Related Manuals for BSL strautmann Zelon CFS 2501
Summary of Contents for BSL strautmann Zelon CFS 2501
- Page 1 Translation of the Original Operating Instructions Short-cut forage wagon Short-cut forage wagon with beaters Zelon CFS 2501, 2901, 3301 Zelon CFS 2501 DO, 2901 DO, 3301 DO 74400904 0.000 04.15...
- Page 2 EC Declaration of Conformity according to the EC machinery directive 2006/42/EC, Annex II, 1.A Manufacturer: B. Strautmann & Söhne GmbH u. Co. KG Bielefelder Str. 53 D-49196 Bad Laer Legal person established within the EC and authorized to compile the technical documentation: B.
- Page 3 Identification data Identification data Please enter the machine’s identification data here. They are registered on the type plate. Manufacturer: B. Strautmann & Söhne GmbH u. Co. KG Vehicle/Machine ID number: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Type: Year of manufacture: Manufacturer’s address...
- Page 4 Foreword Foreword Dear customer, You have decided in favour of a quality product from the large B. Strautmann & Söhne GmbH u. Co. KG product range. We thank you for the confidence you have shown in us. Upon receipt of the machine, please check for transport damage or missing parts! Check the delivered machine for its completeness, including the ordered optional extras, by means of the delivery note.
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Page 5: Table Of Contents
Contents Contents User information 10 Purpose of document 10 Keeping of operating instructions 10 Location details in the operating instructions 10 Applied modes of specification 10 Applied terms 11 Activity-related safety instructions and important information 12 1.6.1 Activity-related safety instructions 12 1.6.2 Important information 12 Product description 13... - Page 6 Contents Risks in case of non-observance of safety instructions and warning signs 45 Loading of machine 46 Loading by means of tractor 46 Loading by means of lifting devices 47 Commissioning 48 Check tractor's compatibility 49 5.1.1 Calculate actual values 49 5.1.2 Preconditions for the operation of tractors with rigid drawbar trailers 50 5.1.2.1...
- Page 7 Contents 5.12.1 Mount body side panels, ropes and body tarpaulin 81 5.12.2 Unfold / Collapse folding grille 84 5.13 Tailgate with telescopic function 85 5.13.1 Prepare tailgate for telescopic operation 85 5.13.2 Prepare tailgate for normal operation 87 5.14 Activate / Deactivate silage additive pump (with easy-to-use control) 88 Operation 89 Easy-to-use control 89 6.1.1...
- Page 8 Contents Service and maintenance plan - Overview 139 Cleaning of machine 141 Lubrication of machine 142 9.4.1 Lubrication plan 143 9.4.2 Check / Top up central lubrication 144 Check/top up/change gear lubricant oil 145 9.5.1 Feed gearing of transport floor 145 9.5.2 Main gearbox of cutting unit 146 9.5.3...
- Page 9 Contents 10.2 Replace bolt of shear bolt coupling 178 10.3 Emergency manual operation in case of failure of electrical system 178 10.4 Overview of other malfunctions and remedial actions 182 10.4.1 Hydraulics 182 10.4.2 Electrics 183 10.4.3 Working 184 11 Disassembly / Disposal 185 12 Circuit diagrams 186 12.1 Hydraulics 186 12.2 Electronics –...
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Page 10: User Information
User information User information The chapter “User information“ provides information about how to use the operating instructions. Purpose of document These operating instructions: describe the operation, service and maintenance of the machine, provide important information about safety-conscious and efficient handling of the machine. Please contact us for further inquiries. -
Page 11: Applied Terms
User information A line without an arrow the component can be seen in the figure, head means: A line with an arrow head the component cannot be seen in the figure (e.g. means: hidden by protective device). References An arrow head (►) in front of a sentence indicates a reference to further information elsewhere in the operating instructions. -
Page 12: Activity-Related Safety Instructions And Important Information
User information Activity-related safety instructions and important information Activity-related safety instructions and important information are included in the operating instructions. Signal words and symbols help to identify activity-related safety instructions and important information at a glance. 1.6.1 Activity-related safety instructions Activity-related safety instructions: ... -
Page 13: Product Description
Product description IMPORTANT marks an obligation to behave in a particular manner or to act in a certain way, in order to use the machine properly. Non-observance of these instructions may cause malfunctions of the machine or in its vicinity. INFORMATION marks user hints and particularly useful information. -
Page 14: General Overview Of Machine
Product description General overview of machine Fig. 1 Zelon CFS 2501, 2901, 3301 / Zelon CFS 2501 DO, 2901 DO, 3301 DO 04.15... -
Page 15: Drawgear
Product description Beater (19) Additional guide wheel Tailgate (20) Main gearbox for conveying unit Body side panels (21) Spur gear for feeder rotor Ropes (22) Access door with ladder Body tarpaulin (23) Front angular gear (for beaters) Tubular support (24) Rear angular gear (for beaters) Load-protection bars with automatic (25) -
Page 16: Conveying Unit
Product description Conveying unit Pick-up Spring-loaded tines Strippers CFS drum Conveying trough Conveyor duct Feeder rotor Conveying tines Stripper (10) Cutting knife (11) Knife protection system (12) Upper link Fig. 3 Zelon CFS 2501, 2901, 3301 / Zelon CFS 2501 DO, 2901 DO, 3301 DO 04.15... -
Page 17: Brake System
Product description Brake system 2.4.1 Dual-line compressed-air brake system with mechanical automatic load- sensitive brake (ALB) regulator (1) Feed line with hose coupling (red) (2) Brake line with hose coupling (yellow) (3) Blank connection for brake line (4) Trailer brake valve (5) ALB regulator (mechanical) The setting dimension (L) must not be changed! It must correspond to the value... -
Page 18: Braking Axle
Product description 2.4.2 Braking axle (1) Diaphragm brake cylinder (2) Slack adjuster for brake camshaft (3) Brake camshaft (4) Connecting rods for parking brake (5) Test connection for pressure gauge Fig. 5 Stop-cock for securing tailgate The stop-cock for securing the tailgate is located at the right-hand rear of the machine. -
Page 19: Supply Lines Between Tractor And Machine
Product description Stop-cock on machine with beaters Fig. 8 Fig. 9 Stop-cock open Stop-cock closed Tailgate can lift and lower Tailgate is secured against lifting and lowering. Supply lines between tractor and machine (1) Hydraulic connector "Flow line" SN 16 (red) (2) Hydraulic connector "Return line"... -
Page 20: Marking Of Hydraulic Supply Lines
Product description 2.6.1 Marking of hydraulic supply lines Hydraulic connector "Flow line" Label Arrows: white Background: red Hydraulic connector "Return line" Label Arrows: white Background: blue Explanation of hydraulic connector symbols P: Pressure pipe (red) T: Tank line (blue) Load-sensing connector ... - Page 21 Product description (1) Type plate with CE symbol (2) Vehicle/Machine ID number (embossed into the frame) (3) ALB plate Fig. 11 Information on the type plate: (1) Manufacturer (2) CE symbol (3) Vehicle/Machine ID number (4) Type (5) Empty weight [kg] (6) Gross vehicle weight rating [kg] Fig.
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Page 22: Technical Data
Product description Technical data 2.8.1 General data Fig. 13 Zelon CFS 2501 2901 3301 2501 2901 3301 Total length (X) 7.85 8.45 8.65 9.29 9.45 10.10 Total width (Y) 2.51 2.51 2.56 2.56 2.81 2.81 Total height (Z) 3.68 3.68 3.82 3.82 3.92... -
Page 23: Tyre Pressure
Product description Figures, technical data and weights may change due to technical development and are not binding for delivery. 2.8.2 Tyre pressure If the vehicle width of 2.55 m is exceeded due to the use of wide-base tyres, these must, according to the StVZO (note of transl.: German Road , possess the load capacity required for reaching Traffic Licensing Code) - Page 24 Product description Electrical system Battery voltage: 12 V (volt) Socket for lighting: 7-pole Socket for control set: 3-pole (DIN 9680). The feed line of the 3-pole socket should have a minimum cable cross section of 4 mm². Hydraulics ...
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Page 25: Safety Instructions
Safety instructions Brake system Brake system Required connectors Dual-line compressed-air brake 1 hose coupling (red) for the feed line system 1 hose coupling (yellow) for the brake line Hydraulic brake system 1 hydraulic clutch according to ISO 5676 Safety instructions Correct use The machine:... -
Page 26: Organisational Measures
Safety instructions For the safety-conscious operation of the machine, please observe: ● these operating instructions, in particular: ● the basic safety instructions, the activity-related safety instructions and the instructions what to do, ● the instructions regarding correct use. ● the warning signs on the machine, ●... -
Page 27: Qualification Of Operator
Safety instructions If the operator notices that a device is not in a sound safety-related condition, the operator shall be obliged to immediately eliminate this defect. If this is not part of the operator’s scope of tasks or he/she lacks adequate expert knowledge, the operator shall be obliged to report this defect to his/her superior or to the user. -
Page 28: Safety-Conscious Operation Of Machine
Safety instructions Risks may arise: due to work-related movements of the machine and its working tools, due to substances or foreign objects blown out of the machine, due to accidental lowering of the lifted machine/of lifted machine parts, ... -
Page 29: Spare And Wearing Parts, Auxiliary Materials
Safety instructions the operating license according to national and international regulations will remain unaffected, perfect functioning of the machine will be ensured. The manufacturer will not assume any liability for damage resulting from: unauthorized alterations of the machine, ... - Page 30 Safety instructions Observe the warning and instruction signs attached to the machine. They provide important information for the safe and trouble-free operation of the machine! Observe the activity-related safety instructions included in the other chapters in addition to the basic safety instructions included in this chapter! ...
- Page 31 Safety instructions Always park the unhitched machine in a stable position! Pay attention to the ground condition. Beware of soft surfaces. Use of machine Acquaint yourself with all mechanisms and operating elements of the machine and their functions before starting work! During operation it will be too late.
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Page 32: Hydraulic System
Safety instructions Set all movable machine parts to transport position and secure them before carrying out transport journeys! Use the transport locks provided for this purpose! 3.5.2 Hydraulic system Only an authorised workshop is allowed to carry out work on the hydraulic system! ... -
Page 33: Propeller Shaft Operation
Safety instructions connection: first connect the plus pole, then the minus pole, disconnection: first disconnect the minus pole, then the plus pole! Avoid sparking and open fire in the vicinity of the battery! Risk of explosion! The machine can be equipped with electronic components and parts, the functioning of which may be affected by electromagnetic emissions of other devices. -
Page 34: Hitched Machines
Safety instructions Observe the transport and working position of the specified tubular covers of the propeller shafts! People are not allowed within the range of the rotating propeller shaft when work with the propeller shaft is being carried out! Always switch the propeller shaft off if the angular misalignments occurring are too large or when ... -
Page 35: Axles
Safety instructions ● Observe the fact that the braking axle needs to run in during the first service hours – the brake lining is adjusting to the brake drum. Full braking power is only reached after this running-in period. Compressed-air brake system ... -
Page 36: Operation Of Machine
Safety instructions Deflate the tyre before removing it! Regularly check the tyre pressure! Observe the maximum admissible tyre pressure. Risk of explosion in case of excessive pressure! Retighten all fastening screws and nuts according to the manufacturer’s specifications! 3.5.9 Operation of machine ... -
Page 37: Warning And Instruction Signs
Safety instructions Warning and instruction signs The following warning and instruction signs are attached to the machine: Warning signs mark dangerous spots on the machine and warn about residual risks, which cannot completely be eliminated due to the machine’s operational safety. ... - Page 38 Safety instructions Order number and explanation Warning signs 87010270 Please read and observe the operating and safety instructions before commissioning! 87007120 Risks when carrying out work on the machine such as mounting, adjusting, trouble-shooting and maintenance, due to accidental starting or rolling of tractor and machine! This risk may cause most serious injuries or even death.
- Page 39 Safety instructions 87007122 Risk of electrical shock or burns due to accidental touching of electrical overhead lines or due to inadmissible approach to high-voltage overhead lines! This risk may cause most serious injuries or even death. Keep sufficient safe distance to high-voltage overhead lines. Nominal voltage Safe distance to overhead lines up to 1 kV...
- Page 40 Safety instructions 87007130 Risk to any part of the body of being crushed if people stand within the swivelling range of the drawbar between the tractor and the hitched machine! This risk may cause most serious injuries or even death. ...
- Page 41 Safety instructions 87010281 Risk to fingers or hands of being crushed due to accessible movable machine parts! This risk may cause most serious injuries including loss of limbs. Never reach into the hazardous area as long as the tractor engine is running with the propeller shaft coupled/the hydraulic/electronic system connected.
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Page 42: Instruction Signs
Safety instructions 87010289 Risk to any part of the body of being drawn in and becoming entangled due to powered working tools (pick-up and feeder rotor)! This risk may cause most serious injuries or even death. Keep sufficient safe distance to powered working tools. ... - Page 43 Safety instructions 74406509 Tyre pressure chart 74407500 Lubrication plan 74407501 Operation of telescopic tailgate (optional extra) 87007132 The required drive speed of the machine is 1000 min Before switching the propeller shaft on, check whether the selected speed and sense of rotation of the tractor's p.t.o. shaft have been adjusted to the admissible speed and sense of rotation of the machine.
- Page 44 Safety instructions 87007550 Adjust length of propeller shaft. Before commissioning the machine, shorten the propeller shaft, in order to avoid damage to the tractor and the machine. Absolutely observe the information in the chapter "Adjust length of propeller shaft to tractor", page 64 as well as the operating instructions provided by the propeller shaft manufacturer along with the propeller shaft.
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Page 45: Risks In Case Of Non-Observance Of Safety Instructions And Warning Signs
Safety instructions Risks in case of non-observance of safety instructions and warning signs Non-observance of the safety instructions and warning signs may: cause risk to people, environment and machine such as: risk to people due to non-secured work areas, ... -
Page 46: Loading Of Machine
Loading of machine Loading of machine Only the haulage contractor is authorised to carry out this work! This work requires special know-how and/or specific technical equipment. Otherwise, this work will impair your safety and the functional ability of the machine during and after its execution. Release the compressed-air brake via the release valve, in order to be able to manoeuvre the machine by means of tractors without compressed-air brake system. -
Page 47: Loading By Means Of Lifting Devices
Commissioning Fig. 16 Sling point for lashing Bearing surface for support of conveying unit Loading by means of lifting devices WARNING Risk of crushing and/or impact to people if the lifted machine accidentally comes down! Use appropriate slings which are able to safely carry the machine’s weight. -
Page 48: Commissioning
Commissioning Commissioning This chapter will provide information: on how to proceed when commissioning your machine, on how to check whether the machine is licensed for being attached/hitched to your tractor. Before commissioning, the operator must: have read and understood these operating instructions. ... -
Page 49: Check Tractor's Compatibility
Commissioning Check tractor's compatibility ► See also chapter "Technical data", page 22! WARNING Risk due to incorrect use of the tractor if this causes failure of components, insufficient stability and insufficient steerability and braking ability of the tractor! Check your tractor for compatibility before attaching/hitching the ... -
Page 50: Preconditions For The Operation Of Tractors With Rigid Drawbar Trailers
Commissioning 5.1.2 Preconditions for the operation of tractors with rigid drawbar trailers WARNING Risk due to failure of components caused by incorrect use of the tractor! Ensure: that the coupling device at the tractor has a sufficient admissible tongue load rating for the actually existing tongue load. ... -
Page 51: Calculate Actual D
Commissioning 5.1.2.2 Calculate actual D value for combination to be coupled WARNING Risk to people due to failure of components caused by breaking coupling devices between tractor and machine in case of incorrect use of the tractor! Only combine compatible coupling devices and drawgears. ... -
Page 52: Calculate Tractor's Admissible Towing Capacity
Commissioning The D value: for the coupling device is directly indicated on the type plate of the coupling device/in the operating instructions/in the vehicle registration certificate of your tractor. In case of differing values on the type plates of the trailer bracket and the coupling device, the lower value shall be relevant. -
Page 53: Secure Tractor And Machine Against Accidental Starting And Rolling
Commissioning Secure tractor and machine against accidental starting and rolling WARNING Risk of crushing, shearing, cuts, amputation, becoming entangled, wound up, being drawn in and risk of impact to people during work on the machine: if the unsecured machine not hitched to the tractor accidentally rolls, ... -
Page 54: Hydraulic System Of Machine
Commissioning Hydraulic system of machine 5.3.1 Connect hydraulic hose pipes Check the compatibility of the hydraulic oils before connecting the machine to the hydraulic system of your tractor. Do not mix mineral oils with bio oils! Observe the maximum admissible operating pressure of the hydraulic oil. -
Page 55: Open Hydraulic System
Commissioning 5.3.1.1 Open hydraulic system Always swivel the respective operating element at the control device on the tractor to open-centre position. Turn the tractor engine off. Unscrew the load-sensing screw (1) at the electro-hydraulic control block as far as it will go. -
Page 56: Disconnect Hydraulic Hose Pipes
Commissioning 5.3.2 Disconnect hydraulic hose pipes WARNING Risk of injury and infection due to hydraulic oil squirting out under high pressure and entering the body! Make sure that the hydraulic system on the tractor and on the machine has been depressurised when connecting and disconnecting the hydraulic hose pipes. - Page 57 Commissioning Assembly instructions for authorized workshop: The distance X must be 1380 mm between the ground and the machine frame with the machine with lowered folding drawbar hitched up to the tractor. The mounting height of the folding drawbar in relation to the machine frame must be aligned by means of the threaded spindles of the hydraulic cylinders if the actual distance X is not 1380 mm.
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Page 58: Couple Drawbar
Commissioning Ensure that there is enough free space between the drawgear and the coupling device. In case of a bolt-type coupling, the coupling bolt (4) must not chafe against the borehole of the drawbar lug (5)! Change the level of the bolt-type coupling at the tractor if necessary. -
Page 59: Ball-Type Coupling And Shell
Commissioning 5.4.2.2 Ball-type coupling and shell WARNING Risk of being crushed, drawn in, becoming entangled and risk of impact to people if the machine accidentally loosens from the tractor! Before travelling on extremely uneven ground/over bunker silos, ensure that there is enough free space at the holding down- device above the shell. -
Page 60: Uncouple Drawbar
Commissioning mechanism (holding-down device). 6. Secure the tractor against accidental starting and rolling. 7. Ensure that the tow hook is properly locked. 8. Connect the supply lines. 9. Release the parking brake of the machine. 10. Lift the supporting leg to transport position. 5.4.3 Uncouple drawbar WARNING... -
Page 61: Tow-Hook (Hitch Hook) And Drawbar Lug (Hitch Ring)
Commissioning 5.4.3.3 Tow-hook (hitch hook) and drawbar lug (hitch ring) 1. Secure the tractor against accidental starting and rolling. 2. Secure the machine against rolling. Observe the information in the chapter "Secure tractor and machine against accidental starting and rolling". 3. -
Page 62: Lower Mechanical Supporting Leg To Support Position
Commissioning 1. Lift the machine hitched to the tractor via the hydraulic folding drawbar (1). The supporting leg is relieved. 2. Pull the locking bolt (3) out of the borehole. 3. Use one hand to grip the handle (4) and lift the supporting leg (2) until the locking bolt engages into the borehole (5). -
Page 63: Propeller Shaft
Commissioning Propeller shaft The power transmission between tractor and machine is effected by means of the propeller shaft. Proper use and maintenance of the propeller shaft prevent serious accidents. When coupling the propeller shaft, observe: the admissible drive speed of the machine, ... -
Page 64: Adjust Length Of Propeller Shaft To Tractor
Commissioning 5.6.1 Adjust length of propeller shaft to tractor Shop work WARNING Risk to people of being drawn in and becoming entangled due to assembly work on the propeller shaft carried out improperly or due to unauthorized structural alterations! Only an authorized workshop is allowed to carry out structural alterations on the propeller shaft. -
Page 65: Couple Propeller Shaft To Tractor
Commissioning Fig. 28 7. Reinsert the shortened propeller shaft halves into each other. 8. Lubricate the p.t.o. shaft of the tractor and the propeller shaft of the machine before coupling the propeller shaft. 5.6.2 Couple propeller shaft to tractor WARNING Risk of injury due to movements of tractor and machine or machine parts! Secure tractor and machine against accidental starting and rolling... -
Page 66: Uncouple Propeller Shaft From Tractor
Commissioning 5.6.3 Uncouple propeller shaft from tractor Clean and lubricate the propeller shaft before longer downtimes. WARNING Risk of injury due to movements of tractor and machine or machine parts! Secure tractor and machine against accidental starting and rolling before carrying out any work on the machine! Make sure that people leave the hazardous area of the tractor and the machine or of movable machine parts! CAUTION... -
Page 67: Brake System
Commissioning Brake system Observe the fact that the braking axle needs to run in during the first service hours – the brake lining is adjusting to the brake drum. Full braking power is only reached after this running-in period. ... -
Page 68: Disconnect Brake And Feed Line
Commissioning 4. Remove the hose coupling of the feed line (red) from the blank connection. 5. Properly fix the hose coupling of the feed line (red) to the red marked coupling device at the tractor. When connecting the feed line (red), the system pressure coming from the tractor automatically pushes the push button for the release valve on the trailer brake valve out. -
Page 69: Hydraulic Service Brake System
Commissioning Press the push button (1) of the release valve. → The compressed-air brake is released. Manoeuvre the machine. Pull the push button (1) of the release valve. → The compressed-air brake is applied. Fig. 32 5.7.2 Hydraulic service brake system The controlled hydraulic service brake system is connected to the special brake valve of the tractor. -
Page 70: Emergency Brake Valve
Commissioning 5.7.2.1 Emergency brake valve The brakes must be tested before each journey to refill the pressure accumulator. WARNING Risk of infection to people due to hydraulic oil squirting out under high pressure and entering the body! Always ensure to depressurize the pressure accumulator before carrying out work on the hydraulic system. -
Page 71: Connect Hydraulic Brake System
Commissioning Depressurize pressure accumulator 1. Connect the brake hose to the tractor. 2. Set the brake valve at the tractor such that the hydraulic oil can flow back to the tractor. 3. Press the drain valve (7) at the emergency brake valve (3). -
Page 72: Disconnect Hydraulic Brake System
Commissioning 5.7.2.3 Disconnect hydraulic brake system 1. Apply the parking brake of the machine. 2. Uncouple the hydraulic sleeve (Fig. 36/1). 3. Slip the hydraulic sleeve onto the machine's blanked-off connecting piece (Fig. 36/2). 5.7.3 Parking brake The applied parking brake secures the unhitched machine against rolling. The parking brake is actuated via spindle and cable when turning the crank handle. -
Page 73: Mount Control Set On The Tractor
Commissioning Mount control set on the tractor 5.8.1 Mount easy-to-use control set on the tractor Fix the control set (1) in the cabin within view and reach to the right of the driver seat. Plug the 3-pole plug (DIN 9680) of the power cable (2) into the socket of the tractor. -
Page 74: Pick-Up
Commissioning plug: the ISO socket (5) of the mobile cable harness into the ISO plug of the control unit on the machine. the ISO plug of the control unit into the ISO socket of the tractor. Pick-up 5.9.1 Set operating height WARNING Risk of injury due to movements of tractor and machine or... -
Page 75: Set Holding-Down Device With Pulley
Commissioning ● With the pick-up lifted, the minimum distance between the additional guide wheels and the CFS drum must be 8 mm. ● The frame (5) of the additional guide wheels must only bump against the check screws (6) when the pick-up has been lifted. -
Page 76: Crossover Conveyor
Commissioning 5.10 Crossover conveyor Optional extra 5.10.1 Pull out crossover conveyor 2 people are required for this work! WARNING Risk of injury due to movements of tractor and machine or machine parts! Secure tractor and machine against accidental starting and rolling before carrying out any work on the machine! Make sure that people leave the hazardous area of the tractor and the machine or of movable machine parts! - Page 77 Commissioning Swivel the lever of the stop-cock (3) to closed position (4) such that the tailgate is secured against lowering. Fig. 44 Use the lever (6) to unlock the crossover conveyor (5) and pull the conveyor backwards until it audibly engages. Swivel the lever of the stop-cock (3) to open position (7).
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Page 78: Push In Crossover Conveyor
Commissioning Use the eccentric closures (8) to take up the hooks (9) of the crossover conveyor and lock the eccentric closures. → Tailgate and crossover conveyor are now firmly connected. Never lift the tailgate as long as it is connected with the crossover conveyor! This causes damage to tailgate and crossover conveyor. - Page 79 Commissioning Unlock the eccentric closures (8) to unblock the hooks (9) of the crossover conveyor. Fig. 47 Swivel the lever of the stop-cock (3) to open position (7). Lift the tailgate up to its first opening position. Swivel the lever of the stop-cock (3) to closed position (4) such that the tailgate is secured against lowering.
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Page 80: Open / Close Access Door
Commissioning Swivel the lever of the stop-cock (3) to open position (7). Lower the tailgate almost completely. Swivel the lever of the stop-cock (3) to closed position (4) such that the tailgate is secured against lifting. Stand beside the machine, swivel the bottom part (2) of the tailgate forward by hand and lock it by means of the locking bolts (1) on the left-hand and right-hand... -
Page 81: Body
Commissioning 5.12 Body 5.12.1 Mount body side panels, ropes and body tarpaulin Two people are required for mounting the attachment sections, ropes and the body tarpaulin. DANGER Risk of electrical shock or burns due to machine components accidentally touching electrical overhead lines or approaching high-voltage overhead lines in an inadmissible manner! Make sure not to exceed the maximum vehicle height of 4 m. - Page 82 Commissioning 1. Secure tractor and machine against 7. Screw the upper front grating (4) to the side accidental starting and rolling. panel extensions (3). 2. Mount the tubular supports (1) loosely to 8. Swivel the load-protection bars (5) up. the fixing supports (2); positions of tubular 9.
- Page 83 Commissioning 16. Thread each rope with the loop (1) through a hole (2) in the load-protection bars. 17. Put the other end (3) of the rope through the loop (2). Fig. 55 18. Pull the ropes from the bottom through the eyes of the central tubular support.
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Page 84: Unfold / Collapse Folding Grille
Commissioning Positions of tubular supports long tubular support short tubular support Fig. 58 Zelon CFS 2501 Fig. 59 Zelon CFS 2501 DO Fig. 60 Fig. 61 Zelon CFS 2901 Zelon CFS 2901 DO Fig. 62 Fig. 63 Zelon CFS 3301 Zelon CFS 3301 DO 5.12.2 Unfold / Collapse folding grille... -
Page 85: Tailgate With Telescopic Function
Commissioning Unfold folding grille Connect the hydraulic hose pipe for the folding grille attachment to a single-acting control device of the tractor. Actuate the control device until the folding grille (1) has been completely unfolded. Fig. 64 Collapse folding grille Set the control device of the tractor to open- centre position. - Page 86 Commissioning Lower the tailgate completely. Lock the bolt (1) on both sides of the machine by plugging the linch pin (2) into another socket such that the tubular support (3) cannot lift. Fix the sensor plate (4) on both sides in rear position (4) after unscrewing the screw (5).
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Page 87: Prepare Tailgate For Normal Operation
Commissioning 5.13.2 Prepare tailgate for normal operation WARNING Risk of injury due to movements of tractor and machine or machine parts! Secure tractor and machine against accidental starting and rolling before carrying out any work on the machine! Make sure that people leave the hazardous area of the tractor and the machine or of movable machine parts! Lower the tailgate completely. -
Page 88: Activate / Deactivate Silage Additive Pump (With Easy-To-Use Control)
Commissioning 5.14 Activate / Deactivate silage additive pump (with easy-to-use control) The silage additive pump is not included in the machine's scope of delivery. Press the switch (1) at the front of the hydraulics protective device (2) to activate the silage additive pump. Switch the pick-up to open-centre position to spray silage additives. -
Page 89: Operation
Operation Operation The hydraulic functions of the machine are operated via the easy-to-use or the ISOBUS control. Easy-to-use control 6.1.1 Design Fig. 71 The easy-to-use control mainly consists of: ● the control set (1), ● the power unit (2), ● the control block (3), ●... - Page 90 Operation determine the respective operating state of the selected function / setting, e. g. "Tailgate open". One operating element is required for each function of the machine. The control set: ● is mounted on the tractor within view and easy reach such that the operating elements are easily accessible, ●...
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Page 91: Functions Of The Easy-To-Use Control
Operation 6.1.2 Functions of the easy-to-use control Fig. 72 Functions of switches: (1) Switch operating mode / road travel mode on / switch machine off (2) Switch work lights on / off (3) Switch automatic charging system on / off (4) Adjust feed rate of transport floor (5) Double feed rate of transport floor for complete emptying (transport floor level II) -
Page 92: Switch Road Travel Mode On
Operation Meaning of control lamps: (H1) is flashing (green): Road travel mode is activated lights up (green): Operating mode is activated (H2) lights up (green): Tailgate is open Fig. 73 (H3) is flashing (red): Cutting unit securing function is activated lights up (red): Cutting unit is retracted (H4) lights up (green): Steering axle is locked (H5) lights up (red): Cargo space is full... -
Page 93: Switch Operating Mode On
Operation With the road travel mode switched on: ● apart from the functions "Lock steering axle" and "Unlock steering axle", all other functions on the easy-to-use control set are disabled, ● the work lights are switched off, ● the hydraulic drawbar suspension (optional extra) is switched on, ●... -
Page 94: Switch Machine Off
Operation ● Toggle switch in central switch position The operating mode is switched on. The control lamp H1 ("Operating mode active") lights up. 6.1.2.3 Switch machine off ● Toggle switch in lower switch position The machine is switched off. 6.1.2.4 Switch work lights on/off When switching the road travel mode on, the work lights are... -
Page 95: Switch Automatic Charging System On/Off
Operation 6.1.2.5 Switch automatic charging system on/off Switch the automatic charging system on for uniform and complete filling of the cargo space. The automatic charging system: ● has to be switched on only once, ● automatically switches the transport floor on and off during charging, ●... -
Page 96: Switch Transport Floor On (Level I)
Operation 6.1.2.6 Switch transport floor on (level I) ● If the forage wagon is full, the easy-to-use control set will generate an acoustic signal (horn sound) and a visual signal (control lamp H5: "Forage wagon full"). The automatic charging system is deactivated and the automatic feed function for the transport floor is switched off. -
Page 97: Reverse Feed Direction Of Transport Floor For A Short Time
Operation 6.1.2.8 Reverse feed direction of transport floor for a short time The feed direction of the transport floor must be reversed for a short time if the slip clutch responds during discharge. Thus, the pressing power which the loaded material applies to the beaters, and the starting torque for loosening the beaters are reduced. -
Page 98: 6.1.2.10 Open Tailgate
Operation 6.1.2.10 Open tailgate ● Sensing band in upper switch position Forage wagon without beaters: The tailgate opens as long as the switch position is held or until the end position has been reached. As soon as the tailgate has reached its end position, the control lamp H2 ("Tailgate open") lights up. -
Page 99: 6.1.2.13 Lower Folding Drawbar
Operation ● Leave the key button in its upper switch position until the folding drawbar has been lifted to the desired position or has reached its end position. The ground clearance of the pick-up is increased. 6.1.2.13 Lower folding drawbar ●... -
Page 100: 6.1.2.15 Extend Cutting Unit
Operation 6.1.2.15 Extend cutting unit Extend the cutting unit only with the feeder rotor running. ● Leave the key button in its upper switch position until the control lamp H3 ("Cutting unit retracted") goes out. The cutting unit is completely extended into the conveyor duct. -
Page 101: 6.1.2.19 Lower Pick-Up
Operation ● Leave the key button in its upper switch position until the end position has been reached. The pick-up is lifted. 6.1.2.19 Lower pick-up ● Toggle switch in lower switch position The pick-up lowers and is held in open- centre position such that it can adapt to uneven terrain. - Page 102 Operation Fig. 75 The ISOBUS control mainly consists of: the control set (1), the control unit (2), the sensors (3) to determine operating states, e. g. Steering axle locked or Steering axle unlocked, the connecting cable (4) for the silage additive pump (5) (optional extra). The control set (1) is mounted on the tractor and is connected to the control unit (2) of the machine via the connecting cable (6).
- Page 103 Operation (1) Screen. Depending on the selected function, the following menu appears: Working menu. The Working menu displays the selected functions and the operating states during charging and discharging. Road travel menu. The Road travel menu appears with the road travel mode activated.
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Page 104: Display Information In Working Menu
Operation (11) Switch transport floor on/Set feed rate of transport floor (in combination with keys 9 and 10) (12) Select SET menu/Call service hours and transported loads counter (13) Switch lighting in the cargo space on/off/ Return to Working menu (14) Lower tailgate (15) Lift tailgate (16) Lift folding drawbar... -
Page 105: Functions And Their Symbols
Operation extended/retracted", here "Cutting knives retracted" (10) Operating state "Cutting unit extended/retracted", here "Cutting unit retracted" (11) Operating state "Steering axle locked/unlocked", here "Steering axle unlocked" (12) Operating state "Crossover conveyor ccw rotation on/cw rotation/stop", here "Crossover conveyor cw rotation on" (13) Operating state "Silage additive pump on/off", here "Silage additive pump on"... - Page 106 Operation Switch road travel mode on The screen shows: The road travel mode can only be switched on: with lifted pick-up (attention, the pick-up is not checked for having been lifted completely), with lowered tailgate, with the transport floor stationary, ...
- Page 107 Operation the "Steering axle unlocked" symbol. Switch road travel mode off With the road travel mode switched off: The Working menu appears, all functions of the control set are enabled, the drawbar suspension (optional extra) and the warning beacon (optional extra) are switched off, ...
- Page 108 Operation Switch Discharge mode A II on (Machine without beaters) The Discharge mode A II is automatically switched off when the tailgate is lowered. During discharge, the transport floor feed can be switched on and off as often as desired by pressing the key.
- Page 109 Operation As soon as the p.t.o. shaft is switched on, the beaters start to run and after a short delay, the transport floor automatically starts. With the beaters powered, the "Beaters On" symbol appears. With the transport floor powered, the "Feed On"...
- Page 110 Operation The screen shows: 2. Press the key again. The automatic charging system is switched off. The "Automatic charging system off" symbol appears. Switch transport floor on Information for machines without beaters: When the machine is fully charged, the ISOBUS control set generates an acoustic signal (horn sound) and a visual signal "Forage wagon full".
- Page 111 Operation Double feed rate of transport floor for complete emptying (transport floor level II) The minimum set feed rate must be "40" before doubling the feed rate of the transport floor for complete emptying. The screen shows: 1. Press the key once during discharge.
- Page 112 Operation Reverse transport floor Risk due to failure of components caused by frequent or long reverse of transport floor! Observe the fact that the feed direction of the transport floor is only allowed to be reversed for a short time (max. 3 seconds). Check the transport floor chains for proper tension every day, in order to prevent material damage.
- Page 113 Operation Stop crossover conveyor The screen shows: 1. Press the key once. The crossover conveyor stops. Switch cargo space lighting on/off If the cargo space lighting is switched on: the lighting is automatically switched off if the road travel mode is switched on, ...
- Page 114 Operation Lift tailgate (Machine without beaters) When discharging on the bunker silo, the tailgate is automatically lifted to its full extent after pressing the key. The screen shows: 1. Press the key until the tailgate has reached its end position. ...
- Page 115 Operation Lift folding drawbar The screen shows: 1. Press the key until the folding no additional symbol drawbar has been lifted to the desired position or has reached its end position. The ground clearance of the pick-up is increased. Lower folding drawbar The screen shows: 1.
- Page 116 Operation Extend cutting unit The screen shows: 1. Press the key until the "Cutting unit" symbol is in "Cutting unit extended" position and a beep is emitted. The cutting unit is completely extended into the conveyor duct. Lock steering axle WARNING Risk to people due to insufficient stability and tipping over of the machine if the steering axle is not properly used!
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Page 117: Set Machine Parameters
Operation Unlock steering axle The screen shows: 1. Press the key once. The steering axle can move freely (is unlocked) and follows the turning radius of the corner during cornering. The "Steering axle unlocked" symbol appears and a beep is emitted. -
Page 118: Call Up Set Menu
Operation The machine parameters are set in the SET menu. Depending on the machine model and the machine's equipment, the indicated symbols may differ. The arrow in the centre indicates which parameter may currently be changed. 6.2.4.1 Call up SET menu The screen shows: 1. -
Page 119: Pre-Select Filling Degree Of Loaded Material In Cargo Space
Operation 6.2.4.2 Pre-select filling degree of loaded material in cargo space The higher the set filling degree, the higher the transport floor feed rate and the smaller the filling capacity. The screen shows: 1. Press the keys one after the other. ... -
Page 120: Operating Hours Counter, Service Hours Counter And Transported Loads Counter
Operation 2. Turn the tractor engine off. 3. Apply the parking brake of the tractor. 4. A second person enters the cargo space through the access door. 5. Switch the tractor ignition on. 6. Press and hold the key once. ... -
Page 121: Call Up Counter Menu
Operation The operating hours counter and the transported loads counter are designed each as daily and total counters. The service hours counter is designed as total counter. Daily operating hours counter (operating hours until reset (h)). The operating hours of the machine during which the pick-up is in lowered position are registered. -
Page 122: Transport Journeys
Transport journeys Transport journeys A transport journey is a journey of the charged or empty machine to or from the place of operation. Observe the fact that the braking axle needs to run in during the first service hours – the brake lining is adjusting to the brake drum. -
Page 123: Transport Journeys With Partly Discharged Machine
Transport journeys the drawbar suspension (optional extra) and the warning beacon (optional extra) are switched on, ● the work lights are switched off. 3. Lock the passive steering axle when travelling at a speed of more than 40 km/h. 4. -
Page 124: Use Of Machine
Use of machine Use of machine When using the machine, additionally observe the information included in the following chapters: "Operator’s obligation", page 26, "Qualification of operator", page 27, "Basic safety instructions", page 29, "Warning and instruction signs", page 37. Observance of these chapters serves your safety. -
Page 125: Charging
Use of machine WARNING Risk to people of being crushed, drawn in and becoming entangled due to unprotected powered driving elements during machine operation! Start the machine only with the protective devices completely mounted. It is not allowed to open protective devices: ... - Page 126 Use of machine Before charging the machine: check the set operating height of the pick-up and readjust if necessary, see chapter "Set operating height", page 74. check the set distance between pick-up and holding-down device/pulley and readjust if necessary, see chapter "Set holding-down device with pulley", page 75.
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Page 127: Charging With Easy-To-Use Control
Use of machine WARNING Risk of crushing, shearing and risk of impact when lowering and lifting the pick-up! Make sure that people leave the hazardous area of the pick-up before lowering or lifting the pick-up. WARNING Risk of becoming entangled, wound up and being drawn in within the area of the movable pick-up components! Make sure that people leave the pick-up area before switching the pick-up drive on. -
Page 128: Charging With Isobus Control
Use of machine If the forage wagon is full, the easy-to-use control set will generate an acoustic signal (horn sound) and a visual signal (control lamp (H5): "Forage wagon full"). The automatic charging system is deactivated and the automatic feed function for the transport floor is switched off. -
Page 129: Discharging
Use of machine 10. Press the key once to lift the pick-up. 11. Press the key once to switch on the Road travel mode for transport journeys on public roads. Discharging Lift the pick-up completely! Lock the steering axle! ... -
Page 130: Machine Equipped With Beaters
Use of machine 8. Start to move and select the travelling speed of the tractor according to the height of the desired discharged material stack. For step-by-step discharge, the transport floor feed can be repeatedly switched off by setting switch (6) to the middle position for a short time. ... - Page 131 Use of machine 2. Keep hold of switch (11) in the upper position until the pick-up has sufficient ground clearance. 3. Keep hold of switch (8) in the upper position until the folding drawbar has been sufficiently lifted. 4. Keep hold of switch (10) in the lower position until the steering axle is locked.
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Page 132: Discharging With Isobus Control
Use of machine 8.2.2 Discharging with ISOBUS control 8.2.2.1 Machine without beaters 1. Press the key once to switch the Road travel mode off. 2. Press the key until the pick-up has sufficient ground clearance. The following functions will be automatically carried out one after the other: 2.1 Lock steering axle. -
Page 133: Machine Equipped With Beaters
Use of machine 8.2.2.2 Machine equipped with beaters Press the key only with the tractor's p.t.o. shaft stopped! Non-observance of this information may cause damage to the jaw clutch of the powertrain of the beaters. Reduce the feed rate for the transport floor during discharge if the control set frequently generates the acoustic and visual signal "Forage wagon full"! The beaters may become clogged if the feed rate for the... - Page 134 Use of machine 6.3 Press the key once to reverse the feed direction of the transport floor for 3 seconds. Thus, the pressing power which the loaded material applies to the beaters, and the starting torque for loosening the beaters are reduced. 6.4 Press the again.
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Page 135: Determine Admissible Loading Capacity
Use of machine 12. Press the key until the folding drawbar has been lowered to the desired position. If the folding drawbar is equipped with a drawbar suspension, lower the folding drawbar just as far as to ensure that the hydraulic cylinders of the folding drawbar are still extended by approx. 20 mm. -
Page 136: Service And Maintenance Of Machine
Service and maintenance of machine Service and maintenance of machine Regular and proper service and maintenance: will keep your machine ready for use for a long time and avoid early wear, will reduce downtimes and repairs, is a precondition for our warranty provisions. ... - Page 137 Service and maintenance of machine WARNING Risk of crushing, shearing, cuts, amputation, becoming entangled, wound up, being drawn in and risk of impact to people if: lifted, unsecured machine parts accidentally come down or are unintentionally lowered, tractor and machine accidentally start and roll! ...
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Page 138: Operating Media
Service and maintenance of machine Operating media Exclusively use the operating media specified in these operating instructions and in the included sub-supplier documentation! The manufacturer will not assume any warranty or liability for damage on the machine caused by the use of non-approved operating media. Quantity Filling-up point / Liquid /... -
Page 139: Service And Maintenance Plan - Overview
Service and maintenance of machine Service and maintenance plan - Overview ► See also chapter "Lubrication plan", page 143! ► See also chapter "Lubrication and maintenance plan – Chassis", page 172! Before first start-up and after longer downtimes Check: ● the wheel nuts for tightness, retighten if necessary. - Page 140 Service and maintenance of machine Use compressed air to clean the cutting unit, in particular the retainer of the cutting knives and the knife security system. Every 50 service hours ● Pick-up: ● Check tension of the roller chains of the pick-up drive, tighten roller chains if necessary. ●...
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Page 141: Cleaning Of Machine
Service and maintenance of machine ● Grease and lubricate all movable machine parts (in particular those of the cutting unit). ● Lubricate transport floor chains, in order to prevent the chain links from getting rusty. Cleaning of machine Regularly and thoroughly clean the machine! Dirt may attract humidity thus facilitating the formation of rust. -
Page 142: Lubrication Of Machine
Service and maintenance of machine Cleaning by means of pressure washer / steam blaster It is absolutely imperative to observe the following when using a pressure washer/steam blaster for cleaning: Admissible injection pressure: max. 80 bar. Water temperature: max. 60°C. ... -
Page 143: Lubrication Plan
Service and maintenance of machine 9.4.1 Lubrication plan ► See also chapter "Lubrication and maintenance plan – Chassis", page 172! Zelon CFS 2501, 2901, 3301 / Zelon CFS 2501 DO, 2901 DO, 3301 DO 04.15... -
Page 144: Check / Top Up Central Lubrication
Service and maintenance of machine 9.4.2 Check / Top up central lubrication With the pick-up in open-centre position, the central lubrication starts and supplies grease to the open spur gear of the feeder rotor and the roller chains of the CFS drum and the pick-up drive. Particularly check the open spur gear for sufficient lubrication at regular intervals! Never operate the machine with unlubricated spur gear! The... -
Page 145: Check/Top Up/Change Gear Lubricant Oil
Service and maintenance of machine Check/top up/change gear lubricant oil ► See also chapter "Service and maintenance plan - Overview", page 139! ► See also chapter "Operating media", page 138! CAUTION Risk of damage to machine components when powering gearboxes without gear lubricant oil! Always ensure a sufficient oil level in the gearboxes. -
Page 146: Main Gearbox Of Cutting Unit
Service and maintenance of machine 9.5.2 Main gearbox of cutting unit (1) Oil inspection plug (2) Oil filling screw (3) Oil drain plug Fig. 82 9.5.3 Angular gear of beater unit Front Oil filling screw Oil drain plug Fig. 83 Zelon CFS 2501, 2901, 3301 / Zelon CFS 2501 DO, 2901 DO, 3301 DO 04.15... -
Page 147: Check/Top Up Oil Level
Service and maintenance of machine Rear Oil filling screw Oil drain plug Fig. 84 9.5.4 Check/Top up oil level WARNING Risk of injury due to movements of tractor and machine or machine parts! Secure tractor and machine against accidental starting and rolling before carrying out any work on the machine! Make sure that people leave the hazardous area of the tractor and the machine or of movable machine parts! -
Page 148: Cutting Unit
Service and maintenance of machine 5. Wait for the oil to stop draining out of the oil drain opening. 6. Screw in again and tighten the oil drain plug. Use sealant. 7. Fill the specified oil quantity in through the oil filler neck. 8. -
Page 149: Remove And Install Cutting Knives
Service and maintenance of machine 1. Retract the cutting unit from the conveyor duct. 2. Clean: the gaps (1) between the cutting knives/knife holders. the lever pockets (2) of the individual knife holders. Use the mounting lever (3) and compressed air for this purpose. -
Page 150: Remove Cutting Knives
Service and maintenance of machine 9.6.2.1 Remove cutting knives WARNING Risk of injury due to movements of tractor and machine or machine parts! Secure tractor and machine against accidental starting and rolling before carrying out any work on the machine! Make sure that people leave the hazardous area of the tractor and the machine or of movable machine parts! WARNING... -
Page 151: Install Cutting Knives
Service and maintenance of machine 9.6.2.2 Install cutting knives WARNING Risk of injury due to movements of tractor and machine or machine parts! Secure tractor and machine against accidental starting and rolling before carrying out any work on the machine! Make sure that people leave the hazardous area of the tractor and the machine or of movable machine parts! WARNING... -
Page 152: Grind Cutting Knives
Service and maintenance of machine 9.6.3 Grind cutting knives Sharp cutting knives: reduce the effort required for powering the conveying unit, reduce conveying unit wear, increase the service life of the conveying unit. WARNING Risk of injury due to sharp cutting knives! Wear cut-proof protective gloves when carrying out work on the cutting knives! WARNING... - Page 153 Service and maintenance of machine 1. Completely extend the cutting unit. 2. Lift the folding drawbar to increase the free space to the cutting knives. 3. Enter the cargo space through the access door. 4. Measure: the distance (X) between the cutting knives (1) and the rotor (2) from the cargo space through the slots of the conveyor duct.
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Page 154: Check Distance Between Strippers And Rotor
Service and maintenance of machine Fig. 94 9.6.5 Check distance between strippers and rotor The minimum distance between the strippers and the rotor must be 18 mm over the entire width of the rotor. This distance will prevent the rotor from becoming clogged. The distance must not fall below the minimum value. -
Page 155: Set "Cutting Unit Retracted" Sensor
Service and maintenance of machine 1. Enter the cargo space through the access door. 2. Measure the distance (X) between the strippers (1) and the rotor (2) in the conveyor duct from the cargo space. 3. Replace worn strippers. 3.1 Unscrew the screws (3). 3.2 Remove the safety rail (4) of the stripper holder by pulling it out to the side. -
Page 156: Cfs Drum
Service and maintenance of machine CFS drum 9.7.1 Check / Retighten chain tension of CFS drum Check the tension of the roller chain at the chain tensioner every day. The roller chain must be retightened if the distance between washer and sleeve of the chain tensioner is more than 8 mm. -
Page 157: Bleed Friction Clutch Of Pick-Up
Service and maintenance of machine Open the left-hand side protector. Take off the spring (1). Unscrew and remove the screwed connection (2) and the collar bushing (3). Lift the tailgate to completely extend the hydraulic cylinder (4). Fig. 98 Pull the switch lever (5) towards yourself until you feel it reach the stop such that the minimum distance between the shifting claw (6) and the hub (7) is 1 mm. -
Page 158: Check/Retighten Tension Of Roller Chain For Pick-Up Drive
Service and maintenance of machine 1. Remove the protective casing of the pick- 2. Unlock and unscrew the groove nut (1). Remember exactly the number of turns made to unscrew the groove nut to ensure that the friction clutch can be properly pre-tightened again! 3. -
Page 159: Beaters
Service and maintenance of machine Lower the pick-up completely. Secure tractor and machine against accidental starting and rolling. Unscrew the counter nut (1). Turn the nut (2) such that the distance between washer (3) and sleeve (4) is less than 8 mm. Tighten the counter nut. -
Page 160: Readjust Jaw Clutch Of Beater Circuit
Service and maintenance of machine Retighten the tightening wheel bolt. Close and lock the side protector. 9.9.2 Readjust jaw clutch of beater circuit Readjust the jaw clutch of the beater circuit if the beaters do not automatically switch off when the tailgate is lowered. WARNING Risk of injury due to movements of tractor and machine or machine parts! - Page 161 Service and maintenance of machine Ensure that the transport floor strips on the right-hand and left-hand side do not bump against the frame (1)! Equally shorten the chains of the transport floor if the tension path of the chain tensioners is no longer sufficient to retighten the chains! Fig.
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Page 162: Crossover Conveyor
Service and maintenance of machine 9. Put the shortened chains together again by means of the chain connecting links. At any rate, secure the chain connecting links by means of a new, unbent locking wire! A locking wire bent once may already break when bending it the second time. -
Page 163: Hydraulic System
Service and maintenance of machine to the frame at the return rollers on both sides. Adjust the distance by turning the clamping nuts (3) if necessary. Retighten the counter nut (1) at both radial insert ball bearings (2). 9.12 Hydraulic system Observe the information in the chapter "Basic safety instructions", page 29. -
Page 164: 9.12.1.1 Depressurise Folding Drawbar With Drawbar Suspension
Service and maintenance of machine 1. Relieve the respective hydraulic cylinder via the corresponding operating element with the hydraulic pump switched off. 9.12.1.1 Depressurise folding drawbar with drawbar suspension WARNING Risk of injury due to movements of tractor and machine or machine parts! Secure tractor and machine against accidental starting and rolling before carrying out any work on the machine! -
Page 165: 9.12.2.2 Inspection Criteria For Hydraulic Hose Pipes
Service and maintenance of machine 9.12.2.2 Inspection criteria for hydraulic hose pipes For your own safety: Immediately have hydraulic hose pipes replaced (shop work) as soon as you detect any of the following defects: Damaged outer layer down to the liner (e. g. due to chafing points, cuts, fissures). -
Page 166: Brake System And Chassis
Service and maintenance of machine 1. Disconnect the hydraulic system of the machine from the tractor. The machine is depressurized. 2. Unscrew the filter casing (3) from the filter head. 3. Remove the soiled filter element (1). 4. Clean the filter casing. 5. -
Page 167: Set Compressed-Air Brake System
Service and maintenance of machine Check degree of soiling 1. Check the degree of soiling of the filter elements (1) in the hose couplings of the brake and feed line before connecting the hose couplings to the tractor. The filter element can be inspected through the opening (2) beneath the plastic lid. -
Page 168: Drain Compressed-Air Reservoir Of Compressed-Air Brake System
Service and maintenance of machine 1. Disconnect the brake and feed line of the brake system. 2. Manually actuate the brake lever in pressing direction. 3. Press the circlip at the adjusting screw (1) down and set the free travel (X) by means of the adjusting screw: Free travel (X) = 0.1 x length of brake lever 4. -
Page 169: Set Hydraulic Brake System
Service and maintenance of machine 9.13.4 Set hydraulic brake system Shop work The brake system must be readjusted if the free travel (X) is greater than or equal to 40 mm. WARNING Risk of injury due to movements of tractor and machine or machine parts! Secure tractor and machine against accidental starting and rolling before carrying out any work on the machine! -
Page 170: Check Tyres
Service and maintenance of machine 9.13.5 Check tyres Check the tyre pressure at least every 2 weeks. If the machine has not been used for a longer time, the tyre pressure should be checked before putting the machine into operation again. Always ensure that the tyre pressure is properly adapted to the load and the kind of work which has generally to be carried out by the machine. - Page 171 Service and maintenance of machine 1. Place the lifting device at the marked fixing points. Fig. 116 2. Keep to the specified order when loosening and tightening the wheel nuts. 3. Tighten the wheel nuts at the required tightening torque. 4.
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Page 172: Lubrication And Maintenance Plan - Chassis
Service and maintenance of machine 9.13.7 Lubrication and maintenance plan – Chassis ► See also chapter "Service and maintenance plan - Overview", page 139! ► See also chapter "Lubrication plan", page 143! Relubricate all lubrication points after cleaning the machine by means of pressure washers. -
Page 173: Lubricate Brake Shaft Bearing
Service and maintenance of machine Maintenance work Check all components for damage and wear (visual check). Have spring clamps at the supporting axle checked for tightness (shop work!). Have axle connection at the spring tension casings checked for tightness (shop work!). -
Page 174: Lubricate Standard Slack Adjuster
Service and maintenance of machine Fig. 119 9.13.9 Lubricate standard slack adjuster WARNING Risk of injury due to movements of tractor and machine or machine parts! Secure tractor and machine against accidental starting and rolling before carrying out any work on the machine! Make sure that people leave the hazardous area of the tractor and the machine or of movable machine parts! Lubricate the lubrication points (4) of the slack... -
Page 175: 9.13.11 Check Brake Linings
Service and maintenance of machine Lift the axle until the tyres are free. Release the brake. Place two levers between tyres and ground and check the bearing clearance. If there is a noticeable bearing clearance, have it readjusted (shop work!). Fig. -
Page 176: Tightening Torques
Service and maintenance of machine 9.14 Tightening torques 9.14.1 Tightening torques for metric screws ► See also chapter "Tightening torques for wheel nuts", page 177! These tightening torques are reference values. Differing data specified elsewhere in the operating instructions or the included sub- supplier documentation shall always prevail! Grade and marking of screw heads... -
Page 177: Tightening Torques For Wheel Nuts
Remedy of malfunctions Regularly check the screwed connections for tightness. Always replace screws and nuts by parts of the same quality. Tighten counter nuts with plastic insert and bordered steel counter nuts at approx. 50% of the “dry” value specified in the table. -
Page 178: Replace Bolt Of Shear Bolt Coupling
Remedy of malfunctions 3. Extend the cutting unit back into the conveyor duct when the clogging/blockages have been eliminated. Elimination not from the tractor seat: WARNING Risk to the operator of being drawn in or becoming entangled if the pick-up accidentally starts to run during manual elimination of clogging/blockages! Secure tractor and machine against accidental starting and rolling before manually eliminating clogging/blockages. - Page 179 Remedy of malfunctions Electro-hydraulic control block – Overview Fig. 124 Fig. 125 Lift/Lower pick-up Power crossover conveyor (cw rotation) Lift/Lower tailgate Power crossover conveyor (ccw rotation) Lift/Lower tailgate Bleed valve Reverse transport floor Lock/Unlock steering axle Lift/Lower folding drawbar Lift/Lower folding drawbar Retract/Extend cutting unit Pre-selection valve 30 Pre-selection valve 31...
- Page 180 Remedy of malfunctions Retract cutting unit Screw the knurled screws Y12.1 and Y12.2 at the cutting unit completely in. Screw the knurled screw Y13 at the electro-hydraulic control block completely Use a blunt object (Ø ≤ 3 mm) to push in the pre-selection valve Y31.
- Page 181 Remedy of malfunctions Lower tailgate Screw the knurled screws Y2 and Y3 completely in. Use a blunt object (Ø ≤ 3 mm) to push in the pre-selection valve Y30. → The tailgate lowers. Unscrew the knurled screws completely again. Lift folding drawbar Screw the knurled screws Y9 and Y10 completely in.
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Page 182: Overview Of Other Malfunctions And Remedial Actions
Remedy of malfunctions 10.4 Overview of other malfunctions and remedial actions 10.4.1 Hydraulics Malfunction Cause Remedy No hydraulic function available Interrupted hydraulic oil Switch hydraulic oil circulation circulation between tractor and machine on Check hydraulic plugs for wear Hydraulic hose pipes not Connect hydraulic hose pipes correctly connected (return line correctly... -
Page 183: Electrics
Remedy of malfunctions 10.4.2 Electrics Malfunction Cause Remedy No function working No power at the control set Provide a voltage of 12 V at the tractor Defective fuse Replace fuse Loose contact in socket Remedy loose contact Operating element On/Off not Set operating element to On switched Functions work irregularly... -
Page 184: Working
Remedy of malfunctions The displays of all functions do Defective wiring (short-circuit) Check wires, replace them if not show a status message on necessary the control set Sensors not properly set Adjust sensors Defective sensor/s Replace sensor/s Automatic charging system Range not set Recalibrate automatic charging switches too late... -
Page 185: Disassembly / Disposal
Circuit diagrams Malfunction Cause Remedy Cutting unit cannot be Cutting unit soiled between Clean cutting unit extended cutting knives and conveying trough Conveyor duct clogged Clean conveyor duct Cutting knives bent Align or replace cutting knives Knurled screws of hydraulic Completely screw in knurled cylinders at cutting unit screws... -
Page 186: Circuit Diagrams
Circuit diagrams Circuit diagrams 12.1 Hydraulics Passive steering axle Cutting unit Tailgate Tailgate cylinder Drawbar suspension Folding drawbar Pick-up Transport floor Transport floor, 2-level (10) Only with beaters (11) Crossover conveyor Zelon CFS 2501, 2901, 3301 / Zelon CFS 2501 DO, 2901 DO, 3301 DO 04.15... - Page 187 Circuit diagrams Zelon CFS 2501, 2901, 3301 / Zelon CFS 2501 DO, 2901 DO, 3301 DO 04.15...
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Page 188: Electronics - Cable Harness Overview
Circuit diagrams 12.2 Electronics – Cable harness overview Zelon CFS 2501, 2901, 3301 / Zelon CFS 2501 DO, 2901 DO, 3301 DO 04.15... - Page 189 Circuit diagrams Control unit Pick-up LIN module, weighing device Tailgate Work lights, front grating Tailgate Work light, rear, left-hand Transport floor forward Work light, rear, right-hand Transport floor forward level II Work light, pick-up Reverse transport floor Steering axle XM16 Silage additive pump Folding drawbar 1 XM17...
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Page 190: Electronics - Valves
Circuit diagrams 12.3 Electronics – Valves A1#1 Control unit 1/42 Pick-up 2/42 Transport floor forward Silage additive pump 3/42 Pre-selection valve 31 Central lubrication 5/42 Pre-selection valve 30 7/42 Reverse transport floor XM16 Silage additive pump 8/42 Silage additive pump XM17 Central lubrication 10/42... - Page 191 Circuit diagrams Zelon CFS 2501, 2901, 3301 / Zelon CFS 2501 DO, 2901 DO, 3301 DO 04.15...
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Page 192: Electronics - Sensors
Circuit diagrams 12.4 Electronics – Sensors Zelon CFS 2501, 2901, 3301 / Zelon CFS 2501 DO, 2901 DO, 3301 DO 04.15... - Page 193 Circuit diagrams Control unit LIN module, weighing device 4/42 Supply, potentiometer, automatic charging system 12/42 LIN bus 18/42 12 V sensors 1 20/42 Ground, sensors 1 21/42 Signal, speed, pick-up 22/42 Signal "Tailgate lowered" 23/42 Signal, light barrier 24/42 Signal, cutting unit 25/42 Signal "Tailgate completely lifted"...
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Page 194: Electronics - Work Lights
Circuit diagrams 12.5 Electronics – Work lights A1#2 Easy-to-use control, power unit 6/42 Work light 1+ 17/42 Work light 1- 19/42 Work light 2+ 31/42 Work light 2- Zelon CFS 2501, 2901, 3301 / Zelon CFS 2501 DO, 2901 DO, 3301 DO 04.15... - Page 195 Index Index Automatic charging system (ISOBUS control) ..........119 Cargo space lighting ........113 Activate/Deactivate silage additive pump (with easy-to-use control) ........88 CFS drum Align switch rod of pick-up circuit ....156 Check/Retighten chain tension ....156 Automatic charging system ......109 Maintenance ..........
- Page 196 Index Counter menu .......... 121 Reset daily counters ........ 121 DC value ............51 SET menu ..........118 Delivery rate ..........24 ISOBUS control Field-Operator 120 Disassembly ..........185 Parameters ..........117 Discharge mode .......... 107 ISOBUS control set Field-Operator 120 Discharging ..........
- Page 197 Index Operator Safety-conscious operation ......28 Qualification ..........27 Secure machine against rolling ....53 Overload clutch..........125 Secure tractor against accidental starting ..53 Overview of machine ........14 Service and maintenance ......136 Service and maintenance plan ....139 Service hours counter .........
- Page 199 Verfasser Freigeber Datum Sprache 27.07.2015 Zuordnung Ladewagen Zelon CFS Modell Zelon CFS 2501, 2901, 3301 / 2501 DO, 2901 DO, 3301 DO...