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ROPA Maus 6 Operating Manual

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Table of Contents

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E901444GB
Operating Manual
Maus 6
Edition 1
For models:
Maus 6a
Maus 6c
Maus 6d
Issued: 08/2023
Software version: RM23-001

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Summary of Contents for ROPA Maus 6

  • Page 1 Operating Manual Maus 6 Edition 1 Issued: 08/2023 Software version: RM23-001 For models: Maus 6a Maus 6c Maus 6d E901444GB...
  • Page 2 – with the express approval of ROPA GmbH. Any type of reproduction, distri- bution or storage on data medium in any form and of any type not authorised by ROPA GmbH forms a violation of current domestic and international copyright law and will be judicially prosecuted.
  • Page 3 Contents Contents 3 / 546...
  • Page 4 Contents 4 / 546...

  • Page 5: Table Of Contents

    Contents Preface................. 13 Name plate and important data...............17 Serial number of diesel engine............... 18 Declaration of Conformity................ 19 Safety................21 General....................23 Obligations of the entrepreneur...............23 General symbols and instructions............24 2.3.1 Safety signs..................... 25 Proper use....................26 2.4.1 Foreseeable misuse................26 Hazard zone....................
  • Page 6 Contents 5.1.2 Auxiliary steps on the fuel tank............... 66 Driver's cabin cylinder support..............67 Driver's cabin overview................69 Rear part of cabin................... 70 Cabin ceiling.................... 71 Steering column..................72 5.6.1 Steering column switch................73 Driver's seat.....................74 5.7.1 Rotating driver's seat................79 5.7.2 Driver's seat occupancy identification system.........80 5.7.3 Folding left joystick console..............
  • Page 7 Contents 6.3.2.6 Light control................... 139 6.3.2.6.1 Configuration of light programs............. 141 6.3.2.6.2 Ladder light.................... 142 6.3.2.6.3 Individual headlights................143 6.3.3 Readjusting warning thresholds............144 6.3.4 Warning and status indications on the R-Touch........145 6.3.5 R-Touch auxiliary terminal..............150 6.3.5.1 Display areas on the R-Touch auxiliary terminal........151 6.3.5.2 Operation of video system..............
  • Page 8 Contents 6.11.4 Automatic parking brake (only in the operating mode "Rabbit").... 204 6.12 Steering....................205 6.12.1 Steering in the operating mode "Rabbit"..........206 6.12.1.1 Manual rear axle steering..............207 6.12.1.2 All-wheel steering.................. 208 6.12.1.3 Put rear axle in central position............209 6.12.1.4 Quick description: steering in the "Rabbit"...
  • Page 9 Contents 6.15.3.4 Water-saving operation (timer control)..........293 6.15.3.5 Water-saving operation (pressure control)..........294 6.15.3.6 Configuring water spray programs............295 6.15.3.7 Cleaning of the water filter screen............295 6.15.3.8 Cleaning filter screen in the water nozzles........... 296 6.16 Scales (option)..................297 6.16.1 Design and function................297 6.16.2 Operation of scales................
  • Page 10 Contents 7.1.5.3 Change of coolant................. 363 7.1.5.4 Remarks of ROPA on the coolant (general information)....... 364 7.1.6 Valve clearance adjustment..............364 7.1.7 SCR exhaust after-treatment with AdBlue ® (applicable for c-diesel engine and d-diesel engine)......365 7.1.7.1 Exchange of AdBlue® filter insert............366 7.1.8...
  • Page 11 Contents 7.15.2 Driver's cabin recirculating filter............428 7.15.3 Fresh air intake filter in driver's cabin........... 429 7.15.4 Condensate drain in the air conditioner..........429 7.15.5 Folding down air conditioner..............430 7.15.6 Coolant circuit..................433 7.16 Battery maintenance................435 7.17 Shutdown for a longer period of time............435 7.17.1 Mercedes-Benz regulations for Diesel engine shutdown......
  • Page 12 Product Data Sheet ROPA engineOil E7+ 10W-40.......511 9.4.4 Product Data SheetROPA gearOil GL5 90........... 512 9.4.5 Product Data Sheet ROPA gearOil GL5 75W-90 synth......513 9.4.6 Product Data Sheet ROPA gearFluid ATF..........514 9.4.7 Product Data Sheet ROPA multi temperature grease 2......515 Diesel engine coolant................

  • Page 13: Preface

    Preface Preface 13 / 546...
  • Page 14 Preface 14 / 546...
  • Page 15 They conform to the high ROPA standards for safety and reliability. We would like to point out that parts and accessories not approved by ROPA may not be used on ROPA machines, otherwise the safety and operability of the machine may be impaired.
  • Page 16 We expressly point out that any damage caused by the fact that this operating man- ual is not or not completely followed is not covered by the statutory warranty of ROPA. Even though this operating manual is comprehensive, in your own interest you should completely and carefully read it and slowly familiarize yourself with the machine using this operating manual.

  • Page 17: Name Plate And Important Data

    Preface Name plate and important data Name plate and important data The name plate (2) of the machine is located on the right side of the vehicle, on the vehicle frame next to the front wheel behind the factory number (1). Please enter the data of your machine in the following image of the name plate.

  • Page 18: Serial Number Of Diesel Engine

    Preface Serial number of diesel engine Serial number of diesel engine The serial number of the diesel engine (1) is located on the engine block near the V- belt pulley of the crankshaft. 18 / 546...

  • Page 19: Declaration Of Conformity

    The Declaration of Conformity belongs to separately provided documents and is handed over on the delivery of the machine. The CE marking of the machine is a constituent part of the name plate. ROPA Maus 6 Maus 6a / Maus 6c / Maus 6d from 8*1506...
  • Page 20 Safety 20 / 546...

  • Page 21: Safety

    Safety Safety 21 / 546...
  • Page 22 Safety 22 / 546...

  • Page 23: General

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

  • Page 24: General Symbols And Instructions

    Safety General symbols and instructions General symbols and instructions The following symbols are used for safety instructions in this operating manual. They serve as a warning against possible personal injury or material damage, or provide help in facilitating work. DANGER This signal word warns of imminent danger of fatal accident or serious injury.

  • Page 25: Safety Signs

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

  • Page 26: Proper Use

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

  • Page 27: Hazard Zone

    Safety Hazard zone Hazard zone No one may stay in the hazard zone during operation of the machine. The opera- tor must immediately shut down the machine in case of any threatening hazard and request the persons concerned to leave the hazard zone immediately. He may only restart the machine when there are no more persons in the hazard zone.
  • Page 28 The meaning of each individual pictograph is explained below. In addition, each pictograph has a number. This is the ROPA order number. Stating this number, you may reorder the respective pictograph from ROPA. The number stated in brackets is printed on the respective sticker.

  • Page 29: Safety Stickers On The Machine

    Safety Safety stickers on the machine Safety stickers on the machine I em no I em no I em no I em no I em no I em no I em no I em no I em no I em no I em no I em no I em no...
  • Page 30 Safety Safety stickers on the machine 355007100 (1) 355007900 (04) Before starting up, read the operat- Hazard under loads. Never stay ing manual respectively the main- under this part. tenance manual and observe all remarks on safety. 355007700 (25) 355006300 (33) Hazard that body parts can be Hazard from parts being flung away pulled in.

  • Page 31: Safety And Health Protection

    Safety Safety and health protection 355007400 (06) 355007800 (11) Hazard of swinging Hazard of lowering machine parts. Never machine parts! Staying stay in swivelling area. in the hazard zone is only admissible when the safety lock for the lifting cylinder is engaged. 355007200 (15) 355006500 (37) Hazard from rotating...

  • Page 32: Requirements For Operating And Maintenance Personnel

    All maintenance work which is not specifically the responsibility of the operator may only be carried out by instructed or trained maintenance personnel. Some activities may only be performed by people expressly authorised by ROPA for these activities. In case of doubt, ask the manufacturer whether you may perform a specific activity yourself without any hazard.

  • Page 33: Handling And Process Materials

    Safety Hazards caused by mechanical influences 2.11 Handling and process materials When handling process materials the appropriate protective clothing must always be worn to prevent or reduce skin contact with these materials. Defective, dismantled parts shall be sorted according to material type and routed to the proper recycling channel.

  • Page 34: Hazards Caused By Electricity

    Safety Hazards caused by electricity 2.14 Hazards caused by electricity DANGER Danger of death due to electric voltage. Cables and components are live, there is a danger of injury with deadly conse- quences. Clamping points are under voltage also after shut-off. –...

  • Page 35: Hazards Caused By Process Materials

    Safety Hazards caused by process materials 2.15 Hazards caused by process materials WARNING Oil, fuel and grease can cause the following damages: poisoning by inhalation of fuel vapours, allergies due to skin contact with fuel, oil or grease, fire and explosion hazard due to smoking or the use of fire or naked flame when handling fuel, oil or grease.

  • Page 36: Hazards Caused By Noise

    Safety Hazards caused by pneumatic system 2.16 Hazards caused by noise WARNING Noise Noise can cause loss of hearing (deafness), hearing defects, health disorders such as loss of balance or consciousness disorders, as well as disorders of the heart and circulation.

  • Page 37: Hazards Caused By Hot Substances/Surfaces

    Safety Leakage 2.19 Hazards caused by hot substances/surfaces Burning hazard/hazard of scalding due to: Hot surfaces (hot machine parts). Hot engine oil. Hot hydraulic oil. Hot coolant. Counteractive measures: – Let machine and operating supplies cool down. – Wear protective gloves. 2.20 Personal protective equipment Wear tight-fitting clothing to prevent accidents.

  • Page 38: General Notes On Safety When Handling Acid Batteries

    Safety Prohibition of unauthorised modifications and alterations 2.22 General notes on safety when handling acid batteries Fire, sparks, smoking and open flames are prohibited. Avoid generation of sparks formed by connecting and disconnecting electrical loads or measuring devices directly to battery terminals. Before connecting and disconnecting batteries, switch off the main battery switch.

  • Page 39: General Safety Instructions For The Park Heating System

    Safety Safety and protective equipment 2.24 General safety instructions for the park heating system The heating appliance may not be operated in enclosed rooms, not even under timer control or "Telestart" (e.g. garage or workshops without exhaust-gas extrac- tion). Due to the explosion hazard, the heating system must be switched off at gas sta- tions and fuel dispensing systems.

  • Page 40: Emergency Exit

    Safety Emergency exit Overview Front rotating beacon Battery emergency stop switch in the central electrics box Safety rail at the ladder Protective rubber at the recleaner Guard rail at the truck conveyor Emergency stop switch in the operating console Loud-speaker outside intercom facility 2.26 Emergency exit Depending on the design, the machine is not equipped with a separate emergency...

  • Page 41: Technical Data And General View

    Technical data and general view Technical data and general view 41 / 546...
  • Page 42 Technical data and general view 42 / 546...

  • Page 43: Technical Data

    Technical data ADVICE The Maus 6 is available with 3 different types of diesel engines. These are distin- guished by means of a letter in the Vehicle type field on the name plate. In addition, they can meet different exhaust gas standards. For information on the engine version...
  • Page 44 Exhaust gas standard according to China IV: HJ1014-2020 Capacity: 260 kW Max. torque: 1,400 Nm/1,200 - 1,600 rpm Rated speed (ROPA): 2,200 rpm Maximum rotational speed with machine drive 1,975 rpm switched on: Engine type: Diesel engine 4-stroke, direct fuel injection Displacement: 7,698 cm³...
  • Page 45 Technical data and general view Technical data Tyres front axle: 710/75 R34 Michelin MEGAXBIB 2 (178A8) 800/70 R32 Michelin CEREXBIB 2 (182A8) Tyres rear axle: 710/75 R34 Michelin MEGAXBIB 2 (178A8) 800/70 R32 Michelin CEREXBIB 2 (182A8) Tyres additional axles: 235/75 R17.5 Generator: 150 A...

  • Page 46: Tyre Pressure

    Technical data and general view Tyre pressure Tyre pressure Tyre pressure All data in bars. Tires type min. Recommendation max. Front axle 710/75 R34 800/70 R32 Rear axle 710/75 R34 800/70 R32 Others min. Recommendation max. additional axle 235/75 R17.5 46 / 546...

  • Page 47: General View

    Technical data and general view General view General view This overview is intended to familiarize you with the most important components of your machine. Central electrics cabinet Rear platform wall Air filter Expansion tank for coolant Intake grid for cooler Engine housing Hydraulic oil tank Storage compartment for tools...
  • Page 48 Technical data and general view General view (18) Under-run protective device (19) Fuel tank (20) Counterweight arm (21) Articulation of the truck conveyor (22) Truck conveyor (23) Swivel support for truck conveyor (24) Recleaning (25) Energy ducting chain (26) Rear axle (27) Pickup side section left (28)
  • Page 49 Technical data and general view General view (30) Swivel arm (31) Rotary drive for truck conveyor (32) Rotary drive for swivel arm (33) Swivel support for truck conveyor (34) Swivel arm lock (35) Cylinder axle support (36) Engine storage compartment (37) Counterweight arm lock 49 / 546...
  • Page 50 Technical data and general view General view (38) Control unit operating hydraulics II (39) Fire extinguisher (40) Grease bucket (41) Tank for windscreen washer system (42) Control unit for operating hydraulics I (43) AdBlue tank (not applicable for a-diesel engine and c-diesel engine EFP variants) (44) Side cover on the right, there is right storage compartment or water tank...
  • Page 51 Technical data and general view General view (46) Central mark (47) Frost breaker (48) Fold plates (49) Clearing shield (50) Pinch roller 4 (51) Pinch roller 3 (52) Pinch roller 2 (53) Pinch roller 1 (54) Conveyor roller 3 (55) Conveyor roller 2 (56) Conveyor roller 1...
  • Page 52 Technical data and general view General view Machine ready for driving on roads 52 / 546...

  • Page 53: Transport Draft For Low-Loader Transport

    Technical data and general view Transport draft for low-loader transport Transport draft for low-loader transport All data in mm. 53 / 546...

  • Page 54: Lashing Eyes For Transport By Low-Loader/Ship

    Technical data and general view Lashing eyes for transport by low-loader/ship Lashing eyes for transport by low-loader/ship The front axle is equipped with eyes, located on the right and left side, for clamping it down in ground direction. The rear axle support is also equipped with eyes located on the right and left side for clamping the axle down towards the ground.
  • Page 55 Technical data and general view Lashing eyes for transport by low-loader/ship Lashing point behind the front axle, left Lashing point behind the front axle, right side side Lashing point at the rear axle support Loading onto ship; photo of an earlier model The machine has no attachment points by which it can be lifted.
  • Page 56 General Description 56 / 546...

  • Page 57: General Description

    General Description General Description 57 / 546...
  • Page 58 General Description 58 / 546...

  • Page 59: Function

    General Description Function Function This is a self-propelled working machine for picking up, cleaning and loading of sugar beet from piles at the side of the field. The sugar beet is picked up via a roller system. The first roller, the pickup roller, works several centimetres into the ground, picks up the sugar beet and lifts it over a cleaning roller onto three conveyor rollers.

  • Page 60: Scope Of Delivery

    General Description Scope of delivery Scope of delivery The scope of delivery of the machine includes a cooler, a fire extinguisher, a first-aid kit, two wheel chocks and a tool set with small parts package. The first-aid kit and the cooler are located in the driver's cabin, the fire extinguisher is located on the central electrics cabinet.

  • Page 61: Myropa

    (list of spare parts, operating manual, service information, etc.). Upon the delivery of the machine, ROPA gives the customer access to the myROPA portal in the form of an account owner.

  • Page 62: R-Connect

    Experience the various possibili- ties of the ROPA R-Connect. https://youtu.be/wtMZ7nLRhL4 The Account owner has full access to all machines assigned to his ROPA customer number and equipped with R-Connect. Even without assignment of machine(s) and role(s).

  • Page 63: Operating Components

    Operating Components Operating Components 63 / 546...
  • Page 64 Operating Components 64 / 546...

  • Page 65: Ladders

    Operating Components Ladders Ladders DANGER – Nobody may stay on the platform in front of the driver‘s cabin and in the driver's cabin when the machine works. – Ascend ladders and machine only when the machine stands still! Use of ladders See Page 32 5.1.1 Ladder to driver's cabin...

  • Page 66: Auxiliary Steps On The Fuel Tank

    Operating Components Ladders 5.1.2 Auxiliary steps on the fuel tank Auxiliary steps on the fuel tank in road position respectively folded for refueling Guard rail Locking lever Auxiliary steps WARNING Falling hazard! The auxiliary steps on the fuel tank may be used only for refueling the machine and for re-lubricating via the nipple block.

  • Page 67: Driver's Cabin Cylinder Support

    Operating Components Driver's cabin cylinder support Driver's cabin cylinder support The driver's cabin must not be raised or lowered unless both pickup side sections are folded out and if the driver is sure that there is no obstacle within a height of 5.3 m above the driver's cabin.
  • Page 68 Operating Components Driver's cabin cylinder support The driver's cabin can only be raised or lowered if the safety rail (2) at the boarding steps is closed. 68 / 546...

  • Page 69: Driver's Cabin Overview

    Operating Components Driver's cabin overview Driver's cabin overview Roof console Radio Storage compartment, installation option for radio equipment Rotating driver's seat, with seat brake First aid kit (on the backrest of the driver's seat) Cabin floor with underfloor heating Bottle holder Footrest on A-column Steering column (10)

  • Page 70: Rear Part Of Cabin

    Operating Components Rear part of cabin Rear part of cabin Reading light Pull-out shelf Storage compartment with cooler Blow-out gun Emergency seat, foldable Storage compartment at cabin rear wall, bottom, pull-out Storage compartment at cabin rear wall, top, pull-out Storage compartment at cabin rear wall 70 / 546...

  • Page 71: Cabin Ceiling

    Operating Components Cabin ceiling Cabin ceiling Roller blind left rear Roller blind left front Roller blind front Roller blind right front Roller blind right rear 71 / 546...

  • Page 72: Steering Column

    Operating Components Steering column Steering column DANGER Hazard of deadly injuries if the steering column is moved while driving. In this case, the machine can go out of control and cause the severest damages. – Therefore, NEVER move the steering column while driving! Turn handle (1) for height adjustment Release turn handle (1) (turn to the left), move the steering column to the desired height, retighten the rotating handle (turn to the right) and block the steering column.

  • Page 73: Steering Column Switch

    Operating Components Steering column 5.6.1 Steering column switch – Press lever to the right: Turn indicator right (R) – Press lever to the left: Turn indicator left (L) – Lever down/centre/up: high beam/dimmed headlight/headlight flasher (F) – Pressure switch on the end: Horn (H) –...

  • Page 74: Driver's Seat

    Operating Components Driver's seat Driver's seat Safety instructions: To prevent damage to the driver’s back, the seat must be adjusted for the driver’s weight before use and each time the drivers change. To prevent injury, no objects should be placed within the moving area of the driver’s seat.
  • Page 75 Operating Components Driver's seat Shock absorption The damping of the seat can be adjusted to match the characteristics of the road or field surface. The comfort of the suspension can be adjusted individually. Rotate the lever to the desired setting and release. Position 1 = soft Position 2 = medium Position 3 = hard...
  • Page 76 Operating Components Driver's seat Longitudinal adjustment with operat- ing console Moving the locking lever upward releases lateral adjustment. The locking lever must latch into the desired position. It should not be possi- ble to move the driver’s seat into another position when it is locked.
  • Page 77 Operating Components Driver's seat Seat heating and cooling The active seat air conditioning ensures that the seat surface is always dry. Body moisture in the contact area of the seat is removed. This keeps the seat comfortably cool and dry. Seat heating and cooling can be turned on and off by pressing the switch.
  • Page 78 Operating Components Driver's seat The backrest is adjusted using the locking lever (arrow). The locking lever must latch into the desired position. It should not be possible to move the backrest into another position when it is locked. Horizontal suspension Under certain driving conditions, it is use- ful to activate the horizontal suspension.

  • Page 79: Rotating Driver's Seat

    Operating Components Driver's seat 5.7.1 Rotating driver's seat The rotatable driver's seat has a pneumatic seat brake. This seat brake is operated using the switch (17) on the left joystick. You can fix the seat in the position most favourable for you. An additional mechanical lock (1) always fixes the seat in the posi- tion prescribed by law when driving on roads.

  • Page 80: Driver's Seat Occupancy Identification System

    Operating Components Driver's seat 5.7.2 Driver's seat occupancy identification system ADVICE For the machine to be fully functional, the driver's seat must be occupied. Once the driver gets up from the seat, the system automatically stops all dangerous move- ments a few seconds later. However, brief raising from the driver's seat doesn't influ- ence the machine functions.

  • Page 81: Operating Components On The Floor Of The Driver's Cabin

    Operating Components Operating components on the floor of the driver‘s cabin Operating components on the floor of the driver‘s cabin Opener for cleaning flap Foot-switch look forward Foot switch driving direction Brake pedal Drive pedal 81 / 546...

  • Page 82: Operating Console R-Concept

    Operating Components Operating console R-Concept Operating console R-Concept For a detailed description see Chapter 6 "Operation" (See Page 103). The console is divided into different operating fields: R-Touch auxiliary terminal R-Touch main terminal Keypad I Keypad II Operating panel R-Direct Operating panel R-Select Foldable armrest with storage compartment Switches on operating console...

  • Page 83: R-Touch Main Terminal

    A key to restart the terminal (3) is located at the rear right side of the terminal. Use this key only in emergency cases, e.g. if there is no response from the terminal. ADVICE Use only the USB stick supplied by ROPA or a similar stick formatted in FAT 32. 83 / 546...

  • Page 84: R-Touch Auxiliary Terminal

    Operating Components Operating console R-Concept 5.9.2 R-Touch auxiliary terminal The auxiliary terminal is installed above the main terminal. The R-Touch auxiliary terminal (1) is primarily used to display the images from the built-in video cameras and to select their view formats. The operation of all functions of the auxiliary terminal is described in Chapter 6 (See Page 150).

  • Page 85: R-Select

    Operating Components Operating console R-Concept 5.9.3 R-Select The R-Select (2) (BLUE operating panel colour) allows the driver to perform about 15 different functions without knowing the menu structure. Generally, there are two possi- bilities to operate the selection area of R-Select (2b). You can select the desired func- tions either by rotating the R-Select wheel (2a) or by touching the corresponding keys on the touch screen.
  • Page 86 Operating Components Operating console R-Concept For example, "Speed stage of pickup rollers" is selected: The speed stage of the pickup rollers can be set with the + (4a) and - (3a) keys on the R-Select or with the + (4b) and - Reset: 5 (3b) buttons on the touch screen.
  • Page 87 Operating Components Operating console R-Concept R-Select menu (2d): The R-Select Quick Access Toolbar (2c) is located at the bottom left of the terminal. Here, you can set further functions with the R-Select. By pressing the key (2d) you open the R-Select menu (2e), in which further functions can be selected.

  • Page 88: R-Direct

    Operating Components Operating console R-Concept 5.9.4 R-Direct The R-Direct function area (5) (YELLOW operating panel colour) allows the driver to perform different settings, e.g. access to the main menu with submenus. The R-Touch main terminal accepts commands when you touch one of the R-Direct selecting fields (5) as well as when you turn or press wheel on the R-Direct (5a).

  • Page 89: Keypad I

    Operating Components Operating console R-Concept 5.9.5 Keypad I (10) Raise/lower additional axles: See Page 201. The additional axles are lowered when the LED lights. (11) Light - working lights: See Page 139. (12) Functional key 1: You can save different functions for the key (12) and call them up by pressing this key. The assignment of the function keys can be changed in the menu "Basic settings", submenu "Function keys".

  • Page 90: Keypad Ii

    Operating Components Operating console R-Concept 5.9.6 Keypad II (18) STOP diesel engine: This key shuts the diesel engine down. (19) START diesel engine: This key starts the diesel engine (must be held for at least 3 sec.). (20) Switching operating mode "Turtle/Rabbit": See Page 186 (21) Switching between I/II gear of the operating mode: Operating mode gear I - all-wheel drive is automatically switched on.

  • Page 91: Switches On Operating Console

    Operating Components Operating console R-Concept 5.9.7 Switches on operating console (26) Steer the rear axle right/left (only in "Turtle" operating mode) (27) Emergency stop switch ADVICE The emergency stop switch never switches off the diesel engine and the traction drive! It switches off the machine drive as well as the yellow button (6) on the joystick! In order to unlock, turn the Emergency-Stop switch slightly clockwise.

  • Page 92: Main Steering Switch

    Operating Components Operating console R-Concept 5.9.8 Main steering switch (44) Main steering switch DANGER When the main steering switch is unlocked the driving speed of the machine is lim- ited. – When driving on public roads and paths, the main steering switch must generally be locked.

  • Page 93: Right Joystick With Multi-Functional Handle

    Operating Components Operating console R-Concept 5.9.9 Right joystick with multi-functional handle The joystick enables easy control of a multitude of functions of the machine with a sin- gle hand without distracting the attention of the operator. For better orientation, there are transparent stickers located on the side window of the driver's cabin containing the following schematic overviews of all functions of the joystick with multifunctional han- dle.

  • Page 94: Left Joystick

    Operating Components Operating console R-Concept 5.9.10 Left joystick As soon as the left joystick console is folded up, the machine drive and the traction drive stop automatically. You can find a detailed description of the left joystick opera- tion here: See Page 163 5.9.11 Ignition lock...

  • Page 95: Switches Of The Roof Console

    Operating Components Switches of the roof console 5.10 Switches of the roof console (36) Microphone for outside speaker system (37) Loud-speaker radio (38) Radio with Bluetooth (see separate operating manual) (38a) Hands-free communication microphone (39) Internal lamps on driver's cabin ceiling LED (40) Rotating switch to fold in/out the left rearview mirror (41)
  • Page 96 Operating Components Switches of the roof console (73) USB double socket 5V / 3.6A (USB-A and USB-C) (74) Switch for LED internal lamps on driver's cabin ceiling (75) Not used (76) Battery main switch (See Page 334) 96 / 546...

  • Page 97: Climate Control

    Operating Components Climate control 5.11 Climate control Air vents (round nozzle) in the roof console Air vents (roller nozzle vector nozzle) Air vents (roller nozzle) Air vents (roller nozzle small Louver-S II) Inside temperature sensor Handle (to open the upper side windows) 97 / 546...

  • Page 98: Engine Housing

    Operating Components Engine housing 5.12 Engine housing There is a key (61) in the engine compartment, which serves to switch on or off engine compartment light. When the engine compartment cover is closed, the engine compartment lights switch off automatically after 15 minutes. In order to switch on the engine compartment lighting with either the ignition or the battery main switch switched off, hold the key (61) for 5 sec and then release it.

  • Page 99: Outlet On Fuel Tank

    Operating Components Outlet on fuel tank (64) Pump cover behind climbing ladder (65) Unlock engine housing maintenance hatch in the infeed conveyor duct 5.13 Outlet on fuel tank One more outlet is installed at the rear under the fuel filler nozzle. (66) Outlet on fuel tank 24V / 8A maximum 99 / 546...

  • Page 100: Ladder Light

    Operating Components Ladder light 5.14 Ladder light The key (67) for switching on the ladder light is in the cutout under the engine com- partment cover. In order to switch on the ladder lighting with either the ignition or the battery main switch switched off, hold the key (67) for 5 sec and then release it.

  • Page 101: Battery Emergency Shutdown

    Operating Components Battery emergency shutdown 5.15 Battery emergency shutdown (68) Battery emergency switch-off (See Page 334) ATTENTION Risk of machine damage. If this switch is turned off while the ignition is on, it can lead to data loss. The power supply will be switched off immediately. It may also seriously damage the exhaust gas after-treatment system.
  • Page 102 Operation 102 / 546...

  • Page 103: Operation

    Operation Operation 103 / 546...
  • Page 104 Operation 104 / 546...

  • Page 105: First Startup

    Operation First startup This chapter provides all information for operation of the machine. For most work in an agricultural area, the mode of working and the work results are under the influence of many individual and different factors. The scope of this operating manual would be exceeded if we have considered all conceivable situations (ground condition, sugar beet varieties, weather, local land conditions, etc.).

  • Page 106: Safety Regulations For Operation Of The Machine

    Operation Safety regulations for operation of the machine Safety regulations for operation of the machine – Before starting work, familiarize yourself with the machine and the operating com- ponents. In case of need, obtain instructions from a person already having suffi- cient experience in handling the machine.
  • Page 107 Operation Safety regulations for operation of the machine DANGER Hazard to life due to rotating rollers! There is a risk of the severest or even deadly injuries for people staying in the hazard zone. Especially near the pickup, objects or people may be drawn into rollers by body parts or pieces of clothing.

  • Page 108: Working In The Vicinity Of Power Lines

    Operation Safety regulations for operation of the machine 6.2.1 Working in the vicinity of power lines DANGER Hazard to life due to electrical current! Due to the dimensions of the machine, the landscape and the construction of power lines, the prescribed safety distance may be violated when working in the vicinity of or under power lines.

  • Page 109: R-Concept

    Operation R-Concept R-Concept Both R-Touch colour terminals are the information and command centre of the machine. From here, you can monitor the entire machine, see operating modes, per- formance data, images from the video cameras and adjust parts of the machine. Before you start, make sure that you have become familiar with both R-Touch colour terminals and the various warning and status displays so that you can use the machine safely and effectively.

  • Page 110: Display Areas On The R-Touch Main Terminal

    Operation R-Concept 6.3.1.1 Display areas on the R-Touch main terminal [A] Display area for warning indicators and hints (See Page 145) ADVICE When a warning indicator activates the warning buzzer, you can suppress the sound- ing of the buzzer for a short period clicking on the display area [A] or pressing the key 110 / 546...
  • Page 111 Operation R-Concept [B] Display area beet path Load and warning threshold for pickup roller drive Load and warning threshold for conveyor roller drive Load and warning threshold for drive of 4-part pinch rollers Relief pressure pickup in the cen- Pickup height Set speed and status of drive for pickup rollers Set speed and status of drive for...
  • Page 112 Operation R-Concept [F] Individual display areas Adjust display areas at the top and bottom Swipe sideways on the display field to change it. Already selected in the other display area field is not available for switching. (1) Display field: Steering See Page 205 (2) Display field: Scales See Page 297...
  • Page 113 Operation R-Concept (3) Display field: Operating parameters Voltage vehicle power supply Hydraulic oil level Hydraulic oil temperature Coolant temperature Engine oil temperature (above 60°C is hidden) Pneumatic system reservoir pressure Pressure traction drive – Arrow counterclockwise: higher pressure forward – Arrow clockwise: higher pressure backward Tank level fuel AdBlue tank content only on models with AdBlue-tank...

  • Page 114: Fold Out Quick Access Window

    Operation R-Concept 6.3.1.2 Fold out quick access window Touch the display area on the left top screen with the finger and swipe from top to bot- tom. Identical function also by pressing the OPT key. The quick access window opens. To close the quick access window touch it and swipe from bottom to top.

  • Page 115: R-Touch Cleaning Mode

    Operation R-Concept 6.3.1.3 R-Touch cleaning mode Cleaning mode (See Page 114) starts a screen saver so you can clean the screen with a microfibre cloth without adjusting machine settings. To exit the cleaning mode, press the Return key in the upper right corner until the dis- played time is up.

  • Page 116: Home Key

    Operation R-Concept 6.3.2.1 HOME key The HOME key (8) is always available on the R-Touch colour terminals as well as on the R-Direct operating panel. Press the HOME key once to return to the main screen. Main menu Main settings 6.3.2.2 Main menu All submenus of the main menu can be selected with help of the R-Touch colour ter-...

  • Page 117: Main Settings Menu

    Operation R-Concept 6.3.2.2.1 Main settings menu Main menu Main settings Special functions System Operating data Scales Service Main settings Fuel reserve warning AdBlue reserve warning Reverse-automatic rollers Reversing time of rollers Left joystick keys 18+19 Residual beet pickup Fuel reserve warning % (See Page 170) AdBlue®...

  • Page 118: Special Functions

    Operation R-Concept 6.3.2.2.2 Special functions Main menu Main settings Special functions System Operating data Scales Service Special functions B638 PS fuel pressure fine filter 100 mbar Service fuel filter Load mode Loading Feed - automatic activation Start central lubrication Greasing time 210 sec Start DPF regeneration manually Suppress DPF regeneration...

  • Page 119: System Menu

    Operation R-Concept 6.3.2.2.3 System menu Main menu Main settings Special functions System Operating data Scales Service System Terminal settings Date-time WiFi Units Licenses 119 / 546...
  • Page 120 Operation R-Concept Terminal settings submenu Terminal settings Brightness Volume level errors Volume level system Language Key tone In the line "Brightness" you can set the brightness of the screen. In the line "Volume level errors" you can set the volume level of the warning and advi- sory tones.
  • Page 121 Operation R-Concept Units submenu Units Distance metric Area metric Volume metric Temperature metric Pressure metric Speed metric Weight metric In the “Units” menu you can select various bases of calculation for the physical parameters speed, distance, volume and pressure. Please be careful; if you set, for example, the driving speed at mph instead of km/h, the values on the driving speed display will be completely incomprehensible.

  • Page 122: Menu Operating Data

    Operation R-Concept 6.3.2.2.4 Menu Operating data Main menu Main settings Special functions System Operating data Scales Service Operating data Season statistics Machine statistics 122 / 546...
  • Page 123 Operation R-Concept Submenu Season statistics Season statistics Total Chassis serial number 8N1644 Working-hours engine 00:00 h:mm Consumption engine Field Time field 00:00 h:mm Distance field Consumption field Consumption/time Consumption/distance l/km Loading Time loading 00:00 h:mm Distance loading Consumption loading Loading weight Finish season Season statistics Field...
  • Page 124 Operation R-Concept Submenu Machine statistics Machine statistics Total Chassis serial number 8N1644 Working-hours engine 00:00 h:mm Consumption engine 0.00 Field Time field 00:00 h:mm Distance field 0.00 Consumption field 0.00 Consumption/time Consumption/distance l/km Loading Time loading 00:00 h:mm Distance loading 0.00 Consumption loading 0.00...

  • Page 125: Scale Menu

    Operation R-Concept 6.3.2.2.5 Scale menu See detailed information from Page 297. 125 / 546...

  • Page 126: Menu Service

    Operation R-Concept 6.3.2.2.6 Menu Service Main menu Main settings Special functions System Operating data Scales Service Service Version Diagnosis Teach in Tuning Hardware exchange Software update Data service Error memory For the operator, only the submenus "Version" and "Diagnostics" (see Chapter "Mal- function and Remedies", See Page 460) are of importance in the service menu.
  • Page 127 Operation R-Concept Data service submenu Data service Export parameters Export season statistics Export machine statistics Export error memory The "Data service" submenu is required to import, export and delete databases. 127 / 546...

  • Page 128: Water Spray System Menu

    Operation R-Concept 6.3.2.3 Water spray system menu Water spray system For detailed information See Page 284. 128 / 546...

  • Page 129: Window Wiper Menu

    Operation R-Concept 6.3.2.4 Window wiper menu The window wipers on the machine are controlled via the R-Touch. The Window wiper menu appears when the key (25) on keypad II is pressed for two seconds. Briefly press this key to switch the wipers on or off with the last selected setting. 129 / 546...
  • Page 130 Operation R-Concept Similarly, the menu can be accessed by touching the symbol (E) on the R-Direct func- tional area. Window wipers Switch selected window wiper on/off Adjustment of front window wiper interval Adjustment of left window side wiper Adjustment of right window side wiper Adjustment of rear window wiper interval (incl.

  • Page 131: Configuration Of Window Wiper Program

    Operation R-Concept 6.3.2.4.1 Configuration of window wiper program Window wiper programs 1-3 can be individually assigned as desired. To do this, switch on all window wipers with settings, which you want to add to a program. By touching and holding one of the wiper program touch fields, you can save the current selection to this program.

  • Page 132: Climate Control

    Operation R-Concept 6.3.2.5 Climate control The air conditioning system always ensures optimum climate conditions in the dri- ver‘s cabin. The setting range is between 16 and 30°C. Similarly, the menu can be accessed by touching the symbol (E) on the R-Direct functional area. Defrost Oil tank heating Underfloor heating...
  • Page 133 Operation R-Concept (11) Inside temperature sensor Make sure that the temperature sensor (11) remains free of obstructions and is not covered by clothing or other objects, otherwise the climate control cannot function properly. 133 / 546...

  • Page 134: Oil Tank Heating

    Operation R-Concept 6.3.2.5.1 Oil tank heating The oil in the hydraulic oil tank can be preheated by the oil tank heater. A heating coil connected to the diesel engine cooling system is installed in the hydraulic oil tank. The hydraulic oil tank heater must be switched on at every cold start. The oil tank heating can be switched on and off with the screen button (6).

  • Page 135: Underfloor Heating

    Operation R-Concept 6.3.2.5.2 Underfloor heating The underfloor heating can be switched on and off with the screen button (7). Defrost Oil tank heating Underfloor heating ON/OFF By pressing the screen button (8), you open a menu for setting the stage of the under- floor heating.
  • Page 136 Operation R-Concept Non-heated area of the underfloor heating ADVICE If you want to place something on the floor that should not be heated from below even though the underfloor heating is switched on, there is also a spot for it. The non-heated area is located in front of the storage compartments in the rear wall of the cabin.

  • Page 137: Park Heating

    Operation R-Concept 6.3.2.5.3 Park heating The park heating can be switched immediately on and off with the screen button (9). Defrost Oil tank heating Underfloor heating ON/OFF The screen button (10) opens a menu for preselecting the parking heater activation time and setting the run time.
  • Page 138 Operation R-Concept Park heating runtime Monday Tuesday Wednesday (12) Day of week (13) Switch-on time - hours (14) Switch-on time - minutes (15) Runtime after activation By swiping up and down on the terminal, you can set the time and day of the week when the parking heater should be switched on.

  • Page 139: Light Control

    Operation R-Concept 6.3.2.6 Light control The lighting in the machine is controlled via the R-Touch. The light control menu appears after pressing the key (11) on the keypad I for two seconds. Briefly pressing this key switches the light on or off with the last selected setting. 139 / 546...
  • Page 140 Operation R-Concept Similarly, the menu can be accessed by touching the symbol (E) on the R-Direct func- tional area. Light control Individual Switch light on/off Headlight driver's cabin roof front centre Headlight driver's cabin roof front right Headlight driver's cabin roof right outside Headlight driver's cabin roof rear right Headlight vehicle frame right Truck conveyor headlight(s)

  • Page 141: Configuration Of Light Programs

    Operation R-Concept 6.3.2.6.1 Configuration of light programs The light programs 1-3 can be individually assigned according to your wish. To do this, switch on the lights you want to add to a program. By touching and holding the light program touch fields you save the currently active lights in that light program. Light control The lights and lighting programs can be selected either by touching the screen or by turning and pressing the R-Direct rotary wheel.

  • Page 142: Ladder Light

    Operation R-Concept 6.3.2.6.2 Ladder light The "Coming Home" and "Leaving Home" functions are integrated into the machine. The "Ladder light" key (67) is located in the cutout under the engine compartment cover. These functions are also active when the battery main switch is turned off. Leaving Home A "Leaving Home"...

  • Page 143: Individual Headlights

    600 mm (ROPA item no. 330044900), 3200 mm (ROPA item no. 330022500) and 5,000 mm (ROPA item no. 330027100). You can connect up to two work lights to one plug using an Y-connector (4) (ROPA item no. 322050800). (max. 70 W) The correct function of the individual headlights is only guaranteed with the ROPA work lights (ROPA item no.

  • Page 144: Readjusting Warning Thresholds

    Operation R-Concept 6.3.3 Readjusting warning thresholds The warning thresholds for the drives of pickup rollers, conveyor rollers, 4-part pinch rollers and recleaning can be adjusted on the R-Touch. Load on drive of pickup rollers Load on drive of conveyor rollers Load on drive of 4-part pinch rollers Load on drive of recleaner set warning threshold for the respective drive (blue line)

  • Page 145: Warning And Status Indications On The R-Touch

    Operation R-Concept 6.3.4 Warning and status indications on the R-Touch Orange warning indicators that lead to diesel engine stop Engine oil pressure too low Hydraulic fluid too hot Serious engine problems, shut Lubrication pump distributor gears down diesel engine immediately failed Coolant level too low Hydraulic oil level too low...
  • Page 146 Operation R-Concept Orange warning indicators of electronic problems Speed signal out of range Error data backup Analogue signal out of range Incorrect machine configuration Line break or short circuit found Communication problem with con- trol device A003 Internal memory fault in EEPROM Yellow warning indicators Pickup rollers overloaded Conveyor rollers overloaded...
  • Page 147 Operation R-Concept Yellow hints on operation Please swing out pickup Please close engine housing door Please swing up fold plates Please close rear platform wall Please release "look forward" Please swing down left joystick foot-switch console Please press "look forward" foot Please swivel recleaner into oper- switch ating position...
  • Page 148 Operation R-Concept Please drive slower Please fill up fuel tank Please drive faster Please fill up AdBlue® Differential lock engaged Please release drive pedal to change the operating mode Operating temperature not Please switch analogue-rocker to reached neutral position Please unlock counterweight arm Please lock counterweight arm Please unlock swivel arm Please lock swivel arm...
  • Page 149 Operation R-Concept Status indications Oscillating axle support enabled Central lubrication operating Operating mode "Tuttle" is active Operating mode "Tuttle" is active (loading) (loading) Gear 1 is active Gear 2 is active Operating mode "Rabbit" is active Operating mode "Rabbit" is active (road drive) (road drive) Gear 1 is active...

  • Page 150: R-Touch Auxiliary Terminal

    Operation R-Concept 6.3.5 R-Touch auxiliary terminal Quick access bar is hidden ADVICE Unlike the main terminal, the auxiliary terminal cannot be operated with R-Direct or R- Select. The auxiliary terminal can only be operated by touching. The auxiliary terminal is primarily used to display the images from the built-in video cameras of the machine.

  • Page 151: Display Areas On The R-Touch Auxiliary Terminal

    Operation R-Concept 6.3.5.1 Display areas on the R-Touch auxiliary terminal Quick access bar is shown Standby mode Activate cleaning mode (See Page 115) Configure individual camera 1-3 display HOME key on auxiliary terminal Main menu (See Page 116) Still image monitor Standby mode Use this touch field (1) to put the display of the left color terminal in standby mode.

  • Page 152: Operation Of Video System

    Operation R-Concept 6.3.5.2 Operation of video system 6.3.5.2.1 Switching between the different camera views To change the camera view, swipe the display panel to the right or left. The available camera views are displayed in succession. Quick access bar is shown Standard camera display S1 - S3 Active camera display Individual camera 1-3 display (optional)

  • Page 153: Configuration Of Individual Camera Views

    Operation R-Concept 6.3.5.2.2 Configuration of individual camera views To configure the individual camera views, press the Configure individual camera view screen button (3). Users can configure up to three different individual camera views. To do this, press the screen button for adding individual camera view (10). Individual video layout Layouts (10)
  • Page 154 Operation R-Concept Individual video layout Layouts Camera selection Depending on the equipment options, by touching the Select camera view to be dis- played in this window (12) field, you can choose between the following cameras. Central mark camera Cabin roof camera (option) Recleaner camera (option) Truck conveyor camera (option) Rear area control camera left...
  • Page 155 Operation R-Concept Define image section Individual video layout Layouts While configuring, you can zoom in the individual camera views to have relevant areas displayed larger. In order to move the zoomed views, use two fingers to move the image. To save and exit the editing process, touch the Return key (14). 155 / 546...

  • Page 156: Deleting An Individual Camera View

    Operation R-Concept 6.3.5.2.3 Deleting an individual camera view Individual camera views that have already been created are displayed on the left. In order to delete an individual camera view, press the Delete button next to the respec- tive view (15). Individual video layout Layouts 156 / 546...

  • Page 157: Right Joystick

    Operation Right joystick Right joystick The right joystick is the most important operating component of the machine. Here the control of the machine essential functions is ergonomically combined in one operating component. Joystick front side Joystick rear side 6.4.1 Right joystick - operating mode "Turtle" Joystick functions in the operating mode "Turtle"...
  • Page 158 Operation Right joystick Joystick movements - multi-key (11) NOT pressed Only the two rotary drives turn! The rotating direction of the swivel arm always depends on the selected loading direction! Joystick FORWARD Turn swivel arm Joystick BACKWARD Turn swivel arm Joystick LEFT Turn truck conveyor to the left Joystick RIGHT...
  • Page 159 Operation Right joystick X-Y button (4) Support feet FRONT LEFT Raise supporting foot left FRONT RIGHT Raise supporting foot right Pickup rollers work deeper in the ground REAR LEFT Lower supporting foot left REAR RIGHT Lower supporting foot right Pickup rollers work more shallow in the ground ADVICE If the multi-key (11) is pressed at the same time as the X-Y key (4), both support feet are always adjusted simultaneously, regardless of which side the X-Y key is moved...
  • Page 160 Operation Right joystick Key (7) drive pickup rollers and conveyor rollers PRESS KEY SHORTLY Pickup rollers and conveyor rollers On/Off PRESS AND HOLD KEY Reverse pickup rollers and conveyor rollers Key (8) drive 4 pinch rollers PRESS KEY SHORTLY 4 pinch rollers On/Off PRESS AND HOLD KEY Reverse 4 pinch rollers Key (9) drive recleaning...

  • Page 161: Right Joystick - Operating Mode "Rabbit

    Operation Right joystick 6.4.2 Right joystick - operating mode "Rabbit" Joystick functions in the operating mode "Rabbit" Joystick FORWARD not used Joystick BACKWARD Cruise control OFF Joystick LEFT Steer rear axle to left Joystick RIGHT Steer rear axle to right Key (9) front window wiper PRESS KEY SHORTLY Window wiper(s) On...
  • Page 162 Operation Right joystick Key (3) or multifunctional key (11) rear axle central position PRESS KEY (3) OR (11) SHORTLY Put rear axle in central position Key (12) and (13) all-wheel steering PRESS KEY (12) AND (13) BRIEFLY AT All-wheel steering On THE SAME TIME Key (13) Radio PRESS AND HOLD KEY...

  • Page 163: Left Joystick

    Operation Left joystick Left joystick As soon as the left joystick console is folded up, the machine drive and the traction drive stop automatically. ADVICE All functions can only be executed using the joystick if the seat console is swung all the way down and the machine is operated in Turtle I or Turtle II mode or the machine is operated in Rabbit I or Rabbit II mode with unlocked main steering switch.
  • Page 164 Operation Left joystick Mini joystick (15) FORWARD Telescopically extend pile pickup BACKWARD Telescopically retract pile pickup LEFT Rotate residual beet pickup to the left RIGHT Rotate residual beet pickup to the right X-Y key (16) Only in the operating mode "Turtle" FORWARD Increase diesel engine speed BACKWARD...
  • Page 165 Operation Left joystick X-Y key (16) Only in the operating mode "Rabbit" LEFT Manual diesel engine speed control RIGHT Automotive diesel engine speed control In order to switch over, push the X-Y key (16) in the required direction and hold it briefly in the end position.

  • Page 166: Switching Joystick Left Keys 18+19

    Operation Left joystick 6.5.1 Switching joystick left Keys 18+19 "Rotate residual beet pickup" is the standard function of both keys (18) and (19) on the left joystick. Both buttons can be reassigned in the main menu, Basic settings submenu, Joy- stick left keys 18+19 line.

  • Page 167: Radio Control

    PTT function on both joysticks. This allows speaking via external microphone without releasing the joystick. ADVICE A control line already laid by ROPA up to the roof console must be connected to a compatible radio. When activated via the PTT buttons, the control line (cable number: 851 --> CB:1) is at 24V.

  • Page 168: Diesel Engine

    Operation Diesel engine Diesel engine A summary of the maintenance work required on the diesel engine can be found in the operating manual and original maintenance documentation from MTU/Mer- cedes-Benz. Information regarding procedure to be followed in the event of malfunctions can be found in the "Malfunctions and Remedies"...
  • Page 169 Operation Diesel engine In case of engine problems, the R-Touch displays the following warning mes- sages: Engine oil pressure too low. IMMEDIATELY SHUT DOWN and refill engine oil. Engine oil level too low. IMMEDIATELY refill engine oil. (See Page 340) Coolant temperature too high.
  • Page 170 Operation Diesel engine LIM control light, diesel engine torque limiting is active. Spare fuel quantity reached! When this warning icon is displayed on the R-Touch, the spare fuel quantity set by you has been reached. AdBlue reserve quantity reached. When this warning icon is displayed on the R- ®...

  • Page 171: Start/Shut Down Diesel Engine

    Operation Diesel engine Water content The maximum permissible water content in diesel fuel is 200 mg/kg. 6.7.1 Start/shut down diesel engine If the drive pedal is not in resting position during starting, then for safety reasons, trac- tion drive is blocked. The block remains until the drive pedal is completely released and pressed again.

  • Page 172: Engine Speed Adjustment

    Operation Diesel engine If the diesel engine does not start immediately, then the electronic system switches off the starter after a certain period of time. In this case, wait at least 2 minutes until new start attempt so that the starter can cool down sufficiently. Help for engine start.

  • Page 173: Engine Speed Adjustment In Turtle Operating Mode

    Operation Diesel engine Manual adjustment of the engine speed Manual engine speed adjustment in the Rabbit operating mode can only be performed using the rotary wheel (14) on the right joystick. The highest engine speed is at about 1,500 rpm. This variant is the most suitable for driving on uneven terrain. 18.2 1335 18.0...
  • Page 174 Operation Diesel engine Machine drive On/Off When adjusting the engine speed manually, once the machine drive has been switched on, the diesel engine speed is automatically adjusted to the value that was set before the machine drive was switched off for the last time. The diesel engine speed limits the possible speed of the machine drives.

  • Page 175: Power Reduction Scr System (Applicable For C-Diesel Engine And D-Diesel Engine)

    Operation Diesel engine 6.7.3 Power reduction SCR system (applicable for c-diesel engine and d-diesel engine) There are 3 types of targeted power reductions regarding the SCR system: – Empty AdBlue-tank – Violation of the permissible European or EPA limits/poor AdBlue quality ®...

  • Page 176: Power Reduction Adblue® Filling Level (Applicable For C-Diesel Engine And D-Diesel Engine)

    Operation Diesel engine 6.7.3.1 Power reduction AdBlue® filling level (applicable for c-diesel engine and d-diesel engine) AdBlue® level System impact Capacity approx. 10 % – 7.5 % DEF warning light is on Normal approx. 7.5 % – 5 % DEF warning light flashes Slight reduction LIM warning light is on Torque reduction to 75% of the nomi-...

  • Page 177: Power Reduction Adblue® Quality/System Error (Applicable For C-Diesel Engine And D-Diesel Engine)

    Operation Diesel engine 6.7.3.2 Power reduction AdBlue® quality/system error (applicable for c-diesel engine and d-diesel engine) Error System impact Capacity By detection of poor DEF control light is on after 60 min for 60 Normal quality/system error min. 60 min. after detection DEF warning light flashes Slight reduction LIM warning light is on...

  • Page 178: Power Reduction Process

    Operation Diesel engine 6.7.3.3 Power reduction process Strong Full Error detection Warning Slight reduction reduction reduction 100% 100% - 60% nominal rotational speed (25 min.) 100% - 75% torque 75% - 50% torque (1% / 25 min.) (in 15 min.) 60% - idling speed (10 min.) 50% - 20% torque (10 min.) Time in minutes...

  • Page 179: Diesel Particulate Filter

    Operation Diesel engine 6.7.4 Diesel particulate filter (abbreviated as "DPF", applicable for d-diesel engine) DANGER Hazard of fire due to combustible materials in the engine compartment or on the exhaust gas system Flammable materials may ignite. • For this reason, check regularly whether there are any flammable foreign materials in the engine compartment or on the exhaust gas system.
  • Page 180 Operation Diesel engine Zone 0 Particle filter passive regeneration. No action required. DPF is always protected by passive regeneration when the diesel engine is running. Zone 1 The active automatic regeneration of the DPF is on. Warning indicator lights up to inform the driver. No action required.
  • Page 181 Operation Diesel engine Zone 3 Particle filter filling level very high, initiate manual regeneration immediately. Warning indicators are Action required within the next 30 minutes. Carry out high idle regeneration at a standstill in the "Special functions" menu, "Start DPF regeneration manually" line (See Page 182).

  • Page 182: Diesel Particulate Filter (Dpf) Regeneration Applicable For D-Diesel Engine)

    Operation Diesel engine 6.7.4.1 Diesel particulate filter (DPF) regeneration applicable for d-diesel engine) To start DPF regeneration (High Idle Regeneration) open the main menu, "Special Functions", "Diesel Engine Regeneration" submenu. In the line "Start DPF regeneration manually", choose the "On" option. If you need to avoid the higher exhaust gas temperature that occurs during regen- eration, e.g.

  • Page 183: Amendments Or Supplements To The Mercedes-Benz Engine Operating Manual

    The warning lamps mentioned in the MTU/Mercedes-Benz operating manual are replaced on ROPA machines by the warning indications on the R-Touch. But the meaning of these indications is identical to the lamps described in the MTU/Mer- cedes-Benz operating manual.

  • Page 184: Operating Modes "Turtle" And "Rabbit

    Operation Operating modes "Turtle" and "Rabbit" Operating modes "Turtle" and "Rabbit" The icon ("Turtle"/"Rabbit") of the currently active operating mode is displayed on the R-Touch. The machine can be operated in the following modes: "Turtle I" = Loading operation "Turtle II" = While it is possible to switch into this operating mode, in practice, however, it does not make any sense because this would switch off the all-wheel...

  • Page 185: Diesel Engine And Traction Drive Overspeed Warning

    Operation Operating modes "Turtle" and "Rabbit" 6.8.1 Diesel engine and traction drive overspeed warning ATTENTION Hazard of severe damage to traction drive! Hazard of severe damage to diesel engine If this warning appears on the terminal, immediately reduce the speed of the machine by activating the operating brake.

  • Page 186: Operating Mode Change

    Operation Operating modes "Turtle" and "Rabbit" 6.8.2 Operating mode change – To switch the operating mode completely release the drive pedal and stop the vehi- cle. – Select the desired operating mode using keys (20) and (21) on keypad II. In "Turtle"...

  • Page 187: Differential Lock

    Operation Operating modes "Turtle" and "Rabbit" 6.8.3 Differential lock The differential locks for the front and rear axles can be activated independently of each other. The front axle is switched on/off with the key (22) and the rear axle with the key (23) on the keypad II.
  • Page 188 Operation Operating modes "Turtle" and "Rabbit" Switch on differential lock of front axle: – To switch on the differential lock, release the drive pedal completely and stop the vehicle. – Press the key (22) on keypad II. – The icon appears on the R-Touch if the engagement position of the axle is not achieved.

  • Page 189: Driving

    Operation Driving Driving The electronic control relieves the driver and protects the environment thanks to the automotive driving. Automotive driving means that the driving speed is preselected by the pressure on the gas pedal. The electronics control the hydrostatic drive and the diesel engine so that the preselected speed is always driven at the lowest possible engine rotational speed, independent on the fact whether you are driving uphill or downhill.
  • Page 190 Operation Driving Hydrostatic drives are deemed very safe. The following measure additionally increases this safety, if there should be any operating faults of the drive. If, when releasing the driving pedal, the machine should neither reduce driving speed nor stand still, then a safety circuit is activated by engaging the parking brake (32). This safety circuit bypasses the standard control behaviour of the hydraulic system and opens a safety valve that quickly shuts off the traction drive.

  • Page 191: Driving, "Rabbit" Operating Mode

    Operation Driving If it is not possible to move the vehicle, then the cause for this is shown on the R- Touch: Please release parking brake. Please release the brake pedal. Compressed air brake reservoir pressure is too low! Error of the drive pedal sensors! Release pressure parking brake too low! Call customer service Supply pressure in hydrostatic drive very low!

  • Page 192: Selection Of The Driving Direction (Forward/Backward) In Operating Mode "Rabbit

    Operation Driving 6.9.1.2 Selection of the driving direction (forward/backward) in operating mode "Rabbit" Foot switch driving direction (3): NOT PRESSED Driving direction "forwards" PRESSED Driving direction "backwards" Foot switch driving direction Drive pedal ADVICE Only for "Rabbit II" operating mode: the driving pedal (5) must be released completely for switching to drive in the reverse direction.

  • Page 193: Cruise Control

    Operation Driving 6.9.1.3 Cruise control In order to relieve the driver, the vehicle is equipped with a cruise control. Therefore, only in the operating mode "Rabbit II", the driving speed may be preselected either by pressing the gas pedal or by switching on cruise control. 6.9.1.3.1 Switching on cruise control Cruise control may only be switched on if the following conditions are met:...

  • Page 194: Switching Off Cruise Control

    Operation Driving The cruise control assumes the speed set by the drive pedal at the moment the key (10) is pressed. This speed is not necessarily the actual speed. Example: The currently driven speed is 11 km/h. The driver quickly presses the drive pedal to the end-stop.

  • Page 195: Driving, "Turtle" Operating Mode

    Operation Driving 6.9.2 Driving, "Turtle" operating mode In the "Turtle" operating mode, the traction drive is operated almost exclusively using the keys (2) and (3) and the rotary wheel (14) on the right joystick. If driving forward is activated using the key (2), then the terminal displays the icon This key is used to switch on the traction drive forwards.

  • Page 196: Automatic Feed Switch-On

    Operation Driving 6.9.2.1 Automatic feed switch-on Each time the ignition is switched on and the operating mode is changed (Rabbit ↔ Turtle), the following window appears on the R-Touch after the machine drive is switched on (yellow button (6)): Feed - automatic activation Automatic activation of feed Reset: Off Now select "On"...

  • Page 197: Driving Backward In The Operating Mode "Turtle

    Operation Driving However, if you wish to reactivate the currently deactivated automatic feed switch-on, please open the "Special functions” menu and select the "Feed automatic activation" line. Special functions B638 PS fuel pressure fine filter 100 mbar Service fuel filter Load mode Loading Feed - automatic activation...

  • Page 198: Road Traffic

    ADVICE ROPA expressly wants to point out that the driver and owner of the machine are always alone responsible for compliance with the respective regulations and condi- tions of the competent road traffic authorities.
  • Page 199 Operation Road traffic The following generally applies before driving on public roads in the territory of the Federal Republic of Germany: – The recleaner must be folded to transport position and then the truck conveyor must be laid down in transport position. –...
  • Page 200 You will find a form for this instruction in Chapter 9 (See Page 532). ROPA recommends copying this form before completing it. As already mentioned, the regionally competent road traffic authorities may estab- lish additional conditions or conditions different from listed above. It is the sole responsibility of the vehicle owner and the driver to gain knowledge of these regu- lations and to comply with them.

  • Page 201: Additional Axles

    Operation Road traffic 6.10.2 Additional axles The additional axles must be activated when driving on the road. The highest speed can be reached only when the additional axles are activated. The additional axles are activated with the key (10) on keypad I. The LED lights up when the additional axles are lowered.

  • Page 202: Braking System

    Operation Braking system 6.11 Braking system The braking system of the machine is a pneumatically actuated dry drum brake. For safety reasons, the braking system consists of two independent brake circuits: The operating brake activated by the brake pedal on the driver's cabin floor. The parking brake, which is activated by the toggle switch.

  • Page 203: Engine Brake

    Operation Braking system Brake pedal Drive pedal DANGER When a warning icon is displayed on the R-Touch pointing at problems with the braking system, then there is the severest hazard to life for the driver and bystanders as well as other road users. –...

  • Page 204: Parking Brake

    Operation Braking system 6.11.3 Parking brake The parking brake is operated via the toggle switch (32) in the console (See Page 91). The parking brake affects front wheels. Even when the ignition is switched off and the pneumatic system is pressureless, the parking brake is automatically engaged and active.

  • Page 205: Steering

    Operation Steering 6.12 Steering Display field: Steering Display of active steering mode (in this case: manual rear axle steering) Position display for front axle steering Position indication rear axle steering Overview of steering modes in "Rabbit" operating mode Rear axle in straight position All-wheel steering ADVICE In the "Rabbit"...

  • Page 206: Steering In The Operating Mode "Rabbit

    Operation Steering 6.12.1 Steering in the operating mode "Rabbit" In the operating mode "Rabbit", the rear wheels may be steered by moving the joystick back and forth, if the main steering switch (44) is unlocked. When driving on public roads and paths, the main steering switch must generally be locked. It may ONLY be unlocked for driving through narrow curves and at low speed (below 12 km/h).

  • Page 207: Manual Rear Axle Steering

    Operation Steering 6.12.1.1 Manual rear axle steering In the operating mode „Rabbit“, the rear axle may be steered independently from the front axle by moving the right joystick left/right. Additionally, the main steering switch unlocked. The symbol appears on the R-Touch main terminal. When driving in the operating mode "Rabbit"...

  • Page 208: All-Wheel Steering

    Operation Steering 6.12.1.2 All-wheel steering All-wheel steering can be used to steer both front and rear axles simultaneously with the steering wheel with no further driver input. The rear axle steers in the opposite direction to the front axle. This steering mode simplifies manoeuvring for less skilled drivers.

  • Page 209: Put Rear Axle In Central Position

    Operation Steering If the all-wheel steer was not activated, then the cause of it is shown on the R- Touch: – Unlock main steering switch (44) – Drive faster, the minimum speed (0.5 km/h) shouldn’t be reached. – Driving speed too high. Please continue reducing the speed. ADVICE Once the main steering switch is opened in the operating mode "Rabbit", the speed is reduced automatically for the safety reasons.

  • Page 210: Quick Description: Steering In The "Rabbit" Operating Mode

    Operation Steering 6.12.1.4 Quick description: steering in the "Rabbit" operating mode Start diesel engine. ↓ Select the "Rabbit" operating mode. ↓ Drive slowly (below 12 km/h). ↓ Unlock the main steering switch. ↓ ↓ Rear wheels may be steered to the Activate theall-wheel steering.

  • Page 211: Steering In The Operating Mode "Turtle

    Operation Steering 6.12.2 Steering in the operating mode "Turtle" During loading operation, the rear axle is steered using the toggle switch (26) on the operating console. Precondition: The main steering switch (44) is unlocked. There are the following limitations for this type of steering: –...

  • Page 212: Folding The Machine Out/In

    Operation Folding the machine out/in 6.13 Folding the machine out/in With the help of automatic folding the machine can be set into loading or transport position. – Switch on the oscillating axle support for the rear axle before folding out the machine.
  • Page 213 Operation Folding the machine out/in WARNING Hazard of extremely severe injuries. – Make sure, that nobody stands in the hazard zones when the machine is started. – Make sure that there are no persons on the boarding platform. – The driver is responsible for ensuring that there is nobody in the area between the safety rail at the boarding steps and the cabin door when lifting or lowering the cabin.

  • Page 214: Folding Out Machine With The Help Of Automatic Folding At Rear

    Operation Folding the machine out/in 6.13.2 Folding out machine with the help of automatic folding at rear Condition for this is that the machine front is already folded out and the driver's cabin is raised to the end-stop (See Page 212).
  • Page 215 Operation Folding the machine out/in WARNING Hazard of extremely severe injuries. – Make sure, that nobody stands in the hazard zones when the machine is started. The following processes are executed automatically. During these processes, several movements are performed simultaneously: 1 The speed of the diesel engine increases.

  • Page 216: Folding In Machine Automatically In Front

    Operation Folding the machine out/in 6.13.3 Folding in machine automatically in front The condition is that the machine rear is completely folded in and the truck conveyor rests on the transport support. WARNING Hazard of extremely severe injuries. – Make sure, that nobody stands in the hazard zones when the machine is started. –...
  • Page 217 Operation Folding the machine out/in – Insert the safety chains and secure the pickup. There is one safety chain for the right side and one safety chain for the left side of the front chassis. When driving on public roads, these chains must be fastened to the pickup central part. Fasten the chains on the central part of the pickup, when you have swung in the pickup and are leaving the machine.

  • Page 218: Folding In Machine Automatically At Rear

    Operation Folding the machine out/in 6.13.4 Folding in machine automatically at rear – Remove large accumulations of soiling and deposits of earth. Pay particular atten- tion that the area around the lower pivot point of the roller recleaner is free of earth deposits.
  • Page 219 Operation Folding the machine out/in WARNING Hazard of unwanted swivelling movements! The machine may not be moved on roads or moved to another place if the counter- weight and swivel arm are not locked. The counterweight and swivel arms must always be locked when driving on public roads.

  • Page 220: Folding Out Machine Manually In Front

    Operation Folding the machine out/in 6.13.5 Folding out machine manually in front If the automatic folding does not operate, the machine can be "manually" folded step by step to loading or transport position. – Switch to the "Turtle I" operating mode. (See Page 186) –...
  • Page 221 Operation Folding the machine out/in WARNING Hazard of extremely severe injuries. – Make sure, that nobody stands in the hazard zones when the machine is started. For folding out perform the following actions consecutively: – Extend the telescopic mechanism of the pile pickup slightly and raise the pile pickup as high as possible.
  • Page 222 Operation Folding the machine out/in WARNING Hazard of extremely severe injuries. – Make sure that there are no persons on the boarding platform. – The driver is responsible for ensuring that there is nobody in the area between the safety rail at the boarding steps and the cabin door when lifting or lowering the cabin.
  • Page 223 Operation Folding the machine out/in Swinging up the fold plates is only possible when the R-Touch displays that both pickup side sections are folded out. It is displayed on the R-Touch as follows: – Move pickup to operating depth To do it, push the X-Y key (4) FORWARD LEFT Retract the left support foot to the estimated operating height of the pickup...
  • Page 224 Operation Folding the machine out/in ATTENTION Danger of damage to the pickup. In any case, avoid pressing the pickup to the ground when lowering it so much that the front axle becomes unloaded. This may damage the pickup. Push the mini joystick (1) forward and lower the complete pickup to the ground. This makes it almost impossible to tip the machine over during fold-out of the truck con- veyor.

  • Page 225: Folding Out Machine Manually At Rear

    Operation Folding the machine out/in 6.13.6 Folding out machine manually at rear Condition for this is that the machine front is already folded out and the driver's cabin is raised to the end-stop. (See Page 212) – Raise counterweight (fuel tank). Raise/lower counterweight Choose this function with R-Select.
  • Page 226 Operation Folding the machine out/in (18a) Counterweight arm lock opened (18b) Counterweight arm lock at the end-stop (18c) Counterweight arm lock closed ATTENTION When the swivel arm is swung under the counterweight arm, the lock (18a) of the counterweight arm must be fully open, otherwise the machine might be damaged. 226 / 546...
  • Page 227 Operation Folding the machine out/in – Use the mini joystick (1) to swivel the counterweight arm somewhat out of the cen- tral position. DANGER A person, swept into the machinery during swivelling of the counterweight arm and trapped there, might sustain fatal injuries! –...
  • Page 228 Operation Folding the machine out/in loading direction left loading direction right Pickup Joystick Driver's seat Infeed conveyor Swivel arm Truck conveyor DANGER A person, swept into the machinery during swivelling of the truck conveyor and trapped there, might sustain fatal injuries! –...
  • Page 229 Operation Folding the machine out/in – Fold out truck conveyor. For this purpose: – Press and hold the multi-key (11) on the right joystick, simultaneously, lightly pull backward the right joystick to slightly (about 5cm) lift the truck conveyor above the transport support.
  • Page 230 Operation Folding the machine out/in – Swivel the recleaner into operating position. Swivel recleaning Choose this function with R-Select. + key = swivel recleaner into operating position - key = swivel recleaner into transport position Recleaner in transport position Recleaner in working position Cylinder swivel recleaner into transport position 230 / 546...
  • Page 231 Operation Folding the machine out/in Recleaner in transport position Recleaner neither in transport nor in working position Recleaner in working position The truck conveyor must be rotated out far enough from the machine contour. Immi- nent collisions (10) are displayed on the R-Touch. Collision avoidance stop Truck conveyor rotation 231 / 546...
  • Page 232 Operation Folding the machine out/in – Unlock the swivel arm lock. For this purpose: Swivel arm lock Choose this function with R-Select. + key = unlock swivel arm - key = lock swivel arm Swivel arm unlocked – If the transport vehicle is located to the right of the machine, then swivel the truck conveyor over the vehicle and begin loading.
  • Page 233 Operation Folding the machine out/in – Position the truck conveyor into the "left loading" direction. When moving into this loading direction, the truck conveyor crosses over with the counterweight arm. – To do so, generally lift the counterweight all the way. –...

  • Page 234: Folding In The Machine Manually At Rear

    When swinging in the truck conveyor, work very diligently and concentrated, since otherwise, you could severely damage the machine. ROPA therefore urgently recom- mends that a second, reliable person be called in as flagman during the first experi- mental attempts.
  • Page 235 Operation Folding the machine out/in – Activate swivel arm lock. For this purpose: Swivel arm lock Choose this function with R-Select. + key = unlock swivel arm - key = lock swivel arm The locking lever first begins to close when its roller (5) starts rolling along the cam track (6).
  • Page 236 Operation Folding the machine out/in – Turn swivel arm into transport position. The activated swivel arm lock automatically latches in position and is displayed like this (8). Swivel arm locked 236 / 546...
  • Page 237 Operation Folding the machine out/in – Swivel recleaning to transport position. Swivel recleaning Choose this function with R-Select. + key = swivel recleaner into operating position - key = swivel recleaner to transport position Recleaner in transport position Recleaner in working position Cylinder swivel recleaner into transport position 237 / 546...
  • Page 238 Operation Folding the machine out/in Recleaner in transport position Recleaner neither in transport nor in working position Recleaner in working position – Lower the truck conveyor articulation down to the end-stop. – Turn the inner side of truck conveyor until it is just above the outer end of the trans- port support (3).
  • Page 239 Operation Folding the machine out/in Truck conveyor correctly rested on the transport support. Completely lower the truck conveyor to the transport support (3) until the safety guard rail (4) is pressed. The safety guard rail indicates this by displaying the (9) icon on the R-Touch.
  • Page 240 Operation Folding the machine out/in – Move the counterweight arm lock to the end-stop. To do so, select the " Counter- weight arm lock" function on the R-Select, press and hold the - key until the lock status display on the R-Touch displays the end-stop position (18b). When the dri- ver's cabin is raised, one can also view the mechanism from the driver's seat.
  • Page 241 Operation Folding the machine out/in – Swivel the counterweight arm into the central position until the roller of the locking lever rest lies on the lateral end-stop (19). – Close the counterweight arm lock up to the end-stop. To do so, select the function "...
  • Page 242 Operation Folding the machine out/in – Lower the counterweight completely to the end-stop. To do so, select the function "Lower counterweight" on the R-Select and press the key - for so long until the counterweight is completely swung down. Raise/lower counterweight Choose this function with R-Select.

  • Page 243: Folding In The Machine Manually In Front

    Operation Folding the machine out/in 6.13.8 Folding in the machine manually in front The condition is that the machine rear is completely folded in and the truck conveyor rests on the transport support. WARNING Hazard of extremely severe injuries. – Make sure, that nobody stands in the hazard zones when the machine is started. –...
  • Page 244 Operation Folding the machine out/in The pickup height indicator has to show minimum 98 %. – Swing down the fold plates to the end-stop. Select the function "Fold plates in/out" on the R-Select, press the key - and hold it until the fold plates, clearing shields and support feet move completely into the transport position.
  • Page 245 Operation Folding the machine out/in – Lower the driver's cabin to the end-stop. Select the function "Lower/raise driver's cabin" on the R-Select, press the key - and hold it for so long, until the driver's cabin is completely lowered. Raise/lower driver's cabin Choose this function with R-Select.
  • Page 246 Operation Folding the machine out/in – Fold in the pickup side sections completely to the end-stop. For this purpose, pull the X-Y key (5) on the right joystick diagonally backwards. To fold in faster, press the multi-key ( 11) and hold it in this position. If you then slide the X-Y key (5) diagonally to backward left or backward right, then both pickup side sections are simultaneously folded in.
  • Page 247 Operation Folding the machine out/in – Switch off oscillating axle support. – Insert the safety chains and secure the pickup. There is one safety chain for the right side and one safety chain for the left side of the front chassis. When driving on public roads, these chains must be fastened to the pickup central part.

  • Page 248: Loading Operation

    Operation Loading operation 6.14 Loading operation 6.14.1 General information regarding loading DANGER There is a risk of serious or even fatal injuries for persons staying in the hazard zone. Especially in the pickup area, persons or objects may be drawn into running shafts by body parts or clothing.

  • Page 249: Safety Circuits For Loading Operation

    Neither "Loading direction to the right" nor "Loading direction to the left" has any effect on the quality of work, beet flow or stability of the machine. ROPA machines enable you to load either to the right or to the left with the same work speed and quality.
  • Page 250 Operation Loading operation The driver's seat must be occupied, See Page Rotate the driver's seat to the forward direction. First sound the horn briefly to notify all people in the vicinity that the machine drive is being started and they must keep clear of the machine.

  • Page 251: Pickup Depth Setting

    Operation Loading operation 6.14.4 Pickup depth setting – Depth guide of the pickup is assumed by the two support feet (10) adjustable in height (except for external side of the two lateral parts of pickup) and the central part (central mark). –...

  • Page 252: Relieving The Pickup

    Operation Loading operation 6.14.4.1 Relieving the pickup The pickup must be relieved so that it does not sink into the ground too deeply during loading on softer pile terrain. 6.14.4.1.1 Relieving the pickup side sections The support feet are only required to partially carry the weight of the pickup side sec- tions.

  • Page 253: Relieving The Pickup Central Section

    Operation Loading operation 6.14.4.1.2 Relieving the pickup central section The relief pressure of the central part is set using the mini joystick (1) so that the front axle is loaded. This improves traction of the front tyres and the drive train is loaded more evenly.

  • Page 254: Clearing Shields

    Operation Loading operation (11) Skids under the central mark (adjustable) Working too deep in the ground increases the power requirements of the pickup drive and substantially increases roller wear! The depth setting must constantly be adjusted to the ground profile and the load on the pickup by the beet weight. 6.14.5 Clearing shields The clearing shields (1) limit the pickup width and guide the beets from sides onto the...
  • Page 255 Operation Loading operation (28) Clearing shield left press forward = unfold, press backward = fold. (29) Clearing shield right press forward = unfold, press backward = fold. If you do not need the maximum pickup width, then please always set the clearing shields straight forward.

  • Page 256: Beet Path

    Operation Loading operation 6.14.6 Beet path This section of the R-Touch depicts in symbols the flow of beets through the machine. This clearly presents all important operational parameters to you. The following general meaning is allocated to the individual colours and icons: grey arrows = component is switched off blue arrows...
  • Page 257 Operation Loading operation The feed speed of the traction drive also influences the degree of cleaning: – Low feed speed = thin beet cover on the rollers = all beets pass through a double cleaning path = greater cleaning effect. –...
  • Page 258 Operation Loading operation The greater your experience with the machine, the better your precision at esti- mating the optimum speeds. Speed of pickup rollers Speed of conveyor rollers Speed of 4-part pinch rollers Infeed conveyor speed Recleaner speed Truck conveyor speed 258 / 546...

  • Page 259: Truck Conveyor (Drive A)

    Operation Loading operation 6.14.7 Truck conveyor (drive A) (See Page 256) The truck conveyor moves the beets from the recleaner to the transport vehicle. The beets should be treated as gently as possible during this process. This drive is switched on or off jointly with the machine drive using the yellow button (6) on the right joystick.

  • Page 260: Truck Conveyor Fast Motion

    Operation Loading operation 6.14.7.1 Truck conveyor fast motion Sometimes, a larger quantity of soil sticks to the conveyor, e.g. when loading under unfavourable conditions. To be able to fling this soil off the conveyor, the truck con- veyor is equipped with a quick motion switch. You can switch on quick motion using the toggle switch (33).
  • Page 261 Operation Loading operation Recleaner speed The rotational speed of the recleaner may be set to one of 10 stages. Choose this function with R-Select. + key = more aggressive recleaning - key = gentler recleaning Only with 8-set pinch roller recleaner: If the key + is released after the stage 10 is reached and then pressed for at least three seconds, the "Max"...

  • Page 262: Sieve Conveyor Cleaner (Option)

    Operation Loading operation 6.14.8.1 Sieve conveyor cleaner (option) The cleaning effect of the sieve conveyor is mainly achieved by the fact that the conveyor is moving faster forward than the beet flow. The beets start to roll and are cleaned in this manner. If the warning limit of the sieve conveyor cleaner is exceeded, then the following icon is displayed on the R-Touch.

  • Page 263: Fast Speed Sieve Conveyor Cleaning

    Operation Loading operation 6.14.8.1.1 Fast speed sieve conveyor cleaning Sometimes, a larger quantity of soil sticks to the conveyor, e.g. when loading under unfavourable conditions. The sieve conveyor cleaning is fitted with a fast speed switch to allow this soil to be thrown off the conveyor. Special functions Load mode Loading...

  • Page 264: 8-Set Pinch Roller Cleaning (Option)

    Operation Loading operation 6.14.8.2 8-set pinch roller cleaning (option) If the warning limit is exceeded at the pinch roller cleaner, then the following icon displayed on the R-Touch. If the pinch roller cleaner is blocked, then the following icon is displayed on the R- Touch.

  • Page 265: Beet Brake (Only For 8-Set Pinch Roller Cleaner)

    Operation Loading operation 6.14.8.2.1 Beet brake (only for 8-set pinch roller cleaner) Beet brake Braking bars For the roller cleaner, the cleaning effect is mainly achieved by the fact that the rollers pull dirt and trimmings off in a downward direction. In addition, a swivelling beet brake (1) is mounted.

  • Page 266: Infeed Conveyor (Drive C)

    Operation Loading operation 6.14.9 Infeed conveyor (drive C) (See Page 256) The infeed conveyor (1) moves the beets from the pickup to the recleaner. This drive is switched on or off using the button (10) on the right joystick. The infeed conveyor only runs when the recleaner is already running. If this drive is stopped, all forward drives will also stop.

  • Page 267: Infeed Conveyor Fast Motion

    Operation Loading operation 6.14.9.1 Infeed conveyor fast motion Sometimes, a larger quantity of dirt sticks mainly in the section of the infeed and the deflection rollers of the infeed conveyor. This usually happens when loading under very unfavourable conditions. To be able to fling this soil off the conveyor, the infeed conveyor is equipped with a quick motion switch.

  • Page 268: 4-Part Pinch Rollers In The Pickup (Drive D)

    Operation Loading operation 6.14.10 4-part pinch rollers in the pickup (drive D) (See Page 256) The 4-part pinch rollers in the pickup move the beets to the center of the pickup onto the infeed conveyor. They only move in the feed direction when the machine drive is switched on and the infeed conveyor is running.
  • Page 269 Operation Loading operation Speed of 4-part pinch rollers The rotary speed of the 4-part pinch rollers can be adjusted in ten steps. Choose this function with R-Select. + key = increase rotational speed (more aggressive cleaning and transport) - key = reduce speed (gentler cleaning and transport) To treat the beets as carefully as possible, the speed of 4-part pinch rollers should not be selected higher than necessary.

  • Page 270: Conveyor Rollers (Drive E)

    Operation Loading operation 6.14.11 Conveyor rollers (drive E) (See Page 256) The conveyor rollers preclean the beets and guide them to the outside. A greater cleaning effect is achieved due to the longer cleaning path. The conveyor rollers always move in operating direction if the 4-part pinch rollers also move in operating direction.
  • Page 271 Operation Loading operation Speed of conveyor rollers Choose this function with R-Select. + key = increase speed (rollers rotate faster) - key = decrease speed (rollers rotate slower) To treat the beets as carefully as possible, the speed of the conveyor rollers should not be selected higher than necessary.

  • Page 272: Pickup Rollers (Drive F)

    Operation Loading operation 6.14.12 Pickup rollers (drive F) (See Page 256) The pickup rollers have different tasks. They pick up the beets from the ground and transfer them to the cleaner rollers. These forward the beets to the conveyor rollers and simultaneously clean the pig tails of the pickup rollers.
  • Page 273 Operation Loading operation Speed of pickup rollers Choose this function with R-Select. + key = increase speed (rollers rotate faster) - key = decrease speed (rollers rotate slower) To treat the beets as carefully as possible, the speed of the pickup rollers should not be selected higher than necessary.

  • Page 274: Automatic Reversing Function For All Roller Drives

    Operation Loading operation 6.14.13 Automatic reversing function for all roller drives You can set the automatic reversing function in the menu "Basic settings" to "ON" or "OFF" for all roller drives. Main settings Fuel reserve warning AdBlue reserve warning Reverse-automatic rollers Reversing time of rollers Left joystick keys 18+19 Residual beet pickup...
  • Page 275 Operation Loading operation In the "Reversing time rollers" line you can set in seconds for how long the rollers should rotate backward during automatic reversing. Main settings Fuel reserve warning AdBlue reserve warning Reverse-automatic rollers Reversing time of rollers Left joystick keys 18+19 Residual beet pickup You can manually start additional reversing attempts by using the keys (7), (8) or (9) on the right joystick.

  • Page 276: Driving Into The Beet Pile - Loading Mode Start

    Operation Loading operation 6.14.14 Driving into the beet pile – Loading mode START If a truck is not ready for loading under the truck conveyor, before switching on the machine drive set the selection in the "LOAD MODE" line from "LOAD" (default set- ting) to "START".

  • Page 277: Loading A Transport Vehicle

    Operation Loading operation 6.14.15 Loading a transport vehicle When loading trucks the following directions must be observed at all times to ensure that the beets are handled as gently as possible during the loading process. – Never change the direction of the beet flow between the infeed conveyor, pre- cleaning and truck conveyor by 90°...

  • Page 278: Special Features During Loading

    Operation Loading operation 6.14.17 Special features during loading 6.14.17.1 Frozen beet pile A lightly frozen beet pile can be broken up or loosened with the pile pickup. A very frozen beet pile must never be broken up with the pile pickup. Always use suitable heavy equipment (e.g.

  • Page 279: Extremely Narrow Beet Pile

    Operation Loading operation Frost breaker on the additional axle rear 6.14.17.2 Extremely narrow beet pile Even if the beet pile is very narrow and it appears that only half of the pickup width would be sufficient, the pickup must always be completely extended and used for loading.

  • Page 280: End Load Mode

    Operation Loading operation 6.14.18 END load mode For fuel-saving operation, it is recommended to reduce the speed in the entire beet path at the end of the pile, because at that stage the pile pickup will only be delivering small quantities of beets onto the pickup. The weighing result is also more accurate if the truck conveyor reaches a specific minimum fill level.

  • Page 281: Pick Up Remaining Beets With Pile Pickup

    Operation Loading operation 6.14.19 Pick up remaining beets with pile pickup The pile pickup can be used to move the tip of a beet pile to the outsides of the pickup. The remaining beet pickup (plastic part) is attached to the pile pickup. It is used to pull the last beets from a pile onto the pickup.
  • Page 282 Operation Loading operation Pile pickup raised As long as the pile pickup is raised sufficiently high, the R-Touch shows no warning indicators. The safety circuit does not have any effect during loading process. The pile pickup can be used without restriction as long as it does not fall below a specific mini- mum height (e.g.
  • Page 283 Operation Loading operation The pickup must be lowered before swivelling the pile pickup far to the right or left. If the pickup is not lowered sufficiently, the R-Touch shows the following icon Before picking up remaining beets, we recommend lowering the pickup a few centime- tres at very low speed and picking the remaining beets as follows: –...

  • Page 284: Water Spray System (Option)

    Operation Water spray system (option) 6.15 Water spray system (option) 6.15.1 Structural design of the water spray system The water spray system is designed for wetting the pinch rollers in particularly sticky soil conditions. It is also ideal for gentle loading of beets that have become extremely soft and dry due to exposure to sun and wind.

  • Page 285: Pickup Water Spray Nozzles

    Operation Water spray system (option) ATTENTION Risk of machine damage. If the pressure reducer is set above 5 bar, the compressed air escapes through the safety pressure valve (6 bar). The air compressor runs continuously due to such incorrect operation and may overheat or even malfunction. 6.15.1.1 Pickup water spray nozzles Pickup water spray nozzles on DUO water spray system (option)

  • Page 286: Recleaner Water Spray Nozzles

    Operation Water spray system (option) 6.15.1.2 Recleaner water spray nozzles Recleaner water spray nozzles on DUO water spray system (option) (14) Front spray nozzles on the recleaner (15) Central spray nozzles on the recleaner (16) Rear spray nozzles on the recleaner (17) Stop valve for the rear half of the centre spray nozzles (18)

  • Page 287: Filling Water Tank

    – The setting of this safety component must not be changed under any circum- stances, because any changes may result in serious injury or major property dam- age. – In case of replacement, install only an original ROPA spare part. 287 / 546...

  • Page 288: Filling Water Tank With Optional Geka Coupling

    Operation Water spray system (option) 6.15.2.1 Filling water tank with optional GEKA coupling With the GEKA coupling option (23), you can refill the water tank during load- ing. Always make sure that you are outside the hazard zone of the machine (See 27).

  • Page 289: Operation Of Water Spray System

    Operation Water spray system (option) 6.15.3 Operation of water spray system 6.15.3.1 Setting of the four ball valves in the four operating modes Set the four ball valves to the required operating mode. Operating mode I To deactivate the water spray system, set the ball valve (1) to the position of operating mode I.
  • Page 290 Operation Water spray system (option) Operating mode II To activate the water spray system, set four ball valves to the position of operating mode II. Operating mode III Draining water and emptying the tank If there is a possibility of freezing or before extended downtime we recommend drain- ing the water from the system completely to prevent damage to the water spray sys- tem.

  • Page 291: Duo Water Spray System (Option)

    Operation Water spray system (option) 6.15.3.2 Duo water spray system (option) With the optional Duo water spray system one additional water valve is installed in each side pickup section and in the recleaner. This water valve switches additional spray nozzles. These water valves are switched on and off individually via the switch panels (26), (28) and (30).
  • Page 292 Operation Water spray system (option) Similarly, the menu can be accessed by touching the symbol (E) on the R-Direct func- tional area. Water spray system Overview of water spray system menu (with optional DUO water spray system) Opens the water spray system menu (13) Activate/deactivate water spray system (24)

  • Page 293: Water-Saving Operation (Timer Control)

    Operation Water spray system (option) ADVICE The level sensor evaluates the filling level only in 5 stages (20 %), therefore small steps in the adjustment of the warning threshold are sometimes not effective. 6.15.3.4 Water-saving operation (timer control) The system only sprays if the machine drive is switched on. Touch the switch panel (13) to activate timer control.

  • Page 294: Water-Saving Operation (Pressure Control)

    Operation Water spray system (option) 6.15.3.5 Water-saving operation (pressure control) Touch the switch panel (35) to activate the pressure control of 4-part pinch rollers and the switch panel (36) to activate the pressure control of the recleaner. Touch the switch panel (13) to switch on the water spray system. If the pressure thresholds that are set in this menu via the indicator bars (37) and (38) are exceeded, the water spray system will start spraying.

  • Page 295: Configuring Water Spray Programs

    To open the water filter, close the ball valves (1), (2) and (3). Then open ball valve (4) to release the pressure. If the filter screen is damaged, a new one can be ordered under ROPA item no. 208003200. 295 / 546...

  • Page 296: Cleaning Filter Screen In The Water Nozzles

    Cleaning filter screen in the water nozzles Each nozzle holder of the water spray system also contains a filter sieve. When the nozzle is removed, you can take out the filter and clean it. Filter (ROPA item no. 420057600) in nozzle holder 296 / 546...

  • Page 297: Scales (Option)

    Operation Scales (option) 6.16 Scales (option) 6.16.1 Design and function This is a conveyor scale. The amount of beet is recorded on a weighing frame inside the truck conveyor articulation part before overloading. It weighs the load with the dirt content (referred to in general as sugar beet) transported to the truck by the conveyor via two highly sensitive electronic weighing cells.

  • Page 298: Operation Of Scales

    Operation Scales (option) 6.16.2 Operation of scales The following items are vitally important to ensure an optimal weighing result: – The belt tension should be as low as possible. – Clean the support rollers on the weighing frame (1) and also the support rollers (2) in front of and behind the weighing frame on a regular basis.

  • Page 299: Scale Display Field And Menu

    Operation Scales (option) 6.16.2.1 Scale display field and menu Access via the R-Direct main menu or directly by touching the switch panel (14) on the scale display field. Scales Total of scales Scale zeroing Scale calibration Amount limit scales 1.50 Loading target weight 26.0 Scale menu...

  • Page 300: Commissioning After Delivery Of Machine

    Operation Scales (option) Display field Scales Start/end weighing Reset the currently loaded weight Reset the weight of the day counter Current fuel consumption Weight of the day counter (10) Current capacity (11) Display of loading angle (inclination of truck conveyor articulation) (12) Display of set summation limit (13)

  • Page 301: Start/End Weighing

    Operation Scales (option) 6.16.2.3 Start/end weighing Touch the field (5) to start the weighing process. Weighing started: Scale touch field highlighted in green To end or stop the weighing process touch the field (5) as well. Weighing finished or interrupted: Scale touch field highlighted in grey 301 / 546...

  • Page 302: Amount Limit Scales

    Operation Scales (option) 6.16.2.4 Amount limit scales The indicator status bar (13) displays the load on the weighing cells. The amount limit (12) (= blue mark) is the minimum load on the weighing section above which the vol- ume on the conveyor is detected and the weight is added up. The volume on the con- veyor is displayed in the bargraph (13), coloured green.

  • Page 303: Reset The Currently Loaded Weight

    Operation Scales (option) ADVICE Example of an amount limit set too low: There are no beets on sieve chain of the truck conveyor, yet the weight of the current loading increases slowly. Cause: The amount of dirt adhering to the conveyor since the last zeroing causes a load that is already above the amount limit.

  • Page 304: Run Scale Zeroing

    Operation Scales (option) 6.16.2.6 Run scale zeroing WARNING Hazard of severe injuries. Always make sure that no one is present in the hazard zone. Select the "Scale zeroing" submenu, in the "Scales" menu. Scales Total of scales Scale zeroing Scale calibration Amount limit scales 1.50 Loading target weight...
  • Page 305 Operation Scales (option) Scale zeroing Z o- o Press the "Start" screen button. Indicator of the previous zero point of the scale Scale zeroing Zero-point Switch on machine drive. The following message appears: "Switching on Start machine drive".. Scale zeroing Zero-point The truck conveyor is emptied.
  • Page 306 Operation Scales (option) Scale zeroing Zero-point Zero point adjustment in progress. The following message appears: "Zero point adjustment in progress". The indicator graph below must now progress to the Start right end. ADVICE Do not switch off the machine drive during this period! Switch it off only in case of emergency! Scale zeroing Zero-point...

  • Page 307: Scale Calibration

    Operation Scales (option) 6.16.2.7 Scale calibration ADVICE Calibration is not a daily process. The calibration value should always be adjusted after consulting a responsible person! Clean the rollers on the weighing frame as well as preceding and following rollers. The truck conveyor belt and its carriers should be kept either clean or only very slightly dirty.
  • Page 308 Operation Scales (option) Scale calibration Weight scales Maus Weight external scale Calibration value new Calibration value so far Save ADVICE There should be no beginning or end of pile within this loading. Weight scales Maus 137.5 Calibration value of conveyor scale weighing A026 Fill in the weight, that you have recorded, here: "Weight scales Maus".
  • Page 309 Operation Scales (option) Scale calibration Weight scales Maus 137.5 Weight external scale Calibration value new Calibration value so far Save Enter in the "Weight external scale" the actual weight that was determined for this loading with the external calibrated scales of the consignee and confirm the input. The system now calculates the new calibration value and displays the previous and the new calibration value.

  • Page 310: Continuing Operation Of Scales

    Operation Scales (option) Once the correct calibration value has been determined, the calibration value can also be refined using the deviation of the amount per week (only if the scales are operated in a consistent manner and the loading conditions are reasonably similar). 6.16.2.8 Continuing operation of scales Follow the directions in...

  • Page 311: Reset Scale Counter

    Operation Scales (option) 6.16.2.10 Reset scale counter Select "Reset the weight of the day counter" (19) on the scale display field. Reset day counter? Confirm the "Reset day counter?" query touching the "Yes" button (2). Or select "No" to exit the menu without clearing the counter. The "Amount season"...

  • Page 312: Loading Target Weight

    Operation Scales (option) 6.16.2.11 Loading target weight In the menu "Scale", submenu "Loading target weight", you can set a target weight whereby a signal tone sounds as soon as this weight has been reached during load- ing. Scales Total of scales Scale zeroing Scale calibration Amount limit scales...

  • Page 313: Pump Distributor Gears

    Operation Pump distributor gears 6.17 Pump distributor gears The pump distributor gears is directly flanged to the diesel engine and transfers engine power to the individual hydraulic pumps. The hydraulic pumps required for loading are connected by a multiple disc clutch. Briefly press the yellow key (6) on the right joystick to switch this clutch and thus the machine drive on and off.
  • Page 314 Operation Pump distributor gears If the machine drive is switched on the oil pressure in the multiple plate clutch is too low, the following warning icon is displayed on the R-Touch (pump distributor gears clutch pressure). In this case the machine drive must be switched off immediately and the cause of the low oil pressure found and corrected.

  • Page 315: Hydraulic System

    Hydraulic oil temperature Check the hoses of the hydraulic system for aging and damage on a regular basis! Immediately exchange damaged or aged hoses. Use only original ROPA hoses or hoses fully conforming to the technical specifications of the original hoses! Observe the regionally applying safety regulations on the service life of hydraulic hoses.
  • Page 316 Operation Hydraulic system The level should be kept in a range between 80% and 100%. Avoid overfilling above 100 %. If the hydraulic fuel level is too low, then the R-Touch displays the warning icon: hydraulic fluid level too low. Shut the diesel engine IMMEDIATELY down! If the dri- ver ignores this warning, the diesel engine switches off automatically within a short time.
  • Page 317 Operation Hydraulic system Hydraulic pumps: (10) Transmission with one traction drive motor (11) Transmission with two traction drive motors Pos. Function Traction drive Pump operating hydraulics/front axle steering Pump for water/charge air/oil cooler fan drive Pump for 4 pinch rollers Pickup roller pump Pump for conveyor rollers Recleaner drive...

  • Page 318: Pneumatic System

    Operation Pneumatic system 6.19 Pneumatic system The pneumatic system supplies the brake system and the pneumatic system with compressed air. The following processes of the machine are performed by the pneumatic system: Switch off all-wheel drive. Switch on differential locks. Fold the rear view mirror.

  • Page 319: Air Compressor

    Operation Pneumatic system 6.19.1 Air compressor The entire pneumatic system of the machine is supplied with compressed air by a compressor. It is flanged directly to the diesel engine. The air compressor draws air via the air filter of the diesel engine. Once the preset maximum pressure is reached the pressure regulator blows off automatically.

  • Page 320: Compressed Air Reservoir

    Operation Pneumatic system 6.19.3 Compressed air reservoir The machine has five compressed air reservoirs, which are installed under the right side cover. The four large compressed air reservoirs supply the brake system and the pneumatic system with compressed air. The small compressed air reservoir (3) is for regeneration of the air dryer.

  • Page 321: Central Lubricating System

    Operation Central lubricating system 6.20 Central lubricating system The machine is fitted with a central lubricating system and has two lubricating circuits in the models with sieve conveyor cleaner and stone remover or three in the model with 8-setpinch roller cleaner. Lubricating circuit 1 support Lubricating circuit 2 chassis Lubricating circuit 3 8-set pinch rollers cleaner...

  • Page 322: Central Lubricating System Mode Auto

    Operation Central lubricating system 6.20.1 Central lubricating system mode AUTO Every time the machine drive is switched on the lubrication pump is switched on for the period that the operator has selected in the "Main settings" menu. The factory set- ting for this period is 210 seconds.

  • Page 323: Intermediate Lubrication In Central Lubricating System

    Operation Central lubricating system 6.20.2 Intermediate lubrication in central lubricating system The lubrication system can be manually activated at any time. Switch the option in the R-Touch menu "Special functions", line "Start central lubrication" line from "AUTO" to "ON". Special functions B638 PS fuel pressure fine filter 0 bar Service fuel filter...
  • Page 324 Operation Central lubricating system Regularly check the lubricating pipe system. Check the lubricating system daily for faults. One option is to check the two or three main distributors. An indicator pin is installed there for checking the function. This indicator pin moves slowly when the grease flows through the main distributor.

  • Page 325: Filling Up Grease Gun

    Operation Central lubricating system 6.20.3 Filling up grease gun Central lubrication refill pump 18-kg grease bucket Stopcock Nipple for filling up the hand lever grease gun A stopcock (8) and a plug-in connector (9) for filling the hand lever grease gun is located in the supply hose to the lubricating pump.

  • Page 326: Video System

    Operation Video system 6.21 Video system WARNING The video system is solely for assistance and may show obstacles in a distorted per- spective, incorrectly or do not show at all. It is not a substitute for your attention. The video system cannot display all objects that are very close and/or above the rear view camera.

  • Page 327: Back Run Camera

    Operation Video system 6.21.1 Back run camera The machine is equipped with a rear view camera as standard. This camera is installed at the top of the rear part of the vehicle and is used to provide a better view when reversing.

  • Page 328: Central Mark Camera

    Operation Video system 6.21.2 Central mark camera The cetral mark camera is installed at the front under the central mark and is used to determine the correct working depth. Always switch on the lights for the central mark camera while loading in the "Light control" menu (See Page 139).

  • Page 329: Cabin Roof Camera (Option With R-Connect Monitor)

    Operation Video system 6.21.3 Cabin roof camera (option with R-Connect monitor) Optionally, the machine can be equipped with a front camera. This camera is located at the top of the cabin front and is used to monitor the pickup during loading. Cabin roof camera In the future, this option can be used to document the conditions at the beet pile by transmitting images in the R-Connect system.

  • Page 330: Recleaner Camera (Option)

    Operation Video system 6.21.4 Recleaner camera (option) Optionally, the machine can be equipped with a camera that monitors the recleaner. Recleaner camera 330 / 546...

  • Page 331: Truck Conveyor Camera (Option)

    Operation Video system 6.21.5 Truck conveyor camera (option) An optional video camera can be installed on the truck conveyor of the machine to monitor the loading process. This camera provides a view between the sides of a high transport vehicle. Truck conveyor camera 331 / 546...

  • Page 332: R-View Cameras (Option)

    Operation Video system 6.21.6 R-View cameras (option) Your machine can be fitted with the optional "R-View" video system. The images of the rear area control camera left and the rear area control camera right are displayed together with the back run camera. The image shows the environment around the rear part of the machine.

  • Page 333: Electrical System

    Operation Electrical system 6.22 Electrical system 6.22.1 Voltage monitoring The battery voltage is monitored by the system. If the voltage is too high or too low, then the warning icon is displayed on the R-Touch. The battery voltage may not exceed 32 V and may not fall below 24 V.

  • Page 334: Battery Disconnect Relay

    Operation Electrical system 6.22.2 Battery disconnect relay 6.22.2.1 Battery main switch function When you disconnect the power supply from the main battery switch (76) the power supply does not switch off until 6 minutes later (provided the ignition lock is in 0-posi- tion).

  • Page 335: Battery Emergency Stop Switch

    Operation Electrical system 6.22.2.2 Battery emergency stop switch The switch (68) for battery emergency stop is located in the central electrics cabinet. This switch may be actuated IN CASE OF EMERGENCY ONLY. In case of emergency (e.g. fire in the vehicle), activate the battery emergency stop switch.

  • Page 336: Shutting Down The Machine During The Harvest Season

    Operation Shutting down the machine during the harvest season 6.23 Shutting down the machine during the harvest season Park the machine so that nobody is impeded or endangered. Also make sure of a suf- ficient safety distance to freely suspended power lines. –...

  • Page 337: Maintenance And Service

    Maintenance and Service Maintenance and Service 337 / 546...
  • Page 338 Maintenance and Service 338 / 546...
  • Page 339 Maintenance and Service WARNING During all maintenance work, there is the hazard of heavy or severe injury and the hazard of damage to the machine. – Do not climb over the rear platform wall. – Shut down the machine before carrying any maintenance and repair work (See Page 336).

  • Page 340: Diesel Engine

    Maintenance and Service Diesel engine Diesel engine To open the cover of the engine compartment, first press the unlocking button in the handle. Reach into the opening on the engine compartment cover and press the latch (1) upwards. Now the cover can be opened. ATTENTION Hazard of engine damages! –...

  • Page 341: Dry Air Filter

    Maintenance and Service Diesel engine 7.1.1 Dry air filter The diesel engine is equipped with one dry air filter, consisting of one main filter ele- ment and one safety cartridge. ATTENTION Hazard of engine damages! – During filter change make sure of utmost cleanliness. –...
  • Page 342 Maintenance and Service Diesel engine The filter cartridges may only be removed when the diesel engine is shut down. The safest, quickest and cleanest way of maintaining the filter cartridges is exchanging them for new cartridges. The main element may, as described below, be cleaned. Since minor damage is often very difficult or impossible to detect, always use new filter cartridges to protect the diesel engine.
  • Page 343 Maintenance and Service Diesel engine – This pipe is not commercially available, but may be self-made without any problem. It should be long enough to reach the bottom of the cartridge. – Set the pressure reducer to max. 5 bar and blow out the filter cartridge with dry compressed air until no more dust comes out.
  • Page 344 Carefully inspect each crease individually using a suitable flashlight. Damaged filter cartridges may never be reused in any case. Use only original filter cartridges (ROPA main element item no. 301022500; ROPA safety cartridge item no. 301022600). In no case install filter elements with metal outside sheathing.
  • Page 345 Maintenance and Service Diesel engine Safety cartridge exchange: The safety cartridge must be exchanged at every fifth maintenance for the main ele- ment or at the latest after two years for a new safety cartridge. The safety cartridge may not be cleaned or reused after uninstalling. –...

  • Page 346: Changing Engine Oil In The Diesel Engine

    Maintenance and Service Diesel engine 7.1.2 Changing engine oil in the diesel engine The engine oil filter must be exchanged for each oil change. Only change oil in a diesel engine warm from operation. Before performing the oil change, park the machine on even ground and secure it against rolling away.
  • Page 347 Maintenance and Service Diesel engine Engine oil filling cap Engine oil drain valve Engine oil filter cover Proceed as follows for an oil and filter exchange: – Before oil change, clean some wide area around the cap of the engine oil filter (4) and the oil filler cap (3).
  • Page 348 Maintenance and Service Diesel engine Filling in engine oil Fill in fresh engine oil through the oil filling cap (3). d-diesel engine, with particle filter Prescribed oil types: Engine oil, low SAPS MB standard 228.52 Filling volume: approx. 27 litres a-diesel engine and c-diesel engine, without particle filter Prescribed oil types: Engine oil, semi-synthetic...

  • Page 349: Refuelling With Diesel Fuel

    Maintenance and Service Diesel engine 7.1.3 Refuelling with diesel fuel WARNING Improper refuelling and improper actions around fuel may cause explosions, fire, serious burns and other injuries. – Make sure that the filler cap (1) is correctly closed to prevent ingress of dirt into the diesel fuel tank.
  • Page 350 Maintenance and Service Diesel engine Diesel fuel Engine Required quality of diesel fuel • If possible: a-diesel engine DIN EN 590 (max. 0.001% sulphur by weight) (10 ppm) • if not available: (max. 0.005% sulphur by weight) (50 ppm) c-diesel engine ASTM D975 1-D and 2-D (max.

  • Page 351: Fuel System

    Maintenance and Service Diesel engine 7.1.4 Fuel system ADVICE Hazard of damage to the environment from leaking fuel. When working on the filter, first set up the catching pan and properly dispose of fuel caught. WARNING Burning hazard when handling diesel fuel. Smoking, fire and open flames are prohibited when handling diesel fuel, because fuels are easily combustible and fuel fumes cause an explosion hazard.
  • Page 352 Maintenance and Service Diesel engine Drain valve intermediate tank Inspection glasses as fill level indicator for the intermediate tank Intermediate tank The filter cartridges must be exchanged according to the maintenance plan. The fuel filters at the diesel engine must be immediately exchanged, independent of operating hours, if the icon appears on the R-Touch.

  • Page 353: Replacing/Draining Water Of The Fuel Prefilter Insert At The Electric Pump

    – Remove the lid (11) (wrench size 46) from the filter housing. – Uninstall the old filter insert and exchange it for a new one with the ROPA item no. 303016700. – Dispose of the old filter insert in compliance with the local disposal regulations.

  • Page 354: Exchange Fuel Fine Filter And Prefilter On The Diesel Engine

    7.1.4.2 Exchange fuel fine filter and prefilter on the diesel engine The fuel fine filter insert (14) (ROPA item no. 303025500) and the fuel prefilter insert (15) (ROPA item no. 303025400) on the diesel engine must be replaced when the engine oil is changed for the first time and at least once a year since then.
  • Page 355 Maintenance and Service Diesel engine – Unscrew the cap of the fuel fine filter (14). – Slightly pull the screw-on lid with the filter insert from the filter housing and let the fuel drain. – Take off the screw-on lid including filter insert. –...

  • Page 356: Bleeding The Fuel System

    Maintenance and Service Diesel engine 7.1.4.3 Bleeding the fuel system – Park the vehicle and shut down the diesel engine. – Shut off the fuel connection to the intermediate tank. Move the service lever (7) on the fuel supply control unit (6) by 45° backward to the SERVICE position. Thus, fuel from the intermediate tank can no longer flow into the diesel engine.

  • Page 357: Microorganisms In The Fuel System

    Remedial measures If infestation by microorganisms is detected in storage or vehicle tanks, we recom- mend the following disinfectant against it: Product: GrotaMar 82 ROPA item no. 435006000 (1.0 l) Manufacturer: Schülke & Mayr D-22840 Norderstedt Phone: 040/52100-0...

  • Page 358: Cleaning Of The Cooling System

    Maintenance and Service Diesel engine ADVICE Corrosion protection/antifreeze agents are hazardous for the environment. When handling these materials, always make sure that the corrosion protec- tion/antifreeze agents do not enter the environment, but are disposed of in a manner compatible to the environment. Always make sure of sufficient antifreeze and only use corrosion protection/antifreeze agents expressly permitted according to Mercedes-Benz factory standards 325.5 or 326.5.
  • Page 359 Maintenance and Service Diesel engine When R-Touch displays the warning icon "Cooling water temperature" , the cooling system must be cleaned immediately. The coolant in the coolant circuit of the diesel engine may not exceed the permissible temperature of 105 °C. DANGER Hazard of extremely severe injuries due to starting infeed conveyor –...
  • Page 360 Maintenance and Service Diesel engine CAUTION Danger to eyes and skin injury due to foreign bodies blowing out. The powerful air flow of the fan may cause injuries to eyes and skin by particles of dirt blown by the air stream. –...
  • Page 361 Maintenance and Service Diesel engine – Check the cooling system for dirt. – Remove the coarse dirt by hand, by cleaning the cooling system with the water hose or using compressed air. Use a pressure cleaner only with a flat spray at reduced pressure and from at least 30 cm away.

  • Page 362: Coolant Check

    Maintenance and Service Diesel engine 7.1.5.2 Coolant check If the liquid level in the expansion tank (10) seems too low, the following warning icon is displayed on R-Touch: . The cooling-water expansion tank is located in front of the intake grid. It is easily accessible from the boarding platform. Compensation tank for coolant (10) Expansion tank for coolant...

  • Page 363: Change Of Coolant

    Maintenance and Service Diesel engine 7.1.5.3 Change of coolant Use only corrosion protection/antifreeze agents approved by Mercedes-Benz. The coolant must be exchanged every three years. In any case, comply with the regionally applicable regulations on environmentally compatible disposal of coolant. (12) Drain valve for coolant at cooling water pipe Before renewing the coolant, check the cooling and heating system for leaks and con-...

  • Page 364: Remarks Of Ropa On The Coolant (General Information)

    Maintenance and Service Diesel engine 7.1.5.4 Remarks of ROPA on the coolant (general information) Normally, coolant consists of water and corrosion protection/antifreeze agent. The cor- rosion protection/antifreeze agents (ethylene glycol with corrosion inhibitors) have the following tasks in the cooling system: Sufficient corrosion and cavitation protection for all components of the cooling sys- tem.

  • Page 365: Scr Exhaust After-Treatment With Adblue ® (Applicable For C-Diesel Engine And D-Diesel Engine)

    Maintenance and Service Diesel engine 7.1.7 SCR exhaust after-treatment with AdBlue ® (applicable for c-diesel engine and d-diesel engine) The machine is equipped with an SCR exhaust after-treatment system. In any case, comply with the notes on handling AdBlue (See Page 529).

  • Page 366: Exchange Of Adblue® Filter Insert

    Maintenance and Service Diesel engine ATTENTION Danger of machine damage! Even filling in small amounts of other liquids leads to great damage to the SCR exhaust after-treatment system. No accommodation will be granted for such kind of damage. – Utmost cleanliness must be ensured when filling up AdBlue®. –...

  • Page 367: Exchange Diesel Particulate Filter (Applicable For D-Diesel Engine)

    AdBlue® pump module. – The filter insert should be disposed of according to the local regulations. – Use a new AdBlue® filter insert (ROPA item no. 303019500). ATTENTION Use only the supplied lubricant spray from Mercedes-Benz for greasing. Make sure this lubricant is used extremely sparingly, otherwise it may cause damage to the AdBlue®...

  • Page 368: Pump Distributor Gears (Pdg)

    Maintenance and Service Pump distributor gears (PDG) Pump distributor gears (PDG) The pump distributor gear unit is directly flanged to the diesel engine and transfers engine power to the individual hydraulic pumps. The oil level of the pump distributor gears must indispensably be checked daily. Check the oil level, before you start the diesel engine! Once the diesel engine is started, the oil level can no longer be checked.
  • Page 369 Maintenance and Service Pump distributor gears (PDG) Lubrication pump distributor gears failed! – Start diesel engine and watch the R-Touch. The warning icon should disappear from the R-Touch within 10 seconds. – If the warning icon does not disappear in 10 sec., shut down the diesel engine immediately and bleed the transmission.

  • Page 370: Oil Change/Filter Exchange On Pump Distributor Gears

    – Screw out the 4 bolts (SW13) on the filter flange (6) and pull out the filter insert. – Exchange the filter element for a new one (ROPA item no. 181060100). For instal- lation always use a new paper gasket (ROPA item no. 181051700) and a new O- ring (ROPA item no.

  • Page 371: Oil Cooler Pump Distributor Gears

    – Screw the pressure filter bowl (7) with the SW24 spanner out of the gear steering unit (8) and exchange the filter insert for a new one (ROPA item no. 270044200). – Also exchange the O-ring at the pressure filter bowl (7) for a new O-ring.

  • Page 372: Hydraulic System

    Immediately exchange damaged or aged hoses. Only use hoses for replacements conforming to the specifications of the original hose! For cost reasons, we recommend ordering replacement hoses directly from ROPA, because original ROPA hydraulic hoses are generally significantly more economical than competitive products.

  • Page 373: Hydraulic Oil Tank

    Maintenance and Service Hydraulic system WARNING Burning hazard! All coolers heat up during operation. Hazard of severe burnings! Wear protective gloves! Let the machine cool down sufficiently before starting any work on the cooling sys- tems! – Check the cooling system for dirt. –...

  • Page 374: Hydraulic Fluid Change

    'hissing' sound. This sound is normal. The filling lid (ROPA item no. 270070000) (2) is both a filler and vent filter. It main- tains the required air balance as the fluid level varies (e.g. due to the fluid tempera- ture).
  • Page 375 This increases the purity of the oil in the hydraulic system. A suitable filling hose with the correct connector for the filling valve (4) is available with ROPA item no. 632040900. Never use the same hose which you use to drain waste oil. Prescribed oil types:...
  • Page 376 Maintenance and Service Hydraulic system Filling valve for hydraulic oil on machines with one traction motor (up to 32 km/h), on the traction drive motor Filling valve for hydraulic oil on machines with two traction motors (up to 40 km/h), on the rear traction drive motor 376 / 546...

  • Page 377: Cleaning Intake Sieves

    – Place the gasket and the metal lid onto them. – Before installing them, coat the bolts for fastening the metal lid with sealing com- pound (ROPA item no. 017002600) and tighten the bolts. – Before filling with fresh hydraulic fluid, replace both filter elements of the hydraulic system.

  • Page 378: Exchange Suction Return Filter Element

    Hydraulic system 7.3.2.3 Exchange suction return filter element The suction return filter is situated at the hydraulic oil tank (1). (Filter element ROPA item no. 270088600). ADVICE The filter element is a disposable product. It may not be cleaned. The filter element can be destroyed by cleaning.
  • Page 379 Maintenance and Service Hydraulic system Take off the lid (3) of the suction return filter. Then lift the metal bracket of the sepa- rating plate (4). Lid of suction return filter Separating plate with metal bracket With a slight twisting motion, take out the separating plate (4) holding it on the metal bracket.
  • Page 380 Maintenance and Service Hydraulic system Using the special tool (ROPA item no. 018139800) (5), loosen the old filter element by aligning it cen- trally and turning it anti-clockwise in the direction of the "OPEN" marking (6). Finally, pull the old filter element out upwards.
  • Page 381 Maintenance and Service Hydraulic system Using the special tool (ROPA item no. 018139800) (5), turn the new filter element clockwise in the direc- tion of the "CLOSE" marking (6) until a slight resistance is felt. After you feel some resistance, turn a lit- tle further clockwise until a greater resis- tance is felt.
  • Page 382 Put the cover (3) back on and retighten the fixing screws (2). The tightening torque for the fixing screws is 40 Nm. Fixing screw M12 (SW19) Designation ROPA item no. unit count Suction return filter element 270088600 O-ring 412060800 Specialized tool...

  • Page 383: Replacing Pressure Filter Element

    Maintenance and Service Hydraulic system 7.3.3 Replacing pressure filter element Pressure filter operating hydraulics ADVICE The filter element is a disposable product. It may not be cleaned. The filter element can be destroyed by cleaning. The hydraulic system might sustain heavy damage. Pressure filter operating hydraulics The pressure filter for the operating hydraulics is located on the gearbox on the right next to the drive of the front cardan shaft.

  • Page 384: Mechanical Drive For Steering Axles

    – Moisten the thread and sealing surfaces of the filter bowl and head as well as the O-ring of the bowl and element with clean hydraulic fluid. – Install a new element (ROPA item no. 270043000). – Carefully install the filter element on the element holding pin.

  • Page 385: Cardan Shafts From Gearbox To The Steering Axles

    Maintenance and Service Mechanical drive for steering axles 7.4.1 Cardan shafts from gearbox to the steering axles All drive shafts on the machine must be lubricated after every 200 operating hours. DANGER Hazard to life due to rotating machine parts! When the engine is running, body parts or pieces of clothing may be caught by rotat- ing drive shafts and pulled into the machine.

  • Page 386: Manual Transmission (4-Gear)

    Maintenance and Service Manual transmission (4-gear) Manual transmission (4-gear) The manual transmission is used to switch the "Turtle" and "Rabbit" operating modes and also gear I and II and all-wheel drive. The oil level must be checked every 50 operating hours. It is checked at the inspection glasses (2).
  • Page 387 Maintenance and Service Manual transmission (4-gear) The machine has 2 models available for the traction drive: Model 1; 1 traction drive engine Maximum speed 32 km/h Model 2: 2 traction drive engines Maximum speed 40 km/h 1 traction drive engine 2 traction drive engines Oil filling screw Inspection glass...
  • Page 388 Maintenance and Service Manual transmission (4-gear) Follow the procedure below to change the oil: – Change oil only with gears warm after operation. – Park the machine on level ground. – Put an oil-resistant collecting vessel of sufficient size underneath. –...

  • Page 389: Axles

    Maintenance and Service Axles Axles 7.6.1 Planetary gears (applies to both axles) The first oil change is required after 50 operating hours, further oil changes must be performed annually. Park the machine so that the respective wheel is sitting as shown in the illustration. Oil filling opening and oil level control screw Oil drain screw Bleeding screw...
  • Page 390 – Open the bleeding screw (3). Close the ROPA planetary gear oil filler at the oil filler opening (1). – Fill up the planetary gears using the ROPA planetary gear oil filler so far until the oil level reaches the lower edge of the oil filling opening.

  • Page 391: Differential Gears On Front And Rear Axle

    Maintenance and Service Axles 7.6.2 Differential gears on front and rear axle The first oil change is required after 50 operating hours, further oil changes must be performed annually. Front axle Oil drain screw Oil filling opening and oil level control screw Rear axle DANGER Injury hazard!
  • Page 392 Maintenance and Service Axles Follow the procedure below to change the oil: – Change the oil only with gears warm after operation. – Park the machine on level ground. – Put an oil-resistant collecting vessel of sufficient size underneath. – Unscrew the oil drain bolt of the differential gear. It is located at the bottom, at the lowest part of the axle body.

  • Page 393: Pneumatic System

    The compressor is maintenance-free. The air dryer and the five compressed air reservoirs are installed under the right side cover. The dryer cartridge (1 ROPA item no. 261003500) of the air dryer must be replaced once a year.

  • Page 394: Pickup

    Maintenance and Service Pickup Pickup 7.8.1 Central mark Check the bottom of the central mark for dirt every day when the side pickup sections are folded in (visual inspection). Heavy dirt should be removed immediately. The central mark cover (2) can be partially removed after unscrewing three screws (1). The mark (3), i.e.

  • Page 395: Pickup Gears

    Maintenance and Service Pickup 7.8.2 Pickup gears The machine is fitted with three gearboxes on the outside right and left of the pickup. Park the machine on level ground. The oil level of the six gearboxes must be checked daily with the pickup folded out and lowered. The oil level can be read in the inspec- tion glass (2).

  • Page 396: Pickup Central Lubrication

    Maintenance and Service Pickup 7.8.3 Pickup central lubrication Check all lines (1) of the central lubrication system that lead to the rollers every day (visual inspection of lines). 396 / 546...

  • Page 397: Removing And Installing Rollers

    Maintenance and Service Pickup 7.8.4 Removing and installing rollers (46) (53) Central mark Pinch roller 1 (47) Frost breaker (54) Conveyor roller 3 (48) Fold plates (55) Conveyor roller 2 (49) (56) Clearing shield Conveyor roller 1 (50) Pinch roller 4 (57) Cleaning roller (51)

  • Page 398: Removing And Installing Pickup And Cleaning Roller

    – Pull the pickup roller (5) from the gearbox. The pickup roller is only held by 12 plastic carriers (6). These 12 plastic carriers (ROPA item no. 100284900) (6) must be replaced every time the pickup roller is removed. The O-ring (ROPA item no. 412021700) (7) must also be replaced.
  • Page 399 ADVICE The hexagonal screws (M 20x360) (ROPA item no. 415005000) (9) must be replaced once a year. The M20 nuts (ROPA item no. 414037000 (4) and 414032000 (13) ) must also be replaced once a year. The cleaner roller does not a lock on the gearbox. The cleaner roller is attached to the gearbox.

  • Page 400: Replacing The Fingers Of The Pickup Rollers

    7.8.4.2 Replacing the fingers of the pickup rollers The pickup rollers are fitted with wear plates on the pickup fingers (ROPA item no. 208003800). Hard-metal plates are soldered to the wear plates. The wear plates are fastened with screws, which allows every single wear plate to be replaced individually quickly and without difficulty once it has become worn.

  • Page 401: Removing And Installing Feed Rollers And Pinch Rollers

    O-ring (O-Ring ROPA item no. 412063500) (14) into the end of the roller. – The four M12 x 80 Allen screws (ROPA item no. 415005100) (15), with which the polyamide couplings (12) are screwed into the rollers, must be coated with special thread-locking compound and must be used only once.
  • Page 402 – When reassembling always replace both O-rings (ROPA item no. 412030900) (22) on the fastener (23) with the new O-rings. The same applies to the O-ring (ROPA item no. 412032000) (24) in the grease duct in the bottom half-shell.
  • Page 403 Before screwing in the M24 fine-thread screws (16) the thread must be thinly coated with copper paste (ROPA item no. 017015900 tube containing 100 gr.). – When installing the rollers, make sure that the turns of the rollers are not aligned.

  • Page 404: Replacing Wear Flange

    As soon as this distance is too high, more grass, weeds, beet leaves etc. will remain stuck at the transition to the following conveyor. ROPA recommends replacing the wear flanges as soon as the distance is 2-3 mm. The replacement process is simple. The replacement does not affect the settings of the taper roller bearings because they are behind the wear flange.

  • Page 405: Installing And Adjusting The Bearings Of The Pinch Rollers Or Conveyor Rollers

    For this reason the two radial shaft seals (ROPA item no. 246002800) (31), the two inner rings (ROPA item no. 240015200) (32) and the two felt rings (ROPA item no. 246002600 (33) and ROPA item no. 246014500) (34) on the gearbox side bearing of the pickup roller must be replaced after approx.

  • Page 406: Build-Up Welding

    ROPA service centres. We recommend ROPA SCREWTEC special filling wire with a diameter of 1.6 mm for build-up welding. It is applied at the factory and can be ordered in 15 kg rolls at ROPA item no. 017013600.

  • Page 407: Pile Pickup With Residual Beet Pickup

    Maintenance and Service Pile pickup with residual beet pickup Pile pickup with residual beet pickup Clean major soiling from the hydraulically actuated parts and coat the telescopic tube with grease as required. Pile pickup Residual beet pickup The play between the outer and inner pipe of the telescopic tube can be adjusted as follows: –...

  • Page 408: Infeed Conveyor

    Maintenance and Service Infeed conveyor 7.10 Infeed conveyor The deflector rollers (1) of the infeed conveyor (front at the conveyor infeed) are fit- ted with wipers (2). They scrape off adhering soil. The screws in the wipers must be checked once a week and replaced as soon as the screw heads are heavily worn. If the screw heads are worn too much, the wiper may come loose and fold into the infeed conveyor.

  • Page 409: Tensioning Infeed Conveyor

    Maintenance and Service Infeed conveyor 7.10.1 Tensioning infeed conveyor WARNING Hazard of severe injuries. The retension of the infeed conveyor belt may only be performed with the drive switched off and the diesel engine shut down. – Before maintenance and repair work, the machine must be shut down and the diesel engine switched off.

  • Page 410: Replacing Infeed Conveyor Drive Wheels

    Maintenance and Service Infeed conveyor Synchronism If the infeed conveyor is severely one-sided on the side flange of the drive wheels, it can be synchronised by moving the oil engine bracket (4) or drive shaft (3). 7.10.2 Replacing infeed conveyor drive wheels ATTENTION Replace drive wheels when required, do not wait until the unloading conveyor belt jumps off!

  • Page 411: Recleaning

    Maintenance and Service Recleaning 7.11 Recleaning Depending on equipment, your machine has a sieve conveyor cleaner, an 8-set pinch roller cleaner or a stone remover. 7.11.1 Sieve conveyor cleaner The cleaning belt must not be too tight. The belt return should sag slightly. WARNING Hazard of extremely severe injuries due to the cleaning belt starting! The cleaning belt must not be tensioned unless the machine drive and the diesel...
  • Page 412 Maintenance and Service Recleaning Fixing screw Lock nut Tensioning bolt – Loosen the fixing screws (1) for the deflector rollers on the right and left. – To tension the belt loosen the lock nuts (2) on the two tensioning bolts (3) on the right and left.

  • Page 413: 8-Set Pinch Roller Cleaning

    Maintenance and Service Recleaning 7.11.2 8-set pinch roller cleaning If the rollers in the pinch roller cleaner are seriously out of balance, never continue working with the rollers for an extended period, because the suspension or recleaner frame may be damaged. The pinch rollers are removed and installed in the same way as the pinch rollers in the pickup.
  • Page 414 Maintenance and Service Recleaning The 8.set pinch roller cleaner is driven by a hydraulic motor. The oil level of the gearbox must be checked once a week. The oil level is checked at the inspection glass. If the oil level is above the middle of the glass, it is not necessary to add oil.

  • Page 415: Truck Conveyor

    Maintenance and Service Truck conveyor 7.12 Truck conveyor 7.12.1 Tensioning the truck conveyor The truck conveyor must be tensioned as required. The belt tension is correctly set if the bottom return side of the belt sags approx. 2 - 3 cm between the rollers with the truck conveyor fully lowered and the conveyor articulation fully extended (truck con- veyor almost straight).
  • Page 416 Maintenance and Service Truck conveyor If the truck conveyor is crooked, it can be made even by adjusting the clamping nuts (4) on the diagonal strut (5) in the conveyor infeed. Synchronism If the truck conveyor belt is severely one-sided on the side flange of the drive wheels, it can be synchronised by moving the counter bearing (7) of the drive shaft (8).

  • Page 417: Scales (Option)

    Maintenance and Service Truck conveyor The side walls of the truck conveyor are wear-resistant plastic plates (6). They are designed to be turned four times quickly and easily. 7.12.2 Scales (option) ATTENTION In general, during any maintenance and repair work, avoid blows and bumps to the weighing frame as they also affect the weighing cells.
  • Page 418 Maintenance and Service Truck conveyor Weighing cell 418 / 546...
  • Page 419 Maintenance and Service Truck conveyor Setting the weighing frame height Place a level or similar straight edge over five rollers or use a tight cord for alignment. Align the rollers to the same height. The weighing frame (6) is fixed to the connecting levers (2). However, the height of the connecting lever to the weighing cell (7) can be adjusted with the mounting bolt (4).

  • Page 420: Remove Dirt Accumulated On The Scales

    Maintenance and Service Truck conveyor Check the gap between the weighing frame and the truck conveyor articulation frame The distance (8) must be the same on both sides. If necessary, change the dimension by adjusting the diagonal brace in the weighing frame (9). 7.12.2.2 Remove dirt accumulated on the scales Remove the dirt that builds up between the weighing frame and the side walls on...

  • Page 421: Exchange Weighing Cell

    Maintenance and Service Truck conveyor 7.12.2.3 Exchange weighing cell ADVICE Never mount the fixing screws (10) of the weighing cells (7) using an impact driver. It may destroy the weighing cells. This is applicable for all major forces applied by screwdrivers.

  • Page 422: Rotary Drives For Swivel Arm And Truck Conveyor

    Maintenance and Service Truck conveyor 7.12.3 Rotary drives for swivel arm and truck conveyor The swivel arm and truck conveyor are driven hydraulically by two chain drives. The chains are automatically tensioned by hydraulic cylinders. DANGER Hazard of extremely severe injuries by chain drives! –...
  • Page 423 Maintenance and Service Truck conveyor Check the chain wear one a year as described below and replace the chain immedi- ately it reaches the wear limit (305 mm). max. 305 mm DANGER Hazard of fatal injuries by uncontrolled rotary movements of swivel arm and truck conveyor if the chain jumps off the sprocket.

  • Page 424: Chassis Energy Ducting Chain To Recleaner Swivel Arm

    Maintenance and Service Truck conveyor 7.12.3.1 Chassis energy ducting chain to recleaner swivel arm The pivot points of the energy ducting chain are maintenance-free. If they start to squeak, coat the pivot points lightly with oil. Energy ducting chain 424 / 546...

  • Page 425: Counterweight Arm

    Maintenance and Service Counterweight arm 7.13 Counterweight arm Adjusting counterweight arm lock stop screws As soon as the clamp is no longer rigid, the stop screws (1) must be adjusted. To do this, loosen the lock nuts (2) on the stop screws and adjust the screws until there is no more play at the clamping position (3) on the swivel arm.

  • Page 426: Braking System

    Maintenance and Service Braking system 7.14 Braking system The front axle has a drum brake actuated by compressed air. The rear axle has a hydraulically-actuated drum brake. Two independent brake circuits guarantee maxi- mum safety, even if one brake circuit fails. After washing the machine run the brakes dry.

  • Page 427: Air Conditioning And Ventilation System

    Maintenance and Service Air conditioning and ventilation system 7.15 Air conditioning and ventilation system If the air conditioning system doesn't cool sufficiently, it may be down to the following causes: – Air conditioning system condenser is clogged. Remedy: clean the air conditioning system condenser. –...

  • Page 428: Driver's Cabin Recirculating Filter

    The printed arrow (4) on the filter must point to the rear of the machine. – Close the cover and fasten it with the two wing nuts (1). This filter element (ROPA item no. 352042200) should be renewed once a year in any case. 428 / 546...

  • Page 429: Fresh Air Intake Filter In Driver's Cabin

    – Reinsert the cleaned filter element in the holding frame and fasten it using the knurled-head screw. – Install the cover hood. This filter element (ROPA item no. 352033200) should be renewed once a year in any case. With removed cover hood 7.15.4...

  • Page 430: Folding Down Air Conditioner

    Maintenance and Service Air conditioning and ventilation system 7.15.5 Folding down air conditioner DANGER Hazard of extremely severe injuries. ALWAYS insert the cylinder support for the driver's cabin when working under the dri- ver's cabin. The air conditioner is installed under the cabin floor between the air intake duct and the air exhaust duct.
  • Page 431 Maintenance and Service Air conditioning and ventilation system – Turn back the lock nut (13) on the screw at the rear pivot point of the air conditioner by approx. 10 mm. Turn back the nut on the screw at the front pivot point (not shown in the picture) of the air conditioner by approx.
  • Page 432 Maintenance and Service Air conditioning and ventilation system – Pull the air conditioner at least 10 mm backwards. The air conditioner can be folded down now. – Unscrew the cover of the air conditioner to access its internal components. Put the air conditioner back in the reverse order. ADVICE Make sure that all seals of the air conditioner are not damaged and fitted correctly.

  • Page 433: Coolant Circuit

    If replacing or refilling the coolant, this should be mixed with the following oil: Fuchs Reniso PAG46 (ROPA item no. 435004600). The air conditioning system may never be operated with other oil additives. Totally, there is 250 ml of oil in the coolant circuit.
  • Page 434 – Have the coolant and collector dryer (17) (ROPA item no. 352041500) replaced by an authorised specialist workshop. A fluorescing agent is added to the coolant by ROPA. This enables quick and cost- effective detection of possible leaks in the air conditioning system.

  • Page 435: Battery Maintenance

    Where necessary, refill with distilled water until the acid level is 10 mm above the upper level of the plates. Use the ROPA battery cell filler with automatic level stop (ROPA item no. 015036400) to complete this task quickly and safely.
  • Page 436 Maintenance and Service Shutdown for a longer period of time WARNING Risk of burns. Battery acid may cause dangerous burns on the skin and within the respiratory sys- tem. – When handling acid batteries, always wear approved personal protective equip- ment (safety goggles, acid-proof gloves, apron) (See Page 37).

  • Page 437: Mercedes-Benz Regulations For Diesel Engine Shutdown

    Maintenance and Service Shutdown for a longer period of time 7.17.1 Mercedes-Benz regulations for Diesel engine shutdown During temporary shutdown of the machines, operated with the diesel fuel B07 (diesel fuel with up to 7% of biodiesel content), the fuel amount control valve may become stuck.

  • Page 438: Dismantling And Disposal

    Maintenance and Service Dismantling and disposal 7.18 Dismantling and disposal If the machine is not disposed of properly at the end of its service life, it can lead to accidents and damages to environment. Hazard may come from: Hydraulic oil/ engine oil Lubricants/process materials Cooling fluid/coolant Fuel...

  • Page 439: Malfunction And Remedies

    Malfunction and Remedies Malfunction and Remedies 439 / 546...
  • Page 440 Malfunction and Remedies 440 / 546...

  • Page 441: Safety Circuits

    – In case of the slightest doubt, call in specialist personnel trained accordingly or enquire with service personnel from ROPA. – Do not perform any repairs on the machine if you do not have the required special- ist knowledge and experience.

  • Page 442: Fuses

    Malfunction and Remedies Fuses Fuses 8.2.1 Fuses The electrical fuses are located in the seat console and in the switch cabinet of the central electrics, installed on the outside right of the cabin platform. The machine is partially equipped with commercially available flat plug fuses (fuses) and self-resetting electronic fuses.

  • Page 443: Fuses In The Battery Case

    Malfunction and Remedies Fuses 8.2.2 Fuses in the battery case The main fuses are situated in the battery case (Mega fuse). F001 (1) to the central electrics, Pin X1. F002 (2) to the central electrics, PinX2. Whether these fuses are intact can be determined using the measuring device (conti- nuity tester).

  • Page 444: Fuses In The Central Electrics

    Malfunction and Remedies Fuses 8.2.3 Fuses in the central electrics ADVICE The machines with chassis numbers 8J1506, 8L1597, 8L1598 and 8L1599 were manufactured before the start of series production. There are minor differences in the electrical system of these machines. In the mentioned above machines the circuit dia- grams may differ slightly from those of the series machines.
  • Page 445 Malfunction and Remedies Fuses Ampere Occupation F028 reserve F029 Hazard warning system F030 24V power supply voltage transformer 1 F031 Pin 30 for radio (DIN chute roof console) F032 Window wiper right front F033 Window wiper right rear Pin 30 from X2 F034 Rear window wiper...

  • Page 446: Fuses In The Driver's Cabin Seat Console

    Malfunction and Remedies Fuses 8.2.4 Fuses in the driver's cabin seat console Ampere Occupation F090 A007 colour terminal Pin 30 F091 reserve from F001 F092 A070 colour terminal F096 Air seat compressor/seat heating Pin 15 F097 Steering column switch after K001 F098 G018 USB double socket Pin 15 directly...

  • Page 447: Electronic Led Fuses In Wago Pins

    Malfunction and Remedies Fuses 8.2.5 Electronic LED fuses in Wago pins In addition to the fuses, there are self-resetting electronic fuses in the seat console. If the light emitting diode (LED) (1) of a fuse glows in red, the fuse is overloaded and the power supply to the connected component is interrupted.

  • Page 448: Fuses On Pcbs In The Central Electrics

    Malfunction and Remedies Fuses 8.2.6 Fuses on PCBs in the central electrics Three identical PCBs are installed in the central electrics. They can be distinguished by their designation A, B and C. PCB A PCB B PCB C These PCBs are energised by the main fuses in the battery case. Each PCB secures one of three main machine computers.
  • Page 449 Malfunction and Remedies Fuses Light emitting diode L12 Light emitting diode L13 Light emitting diode L14 449 / 546...
  • Page 450 Malfunction and Remedies Fuses LED L12 glows green when the ignition is switched on, which means that there is a working power supply to the 24-volt reset fuses in this PCB. LED L13 glows green when the ignition is switched on, which means that there is a working power supply to the 9-volt reset fuses of circuit 1 in this PCB.

  • Page 451: Pcb A

    Malfunction and Remedies Fuses 8.2.6.1 PCB A Ampere Occupation F006.A A001 power supply outputs F007.A A001 power supply outputs Pin 30 F008.A A001 power supply outputs F009.A K002.A relay fan oil cooler PDG F010.A A001 power supply CPU Self-resetting electronic fuses with LED Fr101.A 125mA B107 pressure sensor air chamber reservoir pressure 24 V Fr102.A 125mA B217 pressure LS operating hydraulics (safety)
  • Page 452 Malfunction and Remedies Fuses Ampere Occupation Fr134.A 125mA B305 driving speed 2 Fr135.A 125mA B096 water tank level sensor Fr136.A 125mA not used Fr137.A 125mA not used Fr138.A 125mA not used Fr139.A 125mA not used 452 / 546...

  • Page 453: Pcb B

    Malfunction and Remedies Fuses 8.2.6.2 PCB B Ampere Occupation F006.B A002 power supply outputs F007.B A002 power supply outputs Pin 30 F008.B A002 power supply outputs F009.B Relay not used F010.B A002 power supply CPU Self-resetting electronic fuses with LED Fr101.B 125mA B001 sensor wheel angle front axle 24 V Fr102.B 125mA B002 sensor wheel angle rear axle...
  • Page 454 Malfunction and Remedies Fuses Ampere Occupation Fr134.B 125mA B075 conveyor rollers left Fr135.B 125mA not used Fr136.B 125mA B064 speed 4 pinch rollers right Fr137.B 125mA B065 speed 4 pinch rollers left Fr138.B 125mA S091 engine housing door Fr139.B 125mA S092 folding grid platform 454 / 546...

  • Page 455: Pcb C

    Malfunction and Remedies Fuses 8.2.6.3 PCB C Ampere Occupation F006.C A003 power supply outputs F007.C A003 power supply outputs Pin 30 F008.C A003 power supply outputs F009.C K002.C relay electric pump fuel prefilter F010.C A003 power supply CPU Self-resetting electronic fuses with LED Fr101.C 125mA B026 PS traction drive forward 24 V Fr102.C 125mA B084 PS traction drive backward...

  • Page 456: List Of Relays

    Malfunction and Remedies List of relays Ampere Occupation Fr134.C 125mA B097 speed pinch roller 1 stone remover Fr135.C 125mA B098 speed pinch roller 2 stone remover Fr136.C 125mA B212 pressure sensor parking brake Fr137.C 125mA S128 swivel arm lock Fr138.C 125mA S125 ladder safety lock Fr139.C 125mA B047 rpm driving speed List of relays Designation...

  • Page 457: Color Codes For Electric Wiring

    Malfunction and Remedies Troubleshooting via the R-Touch Color codes for electric wiring Colour codes for electric wiring brown ground brown/white wired ground pin 30 (continuous current) pink pin 15 (ignition current) yellow 9 volt violet 12 volt blue digital signal lines (ON/OFF) green analogue signal lines (changing sensor values) grey...
  • Page 458 Malfunction and Remedies Troubleshooting via the R-Touch Part Position in the Comments Item No. machine in the central A001 Computer A001 electrics, behind PCB Computer A, TTC580 320088700 in the central A002 Computer A002 electrics, behind PCB computer B, TTC580 320088700 in the central A003...
  • Page 459 320089600 Window wiper left A205 left side window, front 320089600 front computer for communication A403 CPC4 Mercedes in the central electrics ROPA with Mercedes at the engine unit, A435 MCM2 Mercedes computer for injection, Mercedes inner side 459 / 546...

  • Page 460: Overview Of Diagnostic Menus

    Malfunction and Remedies Troubleshooting via the R-Touch Expert mode is activated here (See Page 114) 8.5.1 Overview of diagnostic menus Please find below illustrations of the available diagnostics menus on the R-Touch. They facilitate malfunctions diagnostics for service personnel, if you call up the corre- sponding menu items after being requested by service personnel and notify the values or icons displayed to service personnel.
  • Page 461 Malfunction and Remedies Troubleshooting via the R-Touch Main menu Service Main settings Version Special functions Diagnosis System Teach in Operating data Tuning Scales Hardware exchange Service Software update Data service Error memory Diagnosis Diagnosis Digital inputs Diesel engine Analogue inputs Air conditioning system Inputs speed Park heating...

  • Page 462: Digital Inputs

    Malfunction and Remedies Troubleshooting via the R-Touch 8.5.1.1 Digital inputs Diagnosis Digital inputs Digital inputs S001 transmission gear 1 0.000 Analogue inputs S002 transmission gear 2 4,902 S021 rotating beacons 4,477 Inputs speed S022 mirror heating 4,453 Outputs PWM+SW B607 coolant level Functions S030 air filter 4,882...

  • Page 463: Analogue Inputs

    Malfunction and Remedies Troubleshooting via the R-Touch 8.5.1.2 Analogue inputs Diagnosis Analogue inputs Digital inputs A030 swivel arm position 35.00 428.3 ° A031 truck conveyor position 62.08 587.5 Analogue inputs ° B001 front axle 5.13 9,302 ° Inputs speed B002 rear axle -0.29 10,793 °...

  • Page 464: Inputs Speed

    Malfunction and Remedies Troubleshooting via the R-Touch 8.5.1.3 Inputs speed Diagnosis Inputs speed Digital inputs B047 speed traction motor B305 speed traction motor (safety) Analogue inputs B051 PDG greasing Inputs speed B062 rpm pickup rollers right Outputs PWM+SW B063 rpm pickup rollers left Functions B064 speed pinch rollers right Diesel engine...

  • Page 465: Outputs Pwm + Sw

    Malfunction and Remedies Troubleshooting via the R-Touch 8.5.1.4 Outputs PWM + SW Diagnosis Outputs PWM+SW Digital inputs Outputs - lighting Analogue inputs Outputs Inputs speed Outputs - other Outputs PWM+SW Functions Diesel engine Air conditioning system Park heating Control elements Outputs - lighting Outputs PWM+SW Outputs - lighting...
  • Page 466 Malfunction and Remedies Troubleshooting via the R-Touch Outputs Outputs PWM+SW Outputs Outputs - lighting Y001 MV machine on Undef Y001 MV machine on ground Undef Outputs Y005 PV recleaning backward Outputs - other Y006 Y007 SV fold plate Undef Y008 PV recleaning forward Y009 PV pump infeed conveyor speed Y010 PV drive-pump forward Y011 PV drive-pump backward...
  • Page 467 Malfunction and Remedies Troubleshooting via the R-Touch Outputs Outputs Y048 Y049 SV axle lock Undef Y072 MV rotary seat brake Undef Y048 Y049 axle lock ground Undef Y073 SV lower truck conveyor Undef Y052 SV supporting foot R Undef Y073 SV lower truck conveyor ground Undef Y053 SV supporting foot L Undef...
  • Page 468 Malfunction and Remedies Troubleshooting via the R-Touch Outputs - other Outputs PWM+SW Outputs - other Outputs - lighting H013 back up alarm Undef M005 central lubricating pump Undef Outputs M006 window washer pump 1 Undef Outputs - other M010 window washer pump 2 Undef M014 oil cooler fan PDG Undef...

  • Page 469: Functions

    Malfunction and Remedies Troubleshooting via the R-Touch 8.5.1.5 Functions Functions Lighting Traction drive Radiator Steering Hydraulics & greasing Machine drive Pickup Recleaner Truck conveyor Functions Axle lock Axle positions Pile pickup Swivel arm Counterweight Mirror Control devices Coding pins Outputs first startup 469 / 546...

  • Page 470: Diesel Engine

    Malfunction and Remedies Troubleshooting via the R-Touch 8.5.1.6 Diesel engine Diagnosis Diesel engine Digital inputs Engine torque Analogue inputs Engine power Inputs speed B638 PS fuel pressure fine filter Outputs PWM+SW B602 fuel temp. °C Diesel engine set speed Functions B600 diesel engine speed Diesel engine B604 engine oil pressure...

  • Page 471: Air Conditioning System

    Malfunction and Remedies Troubleshooting via the R-Touch 8.5.1.7 Air conditioning system Climate control S053 A/C high/low pressure 0.000 B053 outside temp °C B041 inside temp. °C B037 blow out temp °C B606 coolant temperature °C Set temp. °C B052 potentiometer valve heating Current fan speed Set fan speed Y071 A/C clutch...

  • Page 472: Park Heating

    Malfunction and Remedies Troubleshooting via the R-Touch 8.5.1.8 Park heating Park heating Heating performance Flame detector Flame detector resistance mΩ Combustion air fan Glow plug Fuel pump Coolant pump Interior fan Diagnosis control Diagnosis actuation time Start diagnosis control 472 / 546...

  • Page 473: Control Elements

    Malfunction and Remedies Troubleshooting via the R-Touch 8.5.1.9 Control elements Diagnosis Control elements Analogue inputs A010 joystick right A020 joystick left Inputs speed A040 R-Select-Direct Outputs PWM+SW Functions A041 keypad 1 A042 keypad 2 Diesel engine Air conditioning system Park heating Control elements Camera 473 / 546...
  • Page 474 Malfunction and Remedies Troubleshooting via the R-Touch A010 joystick right Control elements A010 joystick right A010 joystick right Signals A020 joystick left Error A040 R-Select-Direct Non zero A041 keypad 1 A042 keypad 2 A010 joystick right Signals Signals A010 joystick rear Error A010 deflection joystick front/rear Non zero...
  • Page 475 Malfunction and Remedies Troubleshooting via the R-Touch A010 joystick right Non zero Signals A010 joystick front/rear actuated with ignition on Error A010 joystick left/right actuated with ignition on A010 mini joystick front/rear actuated with ignition on Non zero A010 mini joystick left/right actuated with ignition on A010 analogue rocker actuated with ignition on A010 keys actuated with ignition on 475 / 546...
  • Page 476 Malfunction and Remedies Troubleshooting via the R-Touch A020 joystick left Control elements A020 joystick left A010 joystick right Signals A020 joystick left Error A040 R-Select-Direct Non zero A041 keypad 1 A042 keypad 2 A020 joystick right Signals Signals A020 joystick front A020 joystick rear Error A020 deflection joystick front/rear...
  • Page 477 Malfunction and Remedies Troubleshooting via the R-Touch A020 joystick right Non zero Signals A020 joystick front/rear actuated with ignition on Error A020 joystick left/right actuated with ignition on A020 mini joystick front/rear actuated with ignition on Non zero A020 mini joystick left/right actuated with ignition on A020 keys actuated with ignition on A040 R-Select-Direct Control elements...
  • Page 478 Malfunction and Remedies Troubleshooting via the R-Touch A042 keypad 2 Control elements A042 keypad 2 A010 joystick right A042 key 1 engine stop A042 key 1 LED A020 joystick left A042 key 2 engine start A040 R-Select-Direct A042 key 2 LED A041 keypad 1 A042 key 3 transmission group A042 keypad 2...

  • Page 479: Camera

    Malfunction and Remedies Troubleshooting via the R-Touch 8.5.1.10 Camera Camera Truck conveyor camera Recleaner camera Central mark camera Left camera Right camera 479 / 546...

  • Page 480: Pfreundt Scale

    Malfunction and Remedies Troubleshooting via the R-Touch 8.5.1.11 Pfreundt scale Pfreundt scale A091 weighing cell L weight 0.00 A092 weighing cell R weight 0.00 Error status not total Mode Zero-point 0.02 Summation limit 179.5 Calibration value so far Output Weight since drive on Conveyor doesn't move Conveyor runs empty Pfreundt scale...

  • Page 481: Telematics

    Malfunction and Remedies Troubleshooting via the R-Touch 8.5.1.12 Telematics Diagnosis Telematics WiFi Diesel engine Air conditioning system Mobile Park heating Inputs/outputs Control elements Camera Pfreundt scale Telematics CAN bus Ethernet WiFi Telematics WiFi WiFi WiFi general name (SSID) WB60-203687171004 WiFi general signal strength Mobile WiFi general IP address 192.168.201.128...
  • Page 482 Malfunction and Remedies Troubleshooting via the R-Touch Mobile Telematics Mobile WiFi Mobile reception Mobile connection Mobile Available mobile connection 2G, 3G, 4G Inputs/outputs GPS position 262,FFFE,2D6B001,580E 482 / 546...

  • Page 483: Can Bus

    Malfunction and Remedies Troubleshooting via the R-Touch 8.5.1.13 CAN bus Diagnosis CAN bus Diagnosis of CAN bus connections Diesel engine F-CAN Air conditioning system D-CAN Park heating F-CAN status Control elements D-CAN status Camera T-CAN status Pfreundt scale P-CAN status Telematics B-CAN status CAN bus...

  • Page 484: Ethernet

    Malfunction and Remedies Troubleshooting via the R-Touch 8.5.1.14 Ethernet Diagnosis Ethernet Connection status A070 Connected Diesel engine Air conditioning system Park heating Control elements Camera Pfreundt scale Telematics CAN bus Ethernet 484 / 546...

  • Page 485: Terminal Exchange

    If required, the main and the auxiliary terminals can be exchanged, e.g. if one termi- nal does not function properly. Please do not change anything here without consulting your Ropa service partner. Since the data base in the main terminal is not identical to the data base in the auxiliary terminal.

  • Page 486: Jump Starting And Charging The Battery

    Malfunction and Remedies Jump starting and charging the battery Jump starting and charging the battery ATTENTION – Should it become necessary to jump start the machine, then no charging or start- ing aid device connected to the mains or a generator may be used, because use of these devices can lead to irreparable damage of the machine electronics.
  • Page 487 Malfunction and Remedies Jump starting and charging the battery Charging the batteries – Generally, for charging the batteries, the plus terminal (2) must be disconnected and the main battery switch (See Page 334) must be switched off. – Do not remove the plus pole of the battery bridge (1). –...
  • Page 488 – Start the combustion engine of the assisting vehicle and rev it up to a medium speed. – Start the diesel engine of the ROPA machine and make sure, that the start attempt does not last longer than 15 seconds.

  • Page 489: Welding On The Machine

    Welding on structural parts or parts with a safety function may only be performed after enquiry with ROPA, to the extent as it is admissible under the respective applicable regulations. All welding works may only be performed as per applicable standards and the recognized rules of engineer- ing.

  • Page 490: Towing

    – Engage the parking brake and additionally secure the machine to prevent it from rolling with the two wedges (1). – Notify the nearest authorised customer service of ROPA. You need suitable sal- vaging aids and tools. – Switch to "Turtle" or gear 2 operating mode.
  • Page 491 Malfunction and Remedies Towing Model with 1 traction drive engine – Set the reduction gear to neutral. – Pull the shift rod (2) (on the front of the reduction gear) out 26 to 30 mm. Neither of the two gears may be engaged. –...

  • Page 492: Connecting Salvaging Aids

    Connecting of salvaging aids at the front side of the machine is extremely problematic and must be carried out by qualified versed personnel only in an extreme emergency. In case of need, contact ROPA customer service. ADVICE Always make sure of sufficient rigidity of the salvaging aids. Consider that the load caused on the salvaging aids during salvaging of a vehicle may amount to several times the normal vehicle weight.
  • Page 493 – Once the machine is lifted, it has to be additionally secured with massive load bear- ing timbers or similar materials against crashes. For the wheel change we recom- mend fixing the ROPA safety stand (ROPA item no. 018041000)to the wheel hub. 493 / 546...

  • Page 494: Releasing The Parking Brake Manually

    Malfunction and Remedies Releasing the parking brake manually 8.11 Releasing the parking brake manually Working on the spring-loaded actuators is dangerous and may only be performed by people trained for this work and familiar with working on pre-stressed spring piles. Sufficiently high pressure must be available in the pneumatic system to release the parking brake.

  • Page 495: Hydraulic Valves

    Malfunction and Remedies Central lubricating system – bleeding and removal of blocks WARNING Hazard of severe injuries from parts flung away with great force. The parts inside the spring-loaded actuator are pre-stressed with great spring force and may be flung away in case of improper opening, causing severe injuries to peo- ple.

  • Page 496: Emergency Operation Ventilator Drives Emergency Operation

    Page 323) – Shouldn't the method prescribed here lead you to any success, please contact your ROPA service station. Some distributors are provided with a lubricating nipple. This lubricating nipple is used to simplify troubleshooting. All lubrication points of the sub-distributor can be supplied with grease via this lubricat- ing nipple, because there is a check valve in the outlet of the main distributor.

  • Page 497: Adjusting Brake

    Malfunction and Remedies Adjusting brake ATTENTION Hazard of damages to fan drive! Perform the test by disconnecting the plug "Y099" only with the fan running forward. The reversing of the uncontrolled fan at maximum revolutions speed would cause damage to the fan runner or the fan drive. 8.15 Adjusting brake DANGER...

  • Page 498: Park Heating

    Malfunction and Remedies Park heating 8.16 Park heating Should any fault occur, check whether the fuses and plug connectors are intact and tightly seated. If it does not help, please contact a Webasto service centre (www.webasto.com) and specify the model of your park heater (Thermo Pro 90D 24V). Heating switches off automatically = fault shutdown Cause Remedy...

  • Page 499: Lists/Tables/Plans/Diagrams/Maintenance Verification

    Lists/Tables/Plans/Diagrams/Maintenance Verification Lists/Tables/Plans/ Diagrams/Maintenance Verification 499 / 546...
  • Page 500 Lists/Tables/Plans/Diagrams/Maintenance Verification 500 / 546...

  • Page 501: Lubricating And Operating Supplies

    Lists/Tables/Plans/Diagrams/Maintenance Verification Lubricating and operating supplies Lubricating and operating supplies Filling vol- Component Lubricant type Intervals Diesel engine OM 936 Engine oil, low SAPS every 1,000 MB standard 228.52 oper. hrs. (See (only for d-diesel engine, with particle filter) Page 346) approx.
  • Page 502 Lists/Tables/Plans/Diagrams/Maintenance Verification Lubricating and operating supplies Filling vol- Component Lubricant type Intervals Miscellaneous 4-gear manual transmis- sion Model with 1 traction Fully synthetic gear oil approx. drive engine API GL5, SAE 75W-90 12 litres Model with 2 traction approx. drive engines 12.4 litres annually Gear oil ATF...

  • Page 503: Maintenance Table

    Lists/Tables/Plans/Diagrams/Maintenance Verification Maintenance table Maintenance table Maintenance interval Maintenance work after the after the before har- first 50 every 50 first 500 every 500 when annu- vest start daily oper. hrs. oper. hrs. oper. hrs. oper. hrs. needed ally Diesel engine OM936 (applicable for d-diesel engine) see also Mercedes-Benz operating manual Change engine oil and oil filter every 1,000 operating hours, at least every 2 years...
  • Page 504 Lists/Tables/Plans/Diagrams/Maintenance Verification Maintenance table Maintenance interval before har- Maintenance work after the after the vest first 50 every 50 first 500 every 500 when annu- start daily oper. hrs. oper. hrs. oper. hrs. oper. hrs. needed ally 4-gear manual transmission Check oil level Change oil Axles...
  • Page 505 Lists/Tables/Plans/Diagrams/Maintenance Verification Maintenance table Maintenance interval before har- Maintenance work after the after the vest first 50 every 50 first 500 every 500 when annu- start daily oper. hrs. oper. hrs. oper. hrs. oper. hrs. needed ally Driver's cabin Clean recirculating air filter Replace recirculating filter Clean fresh air intake filter Renew fresh air intake filter...
  • Page 506 Lists/Tables/Plans/Diagrams/Maintenance Verification Maintenance table Maintenance interval before har- Maintenance work after the after the vest first 50 every 50 first 500 every 500 when annu- start daily oper. hrs. oper. hrs. oper. hrs. oper. hrs. needed ally Recleaner version with 8-set pinch rollers Check oil level in the gears for 8-part pinch rollers Change oil in the gears for 8-part pinch...

  • Page 507: Lubricating Plan (Lubrication With Grease Gun)

    All lubricating points must also be lubricated after each washing of the machine. After washing of the machine, the central lubrication system must also be lubricated using at least 2 intermediate lubrication cycles. To do this, run all drives at low speed. Grease ROPA item no. 435006200 (See Page 515) as per DIN 51825, NLGI-class 2, type: KP2K-20, at low outdoor temperatures KP2K-30.

  • Page 508: Lubricant Specification Table

    Standard/specification Container size 435001210 = 20 l ISO-VG 46 as per Hydraulic oil HVLP 46 DIN 51524 part 3 ROPA hydroFluid HVLP 46 435001230 = 208 l (containing zinc) See Page 509 435001240 = 1000 l 435015910 = 20 l Mercedes Standard MB 228.52...

  • Page 509: Product Data Sheetropa Hydrofluid Hvlp 46

    ROPA hydroFluid HVLP 46 provides a very high degree of uniformity. The optimal properties for protec- tion from wear, corrosion and oxidation guarantee the best possible functional safety of the hydraulic system. Due to the good filterability of ROPA hydroFluid HVLP 46, it can be used in many hydraulic systems. No filter plugging.

  • Page 510: Product Data Sheet Ropa Engineoil E9 5W-30

    The all-season viscosity range SAE 5W-30 preferred by many engine manufacturers is achieved due to the use of selected base oils of the modern synthesis technology. ROPA engineOil E9 5W-30 allows very long oil change intervals, providing simultaneously an improved engine protection. The modern "Low SAPS"...

  • Page 511: Product Data Sheet Ropa Engineoil E7+ 10W-40

    ROPA engineOil E7+ 10W-40 is a high-performance diesel engine oil that can be used year-round and is recommended for use in Euro III - Euro VI diesel engines. Due to its low ash content this product can be used in a wide variety of exhaust aftertreatment systems.

  • Page 512: Product Data Sheetropa Gearoil Gl5 90

    Information on use ROPA gearOil GL5 90 gear oil is specially designed for heavy-duty hypoid drive axles and for bevel and spur gearboxes, steering boxes and manual transmissions in vehicles and machines with API GL-5 require- ments.

  • Page 513: Product Data Sheet Ropa Gearoil Gl5 75W-90 Synth

    The API GL-4 and API GL-5 requirements are easily met. ROPA gearOil GL5 75W-90 synth can also be used without problems in gear units that require gear oils com- plying with MAN 341 Type E3 and MAN 342 Type M3.

  • Page 514: Product Data Sheet Ropa Gearfluid Atf

    ROPA gearFluid ATF conforms to the General Motors ATF Dexron II D specification and is specified by major motor vehicle manufacturers who use automatic transmission that require Dexron II D. ROPA gearFluid ATF can also be used in automatic transmissions that conform to the Mercedes-Benz MB 236.1 specification.

  • Page 515: Product Data Sheet Ropa Multi Temperature Grease 2

    It especially meets the requirements of BEKA-MAX central lubrication systems and is suitable for the lubrica- tion of roller and sliding bearings, even under high loads. ROPA multi temperature grease 2 can also be used without problems for lubrication points that require grease as per MAN standards (works standard MAN 283 Li-P2) and Mercedes- Benz (delivery specification: DBL 6804.00 - Fuel regulation sheet 267).

  • Page 516: Diesel Engine Coolant

    Lists/Tables/Plans/Diagrams/Maintenance Verification Diesel engine coolant Diesel engine coolant Corrosion protection/antifreeze coolant ROPA item no. Sort Designation Standard/specification Container size Corrosion protec- Diesel engine coolant MB-approval 325.5 435007210 = 20 l tion/antifreeze coolant The coolant is a concentrate in accordance with MB approval 325.5 (Mercedes-Benz Specifications for Operating Fluids).
  • Page 517 Lists/Tables/Plans/Diagrams/Maintenance Verification Diesel engine coolant Water quality Use clean water as soft as possible to prepare the coolant. Mostly, drinking water fulfils the desired requirements. Information on the quality of drinking water can be obtained from the local waterworks or the responsible water supply company on request.

  • Page 518: Filter Cartridges, V-Belts

    Lists/Tables/Plans/Diagrams/Maintenance Verification Filter cartridges, V-belts Filter cartridges, V-belts Maus 6 / BunkerMaus 6 with Mercedes Benz OM936 Diesel engine Mercedes Benz OM936 ROPA item no. Oil filter insert, 1 pc. 303025600 Fuel fine filter insert engine, 1 pc. 303025500 Fuel prefilter insert engine, 1 pc.

  • Page 519: Lubricating Plans

    Lubricating plans Lubricating plans 9.7.1 Central lubrication circle 1 pickup Sub-distributor pickup frame ROPA item no.: 360016300 GE bearing flaps right rear GE bearing flaps left rear GE bearing flaps right front GE bearing flaps left front Fold tie rod cylinder right...

  • Page 520: Central Lubrication Circuit 2 Chassis With Sieve Conv. Cleaner

    Rotate swivel arm chain lubrication Rotate truck conveyor GE bearing top Rotate truck conveyor GE bearing bottom Sub-distributor swivel arm ROPA item no.: 360017600 Recleaner pivot bearing bottom Axle bracket bearing rear Axle bracket bearing front Steering cylinder left inside...

  • Page 521: Central Lubrication Circuit 2 Chassis With 8-Set Pinch Roller Cleaner

    Rotate swivel arm chain lubrication Rotate truck conveyor GE bearing top Rotate truck conveyor GE bearing bottom Sub-distributor swivel arm ROPA item no.: 360017600 Recleaner pivot bearing bottom Axle bracket bearing rear Axle bracket bearing front Steer. cylind. left inside Steer.

  • Page 522: Central Lubrication Circuit 3 8-Set Pinch Roller Cleaner

    To main distributor circuit 1 Pickup Pinch roller 5 Pinch roller 4 Pinch roller 6 Pinch roller 3 Pinch roller 7 Pinch roller 2 Pinch roller 8 Pinch roller 1 Sub-distributor pinch roller cleaner ROPA item no.: 360016700 522 / 546...

  • Page 523: Central Lubrication Circuit 2 Chassis With Stone Remover

    Drive shaft sieve conv. st. remover Sub-distributor frame top ROPA item no.: 360017500 Return line To the sub-distributor Stone remover (see next page) To main distributor Lubricating circuit 1 support Main distributor lubricating circuit 2 chassis Reconstructed from ROPA item no. 360017400 523 / 546...
  • Page 524 Counter bearing knob roller 10 Counter bearing cleaning roller 1 Counter bearing knob roller 9 Counter bearing knob roller 2 Counter bearing cleaning roller 2 Counter bearing knob roller 1 Sub-distributor stone remover ROPA item no.: 360022000 524 / 546...

  • Page 525: Maintenance Verification

    Lists/Tables/Plans/Diagrams/Maintenance Verification Maintenance verification Maintenance verification 9.8.1 Maintenance verification oil change + filter exchange Date: Date: Date: Date: Date: Oper.hrs. Oper.hrs. Oper.hrs. Oper.hrs. Oper.hrs. Diesel engine Engine oil Engine oil filter Valves adjusted Engine fuel prefilter Engine fuel fine filter Fuel prefilter at the electric pump Air filter main cartridge Air filter safety cartridge...
  • Page 526 Lists/Tables/Plans/Diagrams/Maintenance Verification Maintenance verification Date: Date: Date: Date: Date: Oper.hrs. Oper.hrs. Oper.hrs. Oper.hrs. Oper.hrs. Gears Pickup rollers right Pickup rollers left Conveyor rollers right Conveyor rollers left 4 pinch rollers right 4 pinch rollers left 8 pinch rollers (optional) Pump distributor gears Gear oil PDG oil filter (2 filter elements)

  • Page 527: Maintenance Confirmation

    Required: 50 oper. hrs. Maintenance performed on: Date Maintenance performed by: Signature/stamp The maintenance may only be performed by ROPA-Service staff. The 1st diesel engine customer service Maintenance performed after: hours Required: 500 oper. hrs. for a-diesel engine Required: 500 oper. hrs. for c-diesel engine Required: 1,000 oper.

  • Page 528: Torque Table For Bolts And Nuts (Nm)

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

  • Page 529: Adblue® Information Sheet

    Lists/Tables/Plans/Diagrams/Maintenance Verification AdBlue® information sheet 9.10 AdBlue® information sheet Identification AdBlue is the trade name for the diesel engine NOx reduction agent AUS 32 defined by the standard DIN 70070 / ISO 22241. AdBlue® tasks AdBlue reduces toxic nitrogen oxides to water vapour and elementary nitrogen in the exhaust of diesel-powered vehicles with SCR catalytic converter technology.
  • Page 530 Lists/Tables/Plans/Diagrams/Maintenance Verification AdBlue® information sheet Regulations The product does not need to be labelled in accordance with EC directives or respec- tive national laws. National regulations: Statutory Ordinance on Hazardous Inci- not subject to dents: Marking Pumps for dispensing AdBlue are labelled with standard designation DIN 70070 / ISO 22241, or with the AdBlue trade name.
  • Page 531 Lists/Tables/Plans/Diagrams/Maintenance Verification AdBlue® information sheet Disposal of smaller quantities: Due to its easy decomposition, small quantities of spilled AdBlue can be rinsed away without a problem using copious water. Disposal of larger quantities: Disposal of larger quantities of AdBlue must be carried out in compliance with applica- ble recovery and disposal regulations.

  • Page 532: Confirmation About Instructions Given To The Driver

    Lists/Tables/Plans/Diagrams/Maintenance Verification Confirmation about instructions given to the driver 9.11 Confirmation about instructions given to the driver Mrs/Mr date of birth Last name and first name Was instructed about safe handling of the machine about maintenance of the machine from Last name and first name Has demonstrated the required knowledge...

  • Page 533: Safety Instructions

    Lists/Tables/Plans/Diagrams/Maintenance Verification Safety instructions 9.12 Safety instructions The shaded areas shown in the following diagram mark the hazard zones of the Maus. As soon as anyone approaches the hazard zones, the driver must shut down the Maus immediately and stop the loading process without delay. If the driver does not comply with this instruction, the driver is responsible for all consequences resulting from his actions.
  • Page 534 Lists/Tables/Plans/Diagrams/Maintenance Verification Safety instructions Statement (last name and first name) have received this safety information. I have been informed that the driver is under strict instructions to stop the loading process as soon as any person or persons approach the danger zone. I am aware of the locations of the danger zones on the Maus.

  • Page 535: Layout Chart For A Beet Pile

    Lists/Tables/Plans/Diagrams/Maintenance Verification Layout chart for a beet pile 9.13 Layout chart for a beet pile 535 / 546...

  • Page 536: Notes For Beet Harvesting

    This soil content has a certain damp- ing effect during loading, which largely protects the beets from damage, but can be removed without any problem by ROPA cleaner-loaders. A large amount of soil will generally still stick to the beets, particularly with sticky soil, in spite of thorough cleaning.

  • Page 537: Ropa Handover Confirmation

    Lists/Tables/Plans/Diagrams/Maintenance Verification ROPA Handover confirmation 9.15 ROPA Handover confirmation ROPA Fahrzeug- und Maschinenbau GmbH, Sittelsdorf 24, D-84097 Herrngiersdorf Support point address: Chassis number: Type: Sub device no.: Type: Sub device no.: Type: Sub device no.: Type: Sub device no.: Type:...
  • Page 538 (written, by phone or e-mail) about products and services can be received by the ROPA support point and/or ROPA, or passed on to ROPA, as well as stored, processed and used. The non-granting of the consent does not effect on the delivery of the purchased item or services. You can, if desired, partially strike out this consent.

  • Page 539: Ropa First Use Record

    Lists/Tables/Plans/Diagrams/Maintenance Verification ROPA First Use Record 9.16 ROPA First Use Record ROPA Fahrzeug- und Maschinenbau GmbH, Sittelsdorf 24, D-84097 Herrngiersdorf ROPA partner: Customer / site of operation: Chassis No.: Operating hours: Machine type: Lifting/loading hours: Software version: Harvested area: First use date:...
  • Page 540 Index 540 / 546...

  • Page 541: Index

    Index Index 541 / 546...
  • Page 542 Index 542 / 546...
  • Page 543 Index Central mark camera.......... 328 Changing engine oil in the diesel engine.... 346 Charging the battery........... 486 4-part pinch rollers..........268 Cleaning intake sieves........377 Cleaning of the cooling system......358 Cleaning scraper..........105 Clearing shields..........254 8-set pinch roller cleaning........264 Climate control..........
  • Page 544 Index Engine brake............203 Headrest............... 76 Engine compartment..........98 health protection........... 31 Engine compartment lighting........ 98 High beam control..........95 Engine oil............501 HOME key............116 Engine oil level........... 340 Hydraulic fluid change........374 Engine speed adjustment........172 Hydraulic oil cooler..........372 Engine speed adjustment in Rabbit operating Hydraulic oil tank..........
  • Page 545 ROPA engineOil E9 5W-30........ 510 Park heating fault code output......498 ROPA gearFluid ATF.......... 514 Parking brake..........204, 494 ROPA gearOil GL5 75W-90 synth...... 513 Particle filter............179 ROPA gearOil GL5 90........512 Personal protective equipment......37 ROPA hydroFluid HVLP 46........ 509 Pfreundt scale.............
  • Page 546 Index Truck conveyor fast motion........ 260 Tyre pressure............46 Tyres..............45 Safety..............20 Safety cartridge..........345 Safety circuits............. 441 Safety circuits for loading operation....249 Safety equipment..........39 Underfloor heating..........135 Safety instructions..........533 Safety instructions for park heating system..39 Safety regulations for operation of the machine.

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