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Zocon Z050 Operating Manual
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Zocon Z050 Operating Manual

Zocon tipping trailer
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OPERATING MANUAL
Zocon tipping trailer
Zonderland Constructie B.V.
De Koevorde 6, 8502 TZ Joure,
T +31 (0)513 714334
F +31 (0)513 714332
Type: Z030 / Z045 / Z050 / Z080 / Z100
Date: 01-02-2020
Version: v1
DOCUMENT NUMBER: U-Z012002EN
Translated Operating Manual in English, original in Dutch
the Netherlands
info@zocon.eu
E
www.zocon.eu
I

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  • Page 1 Translated Operating Manual in English, original in Dutch Zonderland Constructie B.V. De Koevorde 6, 8502 TZ Joure, the Netherlands info@zocon.eu T +31 (0)513 714334 www.zocon.eu F +31 (0)513 714332 Type: Z030 / Z045 / Z050 / Z080 / Z100 Date: 01-02-2020 Version: v1 DOCUMENT NUMBER: U-Z012002EN...

  • Page 2: Foreword

    FOREWORD Congratulations on the purchase of a Zonderland product. You are now the owner of a quality product that will give you many years of excellent service. Please ensure that you read this Operating Manual carefully to familiarise yourself with the correct control and maintenance procedures so that you can avoid personal injury or material damage.

  • Page 3: Reference Guide

    Indicates a dangerous situation that may lead to minor and/or moderate damage to the product or environment if the safety instructions are not followed. OBSERVATION Provides essential information. Abbreviations used Abbreviation Meaning Zocon Zonderland Constructie B.V. Conformité Européenne (Marking - Complies with European legislation) Personal Protective Equipment...

  • Page 4: Table Of Contents

    CONTENTS FOREWORD ..............................2 .............................. 2 URPOSE OF THE PERATING ANUAL ...................................... 2 ARGET GROUP ................................2 SER OF THE TIPPING TRAILER ....................................3 EFERENCE GUIDE .................................... 3 BBREVIATIONS USED CONTENTS ..............................4 INTRODUCTION ............................7 ..................................7 NTENDED ................................8 NTENDED USE ....................................
  • Page 5 OPERATION ............................36 ..................................36 EAR TAILGATE 5.1.1 Rear tailgate locking hooks ..........................36 5.1.2 Hydraulic rear gate locking ..........................38 5.1.3 Folding doors ................................38 5.1.4 Operation of locking hooks on use of folding of doors ................39 ..................................39 IDE BOARDS 5.2.1 Manual locking of the side boards ........................
  • Page 6 MAINTENANCE ............................. 78 ..............................78 ENERAL MAINTENANCE ..................................79 NSPECTIONS 8.2.1 Handbrake ................................. 79 8.2.2 Functioning of the braking device / break-out safety................79 8.2.3 Adjustment of rear tailgate locking hooks ....................79 8.2.4 Wheel replacement..............................80 ..............................82 ERIODIC MAINTENANCE 8.3.1 Lubrication points ..............................

  • Page 7: Introduction

    INTRODUCTION This Operating Manual is intended for those who will be operating the machine and performing daily maintenance. Users must read the entire Operating Manual before commencing operation of any kind. This Operating Manual covers the correct manner of operation, safety precautions, maintenance and transport.

  • Page 8: Non-Intended Use

    1.2 Non-Intended use ATTENTION Use of the tipping trailer for purposes for which it is not intended may endanger the safety of persons and cause material damage to the tipping trailer. OBSERVATION: Non-intended use of the tipping trailer will invalidate the product warranty. The tipping trailer must not: ...

  • Page 9: Ce Declaration

    Zocon Tipping Trailer Standard function: Tipping trailer for agricultural transport Type: Z030 / Z045 / Z050 / Z080 / Z100 Serial number: From XL9000000J0611050 complies with Directive 2006/42/EC of the European Parliament and Council for machines, dated 17 May 2006, as well as with the amendment of Directive 95/16/EC (Official EU volume L 157/24 of 9 June 2006).

  • Page 10: Operating Environment

    1.6 Operating environment The tipping trailer has been designed for use on agricultural land and on public roads (please note: use of the standard version on public roads may not be permitted). Table Appropriate tyres can be selected depending on the type of surface soil. Please refer to 1.7 Warranty The manufacturer guarantees that the tipping trailer meets the usually applicable requirements and standards, and that it is free from any defect.

  • Page 11: Explanation Of Serial Plate

    Table specifying permissible maximum weights for a 2 trailed trailer, if any - Build year and type of tipping trailer - Zocon brand name and CE logo - Address of manufacturer Figure 1-1: Model of serial plate Vehicle category 1.8.1...

  • Page 12: Type Of Tipping Trailer

    100, represents the approximate loading capacity of the tipping trailer. For example: Type: Z050, loading capacity = 5,000 kg (50 x 100). The range includes 5 types:  Z030 Z030 = 3,000 kg loading capacity*  Z045 = 4,500 kg loading capacity*  Z050 = 5,000 kg loading capacity* ...

  • Page 13: Description

    DESCRIPTION 2.1 Construction The tipping trailer consists of a chassis on wheels [1] onto which a tiltable body [3] is fitted. According to the type of tipping trailer and the options selected, the body can be tipped sideways as well as to the rear. Figure 2-1: Coupling of tipping trailer to tractor 1 - Chassis on wheeled carriage 2 - Hydraulic tilt ram...
  • Page 14 Non-spring-loaded single-axle trailer (with hydraulic brakes) Figure 2-2: The tipping trailer is fitted with a height-adjustable drawbar. This drawbar is adjusted to the height of the linkage point on the tractor. The drawbar is bolted onto the chassis and can be fitted in several positions.

  • Page 15: Technical Specifications

    To facilitate the parking of the tipping trailer as a free-standing vehicle, it is fitted with either a spindle-type parking jack or a hydraulic parking jack. Figure 2-5: Spindle-type parking jack Figure 2-6: Hydraulic parking jack 2.2 Technical specifications Table 2-1 Please refer to for an overview of specifications per type of tipping trailer.
  • Page 16 Table 2-1: Overview of models Z030, Z045 and Z050 with available options Type: Z030 Z045 Z050 Max. loading capacity (kg) 3,000 4,500 5,000 Unladen weight (kg) 1,200 1,400 Max. total weight (kg) 4,550 5,800 6,000 Body dimensions (cm) 240 x 150 x 40...
  • Page 17 Table 2-2: Overview of models Z080 – Z100 with available options Type: Z080 tandem axle Z080 single axle* Z100 tandem axle Z100 single axle* Max. loading capacity (kg) 8,000 8,000 10,000 10,000 Unladen weight (kg) 2,300 2,100 2,700 2,500 Max. total weight (kg) 10,500 12,000 Body dimensions (cm)

  • Page 18: Available Options

    2.3 Available options Three-sided tipping 2.3.1 In addition to the standard rearwards tipping feature, all models with the exception of type Z045 can be equipped for three-sided tipping. In that case, the front of the chassis is fitted with additional supports [5] on which the body can tilt sideways. Locks with rods [3] are mounted to the side boards to facilitate easy opening and locking.

  • Page 19: Extensions

    Extensions 2.3.2 Additional extensions [2] can be fitted to the top of the standard side and rear walls. These extensions have a height of 400 mm and a maximum of 2 extra extensions can be mounted. The purpose of the extensions is to enable the loading of high-volume, lighter loads up to the trailer's maximum charging capacity.

  • Page 20: Folding Doors

    Folding doors 2.3.4 A pivoting rear tailgate is fitted as standard but folding doors can be installed as an option. Please Figure 2-9 refer to . These doors pivot fully outwards, allowing the load to pass through freely. The doors [3] are fitted with an upper and lower lock [1]. The doors are fitted within a frame so that the rear tailgate can also be opened as a whole by means of the upper hinges.

  • Page 21: Drawbar Couplings

    Drawbar couplings 2.3.6 A choice can be made from the following couplings: Figure 2-10: Various couplings 1 - Fixed or pivotable drawbar eye 2 - Non-pivotable drawbar eye in combination with an overrun brake 3 - Ball head coupling with ø 80 mm ball OBSERVATION: In common with all vehicles on public roads in Europe, the tipping trailer must comply with the European Directive 94/20/EG2 in terms of the coupling.
  • Page 22 1 - Rear light with direction indicator and brake light 2 - Licence plate lighting 3 - Licence plate 4 - Rear bumper Figure 2-11: Lighting and licence plate  Retroreflectors: a trailer with a length in excess of 4.6 m (drawbar included) must carry visibility aids on the side in the form of retroreflectors and side lighting.

  • Page 23: Braking Systems

    European Directive 71/320/EEG1.  Non-braked The Z030, Z045 and Z050 models of the tipping trailer are not equipped with a braked axle as standard. These versions are therefore not allowed on public roads in some countries.
  • Page 24 Use of an overrun brake is permitted up to a maximum total weight of 8,000 kg. If the total weight exceeds 8,000 kg, a hydraulic or pneumatic braking system must be used. Tipping trailers equipped with an overrun brake are permitted on public roads up to a maximum speed of 40 km/h.
  • Page 25 Figure 2-15: Hydraulic braking system (single axle, non-spring-loaded) 1 - Brake rod 2 - Double draw-spring (to release brakes) 3 - Brake cylinder (hydraulic) 4 - Braking power regulator (also fixation of overrun brake / handbrake) 5 - Brake lever (2 x) The brakes are controlled by a braking power regulator [4] which is engaged by a pneumatic or hydraulic brake cylinder.
  • Page 26 Figure 2-16: Hydraulic braking system (spring-loaded tandem axle) 1 - Spring-leaf package 2 - ALR valve 3 - Brake spring 4 - Brake cylinder 5 - Brake lever 6 - Brake rod 7 - Brake drum...
  • Page 27  Hydraulically braked, with hand-operated braking power control (2-circuit) Under EU legislation, the maximum speed of tipping trailers equipped with hand-operated braking power controls is limited to 30 km/h. A hand-operated braking power control may only be fitted to tipping trailers without spring-loaded axles. The 4-position valve must be manually adjusted after loading and unloading according to the load.
  • Page 28  Hydraulically braked, with automatic braking power control (2-circuit) The tipping trailer can be fitted with a hydraulically braked axle controlled by a hydraulic 2-circuit braking system. This system meets EU requirements. In addition to the normal braking function, the system includes a supply circuit that controls the system.
  • Page 29 Figure 2-21: Pneumatic brake connections 1 - Supply line (red, towards air vessel) 2 - Brake line (yellow) 3 - Dummy coupling hose support The pneumatic braking system includes a control function which becomes operative when the pressure in the supply line [3] is cut off. In the event of the tipping trailer breaking out, the couplings are detached and the pressure in the circuits is cut off.
  • Page 30 Figure 2-22: Pneumatic hand-operated braking power control 1 - Handbrake 2 - Pneumatic valve block 3 - Braking power control 4 - Air vessel 5 - Quick discharge valve 6 - Brake booster...
  • Page 31  Pneumatic braking with automatic braking power control (2-circuit) (For spring-loaded tandem axle only) The tipping trailer can be fitted with a pneumatically braked axle controlled by a pneumatic 2- circuit braking system. The brake levers are then controlled by pneumatic brake boosters [6]. This system meets EU requirements.

  • Page 32: Safety

    SAFETY 3.1 General Safety Instructions WARNING: Always ensure that nobody is within the unfolding zone of the machine before unlocking the hooks. Always comply with the following points (if applicable).  Only use the machine for the purpose for which it has been designed. ...

  • Page 33: Warning Symbols

     Wear safety shoes when working on the tipping trailer; changing tyres, handling extensions etc.  Table 8-1 Do not pump up the tyres to an excessive pressure. Please refer to for the correct tyre pressures.  Avoid driving over sharp objects due to the risk of a blowout. 3.2 Warning symbols There are warning stickers at several locations on the tipping trailer alerting the user to: ...

  • Page 34: Safety Stickers

    Safety stickers 3.2.1 ATTENTION: Make sure that the stickers remain legible at all times. Replace any damaged or illegible stickers. ATTENTION: Read the Operating Manual Read the Operating Manual before use. Artnr: 76510012 ATTENTION: Maintenance work Switch off the motor and remove the ignition key before carrying out maintenance or repairs to the machine.

  • Page 35: Checks Before Driving Off

    CHECKS BEFORE DRIVING OFF Check the following points before driving off and make sure you comply with all of them.  The lights work.  The side and rear boards are secured.  The tyre pressures are correct.  The handbrake is fully released. ...

  • Page 36: Operation

    Rear tailgate locking hooks 5.1.1 The rear tailgate of models Z030, Z045 and Z050 is fitted with an automatic locking system as standard. The rear tailgate is automatically secured by locking hooks when the body is lowered [1]. Figure 5-1: Rear tailgate locking hooks...
  • Page 37 Figure 5-2: Detail of rear tailgate locking hook 1 - Stop bolt 2 - Rear tailgate locking hook 3 - Draw-spring When the body is lowered, the locking hooks [2] are automatically pushed upwards by the stop bolts [1]. The locking hooks secure the lower edge of the rear tailgate [4] during transport. The locking hooks release automatically when the body is lifted.

  • Page 38: Hydraulic Rear Gate Locking

    Hydraulic rear gate locking 5.1.2 The Z080 and Z100 tipping trailers are fitted with a hydraulic locking system for the rear tailgate as standard. This system is operated from the tractor. Figure 5-3: Hydraulic rear tailgate locking Figure 5-4: Locking hook system 1 - Hydraulic locking ram 2 - Rear tailgate locking hook Folding doors...

  • Page 39: Operation Of Locking Hooks On Use Of Folding Of Doors

    1 - Locking hook 2 - Draw-spring 3 - Locking pin Figure 5-5: Securing of the Z030/Z050 rear tailgate 5.2 Side boards The tipping trailer is fitted with side boards that fold down on fixed lower hinges as standard. If the sideways tipping option is selected, the side boards are designed to pivot on top hinges [4] or can be folded down using the lower hinges.

  • Page 40: Manual Locking Of The Side Boards

    Manual locking of the side boards 5.2.1 The side boards are locked by means of a handle [3] which activates the locks [1] with a locking rod [2]. If the locking system is in operation, the side board can be folded down providing that the top lock [4] has been unlocked.

  • Page 41: Hydraulic Side Board Locking

    Hydraulic side board locking 5.2.2 The side boards of models Z080 and Z100 are secured hydraulically. Using the selection handle [7] the operator can choose between forward and sideways tipping. The direction of tipping is selected by means of the selection handle [6]. A choice can be made between tipping to the left or right.

  • Page 42: Braking System

    5.3 Braking system The wheel brakes are operated by a brake rod [1] actuated by a brake lever [2]. The brake lever can be controlled mechanically by means of a brake cable (overrun brake), hydraulically by means of a brake cylinder, or pneumatically by means of a brake booster. The handbrake is connected to the brake levers by means of brake cables to put the tipping trailer in the handbrake position.

  • Page 43: Overrun Brake

    Overrun brake 5.3.1 The overrun brake system slows down the tipping trailer by the braking of the tractor and the pushing (overrunning) of the tipping trailer. The overrun brake ensures that the brake cable [1] is pulled through a lever on the drawbar when the drawbar eye [3] is pushed in. The brake cable [1] is also pulled when the handbrake [2] is operated.
  • Page 44 Figure 5-11: Overrun braking system 1 - Brake cable 2 - Brake rod 3 - Brake force regulator 4 - Brake lever The brake levers [4] are tightened when the brake cable [1] is pulled, either via the brake force regulator [3] or directly by the brake levers.

  • Page 45: Hydraulic Braking System (1-Circuit)

    Hydraulic braking system (1-circuit) 5.3.2 This braking system consists of a single hydraulic circuit connected to the tractor. The hose becomes pressurised when the brake is applied on the tractor. The other hydraulic hose is part of the mechanism for tipping the body. 1 - Hydraulic hose for tipping 2 - Hydraulic line for braking Figure 5-12: Hydraulic lines of 1-circuit system...

  • Page 46: Hydraulic Braking System (2-Circuit)

    Hydraulic braking system (2-circuit) 5.3.3 Figure 5-14: Components of 2-circuit system 1 - Double coupling including brake and control lines 2 - Main brake line 3 - Supply line 4 - Return line 5 - Steel safety break-out cable (for 1-circuit operation) 6 - Accumulator on manifold block 7 - Adjustment switch for 1-circuit/2-circuit operation 8 - Manual pump...
  • Page 47 pressure in both lines will then be neutralised and the valves in the manifold block will be reset; in this way the accumulator pressure will be directed to the brakes of the tipping trailer. Figure 5-15: Hydraulic brake valve block (on drawbar) 1 - Double coupling 2 - Rest position (to keep the double coupling clean) 3 - Manifold block...

  • Page 48: Manual Pneumatic Braking System (2-Circuit)

    The accumulator [1] will only fill when the brake pedal is applied. For this reason, the brake pedal should be applied several times before driving off each time the tractor/trailer is used in order to fill the accumulator. The indicator light on the dashboard will go out when sufficient pressure has built up in the accumulator.
  • Page 49 A hand-operated braking power control is available to adjust the braking power according to the Figure 5-18 cargo. Please refer to . This 4-position hand-operated valve must be adjusted according to the degree of loading: empty, half-full or fully loaded. OBSERVATION: In accordance with EU legislation, the maximum permitted speed for trailers with a hand-operated braking power control is 30 km/h.
  • Page 50 Figure 5-18: Pneumatic valve block with braking power control (manual) 1 - Spindle-type handbrake 2 - Brake cable 3 - Compressed air supply for tractor brakes 4 - Compressed air supply for tractor supply line 5 - Pressure control 6 - Discharge valve 7 - Air vessel connection 8 - Hand lever for manual load/braking adjustment 9 - Quick release connection to brake boosters...

  • Page 51: Automatic Pneumatic Braking System (2-Circuit)

    Automatic pneumatic braking system (2-circuit) 5.3.5 If the tipping trailer has a spring-loaded tandem carriage, it can be equipped with a pneumatically braked axle. This 2-circuit braking system is controlled by an automatic braking power control and meets EU requirements. In addition to the normal braking function, the system includes a supply line that monitors the system to ensure that the pressure will be cut off if the tipping trailer should unexpectedly become uncoupled from the tractor.

  • Page 52: Tipping The Body

    Each of the pivot points is hinged in two directions, and locking pins are fitted on the side to which the tipping action is directed. For sideways tipping, the locking pins must be shifted to the side selected and secured, and the rear tailgate locking hooks of models Z030 and Z050 must be Figure 7-17.

  • Page 53: Hydraulic Tipping

    Hydraulic tipping 5.4.2 Once the tipping direction has been selected and the appropriate side or rear board has been unlocked the body can be tilted. The tractor tipping valve, which controls the oil flow towards the tilt ram [3], is pressurised to this effect. The tilt ram is fitted with a ball head [3].

  • Page 54: Mechanical Safety Bar

    Mechanical safety bar 5.4.3 If it is required to enter the area underneath a raised body during maintenance, the mechanical safety bar [1] must be installed. The mechanical safety bar can only be installed if the body is tipped backwards. With 3-side tipping selected, the tipping direction must be changed beforehand.

  • Page 55: Commissioning

    COMMISSIONING Always read the entire Operating Manual before operating the tipping trailer for the first time. OBSERVATION: After the hydraulic hoses have been connected to the tractor, all hydraulic components must be filled with oil:  apply the tractor brake vigorously three times to ensure that the accumulator [1] of the 2-circuit braking system is properly filled with oil;...
  • Page 56 ATTENTION: Always ensure that all electric, hydraulic and pneumatic connections are fitted correctly and are functioning properly after the tipping trailer has been coupled to the tractor.

  • Page 57: Operation

    OPERATION 7.1 Preparatory tasks OBSERVATION: Before coupling, always check the tipping trailer for any defects or damage. Be aware of the following points. 1. Check all nuts and bolts and tighten them if necessary. 2. Check that all fitting pins are secure. 3.

  • Page 58: Coupling To The Tractor

    1. Suspend the drawbar securely in a hoist. 2. Dismount the 4 bolts that connect the drawbar to the chassis. 3. Select the correct height, turning the drawbar if necessary. If the drawbar is turned, the coupling must be turned as well.

  • Page 59: For Spindle-Type Parking Jack

    For spindle-type parking jack: 7.3.1 1. Couple the tipping trailer to the tractor. Please refer to paragraph 2. Using the spindle [1], raise the support wheel [6] to a point where the yoke [5] can be turned. Beware of the spring tension. 3.

  • Page 60: For Hydraulic Parking Jack

    For hydraulic parking jack: 7.3.2 1. Couple the tipping trailer to the tractor. Please refer to paragraph 7.3. 2. Connect the hydraulic hose [2] of the parking jack [5] to a single-acting hydraulic spool valve of the tractor. 3. Open the ball valve [1] of the hydraulic hose. 4.

  • Page 61: For Overrun Brake

    For overrun brake: 7.3.3 1. Couple the tipping trailer to the tractor. Please refer to paragraph 7.3. 2. Tighten the brake lever slightly and press the button [1] to lift the catch. 3. Push the lever fully back to release the brakes. 4.

  • Page 62: For Hydraulic Brake (1-Circuit System)

    For hydraulic brake (1-circuit system): 7.3.4 To use a 1-circuit tractor in combination with a 2-circuit tipping trailer please refer to paragraph 7.3.6 1. Couple the tipping trailer to the tractor. Please refer to paragraph 7.3. 2. Connect the hydraulic brake line [1] to the tractor's brake coupling. Figure 7-6: Hydraulic single circuit brake 1 - Hydraulic brake circuit 2 - Hydraulic hose for tipping...
  • Page 63 For break-out safety handbrake: Slightly tighten the handbrake lever [2] and then pull the lever entirely rearwards. Fit the break-out safety cord [1] of the handbrake to a solid point on the tractor. Figure 7-7: Break-out safety feature with handbrake 1 - Break-out safety cord 2 - Handbrake lever...

  • Page 64: For Hydraulic Brake (2-Circuit System)

    For a spindle-type handbrake: Turn the spindle [1] of the handbrake fully counter-clockwise until it will go no further. The brake cable [2] is then released and the brakes are inoperative. Figure 7-8: Spindle-type handbrake 1 - Spindle-type handbrake 2 - Brake cable For hydraulic brake (2-circuit system): 7.3.5 To use a 1-circuit tractor in combination with a tipping trailer with a 2-circuit braking system please...
  • Page 65 Figure 7-9: Double hydraulic brake coupling 1 - Double coupling with brake and control lines 2 - Main brake line 3 - Supply line 4 - Return line Figure 7-10: ABS plug Figure 7-11: Double hydraulic connector...
  • Page 66 Figure 7-12: Rest position of hydraulic connector on manifold block 1 - Hydraulic connector Figure 7-13: Positions of hydraulic brake valve with break-out device...

  • Page 67: For Hydraulic 2-Circuit Braking System And 1-Circuit Tractor

    OBSERVATION: The selection switch is automatically set to the zero position. Please refer to Figure 7-13. (Position 2 is used for the break-out safety cord). For hydraulic 2-circuit braking system and 1-circuit tractor: 7.3.6 1. Couple the tipping trailer to the tractor. Please refer to paragraph 7.3. 2.

  • Page 68: For Pneumatic Brake

    For pneumatic brake 7.3.7 1. Couple the tipping trailer to the tractor. Please refer to paragraph 7.3. 2. Drain the tipping trailer's air vessel. 3. Connect the yellow air supply line [2] to the tractor's yellow coupling. 4. Connect the red air supply line [1] to the tractor's red coupling. 5.

  • Page 69: Uncoupling From The Tractor

    7.4 Uncoupling from the tractor 1. Position the tipping trailer on a firm and even surface. 2. Switch off the tractor and remove the ignition key. 3. Apply the handbrake of the tipping trailer. 4. If necessary, also block the wheels to prevent them from rolling. For spindle-type parking jack: 7.4.1 1.

  • Page 70: Choice Of Tipping Direction

    7.5 Choice of tipping direction Standard rearward tipping: 7.5.1 Position the locking pins of both ball pivots in the rear balls for rearward tipping. Please refer to paragraph 5.4.1 For hydraulic unlocking Figure 7-20 Adjust the hydraulic ball valves to the correct position. Please refer to ...
  • Page 71 To allow for pivoting of the rear tailgate as a whole (Z030 and Z050) upon unfolding doors:  Keep the lock between the folding doors [2] secured. Please refer to Figure 7-17  Unlock the securing pawls [1] of the rear tailgate. Please refer to paragraph 5.1.
  • Page 72 To allow for pivoting of the rear tailgate as a whole (Z045) with folding doors:  Keep the lock between the folding doors [2] secured. Please refer to Figure 7-17  Ensure that the locking pin [1] is positioned in the lowest hole. Please refer to Figure 7-18. ...

  • Page 73: Sideways Tipping

    Sideways tipping: 7.5.2 Check that the locking pins of the ball pivots are both located on the same side of the balls. Figure 7-17. Check that the rear tailgate locking hooks are secured. Please refer to For mechanical unlocking:  Push the handle [1] at the front of the body down slightly out of the hook and then push the handle upwards to unlock the side board.

  • Page 74: Position Of Hydraulic Valves During Tipping Operations

    Position of hydraulic valves during tipping operations 7.5.3 Figure 7-20: Position of hydraulic valves during tipping operations 1 - Valve for left/right tipping; side board locking left/right 2 - Locking valve (rear board/side board left/side board right)

  • Page 75: During Operations

    During operations Loading the body 7.6.1 Load the cargo in such a way that weight is evenly distributed across the body. Unevenly distributed weight has negative consequences for the load on the drawbar and can make the tipping trailer unstable during the tipping operation. If the cargo is small, it is advisable to load closer to the front of the body in order to exert a sufficient load on the trailer's drawbar.

  • Page 76: Hoisting Of Heavy Components

    4. Allow the load to slide gently out of the body. If applicable, drive forward slowly during the unloading process to make space. 5. Set the hydraulic valve in the neutral position to lower the body. 6. Check that the board is locked as the body descends. For a hydraulic locking system, operate the hydraulic valve to lock the board.

  • Page 77: Hoisting Procedure For Side Boards

    Hoisting procedure for side boards 7.7.1 1. Place the slings around the side board well apart (hoisting angle between slings 120° as a maximum). If only one sling is used, it should be positioned in the middle. 2. Unfasten the upper locks. Please refer to Figure 5-6.

  • Page 78: Maintenance

    MAINTENANCE OBSERVATION: Please refer to the maintenance instructions below. These are in force as and when applicable. 8.1 General maintenance ATTENTION: Always take the necessary safety precautions when carrying out maintenance and repairs. ATTENTION: Install the safety bar before entering the area underneath a raised body, Please refer to paragraph 5.4.3 Mechanical safety bar Make sure that: 1.

  • Page 79: Inspections

    8.2 Inspections Handbrake 8.2.1 The handbrake must function properly; check this frequently. Functioning of the braking device / break-out safety 8.2.2 1. Upon the coupling of the tipping trailer to the tractor the braking system of the trailer should go into the working position automatically. 2.

  • Page 80: Wheel Replacement

    Wheel replacement 8.2.4 ATTENTION: Always position the lifting jack on a firm and even surface. Be sure to use a jack with a sufficient lifting capacity. The use of an inappropriate jack can be dangerous! OBSERVATION: Always wear safety shoes when changing a wheel. OBSERVATION: Always use work gloves when changing a wheel.
  • Page 81 (kPa/bar) 10.0/75-15.3 ET0 14PR 130 A8 AW 909 130 A8 1900 710 / 7.1 Z030* 11.5/80-15.3 ET0 10PR 131 A8 AW 909 131 A8 1950 460 / 4.6 Z030 11.5/80-15.3 ET0 14PR 139 A8 AW 909 139 A8 2430 650 / 6.5...

  • Page 82: Periodic Maintenance

    8.3 Periodic maintenance ATTENTION: Always take the necessary safety precautions when carrying out maintenance and repairs. ATTENTION: Install the safety bar before entering the area underneath a raised body, Please refer to paragraph 5.4.3 Mechanical safety bar (If applicable) Lubrication points 8.3.1 1 - Tipping pivots (2 or 4 off) 2 - Carriage (tandem)

  • Page 83: Lubrication Point

    Figure 8-2: Drawbar and handbrake lubrication points Table 8-3: Lubrication schedule 2 Lubrication Lubricant Description Lubrication frequency point Overrun Grease (EP2) Lubricate grease nipples Every 20 operations or twice brake behind the little plastic a year covers Overrun Copper grease Lubricate friction surfaces Every 20 operations, or twice brake slightly with copper grease...

  • Page 84: Daily Maintenance

    Daily maintenance 8.3.3 1. Check tyre pressures. Please refer to Table 8-1. 2. Check the lights and replace any faulty bulbs (faulty LED fittings to be replaced). 3. Check all nuts and bolts before every operation and re-tighten if necessary. 4.

  • Page 85: Failures

    FAILURES 9.1 Break-out braking device Statutorily-braked tipping trailers (with a total weight of more than 750 kg) must be equipped with a break-out braking device. If the coupling between the tractor and the tipping trailer is unexpectedly broken, this device should automatically bring the tipping trailer to a standstill.

  • Page 86: Lighting

    9.2 Lighting If the lights are not working 1. A dirty contact may be the cause, so first clean both the trailer plug and the socket using contact spray. Please refer to paragraph 9.3.2. If the lights still don’t work Check all bulbs for proper functioning: 1.

  • Page 87: Electric Plug Connections

    9.3 Electric plug connections ABS plug for hydraulics 9.3.1 OBSERVATION: The numbering is specified in the plug itself. Figure 9-2: 7-pole ABS plug (hydraulics) Overview of 7-pole socket Pin Function Colour +12 V Permanent for control valves +12 V via contact slot for electronics Black Earth for electronics (pin 2) Yellow...

  • Page 88: Trailer Plug For Lighting

    Trailer plug for lighting 9.3.2 The numbering is specified in the OBSERVATION: plug itself. Specific for 12 V 7-pole cable kit. Figure 9-4: pole plug connection for lighting Overview of 7-pole socket (ISO 1724*) Function Colour 1 / L Direction indicator, left Yellow 2/ 54g Fog light...

  • Page 89: Taking The Tipping Trailer Out Of Operation

    10. TAKING THE TIPPING TRAILER OUT OF OPERATION 10.1 Storage of the tipping trailer Ensure that the storage facility to be used is dry and dust-free. 10.1.1 Preparatory work for short-term storage Park the tipping trailer in a safe manner: ...

  • Page 90: Disassembly And Disposal

    11. DISASSEMBLY AND DISPOSAL 11.1 Disassembly If the tipping trailer is disassembled, the prevailing local regulations for the disposal of waste at the time of the disassembly must be taken into account. 11.2 Disposal The tipping trailer contains harmful substances, and it is illegal to release these into the environment.

  • Page 91: Overview Of Figures And Tables

    Figure 5-2: Detail of rear tailgate locking hook ...................... 37 Figure 5-3: Hydraulic rear tailgate locking Figure 5-4: Locking hook system .......... 38 Figure 5-5: Securing of the Z030/Z050 rear tailgate ..................... 39 Figure 5-6: Sideways tipping ............................39 Figure 5-7: Securing the side boards.......................... 40 Figure 5-8: Hydraulic side board locking ........................

  • Page 92: Tables

    Figure 7-15: Pneumatic brake ............................68 Figure 7-16: Valves for tipping direction ........................70 Figure 7-17: Securing the rear tailgate locking hooks - models Z030 and Z050 ........71 Figure 7-18: Securing the rear tailgate locking hooks - Z045................72 Figure 7-19: Securing the side board .........................

  • Page 93: Appendixes

    13. APPENDIXES  Hydraulic schedule (if applicable)  Pneumatic schedule (if applicable)
  • Page 94 Hydraulic brake schematic Double coupling with brake and control lines Supply line Return line Main brake line Electrical kit Main brake valve Accumulator Brake line to loading degree valve Single axle: Manual loading degree handle Tandem axle: ALR valve Brake line to brake cylinder Brake cylinder...
  • Page 95 Pneumatic brake schematic single axle...
  • Page 96 Coupling yellow Coupling red Release valve Trailer brake valve Manual valve degree of loading Air vessel Air release Brake booster: 9” Z030; 16” Z045+Z050; 20” Z080+Z100 Quick release valve Spindle handbrake...
  • Page 97 Pneumatic brake schedule tandem axle Coupling yellow Coupling red Release valve Trailer brake valve ALR valve Relay valve Air vessel Air release Brake booster: 16” Spindle handbrake...