulating air grid in the cabin blocked

Remedy: Clean circulating air grid.

Maintenance annually:

– Have the air conditioning system checked by an authorized specialist workshop and

repaired if needed.

Maintenance every two years:

– Have refrigerant and collector drier (ROPA item no. 301191) changed/replaced

by an authorized specialist workshop, even if no bubbles should be visible in the

inspection glass of the collector drier.

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7 Maintenance and Service

Chapter.7.

Maintenance and Service

Hint.for.the.specialist.workshop! When exchanging or refilling of refrigerant, the

following oil must be added: Fuchs Reniso PAG 46 (ROPA item no. 435046). The air

conditioning system may in no case be operated using other oil additives. Filling volume

refrigerant about 1.7 kg.

10 ml oil must be circulating in the refrigeration circuit for every 100 ml refrigerant.

All machines are added a fluorescent agent to the refrigerant during initial filling by

ROPA. This enables quick and cost-effective detection of leaks possibly occurring on

the air conditioning system.

7.3 Pump distributor gears

The pump distributor gears (PVG) is directly connected to the engine and transfers the

engine power to the individual hydraulics pumps.

The oil level of the pump distributor gears must indispensably be checked daily. Check

the oil level before starting the Diesel engine! When the Diesel engine has been started,

oil level monitoring is no longer possible.

The machine must be standing on even and level ground to read the oil level and the

engine must have been shut off for at least five minutes.

When the oil level rises or falls without any apparent reason, call in a customer service

mechanic.

The oil level can be read at the inspection glass; it must be within the inspection glass

range (in no case above the upper edge of the inspection glass!). The inspection glass is

located on the left side of the pump distributor gears.

208


Inspection glass

209

7 Maintenance and Service

The first oil change is required after 50 operating hours. Thereafter, the oil must be

changed annually. At each oil change, the intake filter of the pump distributor gears and

the pressure filter cartridge must be replaced.

Oil and filter change

– Before performing the oil change, extensively clean the section around the intake

and pressure filters.

– Change the oil only with the gears at operating temperature.

– Place a catching vessel resistant to oil and of sufficient size underneath.

– Open the closure cap of the drain valve of the pump distributor gears.

– Screw the oil drain hose supplied onto the drain valve of the pump distributor gears.

(the valve opens and the gear oil drains).

– Unscrew the cap nut of the intake line from the filter flange on the internal side of the

gears (this requires a box wrench SW 36).

– Loosen the hexagonal bolted connection on the filter flange (the bolted connection

may ONLY be loosened.

– In no case completely separate the bolted connection (this requires a box wrench

SW 46).

Intake line

Filter flange intake filter

Oil drain valve

– Unscrew the 4 bolts on the filter flange (SW13) and pull out the filter insert.

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7 Maintenance and Service

Chapter.7.

Maintenance and Service

– Replace the filter insert with a new one (ROPA item no.: O-40320010)

(for installation, always use a new paper gasket (ROPA item no.: O-20350003) and

coat this gasket with oil before installation).

– Retighten the bolted connection of flange and hose.

– Unscrew the pressure filter bowl using a wrench SW24 from the inside of the gear

valve manifold and replace the filter insert with a new one (ROPA item no.: 270442).

– The O ring at the filter bowl must also be replaced with a new O ring.

– First, completely screw the pressure filter bowl into the valve manifold, and then

unscrew by one sixth of a revolution.

– Unscrew the oil drain hose and screw on the closure cap.

– Open the oil filler screw and fill up with fresh oil at the filler opening until the oil level

is in the upper range of the inspection glass. Do not use the opening of the bleeding

screw.

Oil filler screw

Gear valve manifold with pressure

filter on the inside

Pressure filter bowl

Prescribed oil type: ESSO ATF D 21611

Filling volume: about 10 Liter

Start the engine and watch the color terminal. The warning icon must disappear

within 10 seconds from the color terminal. If the warning icon does not disappear within

10 seconds, immediately shut off the engine and bleed the gears.

210

Bleeding screw


Bleeding the gears

– Place an oil catching vessel under the valve manifold.

– Remove the closure plug at the connection MP (see illustration).

7.4 Hydraulics system

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7 Maintenance and Service

– Close the engine housing hatch and swing up the pump cover behind the climbing

ladder.

– Watch the connection MP on the valve manifold through the opening.

– Have the engine started by a second, reliable and instructed person and run for so

long (at maximum 15 seconds), until the gear oil emits from the opening at the valve

manifold without bubbles.

– Immediately screw on the closure plug again, when the oil emits free of bubbles, and

tighten it using a torque of 16 Nm.

If the oil does not emit within 15 seconds, then screw in the closure plug again and

call the customer service.

– Wait at least 10 minutes and then again test the oil level, as described above.

– If needed, fill up oil.

Danger!.The pressure reservoir of the hydraulics system is permanently under high

internal pressure, even if the remaining hydraulics system is already pressureless. Work

on the pressure reservoirs may only be performed by especially trained people familiar

with handling of pressure reservoirs. The system must first be rendered pressureless for

all work on the hydraulics system or on the pressure reservoirs. Work on the hydraulics

system may only be performed by people having been instructed about the specific risks

and hazards of working on hydraulics systems.

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7 Maintenance and Service

Chapter.7.

Maintenance and Service

Regularly check the hoses of the hydraulics system for aging and damage! Immediately

exchange damaged or aged hoses. Only use hoses as replacements corresponding to

the technical specifications of the original hose!

When using a vacuum pump, do not set vacuum of less than 0.2 bar.

Observe, that a soiled cooler will achieve a clearly reduced cooling performance. This

substantially reduces the load bearing capacity of the machine. If the hydraulic fluid is

heated up too much, then shut off the engine and try to determine the cause. Usually,

the hydraulic fluid cooler is soiled; possibly, the heating system for the hydraulic fluid

tank has not been shut off.

Warning! Burning hazard! Every cooler is heated up during operation. Wear protective

gloves! Before all work performed on cooling system, let the machine cool down

sufficiently!

7.4.1 Hydraulic fluid tank

Hydraulic fluid cooler

The tank for hydraulic fluid is located on the cabin platform behind the handrail. The

hydraulic fluid level must be checked daily before starting the machine. Fluid level and

fluid temperature may be read at the inspection glass on the front side of the hydraulic

fluid tank. The hydraulic fluid level should always remain in the range between the center

of the inspection glass and the upper edge of the inspection glass. Always make sure

of correct fluid level in the hydraulic fluid tank. During all work on the hydraulics system,

make sure of the utmost cleanliness!

Take note that different types of hydraulic fluid may not be mixed.

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213

7 Maintenance and Service

Unscrew the black filler lid (bleeding head) from the cover of the fluid tank for refilling

hydraulic fluid.

When you open the filler lid for hydraulic fluid, it is possible that you will hear a „hissing“

noise. This noise is normal.

The filling and bleeding filter ensures the required air equalization for fluctuating fluid

level (for instance due to oil temperature). Replace it when it is soiled, but at the latest

every 2 years (ROPA item no.: 270389).

7.4.1.1 Hydraulic fluid change

The hydraulic fluid must be changed annually, best shortly before start of the season.

For this purpose, provide a vessel of sufficient size. Use the fluid drain hose supplied for

changing the hydraulic fluid. Screw the oil drain hose onto the valve on the bottom of the

hydraulic fluid tank. The valve opens and the old fluid drains.

Drain valve

Hydraulic fluid

Filling lid incl.

bleeding filter

Inspection glass

fluid level + fluid

temperature

Approved fluid types: Hydraulik fluid HVLP 46 as per DIN 51524, part 3.

Filling volume: about 190 Liter

In no case use common HLP fluids.

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7 Maintenance and Service

Chapter.7.

Maintenance and Service

7.4.1.2 Check intake strainers

The intake strainers inside of the hydraulic fluid tank must be checked every two years

before filling up with fresh hydraulic fluid, by means of visual inspection, for soiling. If the

intake strainers are soiled, then clean them.

– For this purpose, take off the metal lid of the hydraulic fluid container. Flush the

intake strainers from inside to the outside using sufficient cleaning agent .

– Reinsert the intake strainers.

Intake strainer inside the hydraulic fluid tank

– Place the gasket and the metal lid on them.

– Coat the bolts for fastening the metal lid with sealing compound (ROPA item no.

017026) before inserting them and tighten the bolts.

214

Metal lid

Intake return filter


7.4.1.3 Replacing the hydraulic fluid filter

215

7 Maintenance and Service

Before filling up fresh hydraulic fluid, replace both filters of the hydraulics system. These

filters are one-way products. They may not be cleaned. Cleaning destroys the filters and

the hydraulics system may sustain severe damage.

An intake return filter is located on the hydraulic fluid tank. When replacing the filter

element – as during all work on the hydraulics system – make sure of the utmost

cleanliness. Make sure that hte O ring seals in the filter housing are neither damaged

nor soiled. Before opening the filter housing, make sure that the hydraulics system is

rendered absolutely pressureless and the fluid filler lid is open.

Filter lid

O ring (164.47 x 5.33 NBR contained

in item no. 270483

Separating plate

Filter element ROPA item no 270483

Dirt catch basket

(fastened to the filter element using a

bayonet catch)

Initial replacement of the filter element is required after the first 50 operating hours, then

annually.

For replacing the filter element in the intake return filter, proceed as follows:

– four lid fastening bolts and keep these in a safe place.

– Take off the lid of the intake return filter.

– Using a slight rotating movement, pull the filter separating plate including the

attached filter element out.

– Disassemble the pulled-out unit into the filter separating plate, filter element and dirt

catch basket.

– Clean the housing, lid, filter separating plate and dirt catch basket.

– Examine the filter for mechanical damage. Damaged parts may not be reinstalled

any more (these must be replaced immediately).

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7 Maintenance and Service

Chapter.7.

Maintenance and Service

– Check the O rings and replace possibly damaged parts.

– Before installation, wet sealing surfaces, threads and O rings using fresh hydraulic

fluid.

– Use ONLY a new filter element (ROPA item no. 270483) for installation.

– Use the O ring supplied when inserting the new filter element.

– Install the filter separating plate, filter element and dirt catch basket into one unit.

– Insert the filter separating plate with the attached filter element and dirt catch basket

into the filter head using a light rotating movement.

– Place the lid on again and screw in the fastening bolts. The tightening torque of the

fastening bolts is 40 Nm.

7.4.2 Replacing the pressure filter element

A large pressure filter for operating hydraulics is located above the right front wheel

behind the cabin. The filter element must be replaced annually.

Pressure filter operating hydraulics

Replacing the pressure filter element

– Switch off the engine.

– Unscrew the filter bowl (SW 32) and catch the emitting hydraulic fluid using

a suitable vessel. Dispose of the hydraulic fuel in compliance with the locally

applicable environment protection regulations.

– Pull the filter element from the element stud. Inspect the surface of the uninstalled

filter elements for dirt residue and larger particles. These may point to damage to the

components.

– Dispose of the filter element in compliance with the regionally applicable

environment protection regulations.

– Clean the filter bowl.

– Check the new filter for mechanical damage, especially the sealing surfaces and

threads.

– Replace the O ring on the filter bowl (dirt or incomplete pressure relief during

disassembly may lead to sticking of the bowl thread).

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Element installation

217

7 Maintenance and Service

– Wet the thread and sealing surfaces of the filter bowl and head as well as the O ring

of the bowl and element using fresh and clean hydraulic fluid.

– Install the new element (ROPA item no. 270430 incl. O ring). For this purpose,

carefully place the filter element onto the element stud.

– Screw in the filter bowl to the stop.

– Unscrew the filter bowl by one sixth of a revolution.

– Start the engine and lock the tank (run against pressure) (check filter for leaks).

Remark!.Dispose of hydraulic fluid, filter elements and cleaning rag, etc. in compliance

with the locally applicable environment protection regulations!

7.5 Mechanical drive of the two steering axles

7.5.1 Cardan shafts from the transfer gear to the steering axles

Both jointed shafts of euro-Maus3 must be lubricated after each 200 operating hours.

Danger! Hazard to life due to rotating machine parts. When the engine is running,

body parts or pieces of clothing may be caught by rotating jointed shafts and pulled into

the machine. Before lubricating, immobilize euro-Maus3 and shut off the engine. The

machine must be secured against inadvertent starting of the engine.

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7 Maintenance and Service

Chapter.7.

Maintenance and Service

Example illustration: one lubricating nipple

One lubricating nipple each is installed in each joint. This must be lubricated after each

200 operating hours.

7.5.2 Maintenance cardan joints of the axles

The cardan joints of the double-joint shafts in the steering knuckles of the two steering

axles must be lubricated each 200 operating hours. Each cardan joint has two lubricating

nipples. Both lubricating nipples must be lubricated.

7.6 Manual transmission

The manual transmission is used for switching the operating modes „turtle“ and „rabbit“

as well as speeds I and II and all wheel drive.

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219

7 Maintenance and Service

The oil level of the manual transmission must be checked weekly. Control is performed

using the inspection glass. The oil level is correct if the oil level is in the central range of

the inspection glass. The inspection glass is located at the rear of the transmission next

to the cardan shaft.

The first oil change is due after 50 operating hours; further oil changes are required

annually.

7.7 Axles

Remark!.The complete transmission consists of two units connected by a narrow duct

and therefore having a joint oil circuit. For the oil change, the machine must be standing

completely level. After filling up, wait for at least one hour until final control. Only if after

this waiting period the oil level is on the same level in both inspection glasses and at the

center of the inspection glasses has enough oil been filled up in the transmission.

Attention! Burning hazard. Danger from hot oil! The oil in the manual transmission may

be very hot under certain circumstances. During oil change at the manual transmission,

always wear gloves and suitable protective clothing.

Proceed as follows for oil change:

– Place a catching pan of sufficient size underneath.

– Screw out the two oil drain screws (these are located at the lower corner of the

transmission housing and at the bottom of the reduction gear); the old oil is drained.

– Clean the magnetic oil drain screws of metal filings. Then reinsert the screws and

tighten them.

– Screw out the oil filler screw (it is located on the rear cardan shaft drive) and fill

up fresh oil at the oil filler opening, until the oil level is in the upper range of the

inspection glass.

– Screw in the oil filler screw again.

Prescribed oil type:

Synthetic transmission oil: Mobil Mobilube SHC-LS SAE 75W-90

Other oil brands are not allowed!

Filling volume: about 12 Liter

7.7.1 Planetary gear (applies to both axles)

The first oil change must be performed after the first 50 operating hours. Thereafter, an

oil change is required annually.

Park euro-Maus3 so that the respective wheel is standing as shown in the illustration.

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Maintenance and Service


7 Maintenance and Service

Chapter.7.

Maintenance and Service

Attention!.Injury hazard! Immobilize euro-Maus3 each time and shut off the engine

before performing an oil change on the individual planetary gears. The machine must be

secured against inadvertent starting of the engine. All maintenance and repair work may

only be peformed by trained specialist personnel. Danger.from.hot.oil.emitting.under.

pressure! The oil in the planetary gears may become very hot and – due to heating up

– be under a certain pressure. When perfoming an oil change on the planetary gears,

always wear gloves and suitable protective clothing. Always, at first, screw out the oil

filler screw very slowly and with due care, so that the pressure, which may have built up

in the planetary gears, can be relieved without hazard.

1

Oil level

Proceed as follows for performing an oil change:

– Change the oil only with transmission at operating temperature. Park the machine on

level ground. The oil level control screw („Oil Level“) (1) is level (see illustration).

– Place a catching pan of sufficient size underneath.

– Open the oil drain screw (2) and the oil level control screw and let the old oil drain.

– Screw in the oil drain screw again.

– Fill up the planetary gears using the ROPA planetary oil filler supplied, until the oil

level reaches the lower edge of the opening for oil level control.

– Screw in the oil level control screw again.

– Wait for about 15 minutes and then check the oil level again. If needed, fill up a little

oil.

Remark! The ROPA planetary oil filler should be used for filling up oil (ROPA special tool

item no. 018143). You can exactly and easily fill up the corresponding oil volume using

this special tool.

Prescribed gear oil: Hypoid gear oil as per API GL 5 SAE 85W-90

Filling volume: each planetary gears at the front and rear axle

220

about 3.5 Liter

Bleeding when

filling oil up

Planetary gears

front and rear axles

2


Front axle

7.7.2 Differential gears on the front and rear axles

221

7 Maintenance and Service

The first oil change is required after the first 50 operating hours. Thereafter, an oil

change must be performed annually.

Attention!.Injury hazard. Immobilize euro-Maus3 before the oil change and shut off the

engine. The machine must be secured against inadvertent starting of the engine. All

maintenance and repair work may only be performed by trained personnel.

Differential gears on both axles:

Proceed as follows when performing an oil change:

– Change oil only with gears at operating temperature.

– Place a catching pan of sufficient size underneath.

– Screw out the oil drain screw of the differential gears. It is located at the bottom, at

the lowest position of the axle body.

– Open the oil level control screw and wait until the oil has completely drained.

– Screw in the oil drain screw again.

– Fill up oil in the oil filler opening for so long until the oil level reaches the lower edge

of the oil filler opening.

– Screw in the oil level control screw again.

Prescribed gear oil: Hypoid gear oil as per API GL 5 SAE 85W-90

Filling volume: Differential gears of the front axle about 22 Liter

Differential gears of the rear axle about 20 Liter

Differential gears

Oil filler opening

and oil level

control screw

Rear axle

Oil drain screw

Chapter.7.

Maintenance and Service


7 Maintenance and Service

Chapter.7.

Maintenance and Service

7.8 Pneumatics System – Maintenance and Service

Air drier cartridge

Maintenance work on the pneumatics system is only required on the air drier and the

compressed air reservoirs. The compressor is maintenance-free.

The air drier and the three compressed air reservoirs are located under the right lateral

hatch. The drier cartridge of the air drier must be replaced after each 2000 operating

hours.

Condensed water must be drained from the compressed air reservoirs after each

100 operating hours. If the machine is to be immobilized for a longer period of time (more

than one week), then condensed water must also be drained from the compressed

air reservoirs.

222

Drain valve for

condensed water


7.9 Brake System – Maintenance and Service

223

7 Maintenance and Service

The front axle and, if existing, the additional axle are braked by a compressed-air

operated drum brake. Two independent brake circuits guarantee maximum safety, even

if one brake circuit should fail.

After washing the machine, „drive dry“ the brake. If the machine is started up with brakes

frozen tight (ice formation by ingress of water), then this may lead to severe damage to

the brake system!

7.10 Pickup

Check functioning of the brakes before each drive!

Setting and repair work on the brakes may only be performed by specialist

personnel familiar with maintenance and repair of compressed air brakes due to

vocational training.

Danger! If errors are made during maintenance, repair or setting work, there is extreme

hazard to life for the driver and for other road users.

7.10.1 Stop switch of the pickup

Take off cover

Occasionally clean the stop switch of the pickup. The switches are located to the right

and left behind the hinged plate at the central part of the pickup. If the switches are

blocked by dirt, then the pickup cannot be lowered, and the respective hinged plate

cannot be swung up.

Clean switch

Chapter.7.

Maintenance and Service


7 Maintenance and Service

Chapter.7.

Maintenance and Service

7.10.2 Central mark

After opening the front closing lid, the bearing for the central mark is accessible. The

bearing must be relubricated after each 200 operating hours using the lubricating nipple.

After opening the rear closing lid, the shaft of the eccentric drive is accessible. The

eccentric drive must be relubricated weekly using the lubricating nipple.

Check the lower side of the central mark daily for soiling (visual inspection) with lateral

pickup parts retracted. Strong soiling should indispensably be immediately removed.

Loosen the four bolts under the front closing lid for uninstalling the cover of the central

mark.

Pickup rollers

224

Lubricating nipple pickup roller

Verschlussdeckel

Power transmission from the pickup roller gears to the pickup roller is performed using

an externally toothed shaft at the transmission and internal toothing on the roller. This

toothing must be lubricated weekly using a grease gun.


7.10.3 Pickup roller gears

225

7 Maintenance and Service

euro-Maus3 is fitted to the right and left outside on the lateral pickup parts with one

set of pickup roller gears each. The oil level of these two gear units must be checked

daily with pickup swung out and lowered. The inspection is performed at the inspection

glasses. If the oil level is above the center of the inspection glass, then no oil has to be

filled up.

Pickup roller gears

An oil change is required after the first 50 operating hours, then annually.

Proceed as follows for performing an oil change:

– Swing in the clearing plates.

– Change the oil only with the gear units at operating temperature.

– Place a catching pan of sufficient size underneath.

– Open the oil drain screw and let the old oil drain.

– Retighten the oil drain screw.

Oil filler screw

Inspection glass

Oil drain screw

– Fill up so much fresh oil at the filler opening (simultaneously bleeding plug), until the

oil level with pickup lowered is in the upper range of the inspection glass.

Prescribed gear oil: Hypoid gear oil as per API GL 5 SAE 85W-90

Filling volume per gear unit: about 12.9 Liter

Chapter.7.

Maintenance and Service


7 Maintenance and Service

Chapter.7.

Maintenance and Service

7.10.4 4-fold pinch roller gears

An oil change must be performed after the first 50 operating hours, then annually.

Proceed as follows for performing an oil change:

– - Change the oil only with the gear unit at operating temperature.

- Place a catching pan of sufficient size underneath.

- Open the oil drain screw and let the old oil drain.

- Retighten the oil drain screw.

- Fill up so much fresh oil at the filler opening (simultaneously bleeding plug), until the

oil level with pickup lowered is within the upper range of the inspection glass.

Prescribed gear oil: Hypoid gear oil as per API GL 5 SAE 85W-90

Filling volume per gear unit: about 2.7 Liter

226

4-fold pinch roller gears

euro-Maus3 is fitted with one 4-fold pinch roller gear unit each to the right and left

outside on the lateral pickup parts.

Oil motor tapered roller Inspection glass

Oil drain screw

Oil filler

screw

Gears 4-fold pinch rollers


7.11 Uninstalling and Installing Rollers

227

7 Maintenance and Service

Danger! When uninstalling and installing rollers, there is the danger that the lateral

pickup parts suddingly swing down and that people staying in this sector may be

severely injured. Before starting work, the respective lateral pickup part must be

securely supported or suspended from a crane with sufficient load bearing capacity and

additionally secured. Comply with the applicable accident prevention regulations when

working under raised loads.

Protective cap

Hexagonal recess bolt M12 for

anti-twist protection

Pipe of the central

lubricating system

Perform a weekly check of the pipes of the central lubricating system leading to the

rollers (visual inspection of the pipes, below the protective caps).

Anti-twist protection

M24 fine thread bolt

Chapter.7.

Maintenance and Service


7 Maintenance and Service

Chapter.7.

Maintenance and Service

7.11.1 Uninstallation and installation of the pickup roller and the cleaning roller

Pickup roller and cleaning roller (1 st and 2 nd roller) may only be jointly uninstalled,

because the „pig tails“ of the pickup roller reach between the discs of the cleaning roller.

The cleaning roller is plugged onto the gear unit. After releasing the thrust bearing, it

may be pulled off at the center of the pickup (pedestal bearing with setting ring). There is

no safeguard at the gear unit for the cleaning roller.

The pickup roller is plugged onto a toothed shaft and additionally axially secured at

the gear unit using a bolt (M20 x 350). The gear oil does not have to be drained for

deinstallation. The closure lid of the bearing flange (on the outside of the gear unit) must

be taken off before deinstallation of the pickup roller:

– For this purpose, unscrew the four hexagonal bolts (SW 13) at the closure lid and

remove the lid.

– Remove the two securing screws (grub screws), which are located beside the large

hexagonal bolt (M20 x 350).

– Screw out the hexagonal bolt (M20 x 350).

– Pull the pickup roller from the gear unit.

– During installation of the pickup roller, screw in the hexagonal bolt (M20 x 350)

again.

Lid bearing flange

– Only lightly tighten the bolt and then unscrew it by 1/8 th of a revolution.

– Secure the hexagonal bolt against twisting using the two grub screws.

– Both hexagonal bolts (M20 x 350 ROPA item no. 414725) must be replaced annually.

228

Grub

screw

Bearing flange

Grub screw

Hexagonal bolt M20 x 350


229

7 Maintenance and Service

7.11.2 Exchanging the pig tails of the pickup rollers/build-up welding

The pickup rollers are fitted with turnover plates (ROPA item no. 101677) at the pickup

pig tails.

When the wear limit has been reached, these turnover plates must be rotated.

This ensures long service life. Due to fastening using a bolted connection, each

individual turnover plate being worn may be turned or replaced without problems and

without large installation effort in case of need.

Pig tail with turnover plate

In case of very sandy soil (abrasive ground conditions), we recommend the use of

hard-coatet wear plates (ROPA item no. 102080 incl. mounting bolt). These wear plates

cannot be rotated.

Warning!.Danger of severest contusion injuries in case of improper work on the pig tails

of the pickup rollers. Work in this sector may only be performed when the machine is

completely shut off and has been reliably secured against inadvertent startup (ignition

key pulled off, securely kept by a responsible person and the driver‘s cabin locked).

Only perform build-up welding. When repairing worn pig tails, the welding material may

only be built up to a height of 70 mm (see drawing). In any case, make sure that the

welding material is not built up too high, since the distance to the cleaning roller may not

become too small.

For the cleaning roller, at the corners of the individual disks, build-up welding should be

performed in the form of a lateral seam to extend the service life.

29.06.2007 17:21:23, Wast

70 mm

Wear limit

Chapter.7.

Maintenance and Service


7 Maintenance and Service

Chapter.7.

Maintenance and Service

On the spirals of the feed and pinch rollers, the welding material may only be applied

to the feed sides of the pinch rollers. In no case manually apply a build-up weld bead

directly to the roller shaft. This will warp the complete roller due to the heating effect and

it becomes useless. Make sure that the built-up beads are not higher than 20 mm. If the

surface of your weld beads is rough, then you should smoothen the weld beads using an

angle grinder and a fan disk. By this, you avoid surface damage to the beets at the start

of the season.

In case of especially high wear, build-up welding should be performed on the inner

section of the four feed rollers (two each on the left and right) as well.

The same holds true for the section below the central mark. In case of corresponding

wear effects, we recommend, only here, to weld in laterally oriented pieces of steel bars

(Ø ca. 12 mm) between the coils of the feed rollers.

In case of need, four small hard-coated lateral beads should be applied to the inside

ends of the cleaning rollers and the pickup rollers (directly next to the pedestal bearings).

These must be distributed over the roller surface at the roller ends at 90° angle, so that

two weld beads each are on opposite sides.

A specific welding rod for build-up welding under inert protective gas (Ø 1.2 mm,

15 kg/drum) may be obtained from ROPA with the order number 017014.

For heavy wear ground, we recommend a much greater quality welding rod (containing

tungsten carbide) – with longer service life – for build-up welds. This filler wire with a

diameter of 1.6 mm may be obtained on 15 kg/drum from ROPA, with the order number

017136.

230


Please observe in any case:

231

7 Maintenance and Service

– All retaining collars of the front roller bearings are tighted to the right (clockwise).

– All polyamide plug-in couplings must be greased before sliding them onto the clutch

dogs.

– Insert a new O ring in the clutch dogs before installation.

– The four M12 x 80 hexagonal recess bolts, by which the polyamide plug-in couplings

are fastened to the rollers, must be coated with Loctite 270 bolt retention.

7.11.3 Deinstallation and installation feed rollers

The feed rollers (3 rd and 4 th roller) are plugged onto the gear unit. They may be pulled

off after loosening the thrust bearing at the center of the pickup (pedestal bearing with

retaining collar). There is no further locking device at the gears for the feed rollers.

When installing the feed rollers, make sure that the turns of the rollers are not aligned.

The turns of the rollers should be centrally offset to each other.

– All retaining collars of the front roller bearings are tightened counter to the roller

rotating direction.

– All polyamide plug-in couplings must be greased for sliding them onto the clutch

dogs.

– Before assembly, a new O ring must be inserted in the clutch dogs.

– The four M12 x80 hexagonal recess bolts, by which the polyamide plug-in couplings

are fastened to the rollers, must be coated with Loctite 270 bolt retention.

7.11.4 Deinstallation and installation tapered roller and pinch rollers

The tapered rollers are directly plugged onto the respective drive motors on the outside

(plug-in coupling). The pinch rollers are plugged onto the 4-fold pinch roller gears

(plug-in coupling). To uninstall the tapered roller or pinch rollers, take off the protective

cap above the central lubricating line and first screw out the fine thread bolt M24 below

(inside, at the roller bearing), then the hexagonal recess bolt M12.

All M24 fine thread bolts are fitted with right-handed thread (!) The tightening torque

amounts to 1000 Nm. They are not.secured using liquid bolt retention (Loctite).

Remark!.Before installation, apply a thin coat of copper paste (ROPA order no. 017159

tube containing 100 g) to the thread.

Chapter.7.

Maintenance and Service


7 Maintenance and Service

Chapter.7.

Maintenance and Service

Hinweis! Vor dem Einbau ist das Gewinde der Feingewindeschrauben dünn mit Kupferpaste

For installation, the fine thread bolts M24 must be tightened using a torque of 1000 Nm.

(ROPA Bestell-Nummer 017159) einzustreichen.

The fine thread bolt M24 fastens the roller to the bearing plate using a bushing. The

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

protection of the roller 1000 bearing. Nm festzuziehen. Die Sechskantschraube M24 hält mit einer Buchse die

Walze an der Lagerhalteplatte fest. Die Innensechskantschraube M12 geht durch

eine Bohrung der Lagerhalteplatte in die Verdrehsicherung des Walzenlagers.

Twist protection pinch roller bearing

Verdrehsicherung Zwickwalzenlagerung

Keep at least Hier 0.2–0.5 mindestens mm radial 0,2 clearance – 0,5 here! mm

The bushing Spiel must einhalten!

have clearance in the bore! In

no case should Keinesfalls it have a tight spielfrei fit !!! einbauen !!!

The wear flange is required in two versions: 169

wear flange ROPA item no. 101235 for rollers with right-handed thread

232

(without specific marking)

wear flange ROPA item no. 101230 for rollers with left-handed thread

7.11.5 Replacing the wear flange

(marking: 2 grooves)

The distance between two wear flanges amounts to about 0.5 mm for a new machine.

When this distance becomes too great, more gass, weeds, beet leaves, etc. get caught

at the transition to the next conveyor.

Die Konuswalzen sind außen direkt auf den jeweiligen Antriebsmotor aufgesteckt

(Steckkupplung). Die Zwickwalzen sind auf das 4-fach-Zwickwalzengetriebe aufgesteckt

(Steckkupplung). Um Konuswalze oder Zwickwalzen auszubauen, nehmen

Sie die Schutzkappe über der Zentralschmierleitung ab und drehen zuerst

die darunterliegende Feingewindeschraube M24 heraus (innen an der Walzenlagerung),

abschließend die Innensechskantschraube M12.

Alle M24-Feingewindeschrauben sind mit einem Rechtsgewinde (!) versehen.

Das Anziehdrehmoment beträgt 1000 Nm. Sie sind nicht mit flüssiger Schraubensicherung

(Loctite) gesichert.

Twist Verdrehsicherung

protection item

no. Art.Nr. 101231 101231

Grub screw

ROPA recommends replacing the wear flanges when the distance amounts to 2-3 mm.

This exchange is easy to perform. The settings of the tapered roller bearings are left

untouched, since they are behind the wear flange.

Wear flange

Konuswalze oder

Tapered roller or pinch roller

Zwickwalzen

Fastening bolt wear flange

Safety Sicherheitsscheibe disk S 12 Zn item S 12 no. Zn Art.Nr. 418105

418105

M12*16 hexagonal recess screw D912 steel 10.9

item M 12*16 no. 414436; Inbusschraube use Loctite D912 270 Stahl 10.9 Art.Nr. 414436

tighten Loctite using 270 und 145mit Nm145

Nm festziehen

Fine

Schraube

thread bolt

M 24*1.5*90

M24 with

(Schmierbohrung)

lubrication bore, item

Art.Nr.

no.

101004

101004,

mit

tighten

1000

using Nm 1000 festziehen Nm

Only the fastening bolts of the wear flange must be removed to replace it. If the grub

screw is screwed into the thread, then simultaneously the wear flange is pressed out.

Kapitel 9

Wartung und Pflege


233

7 Maintenance and Service

When uninstalling respectively installing rollers, comply with the following assembly

information applying to all rollers:

– All M12 hexagonal recess bolts of twist protection are fitted with a specific retaining

washer (S12). This retaining washer (ROPA item no. 418105) must be replaced

each time when the hexagonal recess bolt is loosened or screwed out. In addition,

this hexagonal recess bolt must be coated with liquid bolt retention, for

instance Loctite 270. This hexagonal recess bolt (M12) must be tightened using a

torque of 145 Nm.

– All polyamide plug-in couplings must be greased before they are slid onto the clutch

dogs. Besides this, a new O ring must be inserted in the clutch dog before assembly.

– The four M12 x 80 hexagonal recess bolts fastening the polyamide plug-in coupling

to the rollers must be coated with Loctite 270 bolt retention.

To ensure even wear of the rollers, the pinch rollers should, if needed, be installed on the

respective other lateral pickup part; the pinch rollers must be exchanged across for this

purpose.

7.11.6 Assembling/setting bearing of pinch rollers or tapered roller

You indispensably require a special tool for assembly respectively setting of bearings

(adjustable taper roller bearings), which are located at the ends of the pinch rollers

respectively the tapered roller. This tool may be obtained from ROPA under the item

number 018156. But such work is required extremely rarely.

Hint on deinstallation of the tapered roller:

To be able to sufficiently lift up the tapered roller, so that it may be pulled from the plug-in

coupling, it is necessary to tip over the drive motor a little. The drive motor may be tipped

when the 4 fastening bolts of the engine are unscrewed and the three hydraulic lines are

loosened.

Hint on deinstallation of a pinch roller:

To be able to lift a pinch roller from its support, it must be lifted up above the bearing

plate. This is easiest performed using a self-made lifting hook gripping below the roller.

The weight of each roller is about 118 kg. The lifted roller will slightly tilt on the clutch

dog. The pinch roller may knocked off the clutch dog by light axial blows on the roller

turns.

Chapter.7.

Maintenance and Service


7 Maintenance and Service

Chapter.7.

Maintenance and Service

7.12 Pile Pickup With Residual Beet Pickup

The pile pickup withz residual beet pickup (rubber shield) requires low maintenance

effort. Clean the hydraulically moved parts of coarse dirt and occasionally coat the

telescopic tube with lubricating grease.

For machines from model year 2007, the clearance between outside and inside tube of

the telescopic tube may be set as follows, if needed:

– Loosen the 4 locknuts each of the grub screws from the right and below.

– Screw the grub screws into the thread for so long until the clearance corresponds to

your desire.

– Retighten the locknuts.

Grub screws

234

Pile pickup

Residual beet pickup


7.13 Infeed Conveyor

235

7 Maintenance and Service

The deflecting rollers of the infeed conveyor (at the far front at the infeed conveyor inlet)

are fitted with scrapers. They scrape off sticking soil. The bolts in the scrapers must be

checked weekly and when the bolt heads are largely ground off, they must be replaced.

If the bolt heads are worn too much, then the scraper may loosen and swing into the

infeed conveyor. This destroys the infeed conveyor. Such damage is excluded from any

guarantee, warranty or accommodation.

If needed, and depending on wear, the scrapers must be reset or replaced. Depending

on ground condition, the sector of infeed conveyor deflection must be checked several

times a day to weekly and cleaned in case of strong soiling. The strainer chain of the

infeed conveyor must be retightened in case of need.

It may never be tightened too much.

Scraper

Deflecting roller

Chapter.7.

Maintenance and Service


7 Maintenance and Service

Chapter.7.

Maintenance and Service

7.13.1 Tightening the infeed conveyor

Warning!.Danger of severe injuries. Retightening of the infeed conveyor may only be

performed with drive switched off and engine shut down. Pull off the ignition key and

switch off the electric system using the main battery switch.

Only check tension of the infeed conveyor if the pickup is swung out and lowered to

operating height.

Perform a daily check whether all bearing rollers in the infeed conveyor duct are in

proper condition. If rollers are broken, very worn or missing near the front axle, then

the conveyor will slide across the axle. This causes substantial damage to the axle

suspension.

If the infeed conveyor has to be retightened, then loosen the fastening bolt of the

tightening roller (to the right and left behind the front wheel, on the bottom of the frame

tube) and pull the tightening roller down using the tightening screw. Make sure that the

tightening rollers are moved by the same distance on both sides.

236

Tightening screw


7.13.2 Replacing the infeed conveyor drive wheels (finger disk)

The wear limit of the finger disks is reached

7.14 Recleaner

237

7 Maintenance and Service

Replace the drive wheels in due time; do not wait until the strainer chain skips!

Depending on equipment, your euro-Maus3 hat a strainer chain cleaner or an 8-fold

pinch roller cleaner.

7.14.1 Strainer chain cleaner – maintenance

The cleaning conveyor may not be firmly tightened. When beets are transported on

the conveyor, the conveyor must be suspended on the supporting rollers left and right

installed lower.

Supporting roller

installed lower

Chapter.7.

Maintenance and Service


7 Maintenance and Service

Chapter.7.

Maintenance and Service

Warning!.Danger of severest injurites due to the starting cleaning conveyor!

Retightening of the cleaning conveyor may only be performed if the machine drive and

the engine are switched off. Pull off the ignition key and keep it in a safe place (carry it

on your body!) and switch off the electric system using the main battery switch.

– First, remove the short counter support of the rubber cover. For this purpose, remove

the two hexagonal bolts.

– To retighten the conveyor, loosen the locknuts on the two tightening bars right and

left.

– Screw in the tightening bars as far as necessary and retighten the locknuts.

– Make sure that you adjust the tightening bars on both sides by the same length, so

that the conveyor is evenly tightened.

Experience has shown that retightening of the conveyor is required about annually.

euro-maus3 version with strainer chain cleaner

238

tensioning screw

lock nut


7.14.2 8-fold pinch roller cleaner – maintenance

The 8-fold pinch roller cleaner is driven by a hydraulic motor.

The oil level of the spur gear unit must be checked weekly.

239

7 Maintenance and Service

Danger!.Hazard of severest injuries by starting pinch rollers! Work on the 8-fold pinch

roller cleaner may only be performed after the machine drive and the engine have been

shut off. Pull off the ignition key and keep it in a safe place (carry it on your body!) Switch

off the electric system using the main battery switch.

Falling hazard! When working on the pinch roller cleaner, always use ladders safe to

step on or an approved working platform.

Checking the oil level is performed using the inspection glass. If the oil level is above the

center of the inspection glass, then no oil has to be filled up.

The first oil change is required after the first 50 operating hours, then annually.

Oil drain screw

Proceed as follows for performing an oil change:

– - Change the oil only with the gear unit at operating temperature.

- Place a catching pan of sufficient size underneath.

- Open the oil drain screw and let the old oil drain.

- When the oil has drained, insert the oil drain screw and tighten it.

- Fill up with so much fresh oil through the oil filler opening until the oil level is in the

upper range of the inspection glass.

Prescribed gear oil: Hypoid gear oil as per API GL 5 SAE 85W-90

Filling volume: about 4.5 Liter

There are a total of six lubricating nipples at the upper and lower suspension of the

8-fold pinch roller cleaner. These must be lubricated weekly using the grease gun.

Deinstallation and installation of the pinch rollers is identical to deinstallation and

installation of the pinch rollers of the pickup (see page 233, pickup).

Oil filler

opening

Inspection

glass

Chapter.7.

Maintenance and Service


7 Maintenance and Service

Chapter.7.

Maintenance and Service

7.15 Truck Conveyor – Maintenance

7.15.1 Tightening of the truck conveyor

The truck conveyor must be retightened if needed. The conveyor tenseness is correctly

set, if with the truck conveyor completely lowered and with totally straight articulation

(truck conveyor almost completely straight), the lower, empty returning side of the

conveyor sags by about 2-3 cm between the supporting rollers.

1

Proceed as follows for retightening the truck conveyor:

– Loosen the two fastening bolts (1) on the deflection rollers left/right.

– Screw the nuts (2) on the tightening bars (3) left/right so far until the deflecting

rollers left/right have been pushed back far enough.

– Lock the nuts (2) on the tightening bars (3) left/right.

– Retighten the fastening screws (1) of the deflection rollers left/right.

– In any case, make sure that you evenly retighten both sides of the conveyor, so that

the conveyor does not touch on the side and is damaged.

240

2 3


7.15.2 Rotating drives of the swivel arm and truck conveyor

241

7 Maintenance and Service

The drive for rotating the swivel arm and the truck conveyor is made hydraulically using

two hydraulic motors. These motors are flanged to one gear unit each. Each drives its

own rotating assembly using a pinion gear.

Attention!.Hazard of severest injuries due to starting crown gears! Work on the drives

of swivel arm and truck conveyor may only be performed after the engine has been shut

off. Pull off the ignition key and keep it in a safe place (carry it on your body!). Switch off

the electric system using the main battery switch.

Falling.hazard!.During all work performed on the drives of the swivel arm and the

truck conveyor, generally use ladders and climbing aids safe to step on or an approved

working platform. In no case climb around on the machine.

Rotating drive swivel arm Rotating drive truck conveyor

Oil filler screw

Oil control screw

Oil drain screw

Chapter.7.

Maintenance and Service


7 Maintenance and Service

Chapter.7.

Maintenance and Service

The tooth flanks of the rotating assemblies for rotating the swivel arm and truck conveyor

must be sprayed with rotating assembly spray if needed. The oil in the gear units must

be changed annually.

– Proceed as follows to perform an oil change:

- Only change the oil with the gear units at operating temperature.

- Place a catching pan of sufficient size and oil resistant underneath.

- Screw out the oil drain screw and let the old oil drain.

- Also screw out the oil filler screw respectively open the lid of the expansion vessel,

so that the oil can drain quicker.

- When the oil has drained, screw in the oil drain screw again.

- Fill up the expansion vessel of the swivel arm with fresh oil for so long until the oil

almost reaches the upper edge of the expansion vessel.

- Fill up the truck conveyor with fresh oil until the oil reaches the lower edge of the oil

level control opening.

- Reinsert all screws you have removed and close the expansion vessel.

The expansion vessel must always be filled up with oil! If needed, fill up oil in due time.

Prescribed oil type: gear oil of the quality EP,

242

viscosity ISO VG 150 for instance MOBIL Mobilgear 629

as per DIN 51517 part 3

Filling volume swivel arm: about 2.5 Liter

Filling volume truck conveyor: about 3.5 Liter

Further maintenance and repair work on the rotating assembly and swivel drive may only

be performed by ROPA or specialist personnel, which has been expressly authorized for

this work by Ropa.


7.16 Printer (Option)

243

7 Maintenance and Service

After larger printing jobs, depending on the paper quality and disadvantageous

environmental effects, it may be necessary to clean the print head, the sensor and the

drive roller. Especially if some places are no longer properly printed.

– Open the paper hopper lid and remove the paper roll.

– Using a small brush, remove soiling on the paper, sensor as well as the ripping

edge.

– Blow strong into the paper hopper bowl to remove coarse dust.

– Saturate a cotton swab with pure isopropanol alcohol (IPA) and clean the pressure

strip or use the print head cleaning pen/cleaning card.

– Remove further heavy soiling also using a cotton swab (IPA).

Never use sharp objects for cleaning. This might damage the print head.

Chapter.7.

Maintenance and Service


7 Maintenance and Service

Chapter.7.

Maintenance and Service

7.17 Heating and Ventilation System

If the heating and ventilation system should not work at full power, even if the circulating

air grid is fully opened, then the cause for this is usually found in blocked filters.

Therefore, always clean both filters.

7.17.1 Fresh air intake filter

The fresh air intake filter for the cabin is located to the right, outside on the rear cabin

wall.

This filter must be cleaned as follows, if needed:

– Open the cover.

– Unscrew the knurled head screw and take the filter from the bracket.

– Clean the filter element using compressed air.

– Reinsert the cleaned filter element in the bracket and fasten it using the knurled

head screw.

– Reclose the cover.

This filter element should be replaced annually in any case.

244

Fresh air intake filter


7.17.2 Circulating air filter

245

7 Maintenance and Service

The circulating air filter is located in the fan unit below the cover behind the driver‘s seat.

Filter mat circulating air filter

This filter should be cleaned at least annually using compressed air as follows:

– Take off the cover.

– Open bayonet closures.

– Pull out the filter mat upward.

– Blow out the filter mat using compressed air.

– Reinsert the cleaned filter mat.

– Reinstall the cover.

7.17.3 Draining condensed water from the air conditioning system

The condensed water drain of the air conditioning system is located at the cabin floor

below the driver‘s cabin. Regularly check if condensed water is emitting here. If you

should not detect emitting water, then the condensed water drain must be cleaned.

Chapter.7.

Maintenance and Service


7 Maintenance and Service

Chapter.7.

Maintenance and Service

7.18 Immobilization for a longer period of time

If euro-Maus3 is to be immobilized for a period of one to four weeks, then in any case

switch off the main battery switch. In addition, in the central electric system, pull out the

sliding switch S86, since the timer of the independent heating system is supplied with

power from the battery even if the main battery switch is switched off.

If euro-Maus3 is to be immobilized for a period of more than four weeks, then in any

case perform the following additional work:

– Thoroughly wash the machine. Avoid directly spraying bearings and supporting

rollers.

– Drain the condensed water from the three compressed air reservoirs.

– Lubricate the lubricating points of the machine which must be manually lubricated.

– Let the central lubricating system run for at least 30 minutes with machine drive

switched on.

– Grease the geared rims and pinions.

– Spray the whole machine using corrosion protection oil.

– Make sure that no oil or grease touches the tires.

– Grease all piston rods and the collars of the hydraulics cylinders.

– Park the machine in a dry place, protected from weather, if possible, in a hall.

246


247

7 Maintenance and Service

Attention!.Danger of chemical burns. Battery acid may cause dangerous burns on the

skin and the respiratory system. Therefore, when handling acid batteries, always wear

sufficient protective clothing (protective goggles, acid-resistant gloves, apron). Avoid

skin contact with battery acid. Avoid inhaling acid fumes. When handling batteries, make

sure of sufficient ventilation of the workplace. In case of skin contact to battery acid,

immediately flush the skin surface with ample water. Then, immediately consult a doctor.

– Uninstall the batteries. The batteries should be stored cool and dry, but protected

against frost. Before storing, check the acid level and fill up with distilled water, if

needed. Completely charge the batteries before storing them. During storage, check

the battery voltage monthly and recharge the batteries, if needed. Grease the battery

terminals using a specific terminal grease.

Danger!.If acid batteries are improperly charged using unsuitable charging devices

or too high charging voltage, then this may lead to generation of oxyhydrogen gas.

Oxyhydrogen gas is very easily combustible and may explode. Always make sure of the

correct charging voltage. Make sure, that the batteries are charged only in well ventilated

places. Smoking, fire or open flame are strictly prohibited.

Service life of the batteries

In the interest of a long service life of the batteries, exactly comply with the following

hints:

– Check the liquid level. If it is too low, then exclusively fill up with distilled water up to

the maximum acid level mark.

– The self-discharge rate amounts to about 0.2 % of the nominal capacity/day at

20 °C.

– The acid density must be checked at regular intervals to avoid deep discharge.

If the acid density is below 1.21 kg/l, then the batteries must be recharged. The

recommended charging current is 1/10 th of the capacity.

– Deep discharged batteries form lead sulphate. Regeneration by recharging is no

longer possible.

– There are neither guarantee nor warranty claims in case of batteries with sulphate

formation, detectable from the silver plate coating and from turbid battery acid. They

are also excluded from any accommodation, since this damage is due to gross

negligence during maintenance.

Chapter.7.

Maintenance and Service


249

8 Fault and Remedy

Chapter 8

Fault and Remedy

Chapter.8.

Fault and Remedy


8 Fault and Remedy

251

8 Fault and Remedy

Your attention is visually drawn to faults or hazardous situations by warning indications

on the color terminal and acoustically by warning sounds. Individual functions may be

blocked in dangerous situations.

8.1 Safety Circuits

The machine offers the utmost safety for operator and material. Safety switches in the

cabin block individual functions of the machine when the operator leaves the cabin. If

any function cannot be executed from the cabin, or if switches are blocked, at first check

if the left joystick console has been swung down, the rear platform wall has been swung

up and the engine housing lid is closed.

If the fault cannot be remedied in this manner, then read the corresponding sections of

this operating manual about the components concerned respectively without function.

There, you will find hints on safety circuits and possible reasons for a fault.

Warning!.Hazard of severest injuries or damage to the machine. Never defeat safety

installations, safety locks or safety circuits. This may cause severest injuries. Never

perform functional tests if you are not fully informed about all of the consequences

of such a test. Make sure taht during search for faults respectively when remedying

faults a second reliable person is present in case of need, which is familiar with the

machine to the extent that it may immediately shut down the machine as soon as

danger is imminent. Even in case of the slightest doubt, call in specialist personnel

with corresponding training or enquire with service personnel of ROPA. Do not perform

any repairs on the machine if you do not have the required specialist knowledge and

experience.

If you should be able to contact your dealer or the manufacturer by radio or cell phone,

then further fault diagnostics is possible using specific diagnostics menus on the color

terminal. For safety reasons, individual menus are locked for the operator. In case of

improper handling, people could be injured with hazard to life or heavy damage could be

caused to the machine, which would have the consequence of costly repairs.

Chapter.8.

Fault and Remedy


8 Fault and Remedy

Chapter.8.

Fault and Remedy

8.2 Electric System

8.2.1 Fuses

The electric fuses are located on the radio console, the seat console in the driver‘s cabin

and in the switching cabinet of the central electric system, to the right outside on the

cabin platform.

Mainly, euro-Maus3 employs commercially available flat plug-in fuses.

Labels on the inside of the sheet-metal cover designate the fuses.

In addition, in the central electric system, in the plug-in sockets of the reserve fuse

holder, there are three electronic cutouts.

These electronic cutouts are not integrated in the electric circuits and may therefore be

used by you in searching for faults. For this purpose, insert a suitable electronic cutout

in place of the burned-out fuse. In case of overload (for instance short circuit), the

automatic cutout is triggered. By pressing the reset button, the electronic cutout may be

reactivated.

Switching cabinet of the central electric system Lid of the switching cabinet of the central electric

252

system

Fuses F03 to F29 in the switching cabinet of the central electric

system

Electronic cutouts for fault search


Fuses F30 to F45 in the radio console

Fuses F50 to F59 in the seat console

Fuse F47 in the battery box

253

8 Fault and Remedy

Chapter.8.

Fault and Remedy


8 Fault and Remedy

8.2.2 Schedule of Fuses (Fuses)

Schedule of fuses from model year 2005

Version 23.06.2006

Chapter.8.

Fault and Remedy

The battery box contains the main fuses (Mega Fuse fuses). F01 supplies the central

electric system and the seat console of the cabin, F02 the radio console and the working

spotlights. Whether these two fuses are in working condition may only be detected using

a measuring device (circuit indicator).

No. Ampere Function Pos. in the machine

Main power supply, screwed-in Littlefuse MEGA fuses

F01 125 Supply central electric system X1 Battery box

F02 125 Supply lighting radio console Battery box

In the central electric cabinet

F03 20 Kl. 30 MR Daimler Chrysler (A435) in central electric cabinet

F04 10 Kl. 30 ADM2 Daimler Chrysler (A403) in central electric cabinet

F05 15 Kl. 30 computer B (A02) in central electric cabinet

F06 15 Kl. 30 computer B (A02) in central electric cabinet

F07 15 Kl. 30 computer C (A03) in central electric cabinet

F08 15 Kl. 30 computer C (A03) in central electric cabinet

F09 15 Power supply PWM outputs A21 in central electric cabinet

F10 15 Power supply PWM outputs A22 in central electric cabinet

F11 15 Power supply PWM outputs A23 in central electric cabinet

F12 15 Power supply PWM outputs A24 in central electric cabinet

F13 15 Socket rear/tool box in central electric cabinet

F14 15

Heating ventilator for operation of the

independent heating system

254

in central electric cabinet

F15 15 Independent heating system Kl 30 in central electric cabinet

F16 3

Control device air conditioning system during

operation of the independent heating system

in central electric cabinet

F17 15 Engine housing lighting, socket 24 V, lamp ZE in central electric cabinet

Terminal 30

of X1


255

8 Fault and Remedy

Nr. Ampere Funktion Pos. in der Maschine

F20 15 Front window wiper in central electric cabinet

F21 15 Heating ventilator Kl 15 in central electric cabinet

F22 15 Air conditioning compressor, clutch, water pump in central electric cabinet

F23 15 Central lubrication, air dryer, backup lamp in central electric cabinet

F24 3 Kl 15 generators in central electric cabinet

F25 3 Control device air conditioning system Kl 15 in central electric cabinet

F26 3 15 V voltage transformer for sensors in central electric cabinet

F28 7,5 Parking light right in central electric cabinet

F29 7,5 Parking light left dashboard lighting in central electric cabinet

Cabin radio console

F30 10 ASW (= working spotlight) camera, Central mark in radio console, top

F31 15 ASW roof bottom in radio console, top

F32 15 ASW roof center in radio console, top

F33 15 ASW roof outside in radio console, top

F34 15 ASW roof rear in radio console, top

F35 15 ASW cleaning, truck conveyor in radio console, top

F36 7.5 ASW right left in radio console, top

F37 7.5 Rotating beacons in radio console, top

F38 7.5 Mirror heating/mirror adjustment right/left in radio console, bottom

F39 15 Internal lamps, socket 24 V, voltage transformer in radio console, bottom

F40 7.5

Kl 15 RK, video system, timer independent

heating system

in radio console, bottom

F41 7.5 Window wiper left in radio console, bottom

F42 10 Window wiper right and rear in radio console, bottom

F43 7.5 Kl 30 timer independent heating system in radio console, bottom

F44 5

Public address system, 12 V for central electric

system

in radio console, bottom

F45 5 12 V sockets in radio console, bottom

Console driver‘s seat

F50 10 Hazard warning system Kl 30 in seat console

F51 7.5 Terminal Kl 30 in seat console

F52 frei Reserve Kl 30 in seat console

F53 10 Dimmed headlight in seat console

F54 10 Driving light in seat console

F55 10 Air seat, compressor in seat console

F56 10 Rear axle steering, main switch in seat console

F57 10

Steering column switch, horn, direction

indicator, window wiper control, window washer

pump, hazard warning system Kl 15

in seat console

F58 frei Reserve Kl 15 in seat console

F59 7.5

Others

Kl. 15 overall electronics, ESTs, terminal,

joystick, operating section, engine electronics

in seat console

F47 8 Ground, timer, independent heating system in battery box

Terminal

15

of

light

Terminal

30 of F01

Terminal

15

Chapter.8.

Fault and Remedy


8 Fault and Remedy

Chapter.8.

Fault and Remedy

8.2.3 Electronic Cutouts

red LED

8.2.4 Schedule of Electronic Cutouts

The cutouts (F70r to F116r) are implemented as self-resetting electronic cutouts. If the

red light emitting diode (LED) of a cutout is lit, then the cutout is overloaded and power

supply to the component connected is interrupted.

No. For component Function Position in the machine

Sensors operating at 15 Volt

F70r

F71r

F72r

F73r

F74r

B26 DS driving power

B61 DS braking pressure service brake

B20 DS pickup rollers

B21 DS pinch rollers 4-fold

B22 DS cleaner

B27 DS additional axle

B68 DS relief pickup right

B69 DS relief pickup left

B377 Fuel pressure pickup

B60 Reservoir pressure compressed air reservoir

256

in central electric cabinet 15 V

in central electric cabinet 15 V

in central electric cabinet 15 V

in central electric cabinet 15 V

in central electric cabinet 15 V

F75r B51 PVG lubrication in central electric cabinet 15 V

F76r B47 Driving speed sensor in central electric cabinet 15 V

F77r

B46 Fuel tank pickup fuel level

B67 DS relief pickup center

in central electric cabinet 15 V


257

8 Fault and Remedy

No. For component Function Position in the machine

Sensors operating at 8.5 Volt, supply from A02

F80r B01 Sensor wheel angle front axle in central electric cabinet 8.5 V

F81r B02 Sensor wheel angle rear axle in central electric cabinet 8.5 V

F82r

B08 Sensor lateral pile pickup

B10 Sensor pickup depth

(DS = abbreviation for pressure sensor)

in central electric cabinet 8.5 V

F83r B32 Sensor driving pedal 2 in central electric cabinet 8.5 V

F84r

B70 Sensor pile pickup height

B71 Speed sensor truck conveyor

Sensors working at 8.5 Volt, supply by A03

in central electric cabinet 8.5 V

F85r B09 Sensor driving pedal 1 in central electric cabinet 8.5 V

F86r B62 Speed sensor pickup rollers right in central electric cabinet 8.5 V

F87r B63 Speed sensor pickup rollers left in central electric cabinet 8.5 V

F88r B64 Speed sensor 4 pinch rollers right in central electric cabinet 8.5 V

F89r B65 Speed sensor 4 pinch rollers left in central electric cabinet 8.5 V

F90r B66 Speed sensor 8 pinch rollers/infeed conveyor in central electric cabinet 8.5 V

F100r 8.5 V for driver‘s seat signal generation in console 8.5 V

8.3 Schedule of Relays

Nr. Bezeichnung Position in der Maschine Bemerkung Art-Nr.

K01

K03

K04

Relay main load

Kl 15

Relay direction

indicator

Relay fan module/

independent

heating system

in central electrics

rating 70 A, load relay

electrics

320099

seat console flasher relay 320021

in central electrics

only in case of

independent heating

system

320154

K06 Relay window wiper in central electrics switches the front wiper motor 320573

K07

K15

Relay central

lubricating system

Relay reversing

lights

K16 Relay water valve

K17

K19

Relay air

conditioning control/

independent heating

devicesystem

Relay air

conditioning

compressor

in central electrics

in central electrics

in central electrics, only in case of

water spraying system

in central electrics

in central electrics

switches the central

lubricating pump

for reversing beeper and

-reversing lights

for automatic operation of

the water system

for switching the air

conditioning control device

from Kl.15 to Kl.30

for switching the air

conditioning compressor

320154

320154

320154

320154

320154

Chapter.8.

Fault and Remedy


8 Fault and Remedy

Chapter.8.

Fault and Remedy

K01

8.4 Color Code for Electrical Wiring

brown ground

Color code for electrical wiring

red terminal 30

pink terminal 15

yellow 8.5 Volt

violett 12 Volt

red/yellow 15 Volt

K04

K06

K07

blue signal lines digital (ON/OFF)

green signal lines analog (changing sensor values)

grew all lamps (load = light bulbs and warning device (beeper „H“ + „E“))

K15

white electric motors and internal wiring, others

orange control lines to all valves and solenoids (all „Y“)

258

K16

Relay in the switching cabinet of central electrics

K17 K19


8.5 Fault Search Using the Color Terminal

259

8 Fault and Remedy

Malfunctions are partially signaled on the color terminal by warning icons. In case of

electrical or electronic problems, the components concerned are shown, naming the

component.

Example:

= Communication problem to control device

A03 = computer EST C (refer to the table below).

= Analog signal in forbidden range.

On the color terminal, to the right, next to the warning icon, the text field shows which

sensor signal is in an illegal range.

= Line break or short circuit was determined.

To the right, next to the warning icon, the color terminal shows whether this concerns a

line break or a short circuit.

You are also informed about which component is concerned.

= IInternal memory fault EEPROM.

Fault during reading of parameters.

Chapter.8.

Fault and Remedy


8 Fault and Remedy

Chapter.8.

Fault and Remedy

DIN Component Position in the machine Remarks Item no.

A02 EST B

in central electrics box,

center top at the lid

computer B, steering,

positioning truck

conveyor

320615

A03 EST C

in central electrics box,

outside top at the lid

computer C, driving

power, operating drives

320615

A07 Terminal in the seat console top color terminal 320669

A10 Joystick right in the seat console, on CAN 320663

A16

Operating section

machine setting

in the console right with 12 stage switch 320682

A19

Air conditioning

control device

in central electrics on base

plate

for temperature control in

the cabin

320659

A20 Joystick left

in the console left, may be

swung up, on CAN

320712

A21 Computer,

I/O-Modul

in central electrics at the lid,

on the hinge side, internal

module

for pile pickup 320716

A22 Computer,

I/O-Modul

in central electrics at the lid,

on the hinge side, external

module

for transmission and

block switching

320716

A23 Computer,

I/O-Modul

in central electrics at the lid,

for diverse functions

closure side, internal module

320716

A24 Computer,

I/O-Modul

in central electrics at the

lid, closure side, external

module

for feed valve, rabbit

speeds, axle support

320716

8.5.1 Overview of Diagnostic Menus

Below, we are showing illustrations of the available diagnostic menus of the color

terminal. They facilitate fault diagnostics for service personnel, if you call up the

corresponding menu items after being requested to by service personnel and

communicate the values or icons shown to service personnel.

260


261

8 Fault and Remedy

Chapter.8.

Fault and Remedy


8 Fault and Remedy

Chapter.8.

Fault and Remedy

262


263

8 Fault and Remedy

Chapter.8.

Fault and Remedy


8 Fault and Remedy

Chapter.8.

Fault and Remedy

264


265

8 Fault and Remedy

The meaning of error codes

for the Diesel engine is

explained from page 270.

Chapter.8.

Fault and Remedy


8 Fault and Remedy

Chapter.8.

Fault and Remedy

266


267

8 Fault and Remedy

Chapter.8.

Fault and Remedy


8 Fault and Remedy

Chapter.8.

Fault and Remedy

8.6 Error Codes Diesel Engine Mercedes-Benz

The Mercedes-Benz error codes are sent by the ADM2 computer to the color terminal

and may be read there.

The error code is broken down for the following sectors:

SPN number/FMI number

The meaning of SPN/FMI may be found using the following code list.

8.6.1 Error Codes of Diagnostic Version 202

Error codes

SAE J 1939

SPN/FMI

Error

codes

ADM2

45/3 10003 Constant throttle

MBR_KD

45/4 10004 Constant throttle

MBR_KD

Meaning Remedy

cable breakage – Check wiring.

short circuit – Check wiring.

– Check unit for constant throttle for fault.

– Check unit for constant throttle for fault.

98/0 10400 Oil level excess filling – Drain oil in case of high excess filling.

98/1 10401 Oil level low oil level – Fill up oil.

98/14 10414 Oil level very low oil level – Fill up oil.

100/1 10501 Oil pressure low oil pressure – Check pump and oil circuit.

100/14 10514 Oil pressure very low oil pressure – Check pump and oil circuit.

110/0 10900 Engine

temperature

110/14 10914 Engine

temperature

111/1 11001 Cooling water

level KW_SE

111/3 11003 Cooling water

level KW_SE

111/4 11004 Cooling water

level KW_SE

– Remarks: this problem may also occur if the wrong oil pan type has been set

as parameter in PLD-MR.

– Remarks: this problem may also occur if the wrong oil pan type has been set

as parameter in PLD-MR.

coolant temp. too high – Check cooling water level and cooling circuit.

coolant temp. much

too high

low cooling water level – Refill cooling water

cable breakage – Check wiring.

short circuit – Check wiring.

– Check cooling water level and cooling circuit.

– Check wiring, if inspite of refilled cooling water the fault remains active.

– voltage must be greater than 2.0 V.

158/0 11100 Terminal 30 excess voltage – Check system voltage.

158/1 11101 Terminal 30 low voltage – Check system voltage

625/2 12202 CAN zu PLD-MR no connection to

PLD-MR

625/14 12214 CAN zu PLD-MR single wire operation

(MCAN faulty)

629/12 12312 VCU-Intern internal VCU fault –

– parameter 2/08 : check 24/12 V insert for match with system voltage.

– parameter 2/08 : check 24/12 V insert for match with system voltage.

– Check wiring engine CAN.

– Check wiring PLD-MR.

– Check PLD-MR parameter for single wire ability and parameter 1/01 of ADM2

(single wire ability) for identical setting.

– Check PLD-MR parameter for single wire ability and parameter 1/01 of ADM2

(single wire ability) for identical setting.

268


8.6.2 Error Codes of Diagnostics Version 203

Error codes

SAE J 1939

SPN/FMI

Error

codes

ADM2

45/3 10003 Constant throttle

MBR_KD

45/4 10004 Constant throttle

MBR_KD

Meaning Remedy

cable breakage – Check wiring.

short circuit nach

Masse

– Check unit for constant throttle for fault.

– Check wiring.

– Check unit for constant throttle for fault.

98/0 10400 Oil level excess filling – Öl ablassen bei zu starker excess filling.

98/1 10401 Oil level low oil level – Fill up oil.

98/14 10414 Oil level very low oil level – Fill up oil.

100/1 10501 Oil pressure low oil pressure – Check pump and oil circuit.

100/14 10514 Oil pressure very low oil pressure – Check pump and oil circuit.

110/0 10900 Engine

temperature

110/14 10914 Engine

temperature

111/1 11001 Cooling water

level KW_SE

111/3 11003 Cooling water

level KW_SE

111/4 11004 Cooling water

level KW_SE

269

8 Fault and Remedy

– Remarks: this problem may also occur if the wrong oil pan type has been set

as parameter in PLD-MR.

– Remarks: this problem may also occur if the wrong oil pan type has been set

as parameter in PLD-MR.

coolant temp. too high – Check cooling water level and cooling circuit.

coolant temp. much

too high

low cooling water level – Refill cooling water.

cable breakage – Check wiring.

short circuit – Check wiring.

– Check cooling water level and cooling circuit.

– Check wiring, if inspite of refilled cooling water the fault remains active.

– voltage must be greater than 2.0 V.

158/0 11100 Terminal 15 excess voltage – Check system voltage

158/1 11101 Terminal 15 low voltage – Check system voltage

625/2 12202 CAN to PLD-MR no connection to

PLD-MR

625/14 12214 CAN to PLD-MR single wire operation

(MCAN faulty)

629/12 12312 VCU internal internal VCU fault –

– parameter 2/08 : check 24/12 V insert for match with system voltage.

– parameter 2/08 : check 24/12 V insert for match with system voltage.

– Check wiring engine.

– Check wiring PLD-MR.

– Check PLD-MR parameter for single wire ability and parameter 1/01 of ADM2

(single wire ability) for identical setting.

– Check PLD-MR parameter for single wire ability and parameter 1/01 of ADM2

(single wire ability) for identical setting.

Chapter.8.

Fault and Remedy


8 Fault and Remedy

8.6.3 Error Codes of Engine Cont rol (PLD-MR)

Error codes

SAE J 1939

SPN/FMI

Chapter.8.

Fault and Remedy

Error

codes

ADM2

98/2 02517 Engine oil level

sensor

98/3 02515 Engine oil level

sensor

98/4 02516 Engine oil level

sensor

98/5 02509 Engine oil level

sensor

100/2 11617 Engine oil

pressure sensor

100/3 11615 Engine oil

pressure sensor

100/4 11616 Engine oil

pressure sensor

102/2 11417 Charge-air

pressure sensor

102/3 11415 Charge-air

pressure sensor

102/4 11416 Charge-air

pressure sensor

105/3 11215 Charge-air

temperature

sensor

105/4 11216 Charge-air

temperature

sensor

110/3 11515 Coolant

temperature

sensor

110/4 11516 Coolant

temperature

sensor

Meaning Remedy

measuring range

implausible

measuring range

exceeded

measuring range

undercut

– Check oil level.

– Check electrical connections.

– Check sensor, if needed, replace.

– Set point 22 Ohm with full oil pan.

– Check oil level.

– Check line for cable breakage or short circuit to U B .

– Check sensor, if needed, replace.

– Set point 22-25 Ohm.

– Check oil level .

– Check line for short circuit to ground.

– Check sensor, if needed, replace.

– Set point 22-25 Ohm.

cable breakage – Check oil level.

measuring range

implausible

measuring range

exceeded

measuring range

undercut

– Check line for cable breakage.

– Check sensor, if needed, replace.

– Check line for cable breakage.

– Check sensor, if needed, replace.

– Check line for cable breakage or short circuit to UB .

– Check sensor, if needed, replace.

– Check line for short circuit to ground.

Messert unplausibel – Check sensor, if needed, replace.

measuring range

exceeded

measuring range

undercut

measuring range

exceeded

measuring range

undercut

measuring range

exceeded

measuring range

undercut

158/2 12219 Terminal 15 term. 15 detection of

discrepancy of PLD-

MR to ADM2

– Check line for cable breakage.

– Check sensor, if needed, replace.

– Check line for cable breakage or short circuit to U B .

– Check sensor, if needed, replace.

– Check line for short circuit to ground.

– Check line for cable breakage or short circuit to UB.

– Check line for short circuit to ground.

– Check sensor, if needed, replace.

– Set point : 2,4 kOhm (21°C).

– Check line for cable breakage or short circuit to UB .

– Check sensor, if needed, replace.

– Set point : 2,4 kOhm (21°C)

– Check line for short circuit to ground.

– Check fuse 30.

– Check line for cable breakage.

168/3 07542 Terminal 30 excess voltage – Generator or control module broken.

168/4 07543 Terminal 30 low voltage – Battery discharged too much or broken.

174/3 11115 Fuel temp.

sensor

measuring range

exceeded

– Generator/control module/fuse broken.

– Check line for cable breakage or short circuit to UB .

270


Error codes

SAE J 1939

SPN/FMI

Error

codes

ADM2

174/4 11116 Fuel temp.

sensor

175/3 01015 Engine oil temp.

sensor

175/4 01016 Engine oil temp.

sensor

Meaning Remedy

measuring range

undercut

measuring range

exceeded

measuring range

undercut

190/0 10530 Engine speed measuring range

exceeded

609/12 01315 PLD fault,

atmospheric

pressure sensor

609/12 01316 PLD fault,

atmospheric

pressure sensor

measuring range

exceeded

measuring range

undercut

609/12 04024 Internal fault Dry-running computer

failure

609/12 14034 D) Internal fault Highside transistor

prop. valve bank1

(PVB 1) high

resistance

609/12 14035 D) Internal fault Highside transistor

prop. valve bank2

(PVB 2) high

resistance

609/12 14036 D) Internal fault Highside transistor

prop. valve 5 (PV 5)

high resistance

609/12 14038 Internal fault Starter output stage

high resistance (main

branch)

609/12 14039 Internal fault Starter output stage

low resistance (main

branch or emergency

branch)

609/12 14041 Internal fault Prop.valve Highside

transistor burnt

through

609/12 04038 Internal fault Starter output stage

high resistance

(redundant/emergency

branch)

609/12 04040 Internal fault Level detection Starter

faulty

609/14 04037 Internal fault Number of cylinders

implausible

609/14 04047 Internal fault Ignition mapping set

faulty

609/14 04048 Internal fault Number of cylinders

implausible

– Check line for short circuit to ground.

– Check sensor, if needed, replace.

– Set point : 2,4 kOhm (21°C).

– Check line for cable breakage or short circuit to U B .

– Check sensor, if needed, replace.

– Set point : 2,4 kOhm (21°C).

– Check line for short circuit2 to ground.

– Obtain information about allowed max. speed .

– Delete fault memory.

– In case of faults 11415 or 11416 check there.

271

8 Fault and Remedy

– Otherwise check actual values with engine standing still for +/-10 %

– In case of faults 11415 or 11416 check there.

– Otherwise check actual values with engine standing still for +/-10 %

– Check plug-in connections/electric components.

D) = only applies to D models of the PLD-MR control devices.

D) = only applies to D models of the PLD-MR control devices.

D) = only applies to D models of the PLD-MR control devices.

– Check plug-in connections/electric components.

– Check plug-in connections/electric components.

– wenn Fehler 07543, dann dort nachschauen.

– Check plug-in connections/electric components.

– Check plug-in connections/electric components.

– Check plug-in connections/electric components.

– Check plug-in connections/electric components.

– Check plug-in connections/electric components.

609/14 14049 Internal fault Parameter fault – Check plug-in connections/electric components.

609/14 04050 Internal fault False hardware

detection

609/14 04051 Internal fault EEPROM: fault

checksum 1 (CKS1):

all other blocks

– Check plug-in connections/electric components.

– Check plug-in connections/electric components.

Chapter.8.

Fault and Remedy


8 Fault and Remedy

Error codes

SAE J 1939

SPN/FMI

Chapter.8.

Fault and Remedy

Error

codes

ADM2

Meaning Remedy

609/14 14052 Internal fault EEPROM: fault

checksum 2 (CKS2):

blocks vehicle

parameters

609/14 24053 Internal fault EEPROM: fault

checksum 3 (CKS3):

block series or

immobilizer

609/12 14054 Internal fault CAN Datenbereich

defekt

625/2 10104 CAN connection keine Verbindung zu

CAN

625/2 10102 CAN connection CAN Daten

unplausibel

625/14 10100 CAN connection CAN_High Leitung

unterbrochen/

kurzgeschlossen

625/14 10101 CAN connection CAN_Low Leitung

unterbrochen/

kurzgeschlossen

– Check plug-in connections/electric components.

– Check plug-in connections/electric components.

– Check plug-in connections/electric components.

– Check CAN connection to the control device.

– Perform function control.

– Check CAN for line break.

– Check CAN for line break.

625/14 10149 CAN connection Parametrierfehler CAN – Check parameters, correct if needed.

636/1 10310 Crankshaft

sensor

636/3 10309 Crankshaft

sensor

636/4 10308 Crankshaft

sensor

636/7 10311 Crankshaft

sensor

636/8 10312 Crankshaft

sensor

636/14 10313 Crankshaft

sensor

651/5 15027 Injection

cylinder 1

651/6 25028 Injection

cylinder 1

651/7 15026 Injection

cylinder 1

651/12 09044 Injection

cylinder 1

651/14 09045 Injection

cylinder 1

652/5 15127 Injection

cylinder 2

652/6 25128 Injection

cylinder 2

Pegel zu gering – First, pull out the sensor with the engine standing still and perform visual

inspection, then push in sensor with engine standing still to the mechanical

stop.

cable breakage – Check line and sensor for cable breakage with the setpoint 1,2 kOhm.

short circuit nach

Masse

KW/NW-Signal

Zuordnung unplausibel

Timeout (kein

Kurbelwellensignal)

– Check line and sensor for short circuit to ground with the setpoint 1,2 kOhm.

– With engine standing still, pull out both sensors and perform visual inspection,

then push in both to the mechanical stop. Check KW sensor and NW sensor

at the plug N3 for permutation.

– First, pull out the sensor with the engine standing still and perform visual

inspection, then push in sensor with engine standing still to the mechanical

stop.

Sensor verpolt – Correctly connect sensor in the plug of PLD-MR.

control fault plug-in

pumps solenoid valve

cylinder 1 disturbed

short circuit plug-in

pumps solenoid valve

cylinder 2

impact detection plugin

pumps solenoid

valve no impact

cylinder 1

air tranquility controller

limiter cylinder 1

individual cylinder

tuning limiter cylinder 1

control fault plug-in

pumps solenoid valve

cylinder 2 disturbed

short circuit plug-in

pumps solenoid valve

cylinder 2

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– Check electrical supply lines for interconnecting short circuits, short circuit to

ground, short circuit to U B .

– Unscrew electrical bolted connection of the plug-in pump concerned.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– Check electrical supply lines for interconnecting short circuits, short circuit to

ground, short circuit to U B .

– Unscrew electrical bolted connection of the plug-in pump concerned.

272


Error codes

SAE J 1939

SPN/FMI

Error

codes

ADM2

652/7 15126 Injection

cylinder 2

652/12 09144 Injection cylinder

2

652/14 09145 Injection

cylinder 2

653/5 15227 Injection

cylinder 3

653/6 25228 Injection

cylinder 3

653/7 15226 Injection

cylinder 3

653/12 09244 Injection

cylinder 3

653/14 09245 Injection

cylinder 3

654/5 15327 Injection

cylinder 4

654/6 255328 Injection

cylinder 4

654/7 15326 Injection

cylinder 4

655/12 09344 Injection

cylinder 4

655/14 09345 Injection

cylinder 4

655/5 15427 Injection

cylinder 5

655/6 25428 Injection

cylinder 5

655/7 15426 Injection

cylinder 5

655/12 09444 Injection

cylinder 5

655/14 09445 Injection

cylinder 5

656/5 15527 Injection

cylinder 6

656/6 25528 Injection

cylinder 6

Meaning Remedy

impact detection plugin

pumps solenoid

valve no impact

cylinder 2

air tranquility controller

limiter cylinder 2

individual cylinder

tuning limiter cylinder 2

control fault plug-in

pumps solenoid valve

cylinder 3 disturbed

short circuit plug-in

pumps solenoid valve

cylinder 3

impact detection plugin

pumps solenoid

valve no impact

cylinder 3

air tranquility controller

limiter cylinder 3

individual cylinder

tuning limiter cylinder 3

control fault plug-in

pumps solenoid valve

cylinder 4 disturbed

short circuit plug-in

pumps solenoid valve

cylinder 4

impact detection plugin

pumps solenoid

valve no impact

cylinder 4

air tranquility controller

limiter cylinder 4

individual cylinder

tuning limiter cylinder 4

control fault plug-in

pumps solenoid valve

cylinder 5 disturbed

short circuit plug-in

pumps solenoid valve

cylinder 5

impact detection plugin

pumps solenoid

valve no impact

cylinder 5

air tranquility controller

limiter cylinder 5

individual cylinder

tuning limiter cylinder 5

control fault plug-in

pumps solenoid valve

cylinder 6 disturbed

short circuit plug-in

pumps solenoid valve

cylinder 6

273

8 Fault and Remedy

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– Check electrical supply lines for interconnecting short circuits, short circuit to

ground, short circuit to U B .

– Unscrew electrical bolted connection of the plug-in pump concerned.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– Check electrical supply lines for interconnecting short circuits, short circuit to

ground, short circuit to U B .

– Unscrew electrical bolted connection of the plug-in pump concerned.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– Check electrical supply lines for interconnecting short circuits, short circuit to

ground, short circuit to U B .

– Unscrew electrical bolted connection of the plug-in pump concerned.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– Check electrical supply lines for interconnecting short circuits, short circuit to

ground, short circuit to U B .

– Unscrew electrical bolted connection of the plug-in pump concerned.

Chapter.8.

Fault and Remedy


8 Fault and Remedy

Error codes

SAE J 1939

SPN/FMI

Chapter.8.

Fault and Remedy

Error

codes

ADM2

656/7 15526 Injection

cylinder 6

656/12 09544 Injection

cylinder 6

656/14 09545 Injection

cylinder 6

657/5 15627 Injection

cylinder 7

657/6 25628 Injection

cylinder 7

657/7 15626 Injection

cylinder 7

657/12 09644 Injection

cylinder 7

657/14 09645 Injection

cylinder 7

658/5 15727 Injection

cylinder 8

658/6 25728 Injection

cylinder 8

658/7 15726 Injection

cylinder 8

658/12 09744 Injection

cylinder 8

658/14 09745 Injection

cylinder 8

677/3 18005 Starter relay

(from PLD-MR)

677/5 18009 Starter relay

(from PLD-MR)

677/6 18008 Starter relay

(from PLD-MR)

677/7 18086 Starter relay

(from PLD-MR)

677/14 18033 Starter relay

(from PLD-MR)

698/5 17309 PWM driver 2:

proportional valve

2: control engine

brake constant

throttle (MBR-KD)

Meaning Remedy

impact detection plugin

pumps solenoid

valve no impact

cylinder 6

air tranquility controller

limiter cylinder 6

individual cylinder

tuning limiter cylinder 6

control fault plug-in

pumps solenoid valve

cylinder 7 disturbed

short circuit plug-in

pumps solenoid valve

cylinder 7

impact detection plugin

pumps solenoid

valve no impact

cylinder 7

air tranquility controller

limiter cylinder 7

individual cylinder

tuning limiter cylinder 7

control fault plug-in

pumps solenoid valve

cylinder 8 disturbed

short circuit plug-in

pumps solenoid valve

cylinder 8

impact detection plugin

pumps solenoid

valve no impact

cylinder 8

air tranquility controller

limiter cylinder 8

individual cylinder

tuning limiter cylinder 8

starter control: starter

relay external flow

starter control: cable

breakage

starter control: short

circuit to ground

starter control: starter

does not engage

starter control: starter

relay is sticking

Low Side with short

circuit to ground

Remarks: control device

PLD-MR has wrong

parameters/short circuit

to ground

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– Check electrical supply lines for interconnecting short circuits, short circuit to

ground, short circuit to U B .

– Unscrew electrical bolted connection of the plug-in pump concerned.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– Check electrical supply lines for interconnecting short circuits, short circuit to

ground, short circuit to U B .

– Unscrew electrical bolted connection of the plug-in pump concerned.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– After repair of mechanical and electrical faults, set smoothness control to

zero.

– Check the line to the starter relay for short circuit to U B .

– Check starter relay, replace if needed.

– Reinstall electrical connections.

– Disconnect battery .

– Check line to the starter relay for cable breakage.

– Check starter relay, replace if needed.

– Check line to the starter relay for short circuit to ground.

– Check starter relay, replace if needed.

– Check starter electrically and mechanically.

– Perform functional control.

– Check starter relay, replace if needed.

– Perform functional control.

– Check parameters: parameter 7 must be set to NOT ACTIVE, otherwise data

set false.

– If parameters are correct, then check line for cable breakage.

– If parameters false, then set new parameters for the control device.

274


Error codes

SAE J 1939

SPN/FMI

Error

codes

ADM2

698/6 17306 PWM driver 2:

proportional valve

2: control engine

brake constant

throttle (MBR-KD)

Meaning Remedy

Low Side with short

circuit to ground

Remarks: control device

PLD-MR has wrong

parameters/short circuit

to ground

275

8 Fault and Remedy

– Check parameters: parameter 7 must be set to NOT ACTIVE, otherwise data

set false.

– If parameters are correct, then check line for cable breakage.

– If parameters false, then set new parameters for the control device.

723/3 10409 Camshaft sensor cable breakage – Check line and sensor for cable breakage with the setpoint 1,2 kOhm.

723/4 10408 Camshaft sensor short circuit to ground – Check line and sensor for short circuit to ground with the setpoint 1,2 kOhm.

723/8 10412 Camshaft sensor timeout (no camshaft

signal)

723/14 10413 Camshaft sensor sensor wrongly

connected

– Pull out sensor with engine standing still and perform visual inspection.

– Push in sensor with engine standing still to the mechanical stop.

– Correctly connect sensor in the plug of PLD-MR.

Chapter.8.

Fault and Remedy


8 Fault and Remedy

Chapter.8.

Fault and Remedy

8.7 Main Battery Switch

The electrical system may be completely separated from the batteries using the main

battery switch. This is only the case, if additionally the sliding switch F47 in central

electrics is pulled. The main battery switch is located on the left vehicle side in the

opening of the cover between stepladder and battery box.

Attention! Danger of damage to electrics and electronics of the machine. The main

battery switch may not be switched off as long as the machine is running and the ignition

is switched on.

8.8 Jumpstarting and Charging the Battery

Should it be necessary to jumpstart euro-Maus3, then in no case may a charging or

jumpstart device connected to the mains or to a generator be used, since the use of

these devices would lead to irrepairable damage to electronics of euro-Maus3.

Only other motor vehicles with a system voltage of 24 V or vehicle batteries with a

battery voltage of 24 V and sufficient capacity may be used for jumpstarting.

We expressly want to point out, that quick charge devices and mains-connected

jumpstart devices are expressly prohibited for starting of euro-Maus3. Excess voltage

damage caused by use of unapproved charging devices or jumpstart devices are neither

covered by the guarantee nor by the statutory warranty. No accommodation is granted in

case of such damage.

276

main battery switch


Charging the battery/jumpstarting

277

8 Fault and Remedy

Generally, the plus poles must be disconnected and the main battery switch must be

switched off to charge the batteries. Only normal battery charging devices may be used

to charge the battery. Quick charge devices are expressly prohibited!

The charging current may at max. amount to one tenth of the nominal capacity of the

battery.

II䔠

II䔠

2

4V+

0

2

4V+

0

2

0

2

0

2

0

0 2

04V+

Since damage has been incurred several times in the past due to improper charging of

the battery or jumpstarting, we expressly want to point out, that euro-Maus3 may only

be jumpstarted using the following method:

Attention! Injury hazard. In any case, observe the hints on safety of the battery

manufacturer when handling acid batteries.

Chapter.8.

Fault and Remedy


8 Fault and Remedy

Chapter.8.

Fault and Remedy

Jumpstarting

– Exclusively use standardized jumpstarting cables with really sufficient cross-section

of the electric conductors.

– Only use batteries with the same nominal voltage (24 V).

– Make sure of sufficient battery capacity of the assisting vehicle.

– Shut off the engines of both vehicles and switch off the ignition.

– Shut off the main battery switch of euro-Maus3.

– Make sure, that the vehicles do not touch anywhere.

– First connect the minus pole of the battery of the assisting vehicle to the minus pole

of the battery of euro-Maus3. Alternately, a blank metal and electrically conductive

place (for instance ground strap or engine block) of the assisting vehicle may be

connected to a similar place (ground strap or engine block) of the euro-Maus3 to be

started.

– Connect the plus pole of the battery of the assisting vehicle to the plus pole of the

battery of euro-Maus3.

– Switch on the main battery switch of euro-Maus3.

– Start the engine of the assisting vehicle and accelerate this engine to a medium

speed.

– Start the engine of euro-Maus3 and make sure, that any try at starting does not last

for more than 15 seconds.

– Before removing the jumpstart cable, in any case shut down the engine of the

assisting vehicle, since otherwise the electronics of the assisting vehicle may be

damaged.

– Remove the jumpstart cables from both vehicles in reverse order (first plus cable,

then minus cable).

assisting vehicle

278

main battery switch

euro-Maus3


8.9 Welding Work on the Machine

8.10 Towing

279

8 Fault and Remedy

In case of welding work on the machine, the main battery switch must always be

switched off. The ground cable of the welding transformer must be connected as close to

the welding position as possible.

Attention! Welding work on the machine may only be performed by people sufficiently

qualified for the respective work under regional regulations. Welding work on structural

parts or parts with safety function may only be performed after enquiry with ROPA, to

the extent as this is admissible under the respective applicable regulations. All welding

work may only be performed in compliance with applicable standards and recognized

engineering principles. In any case, observe the increase fire hazard when welding near

combustible parts or liquids (fuel, oils, greases, tires, etc.). We expressly want to point

out that ROPA does not assume any warranty for damage to the machine caused by

improper welding work.

If it should be necessary to tow the machine, then always comply with the regionally

applicable regulations for the towing vehicle and for securing the vehicle combination

on public roads and paths. In any case, move the transmission into neutral position. For

this purpose, shut down the machine. Engage the parking brake and additionally secure

the machine against inadvertent rolling away using the two wheel chocks in the engine

housing in front of the fuel tank.

1. Shut off compressed air supply of working pneumatics. For this purpose, turn the red

plastic stopcock (1) above the transmission crosswise to the course of the line.

1

Stopcock open, turn by 90° to close.

2. Push respectively pull the shift rod (to the right outside on the front side of the

transmission) into central position. Neither of the two gears may be engaged.

Chapter.8.

Fault and Remedy


8 Fault and Remedy

Chapter.8.

Fault and Remedy

Warning!.The vehicle is very difficult to steer with the engine standing still! Take care, if

the brake is not in operating condition! Only use vehicles with sufficient braking power to

tow euro-Maus3. For towing, exclusively use load-securing devices with sufficient

load-bearing capacity. No other vehicles may be towed or trailers pulled by euro-Maus3.

It is impossible to start up the engine of euro-Maus3 by tow starting or rolling.

8.11 Coupling of Salvaging Aids

Proceed as follows for coupling of salvaging aids (steel wires, chains, ropes, salvaging

nooses, belts, etc.):

Couple salvaging aid to the rear of the machine:

– Swing tank aside.

– Fasten salvaging aids to to the rear towing lugs, that the machine cannot be

damaged.

280

Shift rod

Rear towing lug


Fastening salvaging aids to the front of the machine:

281

8 Fault and Remedy

– Swing up both lateral parts and secure using the securing chains available.

– Push a shaft with sufficient load-bearing capacity (diameter about 50 mm) through

the connecting pipe of the central pickup frame (about 300 mm above the infeed-

conveyor deflecting rollers) and connect the salvaging aids to both ends of this shaft.

Remark! Always make sure of sufficient stability of the salvaging aids. Consider

that the load caused by salvaging a vehicle may amount to several times the normal

vehicle weight. When salvaging the machine, call in experts with as much experience

as possible and always use devices with sufficient load bearing capacity and suitable

vehicles.

8.12 Manual Release of the Parking Brake

Sufficient pressure must be available in the compressed air system to release the

parking brake.

In emergencies, the parking brake may even be manually released if there is not

sufficient pressure available for the braking system. For this purpose, the spring-loaded

cylinder must be manually deactivated.

slide shaft through here

Danger!.Hazard to life from the machine rolling away. Before releasing the spring-

loaded cylinder, the machine must be secured against rolling away using both chocks.

Work on vehicle brakes may only be performed by specialist personnel (for instance car

mechanics, mechanics for agricultural machinery, brake service, etc.) with corresponding

training, in compliance with the applicable safety regulations.

To deactivate the spring-loaded cylinder, screw out the releasing bolt (1) to the left and

right on the front axle to the stop. The releasing bolt is located on the rear of the cylinder.

Chapter.8.

Fault and Remedy


8 Fault and Remedy

Chapter.8.

Fault and Remedy

Deactivation spring-loaded cylinder right/left:

– Shut off engine and secure against inadvertent start.

– Secure vehicle against rolling away using both chocks.

– Using a box wrench SW24, turn the emergency release bolt (hexagonal bolt at

the center of the cylinder) counter-clockwise for so long (maximum torque 35 Nm,

distance about 70 mm), until a fixed stop can be felt.

– The spring-loaded cylinders are released, the vehicle is completely without brakes.

– The vehicle may, under observance of the corresponding safety regulations, be

towed to the next workshop or a safe parking place.

Danger! Never park the vehicle unsecured when the spring-loaded cylinders are

released. Secure the vehicle against rolling away using chocks of sufficient size. In the

field of vision of the driver, fasten a conspicuous sign bearing the text: „Danger! Vehicle

is without brakes! Spring-loaded cylinders are released“. Keep the ignition key in a safe

place.

Work on the spring-loaded cylinders is dangerous and may only be performed by people

trained for this work and familiar with work on preloaded spring packages.

Warning! Danger of severe injuries from parts flung away with great force. In no case,

open the spring-loaded cylinders forcibly or improperly. The parts inside of the spring-

loaded cylinder are preloaded with great spring force and may be flung away in case of

improper opening and severely injure people. Maximum admissible releasing pressure

8 bar!

When the repairs are complete, the spring-loaded cylinders must be reactivated as

follows:

Releasing bolt

Using the box wrench SW24, screw in the emergency release bolts (hexagonal bolt

at the center of the cylinder) clockwise into the housing to the stop an tighten using a

torque of 30 Nm.

282


8.13 Adjust Brake

283

8 Fault and Remedy

Work on the vehicle brakes may only be performed by specialist personnel (for

instance car mechanics, mechanics for agricultural machinery, brake service, etc.)

with corresponding training, in compliance with the applicable safety regulations.

The wedge brake is fitted with an automated readjusting device. Readjusting the brake is

therefore not required.

8.14 Hydraulics Valves

All hydraulics valves are electrically controlled. Problems on solenoid valves may be

located using specific test cables, which are supplied with each machine. These test

cables may only be connected to the solenoid valves by trained and instructed specialist

personnel.

If an electrically controlled valve should not work, then in every case, without exception,

a specialist must be called in. In no case may a try be made to remedy possible contact

problems or a line breakage by shaking the solenoids concerned. If, during such tries,

the valve is suddenly opened, then the person concerned may sustain deadly injuries.

Warning!.Troubleshooting and fault repairs on all components of the hydraulics system

is exclusively the task of trained specialists. We expressly warn against tries to repair or

arbitrary tests on electromagnetically operated hydraulics valves. If, during such tests

or tries to repair, parts of the hydraulics system are suddenly pressurized, then this may

lead to unwanted machine movements. This may squeeze or even crush people or body

parts.

Chapter.8.

Fault and Remedy


8 Fault and Remedy

Chapter.8.

Fault and Remedy

8.15 Central Lubricating System – Bleeding and Removal of Blocks

Lubrication pump Main distributor

During all work on the central lubricating system, make sure of the utmost cleanliness. In

no case may dirt ingress into the lubricating system.

If the reservoir should, by accident, have been driven empty, then the lubricating pump

must be bled. For this purpose, remove the main line from the main distributor and

switch on the pump for so long until air-free grease emits from the main line. Screw a

lubricating nipple into the input of the main distributor and pump grease into the main

distributor for so long until the grease emits at the bearings. Then, reconnect all line

connections again.

Should the line system be blocked, then the grease is emitted at the pressure relief valve

(directly at the line output of the pump). To remove this block, proceed as follows:

284

Subdistributor

Pressure relief valve

Lubrication point


285

8 Fault and Remedy

– Search for the blocked place in the line system. Follow the stiffer grease line from

the lubricating pump to the main distributor (the blocked line is stiffer, because it

is under pressure) and on to the corresponding subdistributor and from there to

the blocked lubricating point. Please find the organization of the central lubricating

system in the diagram below. You will find a detailed plan in Chapter 9.

– Unscrew the line from the load and screw a lubricating nipple into the corresponding

(sub) distributor.

– Try to loosen the block by strongly pumping grease into the distributor using the

grease gun.

– Proceed systematically: from the grease pump to the main distributor, from there to

the subdistributor, etc.

– When you notice that the line is free again, reconnect the line to the load. Test free

passage by performing intermediate lubrication.

– If you should not be successful using the method described here, then contact your

ROPA service location.

Function of outputs at the lubricating pump

Lubricating circuit 3

8-fold pinch roller cleaner

(option)

Lubricating pump under the cabinet of the central electric system.

Lubricating circuit 2

pickup

Lubricating circuit 1

chassis

Chapter.8.

Fault and Remedy


8 Fault and Remedy

Chapter.8.

Fault and Remedy

8.16 Emergency Operation Fan Drive

To check if the fan wheel of the radiator system is really running at maximum speed, the

plug designated (Y99) may testwise be pulled from the hydraulics pump. Then, the fan

should be running at maximum speed. If the cooling performance does not improve from

this measure, then the machine may only be operated at reduced load.

286

Y 99


287

8 Fault and Remedy

8.17 Independent Heating System (Optional) – Measures in Case of Faults

When faults occur, the fuses and plug-in connections must be checked for perfect

condition and tight fit.

If these measures do not serve to remedy the fault, then please contact a Webasto

service point (www.webasto.com) stating the model of your independent heating system

(Thermo 90 ST.25.D 24V).

Fault code output

Heating is automatically switched off = fault shutdown

Cause Remedy

No combustion after starting and repeated

start; flame goes out during operation.

When a fault occurs, the display of the timer shows a fault message.

Fault code output on the display of the timer

Switch off heating device and switch it on

again. If, again, no heating operation is

performed, then visit a Webasto service

point.

Voltage drop for longer than 20 seconds. Check fuses, plug-in connections and

charging state of the battery.

Heating device is overheated due to lack/

loss of liquid.

Shutdown is caused by temperature limiter

(overheating).

F01 No start (after 2 tries to start)

F02 Flame interruption

F03 Low voltage or excess voltage

F04 Premature flame detection

Fill up coolant as stated in information from

the vehicle manufacturer.

Let the device cool down, then depress

button (1) of the temperature limiter before

restarting.

F05 Flame monitor interruption or flame monitor short circuit

F06 Temperature sensor interruption or temperature sensor short circuit

F07 Dosing pump interruption or dosing pump short circuit

F08 Fan motor interruption or fan motor short circuit or fan motor faulty speed

F09 Glow plug interruption or glow plug short circuit

F10 Overheating

F11 Circulating pump interruption or circulating pump short circuit

1

Chapter.8.

Fault and Remedy


9 Schedules and Tables/Plans and Diagrams/Maintenance Slips

289

Chapter 9

Schedules and Tables/

Plans and Diagrams/

Maintenance Slips

Chapter.9.

Schedules and Tables/Plans and Diagrams/

Maintenance Slips


Komponent Lubricant Type

Diesel Engine

9 Schedules and Tables/Plans and Diagrams/Maintenance Slips

Engine oil for instance Mobil Delvac XHP Extra 10W-40

or engine oils as per MB standard 228.5

Cooling system Corrosion/antifreeze agent -40° MB

operating supplies regulation MB 325.0 a

326.0

Axles

Front axle

Differential gears

Planetary gears 2 pcs.

Rear axle

Differential gears

lanetary gears 2 pcs.

9 Schedules and Tables/Plans and Diagrams/Maintenance Slips

9.1 Lubricants and Operating Supplies euro-Maus3

Gears pickup rollers 2 pcs.

Gears 4-fold pinch rollers

2 pcs.

Gears 8-fold pinch rollers

Swivel arm:

rotating drive large rotating

assembly

rotating drive small rotating

assembly

Mobil Mobilube HD-A 85W-90 API GL5

Gear oil quality EP viscosity ISO VG 150 for

instance Mobil Mobilgear 629

Decisive for filling quantities are oil-level check plugs and inspection glasses!

If the oil varieties stated should not be available, then ONLY oils and greases from the conversion table of ROPA may be used or

mediums completely corresponding to those prescribed by ROPA based on international conversion tables.

291

Filling Quantity

in Liters Intervals

24 - 29

(min-max)

every 400 oper.

h, in case of

operation using

FAME/RME every

150 oper.h

about 25 every 3 years

about 22 ea.

ea. about 3.5 annually

about 20 ea.

je ca. 3.5

ea. about 12,9

ea. about 2,7

about 4.5

about 3.5

about 2.5

annually

annually

Pump distributor gears ESSO/ATF D 21611 about 10 annually

Manual transmission 4-speed Mobil Mobilube SHC LS 75W-90 API GL-5 about 12

Hydraulics system ESSO/Mobil UNIVIS N HVLP 46

as per DIN51524 part 3

Fuel tank Diesel fuel DIN EN 590

Rape seed methyl ester (FAME or RME)

DIN EN 14214

about 190 annually

about 1340

Lubricating points Mehrzweckfett NLGI class 2 as per lubricating

plan

Chapter.9.

Schedules and Tables/Plans and Diagrams/

Maintenance Slips


9 Schedules and Tables/Plans and Diagrams/Maintenance Slips

9.2 Wartungstabelle euro-Maus3

Maintenace Intervals

Before

After

after the every

Maintenance Work

starting

the first every first 400 400 If

harvest Daily 50 oper.h 50 oper. h oper. h oper. h needed Annually

Diesel engine also refer to the operating manual Mercedes-Benz

Check oil level X

Exchange engine oil and oil filter* X X* X* X*

Check valve clearance, tune in case of need X* every 1200 oper. h** X

Exchange cooling liquid every 3 years

Check cooling liquid level, replenish if needed X X X X X

Clean radiator fins X

Replace main element air filter X X

Replace safety cartridge air filter every 2 years or after 5th service main element

Leak and condition inspection of all lines and hoses X X X

Check condition of V-ribbed belt X X X

Exchange V-ribbed belt also refer to the engine maintenance manual Mercedes-Benz

Pump distributor gears

Check oil level X X

Exchange oil X X X

Exchange air intake filter and pressure filter X X X

Transmission

Check oil level X X

Exchange oil X X X

Chapter.9.

Schedules and Tables/Plans and Diagrams/

Maintenance Slips

292

* When using FAME or RME/biodiesel, oil exchange indispensably required after every 150 oper. h.

** At least annually respectively at the latest after every 1200 oper. h.


Maintenace Intervals

If

needed Annually

9 Schedules and Tables/Plans and Diagrams/Maintenance Slips

Before

After

after the every

Maintenance Work

starting

the first every first 400 400

harvest Daily 50 oper.h. 50 oper. h oper. h oper. h

Axles

Check oil level X X

Exchange oil X X X

Hydraulics system

Clean hydraulic fluid radiator X X

Check hydraulic fluid level X

Exchange hydraulic fluid X X

Clean air intake strainers inside the oil tank every 2 years

Hydraulic fluid filters (2 pcs.)

replace cartridges

Exchange refilling lid hydraulic fluid tank

293

X X X X

every 2 years

(bleeding filter)

Check hydraulic lines for damage and chafing X X X X

Pneumatics

Replace cartridge air dryer every 2000 oper. h

Drain water air reservoir X

Battery

Check acid level, replenish if needed X X X

Check voltage, recharge if needed X X

Cabin

Clean circulating air filter X X

Clean fresh air intake filter X X

Replace fresh air intake filter X

Chapter.9.

Schedules and Tables/Plans and Diagrams/

Maintenance Slips


9 Schedules and Tables/Plans and Diagrams/Maintenance Slips

Maintenace Intervals

after the

first 400

After

the first

50 oper.h

Before

starting

harvest Daily

Maintenance Work

If

needed Annually

every 400

oper. h

oper. h

every

50 oper. h

Pickup

Pickup roller gears

Chapter.9.

Schedules and Tables/Plans and Diagrams/

Maintenance Slips

X

Check oil level

Pickup roller gears

X X X

Exchange oil

4-fold pinch roller gears

X

Check oil level

294

X X X

4-fold pinch roller gears

Exchange oil

Infeed convoyer

Check scrapers deflecting rollers

X X

retighten if needed

Check tightness

X X

retighten if needed

Recleaner version confeyor

Check tightness conveyor

X X

retighten if needed

Recleaner version 8-fold pinch rollers

8-fold pinch roller gears

X

Check oil level

X X X

8-fold pinch roller gears

Exchange oil


Maintenace Intervals

after the

first 400

After

the first

50 oper.h

Before

starting

harvest Daily

Maintenance Work

9 Schedules and Tables/Plans and Diagrams/Maintenance Slips

If

needed Annually

every 400

oper. h

oper. h

every

50 oper. h

X

Swivel arm + rotating drives truck conveyor

Gears (2 pcs.) check oil level

Gears (2 pcs.) exchange oil X X

Grease rotating assemblies (spray-on grease) X X

Truck conveyor

Check tightness conveyor, retighten if needed X X

All conveyors, feed ducts and remaining machine

Remove soiling and sticking dirt X

Check all rollers X

295

Refill grease reservoir X

Lubricate lubricating points as per grease plan

Retighten wheel bolts after the first 10 and after the first 50 oper. h

Check tire pressure X X

Air conditioning system

Check air conditioning condenser for soiling, clean

X

if needed

Check hoses and lines for chafing

X X

(visual inspection), have exchanged if needed

Check coolant at the inspection glass of the

X X

collector dryer, have refilled if needed

Have collector dryer and coolant exchanged every 2 years

Chapter.9.

Schedules and Tables/Plans and Diagrams/

Maintenance Slips


9 Schedules and Tables/Plans and Diagrams/Maintenance Slips

9.3 Lubricating Plan euro-Maus3 (Lubrication Using Grease Gun)

Lubricating Point

Chapter.9.

Schedules and Tables/Plans and Diagrams/

Maintenance Slips

296

number

of nippl.

every

oper. h

Telescopic tube pile clearer (cover with grease) 0 if needed

Pickup roller toothing at the gear unit 2 weekly

Roller eccentric drive central mark 1 weekly

Swing swivel heads and bolts hydraulics cylinder pickup 8 100

Lift swivel heads and bolts hydraulics cylinder pickup 8 100

Lift hinge bearing swivel point pickup and bolts 4 100

Swivel point skid pads left and right 2 100

Swivel point cowls on pickup outside 2 100

Swivel point residual beet pickup 2 100

Swivel heads hydraulics cylinder pile clearer right/left 4 100

Swivel heads hydraulics cylinder pile clearer up/down 2 100

Lock fuel tank 2 100

Universal joints front axle and rear axle 8 100

Swivel point central mark pickup (bearing) 1 200

Cardan shafts from transmission to the axles 4 200

Only for Recleaner version 8-fold pinch roller

Suspension pinch roller cleaner top 3 100

Swivel arm pinch roller cleaner bottom 3 100

Only for recleaner version infeed conveyor

Rotating trestle infeed conveyor cleaner bottom on chassis 1 100

Lubricant: multi-purpose grease NLGI-class 2

All lubricating points must also be lubricated after every washing of the machine.

The central lubricating system must lubricate at least 2 intermediate lubricating cycles

after washing of the machine.

Lubricating greases containing solid lubricants may not be used.

Biologically degradable greases are also allowed.


9 Schedules and Tables/Plans and Diagrams/Maintenance Slips

9.4 Filter Cartridges, V-Belts

euro-Maus3 with Mercedes OM926 LA

Engine Daimler OM926 LA ROPA no.

Oil filter cartridge 303073

Fuel filter cartridge 303013

Air filter main cartridge 301225

Air filter safety cartridge 301226

Fuel prefilter M&H Pre-Line -2007 303028

Fuel prefilter type piston pump 2008- 303083

Belt drive Diesel engine

V-ribbed belt generator/air cond./water pump 226061

Hydraulics

High-pressure filter element incl. O ring 79*3, 270430

Suction return filter element incl. O ring 164.47x5.33 270483

Filling lid with integrated bleeding filter 270389

Pump distributor gears

Intake filter PVG coarse O-40320010

Paper gasket for intake filter PVG O-20350003

Pressure filter element PVG including O ring 46*3 270442

Cabin

Intake filter fresh cabin air 352332

Pneumatics

Air dryer cartridge 261035

Only for option independent vehicle heater

Fuel filter independent vehicle heater 301106

Water spray system (option)

Filter strainer 228032

Important: use only original parts from Ropa or Mercedes-Benz!

297

Chapter.9.

Schedules and Tables/Plans and Diagrams/

Maintenance Slips


9 Schedules and Tables/Plans and Diagrams/Maintenance Slips

9.5 Maintenance Slips

9.5.1 Software updates

Version Date Name

9.5.2 Maintenance Certificate

Plan 50 oper. hrs.

May only be

performed by

ROPA-Service

personnel.

Maintenance after

Plan 400 oper. hrs.

May only be

confirmed by

Mercedes-Benz-

service.

_____

completely

performed on:

performed by:

Chapter.9.

Schedules and Tables/Plans and Diagrams/

Maintenance Slips

Signature: ______________________________________________

_____

completely

performed on:

performed by:

1st customer service ROPA machine

1st customer service Merzedes-Benz engine

Signature: ______________________________________________

298


9.5.3 Maintenance Slip Oil Change + Filter Change (only Disel engine)

9 Schedules and Tables/Plans and Diagrams/Maintenance Slips

Date: Date: Date: Date: Date: Date:

Oper. h: Oper. h: Oper. h: Oper. h: Oper. h: Oper. h:

Diesel engine ok ok ok ok ok ok

Engine oil

Engine oil filter

Fine fuel filter

Fuel prefilter

Air filter main cartridge

Air filter safety cartridge

Antifreeze checked

Cooling liquid exchanged

299

Date: Date: Date: Date: Date: Date:

Oper. h: Oper. h: Oper. h: Oper. h: Oper. h: Oper. h:

Diesel engine ok ok ok ok ok ok

Engine oil

Engine oil filter

Fine fuel filter

Fuel prefilter

Air filter main cartridge

Air filter safety cartridge

Antifreeze checked

Cooling liquid exchanged

Chapter.9.

Schedules and Tables/Plans and Diagrams/

Maintenance Slips


9 Schedules and Tables/Plans and Diagrams/Maintenance Slips

Maintenance Slip Oil Change + Filter Change

Date: Date: Date: Date: Date: Date:

Oper. h: Oper. h: Oper. h: Oper. h: Oper. h: Oper. h:

Axles/gears ok ok ok ok ok ok

Front axle

Planetary gears 2 pcs.

Differential gears

Chapter.9.

Schedules and Tables/Plans and Diagrams/

Maintenance Slips

Rear axle

Planetary gears 2 pcs.

Differential gears

Gears

Pickup rollers right

Pickup rollers left

300

4-fold pinch rollers right

4-fold pinch rollers left

8-fold pinch rollers (option)

PVG oil exchange

PVG oil filter exchange

Manual transmission

4-speed

Hydraulics

Hydraulic fluid exchange

Hydraulic fluid filter

exchange 2 fluid filter

elements

Filling lid hydraulic fluid tank

with integrated bleeding

filter


9 Schedules and Tables/Plans and Diagrams/Maintenance Slips

9.6 Torque Table for Bolts and Nuts (Nm)

Metric thread DIN 13

Dimension 6.9 8.8 10.9 12.9

M4 2,4 3,0 4,4 5,1

M5 5,0 5,9 8,7 10

M6 85 10 15 18

M8 21 25 36 43

M10 41 49 72 84

M12 72 85 125 145

M14 115 135 200 235

M16 180 210 310 365

M18 245 300 430 500

M20 345 425 610 710

M22 465 580 820 960

M24 600 730 1050 1220

M27 890 1100 1550 1800

M30 1200 1450 2100 2450

Metric fine thread DIN 13

Dimension 6.9 8.8 10.9 12.9

M8x1 23 27 39 46

M10x1 43 52 76 90

M12x1,5 76 89 130 155

M14x1,5 125 145 215 255

M16x1,5 190 225 330 390

M18x1,5 275 340 485 570

M20x1,5 385 475 680 790

M22x1,5 520 630 900 1050

Tightening moment wheel nuts

Front axle and rear axle 450 Nm

Additional axle 400 Nm

301

Chapter.9.

Schedules and Tables/Plans and Diagrams/

Maintenance Slips


9 Schedules and Tables/Plans and Diagrams/Maintenance Slips

9.7 Lubricating Plans

9.7.1 Machine Recleaner With Version Infeed Conveyor

pinch roller 3

pinch roller 4

conveyor roller

conveyor roller

distributor left

4010.1154

item no. 360094

steering cylinder right inside

pile clearer turn down

pile clearer turn up

steering cylinder left outside

steering knuckle left top

steering knuckle left bottom

shaft infeed conveyor

GE bearing left front

GE bearing left rear

steering cylinder right inside

steering cylinder right outside

steering knuckle right top

steering cylinder right bottom

storage tank top

storage tank bottom

rotating assembly

rotating assembly

Chapter.9.

Schedules and Tables/Plans and Diagrams/

Maintenance Slips

pinch roller 1

pinch roller 2

conical roller

cleanout roller

pickup roller

chassis front

4010.6943

item no. 360146

chassis rear

4010.0778

item no. 360099

rotating assembly 1

4010.1431

item no. 360103

polyamide tube

high-pressure hose

lubricating points

302

main distributor

4010.3742

item no. 360113

steering cylinder left inside

pile clearer up-down right

pile clearer up-down left

steering cylinder left outside

steering knuckle right top

steering knuckle right bottom

GE bearing right front

GE bearing right rear

steering cylinder left inside

steering cylinder left outside

steering knuckle left top

steering knuckle left bottom

swing axle

swing axle

rotating assembly

rotating assembly

shaft cleaning conveyor

Pickup

pinch roller 1

pinch roller 2

conical roller

cleanout roller

pickup roller

drive central mark

rotating assembly

rotating assembly

distributor right

4010.1155

item no. 360095

main distributor

4010.1868

item no. 360097

rotating assembly 2

4010.1430

item no. 360102

pinch roller 3

pinch roller 4

conveyor roller

conveyor roller

return line

rotating assembly

rotating assembly

drive shaft truck conveyor


9 Schedules and Tables/Plans and Diagrams/Maintenance Slips

9.7.2 Machine With Recleaner Version 8-Fold Pinch Roller

pinch roller 3

pinch roller 4

conveyor roller

conveyor roller

distributor left

4010.1154

item no. 360094

steering cylinder right inside

pile clearer turn down

pile clearer turn up

steering cylinder left outside

steering knuckle left top

steering knuckle left bottom

shaft infeed conveyor

GE bearing left front

GE bearing left rear

steering cylinder right inside

steering cylinder right outside

steering knuckle right top

steering cylinder right bottom

storage tank top

storage tank bottom

rotating assembly

rotating assembly

pinch roller 1

pinch roller 2

conical roller

cleanout roller

pickup roller

chassis front

4010.6943

item no. 360146

chassis rear

4010.0778

item no. 360099

rotating assembly 1

4010.1432

item no. 360101

polyamide tube

high-pressure hose

lubricating points

Pickup

main distributor

4010.3742

item no. 360113

steering cylinder left inside

pile clearer up-down right

pile clearer up-down left

steering cylinder left outside

steering knuckle right top

steering knuckle right bottom

GE bearing right front

GE bearing right rear

steering cylinder left inside

steering cylinder left outside

steering knuckle left top

steering knuckle left bottom

swing axle

swing axle

rotating assembly

rotating assembly

rotating assembly

rotating assembly

303

pinch roller 1

pinch roller 2

conical roller

cleanout roller

pickup roller

drive central mark

pinch roller

pinch roller

pinch roller

pinch roller

rotating assembly 2

4010.1430

item no. 360102

distributor right

4010.1155

item no. 360095

main distributor

4010.1868

item no. 360097

pinch rollers

4010.1869

item no. 360100

pinch roller 3

pinch roller 4

conveyor roller

conveyor roller

return line

pinch roller

pinch roller

pinch roller

pinch roller

rotating assembly

rotating assembly

drive shaft truck conveyor

Chapter.9.

Schedules and Tables/Plans and Diagrams/

Maintenance Slips


9 Schedules and Tables/Plans and Diagrams/Maintenance Slips

9.8 Lubricant Translation Table for ROPA Machines

Schmierstoff-Umschlusselungstabelle fur ROPA Maschinen

Alternative Alternate Oil Olhersteller

Manufacturers

Shell BP Aral Fuchs

Werksbefullung

Works filling

Esso/Mobil

Esso/Mobil

Version Stand 25.07.2007 ROPA

ROPAitem

Art.-Nr.:

no.

Chapter.9.

Schedules and Tables/Plans and Diagrams/

Maintenance Slips

Tellus T 46 Energol SHF-HV 46 Vitan HF 46 RENOLIN HVI 46

UNIVIS N / HVLP 46

DIN 51524 Teil 3

Hydraulic Hydraulikol fluid 435012

Titan Cargo LDF

10W-40

MegaTurboral

10W-40

Vanellus C8 Ultima

5W-30

Rimula Ultra 5W-30

Rimula Ultra E5 10W-40

Normina Extra 10W-40

Mobil Delvac XHP Extra

10W-40

435029

Engine Motoroloil MAN M3277,

M3277, DC 228.5, DC fur 228.5, alle for

all Maschinen machines ab from Bj. m.y.

2002

2002

304

TITAN GEAR HYP 90

(SAE 85W-90)

Spirax MB 90 Energear Hypo90 Hyp 85W-90

Mobilube HD-A

85W-90

API GL-5

Gear Getriebeol oil

435020

TITAN GEAR LS 90

(SAE 85W-90)

Spirax A 90LS Energear LS90 Hyp LS 85W-90

Mobilube LS

85W-90

API GL-5

435043

nicht not freigegeben approved nicht not freigegeben approved nicht not freigegeben approved nicht not freigegeben

approved

Mobilube SHC LS

75W-90

API GL-5

435025

Gear Getriebeol oil front Vorder- axle only

in achse differential, nur im only

for Differential, compre-hensive nur im

harvesters Vollernter

Gear oil transmission

Getriebeol Schalt-

drive power, e-T

getriebe Fahrantrieb,

from 2007 auxiliary

transmission

e-T ab 2007 Vorsatz-

2

getriebe 2. Achse

nd axle

435037 ATF D 21611 Shell Donax TA Autran DXII ATF 22 Titan ATF 3000

435030 Mobilgear 629 Omala Ol 150 Energear GRXP 150 Degol BG 150 Renolin CLP 150

Pump Pumpenverteiler-

distributor

gears getriebe

Swivel Schwenkgetriebe gears only for nur

loading mouse

bei Verlademaus

FWR 220

-30ü C bis + 140üC

up to up to up to up to

Aralub HLP 2

-30ü C bis + 130üC

Energrease LS-EP2

-20ü C bis + 120üC

LX 2

-25ü C bis + 150üC

Lubricating Schmierfett grease 435023 MOBILUX EP2

Titan Universal

HD 15W-40

Multi Turborral

15 W 40

Vanellus C4 Global

Universal Engine Oil

15W-40

435019 MOBIL DELVAC MX 15W-40

Motorol nur fur

Maschinen bis Bj.

2001 zulassig


9 Schedules and Tables/Plans and Diagrams/Maintenance Slips

9.9 Excerpt From the Mercedes-Benz Works Standard Operating

Supplies, Engine Oils and Refrigerants/Antifreeze Agents

BB00.40-P-0228-05A

9.9.1 Multigrade Engine Oils (Specification 228.5)

BB00.40-P-0228-05A Mehrbereichsmotorenole (Spezifikation

228.5)

305

Einsatz in Fahrzeugen/Motoren

siehe

Blatt 228.5

Blatt 223.2 BB00.40-P-0223-02A

Product Produktname name 0W-30 10W-40 5W-30 5W-40 Principal, Auftraggeber, Town/Country

Ort/Land

AD SDX 10W40 X AD Parts, S.L., Riudellots de la Selva

(Girona)/Spanien

Addinol Super Truck MD 1048 X Addinol Lube Oil GmbH, Leuna/Deutschland

Addinol Ultra Truck MD 0538 X Addinol Lube Oil GmbH, Leuna/Deutschland

ad-Super Cargo Leichtlauf-Oil X Carat GmbH & Co. KG, Eschborn/Deutschland