Claas Trailer Direct Disc 610 520 Contour 520 Comfort Assembly Instruction Manual - PDF DOWNLOAD

TRAILER DIRECT DISC 610 DIRECT DISC 520 Contour DIRECT DISC 520 Comfort

Assembly and Operating Instructions

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EC Declaration of Conformity according to EC Directive 98/37/EEC

Maschinenfabrik Stolpen GmbH

We

Pirnaer Landstr. 24 D - 01833 Stolpen declare under their sole responsibility that the product

Trailer - Type 469 “TRAILER DIRECT DISC 610” “TRAILER DIRECT DISC 520 Contour / 520 Comfort” to which this declaration applies, complies with the relevant fundamental safety and health requirements of the EU Directive 98/37/EG Appendix 1, and the requirements of the other relevant EU Directives

-/-

For the relevant implementation of the safety and health requirements mentioned in the Directives, the following standard(s) and/or technical specification(s) has (have) been applied:

EN ISO 4254-1

Stolpen, 18.04.2008 (J. Kröhnert)

Machine overview

Machine overview

6

5

7

6

4 3 2 1

8

9

8 12

11

10

1 Machine overview Item no.Designation 1 2 3 4 5 6 7 8 9 10 11 12

1.1

Flange connection Lock Location Gas shock absorber Orientation aid Wheel chock Rear trailer Mudguard Interlock (loading side) Front trailer Parking brake Drawbar

ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort - 000 294 671 2

Introduction

Introduction

2 Introduction INTRODUCTION This operator's manual provides information concerning the use, adjustment and operation of the CLAAS trailer for the CLASS front attachment “DIRECT DISC 610 / 520”.

Please read this manual thoroughly before starting work! Pay particular attention to the section “Safety rules” and the notes concerning dangers in the operator's manual for the front attachment or chopper.

Follow the advice on correct maintenance and servicing in order to ensure maximum performance and a long service life of your transport wagon.

This manual is only valid in combination with the “DIRECT DISC 610 / 520” operator's manual and the applicable chopper operator's manual.

Your CLAAS Service Department

Validity This operator's manual is valid for: TRAILER DIRECT DISC 610 / 520 Contour / 520 Comfort Type 469 from serial number 469 0 0001.

000 294 671 2 - ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort

2.1

Contents

Contents

3 Contents 1. Machine overview 2. Introduction Introduction ............................................................................... 2.1 Validity ................................................................................ 2.1

3. Contents ....................................................................... 3.1 4. Preface Of special importance ............................................................... 4.1 Identification plate ..................................................................... 4.1 Road transport .......................................................................... 4.2 Operating permit ................................................................ 4.2 Operating on public roads ................................................... 4.2 Number plate ...................................................................... 4.3 Regular inspection as required by law ............................... 4.3

5. Safety rules Designated use ......................................................................... 5.1 Identification of warnings and dangers ..................................... 5.1 General Safety and Accident Prevention Instructions ............... 5.1 Tyres ......................................................................................... 5.2 Maintenance ............................................................................. 5.2 Safety decals with warning symbols ......................................... 5.3

Setting the wheel brakes .................................................. 10.5 Basic setting of the wheel brakes ..................................... 10.6 Basic setting of the wheel brakes front ............................. 10.6 Basic setting of the wheel brakes rear ............................. 10.8 Maintenance intervals .................................................... 10.10 After 50 operating hours ................................................. 10.10 Every 200 operating hours ............................................. 10.10 Every 250 operating hours ............................................. 10.10 Problems and their possible causes ............................... 10.11 Chassis ................................................................................. 10.12 Tyres: ............................................................................. 10.12 Wheel changing .............................................................. 10.13 Adjusting taper roller bearing ......................................... 10.13 Fasteners .............................................................................. 10.14 Screw connections ............................................................... 10.14 Frame ............................................................................. 10.14 Cleaning and care ................................................................ 10.14 End of season storage .......................................................... 10.15 Lubrication chart .................................................................. 10.15

11. Lubrication Chart Safety rules ............................................................................. 11.1 Lubricants ............................................................................... 11.1 Lubrication .............................................................................. 11.1

6. Specifications Trailer DIRECT DISC 610 ......................................................... 6.1 Trailer DIRECT DISC 520 ......................................................... 6.1

7. Assembly Loading/unloading trailer ........................................................... 7.1 Assembling trailer ..................................................................... 7.2 Check dimensions .............................................................. 7.4

8. Prior to operation Check and observe the following before operation ................... 8.1

9. Operation Place the front attachment on the trailer ................................... 9.1 Removing the front attachment from the trailer ......................... 9.5 Hitching transport wagon .......................................................... 9.6 Unhitching transport wagon ...................................................... 9.7 Wheel chocks ............................................................................ 9.8

10. Maintenance Important Maintenance Instructions ........................................ 10.1 Wheels / tyres ................................................................... 10.1 Brakes and axles .............................................................. 10.1 Chassis ............................................................................. 10.1 Bolts .................................................................................. 10.1 Fasteners .......................................................................... 10.1 Lubrication ........................................................................ 10.1 Braking system ....................................................................... 10.2 General information .......................................................... 10.2 Function of reverse automatic system .............................. 10.3 Operating and handling .................................................... 10.4

3.1

ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort - 000 294 671 2

Preface

Preface

4 Preface OF SPECIAL IMPORTANCE Please note that, in the following section, the CLAAS front attachment “DIRECT DISC 520” is also simply referred to as the front attachment.

The notes in this operator's manual must be read and observed by all persons who use, maintain, service or check the trailer in order to avoid dangers.

Particular emphasis should be placed on reading and observing the sections “Safety rules” and “Prior to operation”. Also observe the pertinent accident prevention regulations of your country.

The use of parts, accessories and ancillary equipment which are not genuine CLAAS products and which have not been tested and approved by CLAAS can have a negative effect on the required properties of the CLAAS trailer or on its functional capability and can therefore compromise the active and/or passive driving safety and the working safety (accident prevention).

CLAAS will in no way be liable for damage or personal injury caused by the use of other than original CLAAS parts, accessories and additional equipment.

1

Technical data, dimensions and weights are understood with the usual tolerances.

Front, rear, right and left refer to the direction of travel.

IDENTIFICATION PLATE

1

Always state the serial number (Ident. No. / Serial No.) (2) when ordering parts or in case of technical queries. This is necessary in order to ensure correct delivery of spare parts.

The identification plate (1) with the serial number (Ident. No. / Serial No.) (2) is located at the front on the right hand side on the frame.

2

(Fig. 1, 2)

2

000 294 671 2 - ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort

4.1

Preface ROAD TRANSPORT In the Federal Republic of Germany the road traffic approval regulations (StVZO) are applicable.

In other countries observe the relevant national or state regulations.

Note!

The following sections are applicable for the Federal Republic of Germany only.

Trailers with a speed up to 25 km/h require an operating permit.

The machine operator must have a driver's licence and the copy of the general operating permit issued by the federal motor vehicles office.

Trailers with a speed over 25 km/h must be registered.

The vehicle operator must have a driver's licence, the registration certificate and the test booklet.

Operating permit to 25 km/h: over 25 km/h:

Operating permit that allows operation of the tow vehicle is sufficient.

CE operating permit is required.

Operating on public roads Before starting to drive check the correct secure location of the front attachment on the trailer.

Before driving on public roads the trailer must be connected properly to the tractor unit, the lighting cable must be connected and the lighting equipment must be checked for functionality. In addition, if an overrun brake is fitted, the snap cable (trailer safety snap cable) must be connected.

All requirements specified in the copy of the operating permit and vehicle registration must be observed.

If parts of the trailer are modified subsequently, whose consistency is prescribed or whose operation could endanger other roadusers, the road operating licence is revoked and a n application must be made for a new road operating licence. This requires that the trailer be presented to the relevant technical test station for road vehicles for the issue of a certificate (§ 19 Para. 2 StVZO).

If there is any doubt as to whether this is required, please contact us.

4.2

ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort - 000 294 671 2

Preface Number plate to 25 km/h:

over 25 km/h:

Trailers must be fitted with a number plate issued to the vehicle owner for one of his vehicles (unofficial number plate).

Trailers must be fitted with an official number plate with a valid inspection sticker.

Regular inspection as required by law to 25 km/h: over 25 km/h:

000 294 671 2 - ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort

Not required Major inspection ever 24 months

4.3

Safety rules

Safety rules

5 Safety rules

Attention!

Read and follow the operator's manual and the safety instructions before putting the machine into operation!

Sign to indicate instructions which must be observed. Failure to do so could result in damage to the trailer.

DESIGNATED USE

– Measures for avoiding danger to the trailer.

The CLAAS trailer is built exclusively for the transport of the CLAAS front attachment “DIRECT DISC 520” (intended use).

Use in any other way is considered as contrary to the intended use. The manufacturer does not accept any liability for such use; the user accepts all risk arising from such use.

Designated use also includes observing the service, maintenance and repair conditions as prescribed by the manufacturer.

The trailer may only be used, maintained and repaired by persons who are familiar with it and who have been advised of the dangers involved.

Note!

Sign to indicate instructions for a more efficient and economic use of the trailer.

Caution!

This symbol identifies information that must be observed during disassembly and assembly.

Observe the pertinent accident prevention regulations and other generally acknowledged regulations regarding safety and occupational health, as well as the regulations and standards relevant to motor vehicles and traffic.

Failure to observe the instructions identified by this symbol results in damage to the environment.

Unilateral modifications to the trailer exclude the manufacturer from liability for damage which may occur as a result.

The environment is in danger if environmentally hazardous material (e.g. waste oil) is not subject to correct use and/or disposal.

IDENTIFICATION OF WARNINGS AND DANGERS

The warning and information signs fixed to the trailer provide important information for operation without danger. These instructions involve your safety – observe them at all times!

In this manual we have marked the positions which refer to your safety and the safety of the trailer with the following symbol. Please supply all safety instructions to any other user.

Environment!

GENERAL SAFETY AND ACCIDENT PREVENTION INSTRUCTIONS Basic Rule:

Danger!

Before using the machine each time, check the trailer for roadworthiness and operational safety!

Failure to observe the instructions identified by this symbol results in danger for life and limb of the user or other persons.

General:

– Measures for avoiding danger.

Observe the current regulations regarding safety and accident prevention as well as the information in the operator's manual.

The warning and information signs provide important information for operation without danger; These instructions involve your safety – observe them at all times!

When using public thoroughfares the individual regulations must be observed!

5.1

ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort - 000 294 671 2

Safety rules Particular care is required when hitching the transport wagon!

When loading the trailer by crane use the required safety-tested slings to suit the total weight.

Hitch the trailer as specified. With automatic hitch couplings make sure that the automatic hitch coupling is fully engaged.

When slinging on a crane, only use the slinging points marked for fitting the slings.

Nobody may stand between the tractor unit and the trailer unless the vehicle is secured against rolling away by the parking brake and/or chocks!

Secure the trailer against rolling away before uncoupling.

When the trailer is parked up, the parking brake on the overrun device must be applied, the chocks must be placed under the wheels and the safety procedure in accordance with the StVO stipulations in the individual states must be carried out.

Caution when removing the front attachment. Maintain a sufficient safety distance.

Do not stand under the suspended load and do not stand in the danger area.

TYRES When working on the tyres make sure that the trailer is parked safely and is secured against rolling away (chocks)!

The fitting of tyres and wheels requires adequate skill and the use of regulation fitting tools!

Repair work on tyres and wheels must be carried out by qualified technicians using suitable equipment.

Securely position the front attachment on the trailer.

Check the pressure regularly. Observe the prescribed air pressures!

Before starting off, the electrical system must be connected to the trailer, it should be checked for correct functioning, the safety snap cable between the tractor unit and the parking brake on the trailer must be fitted and the parking brake on the trailer must be released.

MAINTENANCE

Before starting to drive check the correct secure location of the front attachment on the trailer.

Before starting off, check the surrounding area (children!). Make sure the field of view is free!

Riding on the trailer is prohibited.

Repair work, maintenance and cleaning and the rectification of functional errors must always be carried out with the drive disengaged and the engine at a standstill!

– Remove the ignition key!

Regularly check nuts and screws for tight fit and tighten them, if necessary!

The maximum permissible speed is laid down in the operating licence.

When carrying out maintenance work on the suspended trailer always ensure that security is ensured by the use of additional supporting elements.

If modifications are made to the trailer which compromise the road safety, then the operating licence is revoked and a new application for an operating licence must be made.

Always disconnect the power supply before working on the electrical system!

Working gloves must be worn to prevent crush and laceration injuries when working on the trailer.

Spare parts must at least comply with the technical standards required by the manufacturer of the implement! This is assured with original spare parts, for example!

When changing wheels, only use a jack with permissible carrying capacity for the total weight of the trailer and the front attachment.

When changing wheels, only attach the jack to those points marked as the jack mounting points. Before doing this, apply the parking brake and secure against rolling away with chocks.

Never work under components which are supported only by the jack. Before starting work, the support must be made safe by using additional safety supports.

Tighten the wheel nuts with a torque wrench and retighten after a working period of 10 hours.

000 294 671 2 - ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort

5.2

Safety rules

Safety rules SAFETY DECALS WITH WARNING SYMBOLS Warning symbols are fitted to the danger areas of this trailer. These safety decals help to alert persons to hazards which can cause personal injury.

The warning symbols in these decals show how to avoid injury and accidents by appropriate behaviour.

The location of the safety decals on the trailer and short text explanations are detailed below.

The CLAAS Part no. of the decal is quoted before each description.

The figures in () show the correct location of the relevant decals on the trailer in the adjacent illustration.

Safety decals that are damaged or cannot be recognised any more must be replaced immediately by new ones.

When parts that have decals are replaced, always make sure to install the relevant new decals with each new part.

1

1

2 Warning symbol 0514 946.1 (1) Before putting the machine into operation, read the operator's manual and follow the safety instructions.

(Fig. 1, 2)

5.3

ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort - 000 294 671 2

Safety rules

2

3

2 5 Warning symbol 0516 047.0 (2) Use chocks before uncoupling or parking the trailer.

(Fig. 3, 4, 5)

4

000 294 671 2 - ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort

5.4

Specifications

Specifications

6 Specifications Note!

Technical data, dimensions and weights are understood with the usual tolerances.

TRAILER DIRECT DISC 610

TRAILER DIRECT DISC 520

Length

mm

10900

10000

Width

mm

2400

2400

mm mm mm

1850 1610 530

1850 1610 530

Empty weight

kg

1250

1200

permissible total weight

kg

5200

5200

permissible front axle loading

kg

2600

2600

permissible rear axle loading

kg

2600

2600

9.00x15.3

9.00x15.3

10.0/75-15.3 10PR

10.0/75-15.3 10PR

Height

- without front attachment - with front attachment - front attachment mounting

Wheel rims Tyres Tyre pressure

bar

4,0

4,0

Tightening torque of wheel bolts (M18x1.5-8.8 with spring washer C18.5 DIN 74361)

Nm

255

255

km/h

40

40

Electrical system

V

12

12

6.1

ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort - 000 294 671 2

approved maximum speed

Assembly

Assembly

7 Assembly LOADING/UNLOADING TRAILER 1 Danger!

Inappropriate loading and transportation means danger of accidents!

– Only suspend the trailer for loading from the slinging points (1)!

– Make sure that the slings are strong enough!

Weight of trailer – see Specifications, page 6.1.

1

1

(Fig. 1, 2)

2

000 294 671 2 - ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort

7.1

Assembly ASSEMBLING TRAILER 1. Fix the orientation aid (6) to the pre-assembled rider (3) using the bolt (7).

6

Secure the bolt (7) with split pin (4).

7

(Fig. 3, 4)

3

3

4

7

4 2. Fit the gas struts (5).

(Fig. 5) 5

5

7.2

ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort - 000 294 671 2

Assembly 3. Align the mountings (1) and (2) in accordance with Fig. 6 and fit to the frame at the marked points (X): • (1) Mounting 1 front 2

• (2) Mounting 2 rear

1

• (8) Hex bolt M16x110 • (9) Contact washer B16 • (10) Plate • (9) Contact washer B16 • (11) Hex nut M16 6

(Fig. 6, 7, 8, 9)

X

7 1

X

8 8 9 10 9 11

9

000 294 671 2 - ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort

7.3

Assembly Check dimensions A

A

A

B

DIRECT DISC 610

1500 mm

3040 mm

DIRECT DISC 520

1500 mm

2560 mm

(Fig. 10) B 10 4. The mountings (12) are fitted ex works in accordance with Fig. 11. To ensure correct location of the front attachment the pin (13) must be inserted into the bottom hole (E).

If, because of the chopper tyres, the pin (13) needs to be inserted in the top hole (D), the mountings (12) must be adjusted accordingly.

(Fig. 11, 12)

12 11

13

D E

7.4

12

ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort - 000 294 671 2

Assembly 5. Insert the lighting cable (14) into the plug socket of the trailer and lay onto the drawbar.

6. Hook the safety snap cable (15) onto the parking brake.

(Fig. 13, 14)

14 13

15 14

14

000 294 671 2 - ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort

7.5

Prior to operation

Prior to operation

8 Prior to operation CHECK AND OBSERVE THE FOLLOWING BEFORE OPERATION 1. Check that all bolts and screws are tight.

2. Check tyres for damage and cracking.

3. Check the securing devices of the front attachment.

4. Check the brakes before every journey.

5. Check tyres for correct inflation, if required correct according to Specifications, page 6.1.

6. Make sure that the wheel nuts are tight. Tightening torques – see Specifications, page 6.1.

7. Check the function of the lighting.

8. Check the safety devices (e.g. covers over drive components, ...) for correct function and location.

9. Thoroughly lubricate the trailer before operation.

10. Before starting off, check the trailer and front attachment for any loose parts being carried.

Securely attach or cover parts which can fall off during travel.

8.1

ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort - 000 294 671 2

Operation

Operation

9 Operation PLACE THE FRONT ATTACHMENT ON THE TRAILER Danger!

Do not leave the operator's platform unless the engine is stopped.

– Remove the ignition key!

Secure trailer to prevent it from rolling away.

– Apply the parking brake!

– Secure the trailer using wheel chocks.

Proceed as follows to place the front attachment on the trailer:

• Release the universal drive shaft, hydraulic and electrical connections between the front attachment and the chopper – see operator's manual “DIRECT DISC 610 / 520”.

• Release all interlocks (1) on the trailer.

1 1

(Fig. 1)

1 1 1

Note!

2

If stands are fitted to the front attachment (2), the stands (2) must be removed from the front attachment before loading – see operator's manual “DIRECT DISC 610 / 520”.

(Fig. 2)

2

000 294 671 2 - ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort

9.1

Operation

Caution!

The trailer can only be loaded from the left hand side. (Seen from the chopper driver's location, the drawbar of the trailer is on the left hand side.)

• Lift the front attachment and slowly approach the trailer centrally from the left hand side. Lift the front attachment in front of the trailer and continue to drive forwards until the front attachment is located above the trailer. When doing this observe the orientation aid (3): The red mark (4) of the orientation aid must always be visible centrally above the front attachment by the chopper driver. Lower the front attachment accordingly.

3

Note!

3

It is helpful to mark an (X) centrally on the hood of the front attachment.

4 (Fig. 3, 4)

3

X

4

9.2

ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort - 000 294 671 2

Operation • Drive forwards until the skids (6) contact the supports (5). The upper section of the orientation aid (3) will then be vertical. The left hand mountings (8) can be seen from the cab of the chopper.

5

Lower the front attachment until the retaining pins (7) on the front attachment are located in the mountings (8).

6

(Fig. 5, 6, 7, 8)

5

3

6

3

7

7

8

8

000 294 671 2 - ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort

9.3

Operation • Switch chopper engine and remove ignition key.

Wait until the engine comes to a standstill before you vacate the driver's cab.

9

• Close the interlock on the right hand side.

A

Pull the lever (10) and swing the interlock (9) inwards.

10

Depending upon the position of the cutting discs, the interlock (9) must be located in position (A) or (B).

(Fig. 9, 10, 11) 9

9

B

10

10 B

• Check that the lever (10) is securely engaged (see

A

arrow).

(Fig. 11)

10

11

• Close the left hand interlock. Slide the lever (11) forwards.

(Fig. 12)

11

• Unhitch front attachment from chopper – see “DIRECT DISC 610 / 520” operator's manual.

12

9.4

ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort - 000 294 671 2

Operation REMOVING THE FRONT ATTACHMENT FROM THE TRAILER Danger!

Do not leave the operator's platform unless the engine is stopped.

– Remove the ignition key!

Secure trailer to prevent it from rolling away.

– Apply the parking brake!

13

– Secure the trailer using wheel chocks.

Proceed as follows to remove the front attachment from the trailer:

• Open the interlock on the right hand side by pulling the lever (2) and swing the interlock (1) outwards.

(Fig. 14)

1 2

14

• Open the interlock on the left hand side by locking the lever (3) in the back position.

(Fig. 15)

3

15

• Drive up to the front attachment with the chopper until the catching pegs of the infeed are located under the catching holes of the front attachment.

• Lift the front attachment and slowly drive away backwards with the chopper.

• Hitching front attachment to chopper – see “DIRECT DISC 610 / 520” operator's manual.

000 294 671 2 - ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort

9.5

Operation HITCHING TRANSPORT WAGON Proceed as follows for hitching the trailer to the tractor unit:

• Apply the parking brake (2)!

• Secure the trailer with the wheel chocks (1).

• Place the drawbar (3) in alignment with the hitch

1

coupling of the tractor unit.

(Fig. 16, 17)

1

16

2

3

17

• Using the help of a second person reverse the tractor until the hitch coupling locks in position.

• Check that the hitch (4) is securely engaged.

• Connect light cable (5) to tractor.

4

(Fig. 18)

5

18

• Secure the safety snap cable (7) to the parking 6

brake lever (6) and on the tractor unit.

(Fig. 19)

• Release the parking brake and stow the wheel

7

chocks in the brackets – see Wheel chocks, page 9.8.

19

9.6

ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort - 000 294 671 2

Operation UNHITCHING TRANSPORT WAGON Danger!

After unhitching the trailer it may start to move of its own accord!

– Before unhitching, apply the parking brake on the trailer and secure the trailer from rolling away with the wheel chock.

– Park the transport wagon on hard level ground only.

To unhitch the transport wagon proceed as follows:

• Drive the transport wagon a hard level site.

• Switch off engine and remove ignition key.

• Do not leave the tractor until the engine is stopped and the parking brake has been set.

1

• Apply the parking brake (4) on the trailer and secure the trailer from rolling away with the wheel chocks (1).

1

• Remove the safety snap cable (2) from the tractor unit and place on the trailer.

20

2

• Remove the lighting cable (3) from the tractor unit.

• Open hitch (5).

(Fig. 20, 21, 22)

• Drive away with the tractor.

3

21

4

5

3

22

000 294 671 2 - ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort

9.7

Operation WHEEL CHOCKS 1

1

The wheel chocks (1) are stored on the rear axle.

The wheel chocks must always be carried.

(Fig. 23)

23 Before unhitching the trailer it should be secured against rolling away with the wheel chocks (1).

(Fig. 24)

1 1

24 After use, place the wheel chocks (1) in the brackets (2) and secure with springs (3).

1

3

(Fig. 25)

2

25

9.8

ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort - 000 294 671 2

Maintenance

Maintenance

10 Maintenance

Brakes and axles Danger!

IMPORTANT MAINTENANCE INSTRUCTIONS

Incorrect repairs on the brake system may cause the brake system to fail.

Danger!

– All repairs and adjustments must be carried out by a specialist workshop only.

Repairs, maintenance and cleaning must only be carried out with the engine stopped!

– Remove the ignition key!

– Follow the manufacturer's recommended maintenance schedule.

– Secure transport wagon to prevent is from rolling (wheel chocks).

– A thorough check of the braking system should be carried out at regular intervals.

Chassis Danger!

Repairs, maintenance and cleaning on the lifted transport wagon or under it must only be carried out with it securely supported!

– Use appropriate supports.

Wheels / tyres

Check that the mounting bolts of the ring hitch are firmly seated after the first 10 hours of operation and then every 50 hours thereafter.

Bolts After about 10 operating hours all bolts and nuts on the trailer should be re-checked and tightened if necessary.

Thereafter check the screws regularly for tightness.

Fasteners Note!

Repair work on tyres must be carried out by qualified technicians using suitable equipment.

Check all safety-relevant fasteners such as pins, screw, bolts etc. regularly for wear and deformation.

If necessary replace the connection components with new parts.

Lubrication Danger!

Excessive pressure may cause tyres to burst.

– Stand clear of the tyre when inflating.

– Check the pressure regularly.

– Maintain the specified tyre pressure – see Specifications, page 6.1.

Use only good quality branded grease for lubricating the trailer. Clean the grease nipples before applying the grease gun. Lubricate regularly following the lubrication chart.

The lubrication intervals stated apply to normal service conditions only. If the trailer is used under difficult conditions more frequent lubrication is required.

Environment!

The wheel mounting bolts must be tightened to the torque specified by the manufacturer.

Dispose of oil and grease according to regulations!

After every wheel change tighten the wheel nuts or bolts after 10 hours of operation and then check the tightness every 50 working hours. For tightening torques see Specifications, page 6.1.

000 294 671 2 - ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort

10.1

Maintenance

Maintenance BRAKING SYSTEM Danger!

Only work under the trailer if securely supported!

– Secure the trailer with suitable supporting elements.

Incorrect repairs on the brake system may cause the brake system to fail.

– All repairs and adjustments must be carried out by a specialist workshop only.

– Follow the manufacturer's recommended maintenance schedule.

– A thorough check of the braking system should be carried out at regular intervals.

General information The following operating, handling, setting and maintenance regulations refer to BPW brakes, transmission, overrun and towing devices. They form a component part of the guarantee stipulations. The relevant operating regulations of the vehicle parts manufacturer must be observed. The maintenance tasks must be carried out at the prescribed intervals to retain the operating and traffic safety of the vehicle.

When fitting parts, we strongly recommend only using genuine BPW parts. The parts released by BPW are subject to regular tests. BPW accepts product responsibility for these parts. Our guarantee becomes void if replacement parts other than genuine BPW parts are used.

10.2

ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort - 000 294 671 2

Maintenance Function of reverse automatic system

1

On the trailer all four wheels are fitted with overrun brakes. As a result of a special brake shoe supporting system in the wheel brake, which releases the braking function during reverse movement, problem-free reverse setting is ensured at all times, even on hills.

This means that a reverse movement blocking lever for a mechanical block is not necessary. The normal braking function is immediately available again when travelling forward.

5

2 4 3 1

The associated overrun device is equipped with a gas-assisted hydraulic shock absorber. This produces virtually jerk-free driving and braking. All the individual components, wheel brake, transmission and overrun device work smoother because of this arrangement.

1 = Secondary brake shoe 2 = Expanding lock 3 = Primary brake shoe 4 = Reverse automatic lever 5 = Direction of travel (Fig. 1)

000 294 671 2 - ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort

10.3

Maintenance Operating and handling

7

6 = Parking brake lever 7 = Safety snap cable 8 = Tensioning lock 9 = Gas strut 1 10 = Gas strut 2 11 = Pull rod

6 X 8

9

Overrun movement X < 120 mm

11

(Fig. 2) 10 2

The braking system works fully automatically and requires no intervention. Please observe the following notes when operating the handbrake lever: Pull the parking brake lever firmly over the dead point (at least 3 teeth).

Attention!

When pulling the parking brake lever, this effects pretensioning of the gas struts after movement over the dead point!

The handbrake lever is automatically tensioned by the gas struts if the trailer has a tendency to roll backwards.

Pushing in the pull rod with the tractor unit makes the operation of the parking brake lever easier. This generally pushes the wheel brake into the automatic reversing unit and the parking brake lever can be pulled to the end position.

The tractor unit must be connected to the parking brake lever on the trailer by a safety snap cable. If the trailer releases from the tractor unit of its own accord, the trailer is stopped by the parking brake lever being applied by the safety snap cable.

10.4

ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort - 000 294 671 2

Maintenance Setting the wheel brakes Carry out the following working steps every 200 operating hours on the front and rear wheels:

• Secure the trailer against rolling away, lift at the relevant axle and make sure that proper support is provided.

• Remove the wheels.

• Release the pull connection on the braking

13

line (13) in the front of the wagon.

3

• Lock the hinged cams of the wheel brake using the auxiliary tool (14) (∅ 4 mm pin) through the plug aperture from the outside (insert pin at least 50 mm).

• Tighten the adjusting nuts (16) on the wheel

14

brakes with a spanner via the adjusting bolt (15) until the movement of the wheel in the direction of travel is stopped.

• Turn the adjusting nut (15) backwards until, when turning the wheel in the forward direction, no braking action can be detected any more.

15 15 68383

16

Attention!

4

Adjusting the wheel brake should only be carried out using the adjusting bolt (15)!

• In the front wagon the pull connection must be fitted to the braking line (13) and adjusted to have no play (Fig. 3).

This means that the pull rod of the overrun device must be fully pulled out and the diverting lever must be in contact with the pull rod. To test apply the parking brake lever slightly and check that the same braking force (in direction of travel) is available at the left hand and right hand brake drum. Also check that the braking effect on each drum takes place simultaneously.

Attention!

Remove the stop (14) (∅4 mm pin) from the brake cam! (Fig. 4)

• Refit the wheels (tightening torque – see Specifications, page 6.1).

(Fig. 3, 4)

000 294 671 2 - ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort

10.5

Maintenance Basic setting of the wheel brakes Basic setting of the wheel brakes front

18

The basic adjustment is carried out in the factory before delivery! Only if pull cables or parts of the support bearing group are replaced is new basic setting required.

Proceed as follows:

• Secure the trailer against rolling away, lift the front axle and make sure that proper support is provided.

13 5

• Remove the front wheels.

• Release the pull connection on the braking line (13) in the front of the wagon.

• Release the forks (18), to which the brake cables 13

of the wheel brakes are fixed, from the right hand and left hand levers of the braking unit in the front wagon.

18

• Lock the hinged cams of the wheel brake using the auxiliary tool (14) (∅ 4 mm pin) through the plug aperture from the outside (insert pin at least 50 mm).

• Tighten the adjusting nuts (16) on the wheel 6

brakes with a spanner via the adjusting bolt (15) until the movement of the wheel in the direction of travel is stopped.

• When carrying out the basic adjustment make sure that the holes in the forks (18) are exactly aligned in angle with the individual holes in the right hand and left hand levers of the braking unit.

In this position the forks must be connected with no play.

14

• Turn the adjusting nut (15) backwards until, when 15

turning the wheel in the forward direction, no braking action can be detected any more.

15 68383

16

7

Attention!

Adjusting the wheel brake should only be carried out using the adjusting bolt (15)!

• In the front wagon the pull connection must be fitted to the braking line (13) and adjusted to have no play.

This means that the pull rod of the overrun device must be fully pulled out and the diverting lever must be in contact with the pull rod.

(Fig. 5, 6, 7)

10.6

ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort - 000 294 671 2

Maintenance • With the parking brake lever slightly applied in forwards motion check the position of the right hand and left hand lever (19) of the braking unit in the front wagon.

19

The angular position of each lever (19) of the braking unit with released parking brake lever is W = 30° from the vertical to the rear, referred to the direction of travel. If necessary readjust the brake setting.

19

(Fig. 8, 9) 8

• Check for equal response of the braking of an axle or unit with slightly applied parking brake. If necessary adjust the brake setting.

Attention!

Remove the stop (14) (∅4 mm pin) from the brake cam! (Fig. 7)

19

• Refit the front wheels (tightening torque – see Specifications, page 6.1).

W

• With the parking brake lever applied in reverse 9

motion check the position of the right hand and left hand lever (19) of the braking unit in the front wagon. The angular position of each lever (19) of the braking unit can be up to 30° from the vertical to the front, referred to the direction of travel. Then readjust the brake setting.

(Fig. 8, 9)

000 294 671 2 - ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort

10.7

Maintenance Basic setting of the wheel brakes rear The basic adjustment is carried out in the factory before delivery! Only if pull cables or parts of the support bearing group are replaced is new basic setting required.

Proceed as follows:

• Secure the trailer against rolling away, lift the rear axle and make sure that proper support is provided.

13 10

• Remove the rear wheels.

• Release the pull connection on the braking line (13) in the front of the wagon.

• Open the cover on the rear wagon.

• Release the forks (19) and (20), which are fixed to

19 20

the brake cables of the wheel brakes, form the intermediate lever in the rear wagon.

• Lock the hinged cams of the wheel brake using the auxiliary tool (14) (∅ 4 mm pin) through the plug aperture from the outside (insert pin at least 50 mm).

• Tighten the adjusting nuts (16) on the wheel 11

brakes with a spanner via the adjusting bolt (15) until the movement of the wheel in the direction of travel is stopped.

• When carrying out the basic adjustment make 14

sure that the holes in the forks (19)and (20) are exactly aligned in angle with the individual holes in the intermediate lever in the rear wagon. In this position the forks of the brake cables must be connected with no play.

• Turn the adjusting nut (15) backwards until, when

15

turning the wheel in the forward direction, no braking action can be detected any more.

15 68383

16

12

Attention!

Adjusting the wheel brake should only be carried out using the adjusting bolt (15)!

• In the front wagon the pull connection must be fitted to the braking line (13) and adjusted to have no play.

This means that the pull rod of the overrun device must be fully pulled out and the diverting lever must be in contact with the pull rod.

(Fig. 10, 11, 12)

10.8

ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort - 000 294 671 2

Maintenance • With the parking brake lever lightly applied, check the position of the bell crank (21) in the front wagon.

• The angular position of the bell crank (21) with the

21

parking brake lever released is W = 30° from the vertical to the back, referred to the direction of travel. If necessary readjust the brake setting.

(Fig. 13, 14)

• With the parking brake lever slightly applied, check simultaneous response of the brakes on the rear axle. If necessary adjust the brake setting.

13

Attention!

Remove the stop (14) (∅4 mm pin) from the brake cam! (Fig. 7)

• Refit the rear wheels (tightening torque

21

– see Specifications, page 6.1).

• Then check the position of the bell crank (21) in

W

the front wagon in reverse travel with the parking brake lever applied. The angular position of the bell crank (21) can be up to 30° from the vertical to the front, referred to the direction of travel. Then readjust the brake setting.

14

(Fig. 13, 14)

000 294 671 2 - ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort

10.9

Maintenance Maintenance intervals After 50 operating hours The brake linings will have bedded in with the brake drums and the transmission system will have settled after the first few kilometres of driving. The play created by this process must be taken up by adjustment.

Proceed as follows:

• Adjusting the wheel brakes – see Setting the wheel brakes, page 10.5.

• Check the overrun movement used with a stop braking procedure. The overrun movement used should not exceed 50 - 60% of the maximum overrun movement (X = 120 mm). If that is the case, the setting of the wheel brake must be repeated.

X

(Fig. 15)

• Now check that the trailer can be pushed backwards slightly by the tractor unit. If the trailer brakes too sharply the setting of the wheel brake should be released slightly.

15

• After setting is complete make sure that the lock nuts are tightened.

Every 200 operating hours

• Check the function of the braking system as described in “After 50 operating hours”.

• Check the thickness of the brake linings. This is done by removing the plastic plug from the viewing hole and performing a visual check. If the brake linings are damaged or if the lining thickness is less than 2 mm, the brake shoes must be replaced. Damaged parts (springs, expanding locks etc.) must also be replaced in this case.

Every 250 operating hours

• Lubricate all bearings. Lubricate the ropes with oil.

• Check the play of the wheel bearings and adjust if necessary – see Adjusting taper roller bearing, page 10.13.

10.10

ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort - 000 294 671 2

Maintenance Problems and their possible causes Problem

Causes

Remedy

Braking effect too weak

Brake linings not bedded in

Improvement after a few braking operations

Ropes are being fully pushed in

Adjust brakes – see Setting the wheel brakes, page 10.5 or Basic setting of the wheel brakes, page 10.6.

Large frictional losses

Check transmission system and oil if necessary

Reverse is difficult

Braking system set too tight

Adjust brakes – see Setting the wheel brakes, page 10.5 or Basic setting of the wheel brakes, page 10.6.

Rough driving behaviour

Shock absorbers on the overrun faulty

Change shock absorbers on the overrun

Braking system set wrongly

Adjust brakes – see Setting the wheel brakes, page 10.5 or Basic setting of the wheel brakes, page 10.6.

Brake linings not bedded in

Improvement after a few braking operations

Large frictional losses

Check transmission system and oil if necessary

Braking system set wrongly

Adjust brakes – see Setting the wheel brakes, page 10.5 or Basic setting of the wheel brakes, page 10.6.

Braking effect of the parking brake too weak

000 294 671 2 - ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort

10.11

Maintenance CHASSIS Tyres: Danger!

Damaged tyres can lose pressure unexpectedly in use and can cause the trailer to swing out. This also endangers stability, particularly when driving on slopes!

– Check tyres for damage and pressure loss regularly.

– Tyres must be repaired by qualified technicians with suitable equipment only.

Avoid an excessive inflation pressure.

Danger of bursting!

– Stand clear of the tyre when inflating.

– Use only compressed air to inflate tyres.

– Do not exceed maximum permissible air pressure.

Check the tyre pressure regularly.

Do not exceed the specified air pressure.

Approved air pressure – see Specifications, page 6.1.

10.12

ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort - 000 294 671 2

Maintenance Wheel changing Change wheels on flat solid ground.

1

Secure trailer to prevent it from rolling away.

Use a suitable jack.

Lift the trailer at the jacking points (1). The jacking points are marked by stickers (2).

(Fig. 16, 17, 18)

16

After every wheel change tighten the wheel nuts or bolts after 10 hours of operation and then check the tightness every 50 working hours.

Tightening torques – see Specifications, page 6.1.

1

17

2

Adjusting taper roller bearing Every three months the wheel bearings should be checked for play. If axial play on the wheel brakes is detected, the taper roller bearings must be adjusted in accordance with the following sequence: 1. Remove wheel cap and split pin.

515 773.0

18

2. Tighten the axle nut until the wheel hub or brake drum brakes slightly.

3. Turn the axle nut back (release) up to the next split pin hole.

4. Check bearing clearance.

5. Reinsert the split pin, tap the wheel cap back into position.

Attention!

Setting too tight leads to bearing damage.

000 294 671 2 - ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort

10.13

Maintenance FASTENERS Check all safety-relevant fasteners such as pins, screw, bolts etc. regularly for wear and deformation.

If necessary replace the connection components with new parts.

SCREW CONNECTIONS After about 10 operating hours all bolts and nuts on the trailer should be re-checked and tightened if necessary.

Thereafter check the screws regularly for tightness.

Frame The mounting bolts (1) of the frame should be checked after the first 10 operating hours and retightened if necessary.

Thereafter check the screws regularly for tightness.

1 Tightening torques of the bolts (1) M16 = 200 Nm.

19

CLEANING AND CARE

• Do not use high pressure cleaners and steam cleaners to clean torque-overload clutches, bearing parts, hydraulic components and electrical parts.

– danger of damage and rust formation.

• Paint damage can be caused by cleaning at too high a pressure.

• The bearing points must be greased before and after cleaning with a high-pressure cleaner!

Then carry out a short test run to squeeze out the water that has entered the bearings.

• There should be a collar of grease present at the bearing locations. This protects the bearing from the ingress of dirt, plant juices and water.

• When storing the trailer outdoors for longer periods the piston rods of the gas struts should be cleaned and then coated in grease.

10.14

ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort - 000 294 671 2

Maintenance END OF SEASON STORAGE 1. Clean all grass and dirt from the trailer. Clean off grease and dust from the exterior of all bearings.

2. Lubricate all lubrication points thoroughly until the grease comes out of the bearings – see Lubrication Chart, page 11.2.

3. Check transport wagon for wear and damage and have it repaired.

4. Clean rust off and repair paint damage.

5. Paint tyres with a protective paint to prevent the rubber from deteriorating.

6. Store transport wagon in a dry weatherproof space away from synthetic fertiliser.

LUBRICATION CHART Component

Specification of lubricant type

Grease nipple

Quality multi-purpose grease DIN 51825 - K2K

Viscosity/SAE class

CLAAS multi-purpose grease EP2 KP 2K-30 Order no.: 400 g cartridge other lubrication points

Change periods/checks

see Lubrication Chart

0147 451.0

Biodegradable lubricating oil CEC-L-33-A-93 > 80% CLAAS roller chain oil BIO HEES 46 Order no.: 5 ltr. PE can.

see Lubrication Chart

0147 457.0

Quality lubrication grease e.g.

FINA

“Marson EPL 2”

ARAL

“Aralub HLP 2”

FUCHS “Rendit TEP 2” SHELL

“Retinax EP 2” or “Alvania G3”

DEA

“Glisando EP”

FAG

“Arcanol L 135 V”

SKF

“LGEP2”

000 294 671 2 - ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort

10.15

Lubrication Chart

Lubrication Chart

11 Lubrication Chart SAFETY RULES Danger!

Before lubricating secure the trailer against rolling away.

– Apply the parking brake!

– Secure the trailer using wheel chocks.

LUBRICANTS Specifications – see Lubrication chart, page 10.15.

LUBRICATION

Lubricate these grease points every 250 working hours.

11.1

ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort - 000 294 671 2

Lubrication Chart

Lubrication Chart

3

1

6

2

5

4

1

2

3

4

5

6

000 294 671 2 - ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort

11.2

At CLAAS KGaA mbH we are constantly improving our products to reflect the latest technological developments.

For this reason, we may from time to time need to make changes to diagrams and descriptions in this documentation which do not reflect products which have already been delivered and which will not be implemented on these machines.

Technical data, dimensions and weights are understood with the usual tolerances. Responsibility for errors or omissions not accepted.

Reproduction or translation of this publication, in whole or in part, is not permitted without the written consent of the CLAAS KGaA mbH. All rights under the provision of the Copyright Act are reserved.

CLAAS KGaA mbH 33426 Harsewinkel Germany Our contribution to the environment: CLAAS have printed this manual on 100% chlorine free paper.

CLAAS KGaA mbH Postfach 1163 33426 Harsewinkel - Germany Tel.: +49 (0) 5247 12-0 www.claas.com

000 294 671 2 ZBA/BA TW DIRECT DISC 610 / 520 Contour / 520 Comfort EN - 04.08 Printed in Germany