Table of Contents
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Table of contents
1.
INTRODUCTION ................................................................................................. 2
1.1.
PURPOSE ...................................................................................................... 2
1.2.
TECHNICAL SPECIFICATIONS ................................................................ 3
1.3.
DESIGN OF THE DEVICE .......................................................................... 4
1.4.
MAIN MODULES ......................................................................................... 5
1.5.
SAFETY DEVICES ..................................................................................... 13
2.
INSTALLATION ................................................................................................ 20
2.1.
UNPACKING .............................................................................................. 20
2.2.
ADJUSTMENTS ......................................................................................... 20
2.3.
WITHDRAWAL FROM USE AND STORAGE ........................................ 20
3.
FUNCTIONAL DESCRIPTION ......................................................................... 21
3.1.
HANDLING IN ROLL ON - ROLL OFF .................................................. 21
3.2.
HANDLING IN TIPPING ........................................................................... 23
3.3.
OPERATION WHEN DRIVING ................................................................ 24
3.4.
CHANGING OPERATING FUNCTION ................................................... 25
3.5.
ELECTRICAL SYSTEM ............................................................................ 26
3.6.
HYDRAULIC SYSTEM ............................................................................. 28
4.
SAFETY INSTRUCTIONS ................................................................................. 30
4.1.
GENERAL ................................................................................................... 30
4.2.
WORKING AT EXTREME CONDITIONS ............................................... 32
4.3.
ACTING IN DANGEROUS SITUATION ................................................. 32
5.
MAINTENANCE / SPARE PARTS ................................................................... 34
5.1.
MAINTENANCE SCHEDULE .................................................................. 34
5.2.
MAINTENANCE OPERATIONS .............................................................. 35
5.3.
SPARE PARTS ............................................................................................ 40
6.
TROUBLESHOOTING ....................................................................................... 51
CONTACT INFORMATION:
Factory:
AS FORS MW
Tule 30
765 05 Saue
Estonia
Tel: + 372 679 00 00
Fax: + 372 679 00 01
E - mail:
info@forsmw.ee
© 2005 Ver. 1 Fors MW Ltd
Aftermarket:
Language spoken is English and Swedish.
FMW Farma Norden AB
Hornsväg 2
605 97 Norrköping
Sweden
Tel: + 46 (0) 165 770
Fax: + 46 (0) 128 370
E - mail:
aftermarket@forsmw.ee
www.forsmw.com
20-24
1
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Table of Contents
Related Manuals for Bigab 20-24
Summary of Contents for Bigab 20-24
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Page 1: Table Of Contents
20-24 Table of contents INTRODUCTION ....................2 1.1. PURPOSE ...................... 2 1.2. TECHNICAL SPECIFICATIONS ..............3 1.3. DESIGN OF THE DEVICE ................4 1.4. MAIN MODULES ..................5 1.5. SAFETY DEVICES ..................13 INSTALLATION ....................20 2.1. UNPACKING ....................20 2.2. -
Page 2: Introduction
Bigab 20 – 24 is the largest trailer within our assortment. Simple, impressive and powerful are expressions that all suit the Bigab 20 – 24. This is a trailer for those in need of extra heavy transportation. For your safety, it is extremely important that you follow the instructions presented in this instruction manual for your particular BIGAB model. -
Page 3: Technical Specifications
20-24 1.2. TECHNICAL SPECIFICATIONS Technical specifications. Table 1. Hooklift trailer 20-24 Frame:Hollow sections 300*100 Bogie:Pendulum Axel distance 1470 mm Hubs: 110*110, 10 bolts Wheels: 600/50-22,5 400*120 on 4 wheels Brake: Hydraulic drum Depending on market Towing eyelet: Type for hitch hook... -
Page 4: Design Of The Device
20-24 1.3. DESIGN OF THE DEVICE The Trailer is constructed out of cold hollow steel sections. Through this construction the trailer receives maximum endurance and stiffness regarding both bending as well as twisting. The trailer is steady both in the tip as well as in the changing movement. -
Page 5: Main Modules
The trailer consists of the following subassemblies and functional devices. 1.4.1. Chassis Chassis is constructed out of cold hollow steel sections. It exists in two different variants. Chassis for Bigab with bogie block system (figure 2a) and chassis for Bigab with frame block system (figure 2b). Guide... - Page 6 20-24 1.4.2. Back frame Back frame is constructed out of cold hollow steel sections Frame Figure 3. Back frame 1.4.3. Hook frame The hooking frame with hydraulic telescope cylinder is constructed from sheet metal. Hook Telescope Frame Stroke 1300 mm Hydraulic cylinder (inside) Figure 4.
- Page 7 20-24 1.4.4. Bogie The Trailer is equipped with a strong pendulum bogie that has been equipped with brakes on all wheels. Brake cylinder Body Axle with brake Figure 5. Bogie 1.4.5. Hook The Trailer is equipped with adjustable hook for two different standard heights.
- Page 8 20-24 1.4.6. Support leg Support leg is designed to be of supporting use when the trailer is under maintenance or when trailer is not in use. Before driving the support leg must be lifted up and fixed with the pin. Also available is adjustable support leg as additional equipment.
- Page 9 20-24 1.4.8. Towing eyelet The eyelet is used to hitch the trailer to the pulling vehicle. It is extremely important that the towing eyelet is checked for defaults every time the trailer is used. The towing eyelet needs to be replaced at least once a year. It is the users responsibility to see to that this is done.
- Page 10 20-24 1.4.10. Steering rollers The steering rollers are designed to guide the container. During handling roll on – roll off the container frame must be inside the rollers. Steering Steering roller roller Chassis Figure 12. Steering rollers 1.4.11. Bogie block The hydraulic bogie block is used for bogie blocking during the handling of roll on –...
- Page 11 20-24 1.4.12. Frame locking The hydraulic frame locking is used for frame blocking during the handling of roll on – roll off. Frame lock hydraulical cylinder Chain to the tractor Figure 14. Frame lock 1.4.13. Wheels Wheels Table 2. Trailer type...
- Page 12 20-24 1.4.14. Hydraulic system The trailer is equipped with a hydraulic system for working movements. See chapter 3.5 1.4.15. Electrical system The trailer is manufactured with 12V electrical system. See chapter 3.4 1.4.16. Brake system The trailer is equipped with hydraulic brake system. Also is available pneumatic brake system as an additional extra.
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Page 13: Safety Devices
20-24 1.5. SAFETY DEVICES 1.5.1. Security post Always use the safety support when carrying out service work in the tipped position. The safety support may not be used under any circumstances when the container bridge is loaded. Chassis Security post Figure 15. - Page 14 20-24 1.5.3. Presentation of decals Figure 17. Warning triangle and instruction manual decal. The trailer is supplied with a warning triangle alongside the instruction manual decal in order to reinforce the requirement for the user to read the entire instruction manual carefully before starting to use the trailer. Ignoring this can entail a danger to life.
- Page 15 20-24 Figure 21. Risk of slipping There is a risk of slipping as the surfaces of the trailer can be slippery due to precipitation in combination with pre-existing oil and/or clay on the surface. The ground around the trailer can also become slippery, as the tyres can tear up the surface and expose clay and soil.
- Page 16 20-24 Figure 24. Use the safety support during all service Leaning under the raised frame is absolutely prohibited unless it is blocked with the safety support. Under no circumstances may the trailer be carrying either a load or a container when using the safety support.
- Page 17 20-24 Figure 27. Tyre inspection The tyres must be tightened and the brakes checked regularly at a minimum interval of 40–50 kilometres. Figure 28. Lubrication. This decal is used to show the importance of regular lubrication of the trailer. Figure 29. Data plate ©...
- Page 18 20-24 Nut tightening torque Table 3 Thread Dished discs Flat discs st 37 Flat discs St52 Screw Class. Screw Class. Nuts with spherical 10.9 collar,conical nuts. N.m. Screws with M18x1,5 spherical collar. M20x1,5 M22x1,5 M18x1,5 Flat collar nut with M20x1,5...
- Page 19 20-24 Hose label colors: • Red - oil from pump. • Blue - oil to tank. • Yellow - Brake Marking for hydraulic hoses Table 4. Color mark Function Yellow Brake Tipping cyl. ( up ) Blue Tipping cyl. ( down )
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Page 20: Installation
20-24 2. INSTALLATION 2.1. UNPACKING Before unpacking, check visually that the trailer is not damaged during transportation. If the trailer is damaged, inform about this to the company that transported the trailer and the manufacturer of the product immediately. • Usage of the trailer is strictly forbidden if safety devices of the trailer are damaged. -
Page 21: Functional Description
HANDLING IN ROLL ON – ROLL OFF Exchange and tipping must be operated from the operator’s seat in the towing vehicle! If your BIGAB is equipped with suspension there is no bogie blocking. Ensure that the trailer is Ensure that the hydraulic... - Page 22 20-24 Figure 3 STOP Stop if the tractor lifts off the ground! Check that the hook hitches around the loop. Check that the frame lock and bogie blocking are activated. On-loading! Check that the load carrier is inside the discs. Release the brakes on both the towing vehicle and the trailer to make it easier to roll on the load.
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Page 23: Handling In Tipping
20-24 3.2. HANDLING IN TIPPING Note! For the models mentioned in this instruction manual, the maximum container bridge length is 6.0 m during tipping. Ensure that the towing vehicle and the trailer are securely coupled before tipping. Figure 1 Ensure that the trailer is in the tipping position... -
Page 24: Operation When Driving
20-24 3.3. OPERATION WHEN DRIVING It is the responsibility of the user to ensure that a sufficiently powerful and heavy towing vehicle is coupled to the trailer in all situations. The use of a towing vehicle that is too small and insufficiently powerful can entails risks for the user and the surrounding environment, as well as leading to damage to the vehicle and trailer. -
Page 25: Changing Operating Function
20-24 3.4. CHANGING OPERATING FUNCTION Figure 21 shows the hydraulic changing drive between the operating functions. The changing unit is located on the middle of the back frame. Tipping position Hook frame Back frame Locking pin Hydraulic cylinder Hooking position Figure 33. -
Page 26: Electrical System
20-24 3.5. ELECTRICAL SYSTEM The trailer is manufactured with 12V electrical system. Configuration depends of options, example reversing light, border light or additional cable connector. 7 pool connection to pulling vehicle Note! For complete connection schedule see the following page Figure 34. - Page 27 20-24 Connections of the cables and lamps. Table 6. Color Function Lamp Flashing left 12V-21W (L1) Brown Reversing light 12V-21W (L5) Brown Spare (without reversing light) Yellow Earth Blue Flashing right 12V-21W (L1) Grey Rear right 12V-21W (L2) Brown Side marking...
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Page 28: Hydraulic System
20-24 3.6. HYDRAULIC SYSTEM 3.6.1. Main hydraulic system The trailer is delivered with filled up and tested hydraulic system. The hydraulic system consists of the functional components showed in the figure 24. Technical data and configuration depends on the type of trailer (see table 1). The hydraulic system is filled up with hydraulic oil VMGZ or SAE100R16. - Page 29 20-24 3.6.2. Frame lock hydraulic system Figure 36. Frame lock hydraulic system. Hydraulic components for frame lock Table 8. Pos. Art. No. Title 313134 Cylinder 90/40-300 915275 Manometer 915271 Pilot operated check valve 915266 Pressure reducing/relieving valve 915280 Hydro-pneumatic accumulator...
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Page 30: Safety Instructions
20-24 4. SAFETY INSTRUCTIONS IMPORTANT: READ AND UNDERSTAND THE USER MANUAL CAREFULLY BEFORE USING THE DEVICE. CONSULT THE USER MANUAL TO SOLVE YOUR PROBLEMS. THE DEVICE HAS AN IDENTIFICATION LABEL ON IT. BEFORE USING THE TRAILER, ENSURE THAT FACTORY SETTINGS HAVE NOT CHANGED AND THAT NO PARTS HAVE LOOSEN DURING TRANSPORTATION. - Page 31 20-24 During maintenance: • Be sure that the trailer is standing on a flat surface. • Be sure that the trailer can’t move. • When lubrication or servicing the trailer, turn off the vehicle engine. • Be sure that the trailer can’t slip when using support leg, jack or similar equipment.
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Page 32: Working At Extreme Conditions
• Recommended load placement - symmetrical. 4.2. WORKING AT EXTREME CONDITIONS Recommended working temperature range for a Bigab trailer is –30°C up to +40°C. Note that working at low temperatures accelerates hydraulic gaskets wearing and increases hydraulic hoses exposure to damages and steel constructions exposure to brittle fracture. - Page 33 20-24 IF YOU ARE INSIDE THE MACHINE Get out of it by JUMPING. Avoid touching any conducting parts. Do not make yourself a wire through which electricity may flow. Get away from the machine by JUMPING so that both feet do not touch the ground at the same time. Electric field at ground can cause fatal voltage between legs.
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Page 34: Maintenance / Spare Parts
20-24 5. MAINTENANCE / SPARE PARTS 5.1. MAINTENANCE SCHEDULE All kinds of maintenance work are subdivided into two groups: operating (preventive) and compulsory (scheduled). The need for operating maintenance is determined based on the results of checking. General • Maintenance works must be carried out regularly to ensure safe and malfunction-free operations. -
Page 35: Maintenance Operations
20-24 • Check if there is enough lubricant on glide surfaces. • Clean and lubricate hydraulic cylinders. • Check hydraulic hoses for damages. Recommended lubricants: BRAND TYPE Energrease LS-EP2, L2M ESSO Beacon EP2, Multipurpose GR Moly MOBIL Mobilux EP2, Mobil Grease MP Special... - Page 36 20-24 5.2.2. Maintenance of the hydraulic units Hydraulic system is shown in chapter 3.5. • Clean and lubricate piston rods of hydraulic cylinders. • Check the hydraulic valves: Check visually hydraulic valves. In case of leaking replace the damaged valve.
- Page 37 If necessary contact our service department! BIGAB models 7 – 10, 8 – 12 and 10 – 14 – the brake show distance to the drum needs to be adjusted through loosening and by doing so adjusting the brake control linkage.
- Page 38 20-24 BIGAB models 12 – 15, 15 – 19 and 20 – 24 – the brake show distance to the drum on the brake cylinder needs to be adjusted through loosening or vice versa tightening the adaptable screw on the brake.
- Page 39 20-24 5.2.8. Lubrication Recommended lubrication cycle is once per week or after 20 working hours. Lubricate points equipped with grease nipples by using a grease gun. See chapter 5.1 for recommended lubricants. • Ensure regularity of lubrication by following the lubricating schedule.
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Page 40: Spare Parts
20-24 5.3. SPARE PARTS 5.3.1. Hook frame Figure 40 Hook frame Hook frame spare parts Table 9. Pos. Art. No. Description Note Hook frame compl 37221269 Telescopic frame 37221079 Telescopic claw 37221112 Axle 37221110 Axle 37221115 Axle 37211180 Distance ring... - Page 41 20-24 5.3.2. Back frame Figure 41. Back frame Back frame spare parts Table 10. Pos. Art. No. Description Note 37221500 Frame 372320370 Axle 320350 Roller Slide bearings Ǿ100 909115 © 2005 Ver. 1 Fors MW Ltd www.forsmw.com...
- Page 42 20-24 5.3.3. Bogie Figure 42. Bogie Bogie spare parts Table 11. Pos. Art. No. Description Note 37221031 Bogie comp. L 37221030 Bogie comp. R 37211040 Bogie axle 916150L Stub axle 916150R Stub axle Slide bearings Ǿ80 909125 916480 Ring nut M22...
- Page 43 20-24 5.3.4. Bogie block Figure 43.Bogie block Bogie block spare parts Table 12. Pos. Art. No. Description Note See chapter 313158 Bogie block / lift cylinder 100/60-180 3.5.1 and 5.3.8 5.3.5. Frame locking Figure 44.Frame lock © 2005 Ver. 1 Fors MW Ltd...
- Page 44 20-24 Frame locking spare parts Table 13. Pos. Art. No. Title 392024 Hydr. frame lock system 37121520 Link 37121525 Link 37121530 Link 37121535 Support 37121522 Axle 37121527 37121532 37121532 37024378 908110 Locking pin 4x45 DIN 94 911250 Stopper ring 20 DIN 471...
- Page 45 20-24 5.3.6. Changing operating unit Back frame 1, 2, 4 Figure 45. Changing operation unit Changing operating unit spare parts Table 14. Pos. Art. No. Description Note Changing unit comp. 37221120 920515 Spring 37221220 Slider plate 37221210 Washer See chapter...
- Page 46 20-24 5.3.7. Hydraulic components For main hydraulic diagram see chapter 3.5.1 Main hydraulic components spare parts Table 15. Pos. Art. No. Description Note 913260L Tipping / Rolling cylinder 160/80-1790 913260R Tipping / Rolling cylinder 160/80-1790 37913255 Sealing kit for hydraulic cyl. 160/80 37913256 Front bush for hydraulic cyl.
- Page 47 20-24 Frame lock hydraulic components spare parts Table 16. Pos. Art. No. Title 313134 Cylinder 90/40-300 37313940 Sealing kit for hydraulic cyl. 90/40 37313942 Front bush for hydraulic cyl. 90/40 37313944 Piston for hydraulic cyl. 90/40 915275 Manometer 915271 Pilot operated check valve...
- Page 48 20-24 5.3.8. Cylinder description Figure 46.Cylinder description Table 17. Pos. Description Note Piston rod Spec. order Tube assy Spec. order Front bush Piston Scrape ring Included in sealing kit Sealing Included in sealing kit Bush Included in sealing kit Sealing...
- Page 49 20-24 5.3.9. Electrical system For electrical scheme see chapter 3.4 Pos. 5-8 concerning spare parts table is not shown in electrical scheme. Figure 47. Rear lamp Electrical spare parts. Table 18. Pos. Art. No. Description Note 920765 Rear lamp 920766...
- Page 50 20-24 5.3.10. Other parts 4, 5 Figure 48. Other spare parts Other spare parts Table 19. Pos. Art. No. Description Note 930105 Grease nipple 920120 Towing eyelet 37221002 Hook Picture shows 37203068 Support leg adjustable leg 37203067 37203085 Security post See figure 15.
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Page 51: Troubleshooting
20-24 6. TROUBLESHOOTING These troubleshooting instructions are provided to help you to determine the cause for a malfunction. Electrical equipment troubles Fault symptoms Reason and action Lights fault Lamp born out. Replace lamp. Check and clean electrical connectors. Wire broken.
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