Page 1 Operating Instructions Silage trailers CAREX 370 S CAREX 410 S CAREX 450 S CAREX 490 S CAREX 390 K CAREX 430 K CAREX 470 K CAREX 510 K SHUTTLE 370 S SHUTTLE 410 S SHUTTLE 450 S SHUTTLE 490 S...
Page 2: General
General General Identification ☐ ☐ ☐ ☐ CAREX 370 S CAREX 390 K CAREX 410 S CAREX 430 K ☐ ☐ ☐ ☐ CAREX 450 S CAREX 470 K CAREX 490 S CAREX 510 K ☐ ☐ ☐ ☐ SHUTTLE 370 S...
Page 3: Preface
You have made a good choice. We would like to thank you for placing your trust in us by purchasing a Bergmann vehicle. As a supplier of agricultural machinery, we offer you efficient machinery at high quality standards with the service to match.
Page 4: Table Of Contents
Identification Plate - Drawbar ......................16 Technical data ........................16 2.5.1 CAREX 370 S / 390 K / 410 S / 430 K / 450 S / 470 K / 490 S / 510 K .......... 17 2.5.1.1 Dimensions ..........................17 2.5.1.2...
Page 5 General 2.7.3 Road traffic regulations ........................33 2.7.4 Coupling, loading, transport......................33 2.7.5 PTO Shaft Operation ........................34 2.7.6 Hydraulic system ..........................35 2.7.7 Brakes and Tires ..........................36 2.7.8 Maintenance ............................ 36 Important Information for Vehicle Operation ..............37 Other Hazards ........................
Page 6 General 3.13.2 Ladder and Access Door ......................... 68 3.13.3 Front Wall - Hydraulic Swivel Mechanism ..................69 3.13.3.1 Front wall elements ......................... 69 3.13.3.2 Front Wall Positions ........................ 70 3.13.3.3 Raising and lowering the front wall ..................71 3.13.4 Front Wall Sensor, Bottom (Right) ....................72 3.13.4.1 Angle sensor ...........................
Page 7 General 4.3.2 Locking the Steering Axle ......................109 4.3.3 Driving ............................110 Weights and Capacity Information ................110 5 Care and Maintenance ..................111 General: .......................... 111 Cleaning and Maintenance in the Cargo Space ............111 Maintenance Schedule ....................112 Screw torques ........................
Page 8 General 5.14.1 Scraper ............................136 5.15 Hydraulics ........................136 5.15.1 Hydraulic Oil Filter (Pilot box / Comfort Control) ................136 5.16 Circuit Diagrams ......................137 5.16.1 Hydraulics ............................137 5.16.2 Electric ............................139 Terminal – BCT 20 ........................ 139 5.16.2.1 Terminal –...
Page 9 General - 9 - 201703 en...
Page 10: Notices For The User
In order to prove that the vehicle and the operating instructions were transferred properly, written confirmation is needed. You will find a transfer statement below which must be filled out and returned to Bergmann after transfer. According to the German product liability law, every farmer is the owner of a business.
Page 11 Notices for the User - 11 - 201703 en...
Page 12: Product Transfer Instructions
Information about optional and extra equipment was provided. Informed that reading the operating instructions is absolutely necessary In order to prove that the vehicle and operating instructions were transferred properly, the transfer statement must be filled out, signed and returned to Bergmann. Ludwig Bergmann GmbH Maschinenfabrik D –...
Page 13: General Information
Notices for the User General Information Read the operating instructions thoroughly and observe safety notices before initial start-up! 2.3.1 Intended Use The "CAREX" / “SHUTTLE” trailer is intended solely for standard use in agricultural work (intended use). Authorised used are loading, transporting and unloading of roughage, green forage, silage and straw. It is also permitted to transport and unload chopped material (grass / maize).
Page 14: Designation
Notices for the User Designation The designation shall include the following: Vehicle identification number (VIN) Identification plate CE Symbol NOTICE The entire designation is a legal document and must not be altered made illegible. 2.4.1 Vehicle Identification Number (VIN) With the vehicle identification number (VIN) it is possible to clearly identify your vehicle. The VIN can be found on the identification plate and is also engraved on the machine frame near the identification plate.
Page 15: Identification Plate - Vehicle
Notices for the User 2.4.3 Identification Plate - Vehicle The following information can be found on the identification plate (Image 2): Manufacturer VIN No. Vehicle identification number Gross vehicle weight Gross vehicle weight Dead weight Dead weight Gross axle weight, Gross axle weight, front front Gross axle weight,...
Page 16: Identification Plate - Drawbar
Notices for the User 2.4.4 Identification Plate - Drawbar In case of inspection, a identification plate is located directly on the drawbar. The following information can be found on the identification plate (Image 4): Manufacturer Drawbar type Ident. No. Identification number Gross trailer weight Gross trailer weight Gross nose weight...
Page 17: Carex 370 S / 390 K / 410 S / 430 K / 450 S / 470 K / 490 S / 510 K
Notices for the User 2.5.1 CAREX 370 S / 390 K / 410 S / 430 K / 450 S / 470 K / 490 S / 510 K 2.5.1.1 Dimensions Image 5: Dimensions 26-00-0701-PLN_20170309 Model 370 S 390 K...
Page 18: Pick-Up
Notices for the User 2.5.1.3 Pick-Up Model 370 S 390 K 410 S 430 K 450 S 470 K 490 S 510 K Pick-up* clearance Clearance with extended high-lift drawbar Pick-up width 2050 2050 2050 2050 2050 2050 2050 2050 Number of knives Piece Shortest theoretic cutting length...
Page 19: Shuttle 370 S / 390 K / 410 S / 430 K / 450 S / 470 K / 490 S / 510 K
Notices for the User 2.5.2 SHUTTLE 370 S / 390 K / 410 S / 430 K / 450 S / 470 K / 490 S / 510 K 2.5.2.1 Dimensions Image 6: Dimensions 26-00-0301-PLN_20170309 Model 370 S 390 K 410 S 430 K 450 S...
Page 20: Pick-Up
Notices for the User 2.5.2.3 Pick-Up Model 370 S 390 K 410 S 430 K 450 S 470 K 490 S 510 K Pick-up clearance Clearance with extended high-lift drawbar Pick-up width 2050 2050 2050 2050 2050 2050 2050 2050 Number of knives Piece Shortest theoretic cutting length...
Page 21: Warning Symbols And Notice Stickers
Notices for the User Warning Symbols and Notice Stickers The warning symbols on the vehicle are provided for the safety of all persons who work with the vehicle, and warn about other dangers. The notices identify vehicle specific characteristics which need to be observed in order to provide for flawless vehicle operation.
Page 22 Notices for the User B06-0541 Read and observe operating instructions and safety notices before initial operation! Cleaning instructions pressure washer use B06-0542 Be careful of moving parts! Never reach into the running machine! Do not open or remove safety equipment while motor is running! B06-0543 Only touch machine parts when they come to a complete standstill! Before working on spreader disks, switch off PTO shaft and motor and remove ignition key!
Page 23 Notices for the User B06-0549 Switch off motor and remove ignition key before maintenance and repair work! B06-0556 Switch off motor and remove ignition key before maintenance and repair work! B06-0602 Jack stand must be in the upper most position during operation. The jockey wheel must be rotated upwards and towards the rear of the vehicle.
Page 24 Notices for the User B06 0626 Keep sufficient distance from hot surfaces. B06-0869 Prior to every use, make sure that no one is in the immediate area (Especially children!) Ensure sufficient view e.g. when backing up! B06-0870 The height can exceed 4000 mm when Machine parts are moved out for work. Be careful of overhead lines and bridge crossings.
Page 25: Drive
Notices for the User 2.6.1.2 Drive B06-0551 The drive speed of the propeller shaft is: max. 540 min-1! (Depends on vehicle type, see ID plate) B06-0599 The drive speed of the propeller shaft is: max. 750 min-1! (Depends on vehicle type, see ID plate) B06-0538 The drive speed of the propeller shaft is: max.
Page 26: Hydraulic
Notices for the User 2.6.1.3 Hydraulic B06-0548 Be careful of high-pressure liquid leaks. Observe notice in technical handbook! B06-0862 Constant current system: Unscrew knob until it stops Constant pressure system / Load-sensing system (LS): Screw in knob until it stops 2.6.1.4 Scraper floor B06-0544...
Page 27: Chassis- Tandem Axle Unit
Notices for the User 2.6.1.6 Chassis- Tandem axle unit B06-1017 On all vehicles with a tandem axle unit and a lubricated middle rocker the lubrication pin in the middle spring saddle must be lubricated every 10 operating hours to ensure proper function and to reduce wear. 2.6.1.7 Chassis - with Hydraulic Axle Compensation B06-0938...
Page 28: Lift Axle
Notices for the User 2.6.1.8 Lift axle B06-0817 When operating a loaded or partially loaded vehicle, lower lift axle before driving on public roads. B06-0939 Lift axle only to be operated when the vehicle is completely empty. B06-0972 With lifted lift axle set the manual control of the air brake system to "half-load". 201703 en - 28 -...
Page 29: Forced Steering
Notices for the User 2.6.1.9 Forced Steering B06-0666 When coupling the hydraulic cylinder, no people are allowed or their limbs should be in the stroke range of the cylinder (risk of injury by sudden movement of piston rod)! Tandem B06-1035 - Type: - Chassis: Tandem...
Page 30 Notices for the User Tridem B06-1038 - Type: M / HW / Vario / SL - Chassis: Tridem - Axle: 1st axle steered - Adjusting the steering variants (Note instructions in the manual under „Initial Start-up and Functions / forced steering”!) B06-1039 - Type: M / HW / Vario / SL...
Page 31: Silage Trailer
Notices for the User 2.6.1.10 Silage Trailer B06-0504 Vehicle side controls left: drawbar right: cutting unit B06-0505 Vehicle side controls raise drawbar / cutting unit on down: lower drawbar cutting unit off B06 0606 Never reach into the pick-up area, as long as the tractor engine is running when the PTO is on. B06-1113 For an optimum pick-up operating height, the pick-up cylinder reference dimension must be correct:...
Page 32: Safety And Accident Prevention Requirements
Notices for the User Safety and Accident Prevention Requirements 2.7.1 Basic rules  Inspect vehicle for road and operation readiness before each use!  In addition to the instructions in this manual also observe general safety and accident prevention regulations. ...
Page 33: Road Traffic Regulations
Notices for the User 2.7.3 Road traffic regulations The following regulations must be observed in Germany (in foreign country-country specific regulations):  When driving on public roads, the vehicle requires operating permit. This permit is issued by the Road Traffic Authorities.
Page 34: Pto Shaft Operation
Notices for the User 2.7.5 PTO Shaft Operation Mount and dismount the PTO shaft only when the motor is off and the ignition key has been removed!  Safety tube and guard cone as well as the drive shaft guard must be mounted and in proper condition! When working on the PTO shaft itself, no one should be in the area of the rotating PTO shaft! ...
Page 35: Hydraulic System
Notices for the User 2.7.6 Hydraulic system  Hydraulic system is under high pressure!  The cutting unit hydraulic system is equipped with a hydraulic accumulator. This can be under high pressure even when the hydraulic system is not!  When connecting hydraulic cylinders and motors, ensure that only prescribed hydraulic hose fittings are used! ...
Page 36: Brakes And Tires
Notices for the User 2.7.7 Brakes and Tires  Check the brakes prior to every use!  A thorough brake system inspection is to be conducted on a regular basis!  Adjustments and repairs to the brake system may only be carried out by a qualified workshop or an authorized brake service! ...
Page 37: Important Information For Vehicle Operation
Notices for the User Important Information for Vehicle Operation  The length of the PTO shaft must be adapted to the tractor being used! Observe the PTO shaft manufacturer's maintenance and installation instructions. Max 1000 rpm  Raise the jack stand and lock it in place prior to operation! ...
Page 38: Other Hazards
Notices for the User Other Hazards  There is a danger of being crushed when raising and lowering the jack stand.  There is also danger of being crushed when closing protective devices.  When driving over rough terrain there is danger of being crushed due to the reduction of the clearance between the tire and frame.
Page 39: Initial Start-Up And Functions
Initial Start-up and Functions Initial Start-up and Functions Vehicle Functions The harvested material is picked up from the ground and transported to the conveyor unit by a pick-up equipped with spring-tines, which is attached to the front of the vehicle. The material is transported by the loading rotor, through the conveyor canal and the cutting unit where it is cut to variable lengths depending on the number of knives.
Page 40: Coupling To The Tractor
Initial Start-up and Functions Coupling to the Tractor When coupling and uncoupling the vehicle with the tractor there is danger of injury! For this reason never stand between or the vehicle and the tractor or behind the trailer during coupling operations if the trailer is not secured against rolling with the parking brake or wheel chocks.
Page 41: Jack Stand
Initial Start-up and Functions Jack Stand The following is to be observed:  The parking area must not exceed a maximum incline of 7°.  The vehicle is to be secured with the parking brake and wheel chocks when using the jack stand. ...
Page 42: Drawbar
Initial Start-up and Functions Drawbar 3.5.1 Drawbar Adjustment (Hydraulic) On vehicles with a hydraulically adjustable drawbar, the drawbar height can be adjusted to tractor height while uncoupled using the cylinders on the drawbar (Image 7). Image 7: Drawbar adjustment while uncoupled to adapt the drawbar height to height of the tractor (Image 8).
Page 43: Vehicle Controls
Initial Start-up and Functions 3.5.1.2 Vehicle controls A controller for operating the drawbar (Image 9) and the cutting unit is mounted on the side of the vehicle frame for easy operation (see chapter “Cutting Unit”). With this, the drawbar can be easily raised and lowered.
Page 44: Pto Shaft
Initial Start-up and Functions PTO shaft Only couple the PTO shaft when the motor is off, the PTO shaft is disengaged and the ignition key has been removed! Never engage the PTO shaft when the motor is off! Before engaging the PTO shaft, ensure that nobody is in the immediate area of the trailer! Before engaging the tractor’s PTO shaft, ensure that the chosen PTO shaft rotational speed and rotation direction correspond to the unit’s allowed rpms.
Page 45 Initial Start-up and Functions Using the Quick Coupling Coupling: The black plastic ring (a) is pushed back and locked into place. Slide the mounting yoke over the coupling shaft. Push the yoke until the catch (a) locks into place (The locking is clearly audible and the black plastic ring slips forward).
Page 46: Pick-Up
Initial Start-up and Functions Pick-up The pick-up (Image 10 / Pos.1) is mounted to the front of the vehicle. It gently picks up the material from the ground and continuously feeds it into the rotor in the conveyor unit. Image 10: Pick-Up The pick-up area consists of the following individual components: pick-up guide wheels (sides)
Page 47: Locking / Unlocking The Pick-Up
Initial Start-up and Functions 3.7.1 Locking / Unlocking the Pick-up WARNING! Danger of injury from unintentional pick-up movement! If the pick-up is not secured, it can move when not intended. This can cause severe injury to persons.  Always secure the pick-up against unintentional lowering before working on or under the pick- ...
Page 48: Raising / Lowering The Pick-Up
Initial Start-up and Functions 3.7.2 Raising / Lowering the Pick-up WARNING! Fingers or hands can be crushed when the pick-up is being raised or lowered!  Ensure that no persons are in range of the pick-up during raising and lowering. ...
Page 49: Switching The Pick-Up On / Off
Initial Start-up and Functions 3.7.3 Switching the Pick-up On / Off WARNING! Danger of the entire body being pulled in or caught on the pick-up and rotor while they are running! These hazards can cause severe injuries and possible death. ...
Page 50: Setting The Pick-Up Working Height
Initial Start-up and Functions 3.7.4 Setting the Pick-up Working Height WARNING! Danger of injury from moving tractor or vehicle, or from vehicle parts!  Before working on the vehicle, secure the tractor and the vehicle against unintentional rolling and starting! ...
Page 51 Initial Start-up and Functions  Remove the spring pin (Image 14 / Pos.2) for securing the coupling rod (Image 14 / Pos.3).  Hold the guide wheel up using the handle (Image 14 / Pos.4) and remove the coupling rod (Image 14 / Pos.3) from the locating pin. ...
Page 52: Guide Wheels
Initial Start-up and Functions 3.7.5 Guide Wheels The vehicle is equipped with wide, air-filled tyres as guide wheels (Image 17 / Pos. 1) for use on less stable ground. Their follow-up steering protects the grass, e.g. in curves. Um den Pendelbereich der Pick-Up optimal nutzen zu können, muss die Arbeitshöhe der Pick-Up eingestellt werden.
Page 53: Guide Roller
Initial Start-up and Functions 3.7.6 Guide roller The guide roller behind the pick-up supports the guide wheel vertical guidance on uneven or soft ground. The guide roller height setting depends on the distance between the ground and the spring tines. This means: Pick-up working height = guide roller working height When adjusting the guide roller working height, proceed as follows:...
Page 54: Guide Comb And Swath Roller
Initial Start-up and Functions 3.7.7 Guide Comb and Swath Roller The vehicle is equipped with a guide comb (Image 19 / Pos.1) and a swath roller (Image 19 / Pos.2), which are located above the pick-up. This ensures flawless pick up of short materials. The guide comb presses the feed against the pick-up tines, which prevents the feed from falling forward.
Page 55: Conveyor Unit
Initial Start-up and Functions Conveyor Unit The conveyor unit (Image 21 / Pos.1) is located in the material flow chain, behind the pick-up. The conveyor rotor with its spirally arranged feed tines transports the material uniformly through the conveyor channel into the vehicle cargo space. Scrapers located between the feed tines prevent the conveyor rotor from clogging.
Page 56: Conveyor Unit Cover
Initial Start-up and Functions E-Controls The conveyor unit is switched on and off using the terminal and tractor PTO shaft. Proceed as follows:  Couple the hydraulic supply lines from the control block on the respective supply system to the appropriate tractor connections.
Page 57: Cutting Unit
Initial Start-up and Functions Cutting Unit When working with the knives, never touch the sharp side of the knives. Danger of injury! Gloves must be worn. Each knife in individually protected against foreign objects. After the safety mechanism has been tripped, the knives move back into cutting position automatically.
Page 58: Sharpening The Knives
Initial Start-up and Functions 3.9.2 Sharpening the Knives Always ensure that the knives are in good and sharp condition. This make easy and material friendly work possible. The knives must be removed for sharpening This must be done as follows: ...
Page 59: Chassis (Hydraulic Axle Balance)
Initial Start-up and Functions 3.10 Chassis (hydraulic Axle Balance) After coupling the trailer the free return hydraulic line must be coupled first! When driving on public roads ensure that the vehicle does not exceed the maximum height of 4.00 meters. 3.10.1 Setting the Clearance The clearance and with that the height of the entire vehicle...
Page 60: Setting
Initial Start-up and Functions 3.10.3 Setting The setting of the clearance may not be done directly on the chassis using the ball valves! Danger of injury! The vehicle must be the same height on both the left and right sides of the chassis! If the chassis is inclined to one side, the ball valve that controls the lower side can be opened for filling.
Page 61: Follow Up Steering
Initial Start-up and Functions 3.11 Follow up Steering The follow-up steering axle makes it possible to drive over vegetation without damaging it. When the steering axle is unlocked, the wheels on the follow-up axle can adjust when driving through curves. If the vehicle is equipped with a follow-up steering axle, the following must be observed: If the following instructions are not followed, there is danger of an accident! The axles must be in the straight position when they are locked, otherwise there is a danger of...
Page 62: Forced Steering
Initial Start-up and Functions 3.12 Forced Steering If desired, the steering axles can be used as forced axles. In practical use a forced steering axle provides for more driving safety, because it absorb transverse forces (such as when cornering) as opposed to a follow-up axle.
Page 63: Adapting The Tractor To The Trailer
Initial Start-up and Functions 3.12.2 Adapting the Tractor to the Trailer To establish the connection to the tractor coupling points are needed on the tractor, which adhere to the standard proposed by the VDMA Special Interest Group Agricultural Machinery (Image: Image of the master cylinder).
Page 64: Coupling
Initial Start-up and Functions 3.12.3 Coupling  Couple the trailer as always.  Open Shut-off valves on the control panel, as shown in Image: Settings 1.-3. Open Axle pos. 1 . If necessary also open the valve on the hand pump. ...
Page 65: Adjusting The Steering
Initial Start-up and Functions 3.12.5 Adjusting the Steering The setting of the steering axle is to be tested after coupling, and daily before operation and corrected if necessary. This is carried out as follows: 1. Park the tractor on a flat, level surface after moving straight forward. 2.
Page 66 Initial Start-up and Functions Driving with follow-up steering axle (Image: Settings 1.-3. Axle pos. 2.1) With follow-up steering shown in valves remain open (Image: Settings 1.-3. Axle pos. 2.1). The wheels of the steering axle are free and can follow the steering movements of the tractor when moving forwards. Reversing is not possible in this position.
Page 67: Cargo Space
Initial Start-up and Functions 3.13 Cargo Space DANGER! Danger of entire body being caught or pulled in when the system is running. These hazards can cause severe injuries and possible death. Never enter cargo space if drive is engaged and motor is running! ...
Page 68: Ladder And Access Door
Initial Start-up and Functions 3.13.2 Ladder and Access Door NOTICE Before driving:  The access door must be closed,  and the ladder must be raised and fixed with the lever. Lowering the ladder and opening the cargo space access door: To lower the ladder (Image 23 / Pos.1) and open the access door (Image 23 / Pos.
Page 69: Front Wall - Hydraulic Swivel Mechanism
Initial Start-up and Functions 3.13.3 Front Wall - Hydraulic Swivel Mechanism WARNING! When extending working elements damage can be caused to the vehicle or accidents can occur if the total height is not observed! This can cause accidents or severe damage to the machine. ...
Page 70: Front Wall Positions
Initial Start-up and Functions 3.13.3.2 Front Wall Positions The front wall’s hydraulic pivoting sections make different positions possible for optimum adaptation to the required operating conditions. The respective positions are described in more detail in the next sections. Position 1 Pivoted back toward the cargo space Front wall...
Page 71: Raising And Lowering The Front Wall
Initial Start-up and Functions 3.13.3.3 Raising and lowering the front wall Operation depends on vehicle configuration and on the hydraulic system. The procedure for raising and lowering the front wall can be seen in the following sections. Preparation:  If the vehicle is equipped with a cargo space cover, the cover must be fully opened first. Only then can the front wall be moved.
Page 72: Front Wall Sensor, Bottom (Right)
The adjustment of display value to the sensor value is possible in the factory menu. If the displayed values are not plausible, please contact your BERGMANN representative or the BERGMANN customer service department. BERGMANN contact information can be found in the chapter "Contact Info & Contact Persons". 201703 en - 72 -...
Page 73: Angle Sensor
Initial Start-up and Functions 3.13.4.1 Angle sensor Pos.1: Angle sensor Detects the position of components. Pos.2: Nuts (2 pcs) For fastening the sensors. Pos.3: Signal transmitter Moving component (e.g. tailgate) Pos.4: Sensor mount Fixed component (e.g. mount) Image 30: Angle sensor Sensor data: Maximum tightening torque: 2.5 Nm...
Page 74: Front Wall Sensor, Middle
Initial Start-up and Functions 3.13.5 Front Wall Sensor, Middle Pos. 1: Front wall sensor, middle Function: Automatic filling system (pressing force) Inductive sensor “Opener” Design The front wall rungs are moved forward to the preset position, so that there is no longer any LED on: overlap with the signal transmitter.
Page 75: Inductive Sensor "Opener" & "Closer
Initial Start-up and Functions Inductive sensor “Opener” & “Closer” 3.13.5.1 Inductive sensor “Opener” & “Closer” Pos.1: Opener: Sensor switches if there is no overlap with the signal transmitter, PIN 1 and PIN 2 are connected. Closer: Sensor switches if there is an overlap with the signal transmitter, PIN 1 and PIN 2 are connected.
Page 76: Tailgate Sensor, Top (Left & Right)
Initial Start-up and Functions 3.13.6 Tailgate Sensor, Top (Left & Right) Pos. 1: Tailgate sensor, top (left & right) Function: Automatic filling system (volumes) Inductive sensor “Closer” Design The filling hood is raised to the point that it has overlapped the signal transmitter. The scraper floor LED on: switches on automatically and runs until the filling hood drops back down.
Page 77: Inductive Sensor "Opener" & "Closer
Initial Start-up and Functions Inductive sensor “Opener” & “Closer” 3.13.6.1 Inductive sensor “Opener” & “Closer” Pos.1: Opener: Sensor switches if there is no overlap with the signal transmitter, PIN 1 and PIN 2 are connected. Closer: Sensor switches if there is an overlap with the signal transmitter, PIN 1 and PIN 2 are connected.
Page 78: Cargo Space, Rear
Initial Start-up and Functions 3.13.7 Cargo Space, Rear Pos. 1: Cargo space, rear Function: Detection of the cargo space fill level Design Ultrasonic sensor If an object is within the set range, LED D1 lights green. LED D1: If no object is within the set range, LED D1 lights red.
Page 79: Extension Walls
Initial Start-up and Functions 3.13.8 Extension Walls WARNING! Damage can be caused to the vehicle or accidents can occur if the total weight is not observed!  When using extension walls, ensure that the authorized axle loads and gross weights are not exceeded! The weights given on the vehicle are binding! The side wall height and thus the loading volume of the machine can be optionally increased using extension walls.
Page 80: Cargo Space Cover
Initial Start-up and Functions 3.13.9 Cargo Space Cover The machine can be optionally equipped with a cargo compartment cover. It serves to cover the entire cargo space and protects the load during transport. WARNING! Risk of damage and accident risk if the vehicle components are not placed in the transport position! This can cause severe damage to the machine or accidents which can lead to severe injuries and possible death.
Page 81: Cargo Space Cover Sensor, Right
Initial Start-up and Functions 3.13.10 Cargo Space Cover Sensor, Right Pos. 1: Cargo space cover sensor, right Function: Check when cargo space cover is closed Inductive sensor “Opener” Design The cargo space cover is not completely closed, it LED on: is not possible to move the front wall LED off: The cargo space cover is completely open...
Page 82: Inductive Sensor "Opener" & "Closer
Initial Start-up and Functions Inductive sensor “Opener” & “Closer” 3.13.10.1 Inductive sensor “Opener” & “Closer” Pos.1: Opener: Sensor switches if there is no overlap with the signal transmitter, PIN 1 and PIN 2 are connected. Closer: Sensor switches if there is an overlap with the signal transmitter, PIN 1 and PIN 2 are connected.
Page 83: Scraper Floor
Initial Start-up and Functions 3.14 Scraper Floor 3.14.1 Scraper floor chains The scraper floor consists of four chain strands with transport bars. The fact that the steel floor is lower in the front reduces the power consumption due to the lower conveyor channel length. This design ensures the load is properly transported to the spreader unit.
Page 84: Dosing Unit
Initial Start-up and Functions 3.15 Dosing Unit The machines can be equipped with 3 aggressive dosing rollers for uniform distribution of the harvested material on the horizontal silo. The dosing unit drive is protected separately by a cam clutch. The dosing rollers are coupled automatically when the tailgate is opened. For this reason the tailgate may only be opened when the tractor PTO shaft is not moving.
Page 85: Inductive Sensor "Opener" & "Closer
Initial Start-up and Functions Inductive sensor “Opener” & “Closer” 3.15.1.1 Inductive sensor “Opener” & “Closer” Pos.1: Opener: Sensor switches if there is no overlap with the signal transmitter, PIN 1 and PIN 2 are connected. Closer: Sensor switches if there is an overlap with the signal transmitter, PIN 1 and PIN 2 are connected.
Page 86: Tailgate
Initial Start-up and Functions 3.16 Tailgate  Only stand in dangerous areas when safety devices are engaged!  Never reach into areas where the hands can be crushed as long as parts are moving! Danger, rotating machine parts! Keep sufficient distance from rotating parts! ...
Page 87: Locking And Unlocking The Tailgate
Initial Start-up and Functions 3.16.1 Locking and Unlocking the Tailgate The hydraulic line to the tailgate cylinders can be closed using a shut-off valve to prevent accidental opening and unintentional lowering. he shut-off valve is located on the right side of the frame. Image: Tailgate shut-off valve Shut-off valve open: In this position the tailgate is not locked and can be opened and closed.
Page 88: Tailgate Sensor, Bottom (Left & Right)
Initial Start-up and Functions 3.16.2 Tailgate Sensor, Bottom (Left & Right) Pos. 1: Tailgate sensor, bottom (left & right) Function: Level indicator (type K) Inductive sensor “Opener” Design The tailgate is slightly open on both sides and the LED on: terminal display signals "FULL".
Page 89: Inductive Sensor "Opener" & "Closer
Initial Start-up and Functions Inductive sensor “Opener” & “Closer” 3.16.2.1 Inductive sensor “Opener” & “Closer” Pos.1: Opener: Sensor switches if there is no overlap with the signal transmitter, PIN 1 and PIN 2 are connected. Closer: Sensor switches if there is an overlap with the signal transmitter, PIN 1 and PIN 2 are connected.
Page 90: Tailgate Sensor, Top (Right)
The adjustment of display value to the sensor value is possible in the factory menu. If the displayed values are not plausible, please contact your BERGMANN representative or the BERGMANN customer service department. BERGMANN contact information can be found in the chapter "Contact Info & Contact Persons". 201703 en - 90 -...
Page 91: Angle Sensor
Initial Start-up and Functions 3.16.3.1 Angle sensor Pos.1: Angle sensor Detects the position of components. Pos.2: Nuts (2 pcs) For fastening the sensors. Pos.3: Signal transmitter Moving component (e.g. tailgate) Pos.4: Sensor mount Fixed component (e.g. mount) Image 46: Angle sensor Sensor data: Maximum tightening torque: 2.5 Nm...
Page 92: Tailgate Positions
Initial Start-up and Functions 3.16.4 Tailgate Positions The tailgate’s hydraulic adjustment make different tailgate positions possible for optimum adaptation to the required operating conditions. The respective positions are described in more detail in the next sections. Position 1 Width of opening: The tailgate is completely open.
Page 93: Hydraulics
 In case of injury, notify a doctor immediately. There is a risk of infection.  Regularly inspect hoses and replace them with original BERGMANN hoses if old or damaged. For this, also observe the instructions and notices in the operating instructions from the tractor manufacturer! 3.17.1...
Page 94: Hydraulic Supply Line Markings
Initial Start-up and Functions 3.17.2 Hydraulic Supply Line Markings WARNING! Danger due to incorrect supply line connection Incorrect connection of the supply lines can lead to considerable hazards for persons due to machine malfunctions.  When coupling the hydraulic lines, always check for correct connection. The hydraulic supply lines for the individual vehicle hydraulic functions are marked with color codes and corresponding function symbols.
Page 95: Hydraulic System "E-Control
Initial Start-up and Functions Hydraulic System “E-Control” 3.17.3 The vehicle can be equipped with an "E-control" hydraulic system depending on the vehicle type and equipment. This is a circulating hydraulic system with an electro-hydraulic control block. After coupling the supply lines to the tractor, the vehicle hydraulic functions can be actuated directly from the terminal. NOTICE The maximum allowable system pressure is 210 bars.
Page 96 Initial Start-up and Functions Image 51: Control block B09-2447 Drawbar Front wall (Top section) Front wall (Total) Pick-up (Raise / Lower) Pick-up (Drive) Cutting Unit Scraper Floor steering axle Tailgate 201703 en - 96 -...
Page 97: Hydraulic System Supply Line "E-Control
Initial Start-up and Functions Hydraulic System Supply Line “E-Control“ 3.17.3.2 In the following list, the hydraulic supply lines which can be used with the types of vehicles are listed with the respective hydraulic system "E-control" markings. The hydraulic supply lines can vary depending on vehicle equipment.
Page 98 Initial Start-up and Functions Supply lines for additional functions with no control block connection: Depending on the type of vehicle and equipment, the vehicle additional hydraulic functions without control block connection can be actuated directly using the tractor controller when the supply lines are coupled to the tractor in accordance with hydraulic system manual control.
Page 99: Supply System With E-Control
Initial Start-up and Functions 3.17.3.3 Supply System with E-control The tractor hydraulic system can vary depending on type and equipment, and determines the power system settings for the coupled vehicle. The change between the different supply systems is done without tools by simply turning the hand wheel on the control block on or off (Image 52 / Pos.
Page 100 Initial Start-up and Functions Supply system with constant system pressure Constant pressure systems are still found in some older tractors. In such systems, the tractor pump always tries to maintain the maximum pressure. If the consumers do not need oil, the pump does not supply any oil.
Page 101 Initial Start-up and Functions Supply system, load sensing (CC) The control block input plate is equipped with a relief controller. 0.7 l/min flow through it and into the tank. Load sensing ensures that the pump is reset as soon as a consumer is switched off. If the pulled vehicle is to be connected to a load sensing system, it must supplied...
Page 102: Coupling The Hydraulic Supply Lines With E-Control
Initial Start-up and Functions 3.17.3.4 Coupling the hydraulic supply lines with E-control NOTICE Ensure that:  When coupling and uncoupling the hydraulic supply lines the hydraulic system is pressureless on both the vehicle and the tractor side. The tractor control units must always be set in the floating position before coupling.
Page 103: Uncoupling The Hydraulic Supply Lines With "E-Control
Initial Start-up and Functions Uncoupling the hydraulic supply lines with “E-control” 3.17.3.5 NOTICE Ensure that:  When uncoupling the hydraulic supply lines the hydraulic system is pressureless on both the vehicle and the tractor side. The tractor control units must always be set in the floating position before coupling.
Page 104: Terminal
Initial Start-up and Functions 3.18 Terminal 3.18.1 Terminal BCT 20 The "Terminal BCT 20" section is only a quick reference for the procedure and the handling for quick start of the machine. For this reason the handling instructions and notices in the separate operating instruction Important! manual "machine control BCT20 / ISOBUS"...
Page 105: Quick Start
Initial Start-up and Functions 3.18.1.2 Quick Start 1. Switch on controls: Press main switch 2. Select menu: Spreader: 2/3 unload Transport trailer 2/4 unload or 4/4 load 3. Switch PTO shaft on (Monitor speed according to type & design) 4. Switch oil supply on (Not necessary with load- sensing) 5.
Page 106 Initial Start-up and Functions Menu 4/4 – Loading the Transport Trailer Scraper floor Menu 4/4 speed Loading Pick- Up Cutting unit Raise / lower Raise / lower Floating Position Lower press & hold Scraper floor High-lift drawbar forward / reverse raise / lower Menü...
Page 107: Operating The Vehicle
Operating the Vehicle Operating the Vehicle  First thoroughly lubricate the vehicle. See [Lubrication diagram].  Couple the vehicle with the tractor. Notices under [Commissioning and Operation] must be observed. If the instructions above are not followed, there is danger of an accident! Loading Procedure ...
Page 108: Unloading Procedure
Operating the Vehicle Unloading Procedure The unloading process is controlled from the terminal in the tractor cabin. The tailgate position can be seen at any time with the indicator on the front wall. 4.2.1.1 Unloading without dosing rollers  Select "Unload" menu ...
Page 109: Driving On Roads
Operating the Vehicle Driving on Roads It is absolutely necessary that the "General Road Safety and Accident Prevention Important! Requirements" in the section "User Notices" are observed. When driving on public roads, the national road traffic regulations must be observed and adhered to.
Page 110: Driving
Operating the Vehicle 4.3.3 Driving The vehicle is to be driven so that it is under control at all times. Here, personal skills are to be considered along with outside conditions such as the road, curves, traffic, weather and visibility. The driving speed is to be adapted to the conditions.
Page 111: Care And Maintenance
Care and Maintenance Care and Maintenance General:  Cleaning and maintenance work may only be done when the PTO shaft is disengaged and the motor is switched off! - Remove the ignition key!  Dispose of used oil properly!  Replace protective equipment after maintenance work. ...
Page 112: Maintenance Schedule
Care and Maintenance Maintenance Schedule For the individual maintenance points in the "Care and Maintenance" section there are maintenance tips and intervals listed on the individual function and components which must also Important be observed and implemented accordingly. In the supplied external documents, such as operating and maintenance instructions from manufacturers of various components (the components are included), such as set time Important intervals, mileage and maintenance intervals are to be observed and complied with.
Page 113 Care and Maintenance After 20 trips (daily)  Lubricate according to lubrication chart  Check light functions  Check brake functions  Check scraper floor tension, adjust or shorten if necessary  Check chain tension in spreader drive / dosing unit drive ...
Page 114: Screw Torques
Care and Maintenance Screw torques Table of standard torque values for bolts 201703 en - 114 -...
Page 115: Cleaning The Machine
Care and Maintenance Cleaning the machine Care of the vehicle includes cleaning as well as lubrication. The following must be observed:  Switch off all drives as well as the power supply!  Disengage PTO shaft, switch motor off and remove ignition key! ...
Page 116: Tires And Wheels
Tires and Wheels Only tires and rims which have been approved by Bergmann may be used. Tire repair work may only be carried out by professionals with the proper tools! When working on the tires the trailer must be safely parked and secured against rolling (wheel chocks)! The required vehicle jack may only be used on the prescribed locations.
Page 117: Tire Pressure
Care and Maintenance 5.7.2 Tire Pressure The tire pressure should be checked at least every 14 days when tires are cold. Caps must be mounted on the valves. PR / CAREX + Tire Size Data from Tyre pressure SHUTTLE* 22.5" 550/60 - 22.5 22.5"...
Page 118: Axles
Care and Maintenance Axles Axles must never be overloaded!  No illegal overloading of the vehicle by exceeding the maximum allowable weight.  Do not exceed the maximum speed.  No one-sided overloading caused by incorrect loading, or by driving for example, on curbs, etc. ...
Page 119: Changing The Grease In The Wheel Hub Bearing
Care and Maintenance 5.8.3 Changing the grease in the wheel hub bearing  Jack up the vehicle safely and release the brakes. Remove the wheels and hub caps.  Remove the cotter pin and unscrew the axle nut.  Pull the wheel hub with brake drum and tapered bearing off of the axle with a proper puller. ...
Page 120: Follow-Up Axles
Care and Maintenance 5.8.4 Follow-up Axles The follow-up steering axle makes it possible to drive over vegetation without damaging it. When the steering axle is unlocked, the wheels on the follow-up axle can adjust when driving through curves. If the vehicle is equipped with a follow-up axle, the notices under [Commissioning and Operation Important! - Follow-up Axle] must be observed.
Page 121: Air Brake System
Care and Maintenance Air Brake System  A thorough brake system inspection is to be conducted on a regular basis!  Adjustments and repairs to the brake system may only be carried out by a qualified workshop or an authorized brake service! ...
Page 122: Cleaning The Line Filter
Care and Maintenance 5.9.4 Cleaning the Line Filter The reserve line and brake line are both equipped with a line filter. These must be cleaned every 3-4 months. This is done as follows:  Press the cap (a) into the housing and remove the retaining ring (b) from the housing after having compressed it.
Page 123: Check Brake Cylinder Stroke
Care and Maintenance 5.9.7 Check Brake Cylinder Stroke The brake cylinder stroke must be checked every 3-4 months. If the stroke is larger than 30 mm during full braking, the brakes must be adjusted. Image: Brake cylinder stroke 5.9.8 Adjusting the Brake Lever ...
Page 124: Parking Brake
Care and Maintenance 5.10 Parking brake The parking brake (Image: The parking brake Pos. 1) should secure the vehicle against rolling when loaded to the maximum total weight on an incline of max. 18°. The parking brake should be adjusted when ...
Page 125: Drive
Care and Maintenance 5.11 Drive The universal spreader drive train consists of drive shafts and sealed oil-bath gearboxes. Only the pick-up is driven by a strong roller chain. On vehicles with dosing units the 2nd and 3rd dosing rollers (depending on vehicle type and equipment) are also driven by a strong roller chain 5.11.1 PTO shaft...
Page 126: Maintenance Intervals
Care and Maintenance 5.11.1.4 Maintenance Intervals Model series Range of application Protection Profile tubes joints storage Image: Lubrication points with wide angles *Extreme Dust or large flexion angle **with P-seals Application-specific maintenance provides for a reduction in maintenance costs. It was for this purpose that GKN Walterscheid introduced maintenance classes.
Page 127: Gearboxes
Care and Maintenance 5.11.2 Gearboxes 5.11.2.1 General: The gearboxes are to be checked for leaks regularly and the oil level checked if necessary. Gearbox oil is to be refilled if necessary. In addition, an oil change should be carried out each year. Gearbox oil: ...
Page 128: Rotor- Planetary Gearbox - Draining Gearbox Oil
Care and Maintenance 5.11.2.3 Rotor- planetary gearbox - Draining gearbox oil To drain the gearbox oil out of the planetary gearbox for the rotor, proceed as follows: 1.) Raise pick-up Before maintenance work, the pick-up must be raised and secured with chocks against unintentional lowering.
Page 129 Care and Maintenance 4.) Mount drain tube and drain oil out front side Place the drain tube (Image: Mounting drain tube (Pos. 6 & 7) through the side wall opening and screw it onto the planetary gearbox drain port. The drain tube is equipped with the so called "Bochumer Connection"...
Page 130: Rotor- Planetary Gearbox - Adding Gearbox Oil
Care and Maintenance 5.11.2.4 Rotor- planetary gearbox - Adding gearbox oil Add the new gear oil through the filling port in the drive stub of the gearbox (Image: Drive stub Pos. 1) The filling port is also the level indicator. ...
Page 131: Roller Chains
Care and Maintenance 5.11.3 Roller Chains The drive chains are equipped with chain tensioners. The chain tension is to be checked daily and the chain is to be shortened if necessary. The chains are to be lubricated with motor oil. Only for vehicles with dosing rollers: One 1“...
Page 132: Clutches
Care and Maintenance 5.11.4 Clutches When the tailgate is opened the rotor and the pick-up switch off and the dosing unit switches on. If the tailgate is closed, the jaw couplings switch again. Dosing Unit Clutch When the tailgate is closed there should be set a distance of approximately 25 mm between the coupling elements of the dosing unit.
Page 133: Scraper Floor Chains
 Retighten the lock nut. 5.12.3 Shorten scraper floor chain if chains are different lengths Should the scraper floor chains be different lengths, please contact BERGMANN customer service to obtain the respective information for the chain shortening procedure. Customer Service: Tel.:...
Page 134: Cutting Unit
Care and Maintenance 5.13 Cutting Unit 5.13.1 Knife Adjustment In order to achieve an optimal material cut length the distanced between the cutting knives (Image: Knife adjustment Pos. 1) and the rotor (Pos. 2) must be approx. 10 - 20 mm. The knives must not come into contact with the rotor drum.
Page 135: Sensor Adjustments
Care and Maintenance 5.13.3 Sensor Adjustments 5.13.3.1 Top Sensor: Indicator "Cutting unit off" To adjust the "Cutting unit off" indicator proceed as follows:  Extend the cutting unit (Image: Top sensor Pos. 1) completely. So that is rests on the adjustment bolts (Pos. 2). ...
Page 136: Conveyor Unit
Care and Maintenance 5.14 Conveyor Unit 5.14.1 Scraper In order to ensure proper scraper function, the distance between the scraper and (Image: Scraper Pos. 3) the rotor (Pos. 1) must be approx. 10 mm. Adjust the scraper as follows:  First loosen the bolts (Pos. 4) on the scraper bar (Pos. 3). ...
Page 137: Circuit Diagrams
Care and Maintenance 5.16 Circuit Diagrams 5.16.1 Hydraulics 26-13-0129-PLN (Blatt1) - 137 - 201703 en...
Page 138 Care and Maintenance 26-13-0129-PLN (Blatt2) 201703 en - 138 -...
Page 139: Electric
Care and Maintenance 5.16.2 Electric Terminal – BCT 20 5.16.2.1 Terminal – CCI 200 5.16.2.2 - 139 - 201703 en...
Page 140: Terminal - Isobus
Care and Maintenance Terminal – ISOBUS 5.16.2.3 201703 en - 140 -...
Page 141: Wiring Harness Bct / Cci / Isobus
Care and Maintenance 5.16.2.4 Wiring harness BCT / CCI / ISOBUS Image 56: Wiring harness 26-14-0122-PLN - 141 - 201703 en...
Page 142: Wiring Harness Legend
Care and Maintenance 5.16.2.4.1 Wiring harness legend ASW ... Work spotlight plug B ... Block no. K ... Cable end no. S ... Sensor plug Q ... Plug source V ... Plug distributor W ... Conduit no. Y ... Plug valve O...
Page 143 Care and Maintenance Tailgate Tailgate Scraper floor overdrive Switching / clutch Front wall flap Front wall flap O ...: Output OPHC1 Pick-up under load OPH1 Pick-up reverse OPH2 Front wall OPH3 Silage additive application system OPH4 Cargo space cover - 2/2-way poppet valve I ...: Input PTO shaft speed Gearbox sensor...
Page 144: Wiring Harness Bct / Cci / Isobus - Expansion Unit
Care and Maintenance 5.16.2.5 Wiring harness BCT / CCI / ISOBUS - expansion unit Image 57: Wiring harness expansion unit 18-14-0678-PLN 201703 en - 144 -...
Page 145: Wiring Harness Legend
Care and Maintenance 5.16.2.5.1 Wiring harness legend B ... Block no. Q ... Plug source V ... Plug distributor W ... Conduit no. - 145 - 201703 en...
Page 146: Brake System
Care and Maintenance 5.16.3 Brake System 5.16.3.1 Air Brake - Tandem 18-16-0103-PLN 201703 en - 146 -...
Page 147 Care and Maintenance Pos. Denomination Description Clutch - Storage Clutch - Brake yellow Release Valve Compressed Air Tank Trailer Brake Valve Brake Effect Regulator - ALB Membrane Cylinder 1st axle Membrane Cylinder 2nd axle - 147 - 201703 en...
Page 148: Air Brake - Tridem
Care and Maintenance 5.16.3.2 Air Brake - Tridem 18-16-0104-PLN 201703 en - 148 -...
Page 149 Care and Maintenance Pos. Denomination Description Clutch - Storage Clutch - Brake yellow Release Valve Compressed Air Tank Trailer Brake Valve Brake Effect Regulator - ALB Relay Valve 1st axle Relay Valve 3rd axle Membrane Cylinder 1st axle Membrane Cylinder 2nd axle Membrane Cylinder 3rd axle...
Page 150: Lubrication
(Except in automatic lubrication systems, where biodegradable Important! greases are not allowed.) Only use oils approved by Bergmann. Ensure that lubricants are properly disposed of. To ensure smooth operation of the vehicle for a long time, a long-term high-quality grease must be used.
Page 151: Lubrication Diagram
Care and Maintenance 5.17.1 Lubrication diagram The lubrication points are shown in the lubrication diagram with the appropriate maintenance intervals (see the following pages). Legend Grease after 20 trips Grease after 40 trips Grease after 100 trips 4 lubrication points Lubricating oil Gearbox oil 1,3 L...
Page 152: Lubrication Diagram Vehicle Type "S
Care and Maintenance 5.17.1.1 Lubrication diagram vehicle type "S" 26-00-0101-PLN_20170321 201703 en - 152 -...
Page 153: Lubrication Diagram Vehicle Type "S
Care and Maintenance 5.17.1.2 Lubrication diagram vehicle type "S" 26-00-0101-PLN_20170317 - 153 - 201703 en...
Page 154: Lubrication Diagram Axle
Care and Maintenance 5.17.1.3 Lubrication diagram axle 14-06-0525-PLN_20160829 201703 en - 154 -...
Page 155: Lubrication Diagram Drawbar (Forced Steering Hydraulic / Normal)
Care and Maintenance 5.17.1.4 Lubrication diagram drawbar (Forced steering hydraulic / normal) 26-05-0115-PLN_20170321 - 155 - 201703 en...
Page 156: Malfunctions
Care and Maintenance 5.18 Malfunctions The following information should help to eliminate malfunctions. Malfunction Cause Solution Too much fodder, foreign objects, Reduce vehicle speed, remove dull knife or excessive material PTO shaft slip clutch responds foreign object, grind knives or turn column above conveyor...
Page 157: Declaration Of Conformity
Declaration of Conformity Declaration of Conformity CAREX - 157 - 201703 en...
Page 158: Shuttle
Declaration of Conformity SHUTTLE 201703 en - 158 -...
Page 159: Contact Details & Contact Persons
Contact Details & Contact Persons Contact Details & Contact Persons In the following sections you can find contact and contact the company Ludwig Bergmann GmbH, as well as their partners. If your operating instructions be older, you can find the current data on the company website www.Bergmann- Goldenstedt.de.
Page 160: Spare Parts Warehouse
Fax: +49 (0)4444 - 2008-43 Hauptstraße 64-66 Mobil: 49424 Goldenstedt E-Mail: kundendienst@l-bergmann.de Emergency service Monteur-Notdienst Mobil: +49 (0)175 - 58 88 82 0 Worldwide Sales Partners Find our worldwide sales partners on our website www.bergmann-goldenstedt.de. 201703 en - 160 -...

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bergmann CAREX 370 S Operating Instructions Manual

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