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ROPA KS 475 Translation Of The Original Operating Manual

Haulm topper
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Translation of the Orig-
inal Operating Manual
Haulm topper
Edition 1
Printed in Germany: 10/2021
E901450GB

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Summary of Contents for ROPA KS 475

  • Page 1 Translation of the Orig- inal Operating Manual Haulm topper Edition 1 Printed in Germany: 10/2021 E901450GB...
  • Page 2 – with the express approval of ROPA GmbH. Any type of reproduction, distri- bution 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.
  • Page 3 Contents Contents 3 / 110...
  • Page 4 Contents 4 / 110...

  • Page 5: Table Of Contents

    Contents Preface................7 Name plate and important data...............11 Declaration of Conformity................ 12 Extended documentation................. 13 1.3.1 Supplier documentation and purchased parts operating manual.... 13 Safety................15 General....................17 Obligations of the entrepreneur...............17 General symbols and instructions............18 2.3.1 Safety signs..................... 19 Proper use....................
  • Page 6 Torque table for screws and nuts (Nm)...........98 Maintenance verification................99 9.6.1 Maintenance verification oil change............99 9.6.2 Maintenance confirmation................99 Confirmation about instructions given to the driver....... 100 Safety instructions................. 101 ROPA Handover confirmation............... 103 9.10 ROPA First Use Record................ 105 Index................107 6 / 110...

  • Page 7: Preface

    Preface Preface 7 / 110...
  • Page 8 Preface 8 / 110...
  • Page 9 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, otherwise the safety and operability of the machine may be impaired.
  • Page 10 We expressly point out that any damage caused by the fact that this operating man- ual is not or not completely followed, is not covered by the statutory warranty of ROPA. Even though this operating manual is comprehensive, in your own interest you should completely and carefully read it and slowly familiarize yourself with the machine using this operating manual.

  • Page 11: Name Plate And Important Data

    Preface Name plate and important data Name plate and important data The name plate (1) of the machine is located on the right side of the three-point for rear attachment to the tractor. Please enter the data of your machine in the following image of the name plate. You will need this data for ordering spare parts.

  • Page 12: Declaration Of Conformity

    Preface Declaration of Conformity Declaration of Conformity The Declaration of Conformity belongs to separately provided documents and is handed over on the delivery of the machine. The CE marking of the machine is a constituent part of the name plate. 12 / 110...

  • Page 13: Extended Documentation

    Preface Extended documentation Extended documentation Additional documents in addition to this operating manual also apply, e.g. Supplier documentation Wiring diagrams 1.3.1 Supplier documentation and purchased parts operating manual The operating manuals for the purchased parts must be followed and they are attached to the technical documentation as separate sections.
  • Page 14 Safety 14 / 110...

  • Page 15: Safety

    Safety Safety 15 / 110...
  • Page 16 Safety 16 / 110...

  • Page 17: General

    Safety Obligations of the entrepreneur General The machine has been manufactured according to the current state of technology and tested for safety. The machine is CE compliant and therefore conforms to the respective European reg- ulations for free movement of goods within the European Union respectively the Euro- pean economic region.

  • Page 18: General Symbols And Instructions

    Safety General symbols and instructions 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 signal word warns of imminent danger of fatal accident or serious injury.

  • Page 19: Safety Signs

    Safety General symbols and instructions 2.3.1 Safety signs The safety signs illustrate a danger source. Warning of a general danger This warning symbol stands for activities where several causes may lead to hazards. Warning of dangerous electrical voltage This warning symbol stands for activities during which the hazards of electrical shocks with possible deadly consequences exist.

  • Page 20: Proper Use

    Safety Proper use Proper use This machine is exclusively meant for: removal of potato haulm or haulm of similar crops. Included in proper use is that the machine is driven under compliance with the applic- able road traffic regulations on public roads. This includes driving forward and back- ward.

  • Page 21: Hazard Zone

    Safety Hazard zone Hazard zone Hazard zone front attachment Hazard zone rear attachment Nobody may stay in the hazard zone during operation of the machine. The opera- tor must immediately shut down the machine in case of any threatening hazard and request the persons concerned to leave the hazard zone immediately.
  • Page 22 Damaged or illegible safety stickers must be replaced immediately. The meaning of each individual pictograph is explained below. In addition, a six- or nine-figure number is given for each pictograph. This is the ROPA order number. Stat- ing this number, you may reorder the respective pictograph from ROPA.

  • Page 23: Safety Stickers On The Machine

    Safety Safety stickers on the machine Safety stickers on the machine Safety stickers on KS 475 23 / 110...
  • Page 24 Safety Safety stickers on the machine Safety stickers on KS 490 24 / 110...
  • Page 25 Safety Safety stickers on the machine 355045000 355045100 Before starting up, read Shut down the engine the operating manual before performing main- respectively the main- tenance and repair work tenance manual and and pull out the ignition observe all remarks on key.

  • Page 26: Safety And Health Protection

    Safety Safety and health protection Safety and health protection The stipulations and regulations listed below must be rigorously observed in order to reduce the risk of personal injury and/or property damage. Furthermore, the region- ally applicable regulations and instructions on safety at work and for safe handling of tractor-towed agricultural machines must be observed at all times.

  • Page 27: Requirements For Operating And Maintenance Personnel

    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 authorised by ROPA for these activities. In case of doubt, ask the manufacturer whether you may perform a specific activity yourself without any hazard.

  • Page 28: Residual Risks

    Safety Hazards caused by mechanical influences 2.11 Residual risks Residual risks are special hazards involved in the use of the machine which cannot be fully eliminated despite a safety-conscious design. These residual risks are not readily recognizable and may result in injury or damage to health. In the event such unforeseen residual risks become apparent, the machine must be shut down immediately and the responsible supervisor informed accordingly (if applic- able).

  • Page 29: Hazards Caused By Process Materials

    Safety Hazards caused by noise 2.13 Hazards caused by process materials WARNING Oil and grease can cause the following damage: poisoning by inhalation of fuel vapours. allergies due to skin contact with oil or grease. fire and explosion hazard due to smoking or the use of fire or naked flame when handling oil or grease.

  • Page 30: Hazards From Gear Oil

    Safety Risks due to drive shafts 2.15 Hazards from gear oil WARNING Gear oil may cause irritation of the skin. Leaking gear oil can be harmful for the envi- ronment High temperatures partially prevail in the angular gear. Gear oil escaping under pressure, in case of defective venting of the angular gear, may enter the body through the skin and cause scalding.

  • Page 31: Personal Protective Equipment

    Safety Prohibition of unauthorised modifications and alterations 2.18 Personal protective equipment Wear tight-fitting clothing to prevent accidents. Particularly, do not wear ties, scarves, rings or chains that may be caught by moving machine parts. Wear appropriate head- gear for long hair. Do not carry highly inflammable objects, e.g.

  • Page 32: Safety And Protective Equipment

    – After maintenance work and before the restart of the machine, make sure in any case that all protective devices are fully assembled and functional. Overview The illustration shows KS 475 Belt drive guards Guard rail Protective rubber Warning sign...

  • Page 33: General View And Specifications

    General View and Specifications General View and Specifications 33 / 110...
  • Page 34 General View and Specifications 34 / 110...

  • Page 35: General Overview

    General View and Specifications General overview General overview This overview is intended to familiarize you with the most important components of your machine. Drawbar eye Angular gear Belt drive Support wheel right Three-point attachment Support wheel left Drawbar Machine ready for driving on roads 35 / 110...
  • Page 36 General View and Specifications General overview 36 / 110...

  • Page 37: Technical Data

    General View and Specifications Technical data Technical data Designation: KS 475 KS 490 Maximum speed 25 km/h with end tow kit: Permitted total weight 1180 kg 1500 kg without end tow kit: Permitted total weight 1250 kg 1600 kg with end tow kit:...

  • Page 38: Tyre Pressure

    General View and Specifications Tyre pressure Tyre pressure Minimum pressure Recommendation Tyre type bar / psi bar / psi Support wheels 185/65 R 14 3.4 / 49.3 3.4 / 49.3 Recommendation Others bar / psi Firming wheels 24x12.00 - 12 0.7 / 10.2 The tyre pressure of the support wheels is intended for the road drive.

  • Page 39: Transport Draft For Truck Transport Of The Machine

    Transport draft for truck transport of the machine Transport draft for truck transport of the machine Tyre sizes: Right: 185/65 R 14 Left: 185/65 R 14 Firming wheels: 24x12.00 - 12 KS 475 in transport frame: All data in mm. 39 / 110...
  • Page 40 General View and Specifications Transport draft for truck transport of the machine KS 490 in transport frame: All data in mm. 40 / 110...

  • Page 41: Transport Draft For Road Travel

    General View and Specifications Transport draft for road travel Transport draft for road travel KS 475 in road travel position: All data in mm. Height with support wheels in central position 41 / 110...
  • Page 42 General View and Specifications Transport draft for road travel KS 490 in road travel position: All data in mm. Height with support wheels in central position 42 / 110...

  • Page 43: Lashing Eyes For Truck Transport/Ship Transport

    General View and Specifications Lashing eyes for truck transport/ship transport Lashing eyes for truck transport/ship transport There are no eyelets on the machine by which it can be tied down to the load plat- form. There is a special transport frame for the machine which allows the machine to be transported on a truck in a space-saving way.
  • Page 44 General Description 44 / 110...

  • Page 45: General Description

    General Description General Description 45 / 110...
  • Page 46 General Description 46 / 110...

  • Page 47: Function

    General Description Function Function The machine is an attached device designed for potato haulm topping. The chopped potato haulm is deposited at the bottom of the ridge between the rows with the help of the guide plates. Depending on the machine configuration, it can work on 4 potato ridges with a row spacing of 75 cm, 80 cm, 85 cm or 90 cm.

  • Page 48: Scope Of Delivery

    General Description Scope of delivery Scope of delivery The scope of delivery of the machine includes: 1 translation of the original operating manual for the haulm topper; 1 original spare parts list for the haulm topper; 1 cardan shaft; 1 bleeding screw for the angular gear. 48 / 110...

  • Page 49: Operating Components

    Operating Components Operating Components 49 / 110...
  • Page 50 Operating Components 50 / 110...

  • Page 51: Overview Of Machine Controls

    Operating Components Overview of machine controls Overview of machine controls Control element left support wheel (See Page Control element right support wheel Upper link arm with ratchet (See Page 51 / 110...
  • Page 52 Operation 52 / 110...

  • Page 53: Operation

    Operation Operation 53 / 110...
  • Page 54 Operation 54 / 110...
  • Page 55 Operation This chapter provides all information for operation of the machine. For most work in an agricultural area, the mode of working and the work results are under the influence of many individual and different factors. The scope of this operating manual would be exceeded if we have considered all conceivable situations (ground condition, potato varieties, weather, individual growing conditions, etc.).

  • Page 56: First Startup

    Operation First startup First startup For safety reasons check all oil levels. Otherwise, all work and actions that must be performed for daily operation are also required for the first startup. All bolted connections must be checked for tightness after the first 10 operating hours and retightened in case of need.

  • Page 57: Safety Regulations During Operation Of The Machine

    Operation Safety regulations during operation of the machine Safety regulations during operation of the machine – Before starting work, familiarize yourself with the machine and the control elements of the tractor. In case of need, obtain instructions from a person already having suf- ficient experience in handling the machine.

  • Page 58: Support Foot

    Illustrations show support foot with end tow kit on KS 475 Illustrations show support foot with crosswise driving device on KS 475 Machine support foot in operating position Support foot safety pin with circlip Support foot guide pin with circlip Machine support foot park position The machine is fitted with a mechanical support foot.

  • Page 59: Coupling And Uncoupling The Machine

    Operation Coupling and uncoupling the machine Coupling and uncoupling the machine 6.4.1 Coupling the machine Proceed as follows to couple the machine with the end tow kit to a suitable tractor: – Move the drawbar from working position to transport position. For the transport position, lock the drawbar using the upper link arm with ratchet, then secure it using safety pin with circlip.

  • Page 60: Attachment/Detachment Of The Machine

    Operation Attachment/detachment of the machine Attachment/detachment of the machine 6.5.1 Attachment of the machine Proceed as follows to attach the machine to the three-point suspension at the front or rear to a suitable tractor: – In order to attach the machine to the three-point suspension at the front or rear to a tractor, first of all prepare the three-point suspension.
  • Page 61 Angular gear protective cap – Check whether the guard cone (1) and the protective cap (2) are installed correctly on the KS 475. If not, dismantle both parts and mount them again on the correct side of the gear. – For the KS 490, check whether the angular gear is installed correctly. If not, dis- mantle the angular gear and mount it again correctly.
  • Page 62 Protective cap – Check whether the guard cone (10) and the protective cap (11) are installed cor- rectly on the KS 475. If not, dismantle both parts and mount them again on the cor- rect side of the gear. – For the KS 490, check whether the angular gear is installed correctly. If not, dis- mantle the angular gear and mount it again correctly.
  • Page 63 Operation Attachment/detachment of the machine (14) Hole lower link arm right (15) Hole lower link arm left – Connect the cardan shaft to the machine. – Drive the tractor backward and fit the machine correspondingly into both holes for the lower link arms. Use the balls for the lower link arms and secure them using both pins with circlip.
  • Page 64 Operation Attachment/detachment of the machine Specific feature of the end tow kit The illustration shows KS 475 (16) Right support wheel in road position (17) Left support wheel in road position (18) Right support wheel holder for field position (19)

  • Page 65: Detachment Of The Machine

    Proceed as follows to detach the machine from the three-point suspension at the front or rear of a suitable tractor: Specific feature of the end tow kit The illustration shows KS 475 Right support wheel in field position Left support wheel in field position...
  • Page 66 Operation Attachment/detachment of the machine Tractor front detachment – Disconnect the vehicle lighting for the crosswise driving device. – Lift the machine using the front hydraulic until the support foot can be mechanically extended to the correct length to park the machine. Then, secure the support foot using safety pin with circlip.

  • Page 67: Road Travel

    ADVICE ROPA expressly wants to point out that the driver and owner of the machine are always alone responsible for compliance with the respective regulations and condi- tions of the competent road traffic authorities.
  • Page 68 The vehicle owner must keep these acknowledgements for at least one year. A form for these instructions is included in Chapter 9 (See Page 100). ROPA rec- ommends copying this form before completing it. As already mentioned, the regionally competent road traffic authorities may estab- lish additional conditions or conditions deviating from the regulations listed.

  • Page 69: Chassis

    Chassis Chassis 6.7.1 Support wheels KS 475 road position with end tow kit Height adjustment of left support wheel end tow kit Height adjustment of right support wheel end tow kit KS 475 field position Height adjustment of left support wheel for field position...

  • Page 70: Drawbar

    The drawbar must engage centrally in the pulling jaw of the tractor without being jammed. Make sure that the machine is in a horizontal position, when driving on roads. KS 475 drawbar in road position KS 475 drawbar in working position Upper link arm with ratchet...

  • Page 71: Firming Wheels

    Operation Firming wheels Firming wheels The illustration shows KS 475 model Firming wheels Optionally, the machine can be equipped with the firming wheels (1). The firming wheels follow the topper. They press the ridge after topping in order to close any cracks in it.

  • Page 72: Angular Gear

    The angular gear is located at the top centre of the machine. On the KS 475, the protective cap (1) and guard cone (3) must be installed, depending on the attachment of the machine to the tractor, i.e. front or rear attachment.

  • Page 73: Shutdown

    Operation Shutdown Maximum permissible input speed indication The maximum permissible input speed is indicated on the safety sticker (4) above the angular gear on the right (in driving direction). 6.10 Shutdown Park the machine so that nobody is impeded or endangered. Also make sure of a suf- ficient safety distance to freely suspended power lines.
  • Page 74 Maintenance and service 74 / 110...

  • Page 75: Maintenance And Service

    Maintenance and service Maintenance and service 75 / 110...
  • Page 76 Maintenance and service 76 / 110...
  • Page 77 Maintenance and service WARNING During all maintenance work, there is a risk of serious or fatal injury and of damage to the machine. – During all maintenance work, make sure that nobody can inadvertently start the machine (remove the ignition key, lock the tractor cabin and always carry the trac- tor ignition key with you).

  • Page 78: Angular Gear

    The angular gear is located at the top centre of the machine and transmits the PTO shaft power of the tractor via a cardan shaft further to the topper drive. The illustration shows KS 475 Oil filling screw with venting Oil drain screw in the centre below the gear Check the angular gear for leaks before switching on the tractor PTO shaft every day.

  • Page 79: Cardan Shaft Above Topper Shaft

    Cardan shaft above topper shaft Cardan shaft above topper shaft The maintenance work on the cardan shaft of the KS 475 or the cardan shafts of the KS 490 can be performed above the topper shaft only if the protective casing(s) are dismantled.
  • Page 80 Maintenance and service Cardan shaft above topper shaft – Carry out work required on the cardan shaft, e.g. according to the lubrication schedule. (See Page – Then mount the protective casing (2) and secure it with four safety screws. Perform a test run.

  • Page 81: V-Belts And V-Belt Pulleys

    Proceed as follows in order to check the V-belt tension: – Switch off the machine and prevent it from restart. The illustration shows KS 475 – Dismantle the protective cover from the V-belt drive. To do this, loosen four nuts (1) and pull the cover upwards.

  • Page 82: Replacement Of V-Belt Pulleys

    PTO shaft speed. On the KS 475: 540 rpm, 750 rpm or 1,000 rpm. On the KS 490: currently only the variant with an input PTO shaft speed of 1,000 rpm.
  • Page 83 Maintenance and service V-belts and V-belt pulleys The illustration shows KS 475 – Dismantle the protective cover from the V-belt drive. To do this, loosen four nuts (1) and pull the cover upwards. Then check the V-belt pulleys visually. The illustration shows KS 475 –...
  • Page 84 Maintenance and service V-belts and V-belt pulleys The illustration shows KS 475 – The V-belt pulleys are fastened to the shafts with the taper lock bushes. In order to dismantle the V-belt pulleys, first loosen the threaded rod bolts (4) and screw them out completely.
  • Page 85 Maintenance and service V-belts and V-belt pulleys The illustration shows KS 475 ADVICE Once the transmission ratio of the V-belt pulleys has been changed, the marking (6) on the safety sticker for the maximum PTO shaft speed must be changed according to...

  • Page 86: Topper Shaft And Flails

    (2) and all four clamp closures. The illustration shows KS 475 – On the KS 475, fold the left cover (3) all the way forward and secure the right cover (4) with the tab (5). On the KS 490, secure both covers with the tabs.

  • Page 87: Shutdown For An Extended Period

    Maintenance and service Dismantling and disposal Shutdown for an extended period In case the machine has to be shut down for more than four weeks, then the following work must be performed: – Wash the machine thoroughly. Avoid direct spraying on the bearings. –...
  • Page 88 Malfunction and remedies 88 / 110...

  • Page 89: Malfunction And Remedies

    Malfunction and remedies Malfunction and remedies 89 / 110...
  • Page 90 Malfunction and remedies 90 / 110...

  • Page 91: Safety Circuits

    Welding work on supporting parts or parts with safety functions may only be carried out after prior agreement with ROPA, to the extent that such work is permissible in accordance with the applicable regulations.
  • Page 92 Lists/Tables/Plans/Diagrams/Maintenance Verification 92 / 110...

  • Page 93: Lists/Tables/Plans/Diagrams/Maintenance Verification

    Lists/Tables/Plans/Diagrams/Maintenance Verification Lists/Tables/Plans/ Diagrams/Maintenance Verification 93 / 110...
  • Page 94 Lists/Tables/Plans/Diagrams/Maintenance Verification 94 / 110...

  • Page 95: Lubricating And Operating Supplies

    Lists/Tables/Plans/Diagrams/Maintenance Verification Maintenance table Lubricating and operating supplies Fill. volume Component Lubricant type in litres Intervals Angular gear KS 475 approx. 1.2 Gear oil annually API GL 5, SAE 90 Angular gear KS 490 approx. 1.7 Grease as per DIN 51825, NLGI Class...

  • Page 96: Lubricating Plan (Lubrication With Grease Gun)

    Bearing topper shaft right, left and central ADVICE All lubricating points must also be lubricated after each washing of the machine. Grease ROPA item no. 435006200 as per DIN 51825, NLGI-class 2, type: KP2K-20, at low outdoor temperatures KP2K-30. No lubricating greases containing solid lubricants may be employed. Biologically degradable greases are also admissible.

  • Page 97: Lubricant Recoding Table

    Gear oil as per DIN 51825, NLGI-class 2, type: 2019-03-06 API GL 5, SAE 90 KP2K-20, at low outdoor temperatures KP2K-30 ROPA ROPA gearOil GL5 90 marking 435002010 = 20 l 435006200 = 18 kg ROPA 435002020 = 60 l 435002300 = 25 kg item no.:...

  • Page 98: Torque Table For Screws And Nuts (Nm)

    Lists/Tables/Plans/Diagrams/Maintenance Verification Torque table for screws and nuts (Nm) Torque table for screws and nuts (Nm) Metric thread DIN 13 Dimension 10.9 12.9 1050 1220 1100 1550 1800 1200 1450 2100 2450 Metric fine thread DIN 13 Dimension 10.9 12.9 M8x1 M10x1 M12x1.5...

  • Page 99: Maintenance Verification

    Oper.hrs. Oper.hrs. Oper.hrs. Oper.hrs. Oper.hrs. Angular gear Gear oil 9.6.2 Maintenance confirmation _____ Maintenance after 1st customer service ROPA machine Plan 50 oper. hrs. May only be performed by completely ROPA performed on: Service Team performed by: Signature: ______________________________________________ _____...

  • Page 100: Confirmation About Instructions Given To The Driver

    Lists/Tables/Plans/Diagrams/Maintenance Verification Confirmation about instructions given to the driver Confirmation about instructions given to the driver Mrs/Mr date of birth Last name and first name Was instructed about safe handling of the machine about maintenance of the machine from Last name and first name Has demonstrated the required knowledge for safe handling of the machine...

  • Page 101: Safety Instructions

    WARNING Should the areas around the ROPA haulm topper, which are designated as hazard areas in the following draft, be entered by persons while the machine is topping, there is a risk of serious physical or even fatal injuries for these persons. The draft below shows these zones shaded.
  • Page 102 Lists/Tables/Plans/Diagrams/Maintenance Verification Safety instructions Statement (last name and first name) have been informed by the owner about the danger zones and safety aspects of the haulm topper during operation. I have completely received this information and understood it. I agree not to enter the hazard zones as long as the machine is run- ning during topping.

  • Page 103: Ropa Handover Confirmation

    Lists/Tables/Plans/Diagrams/Maintenance Verification ROPA Handover confirmation ROPA Handover confirmation ROPA Fahrzeug- und Maschinenbau GmbH, Sittelsdorf 24, D-84097 Herrngiersdorf Support point address: Chassis number: Type: Sub device no.: Type: Sub device no.: Type: Sub device no.: Type: Sub device no.: Type: Client's address:...
  • Page 104 (written, by phone or e-mail) about products and services can be received by the ROPA support point and/or ROPA, or passed on to ROPA, as well as stored, processed and used. The non-granting of the consent does not effect on the delivery of the purchased item or services. You can, if desired, partially strike out this consent.

  • Page 105: Ropa First Use Record

    Lists/Tables/Plans/Diagrams/Maintenance Verification ROPA First Use Record 9.10 ROPA First Use Record ROPA Fahrzeug- und Maschinenbau GmbH, Sittelsdorf 24, D-84097 Herrngiersdorf ROPA partner: Customer / site of operation: Chassis No.: Operating hours: Machine type: Lifting/loading hours: Software version: Harvested area: Record: Any customer complaints: The safe operation and maintenance were explained to the customer.
  • Page 106 Index 106 / 110...

  • Page 107: Index

    Index Index 107 / 110...
  • Page 108 Index 108 / 110...
  • Page 109 Index Angular gear........... 72, 78 Maintenance and service........74 Maintenance verification........99 Malfunction and remedies........88 Manufacturer............9 Modifications and alterations........ 31 Cardan shaft above topper shaft......79 CE compliant............17 Chassis..............69 Coupling the machine........... 59 Name plate and important data......11 Declaration of Conformity........
  • Page 110 Index Uncoupling the machine........59 V-belt tension............81 Welding on the machine........91 110 / 110...

This manual is also suitable for:

Ks 490

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