bergmann CAREX 370 S User manual

Series:
Type:
Type of document:
As of:
Document number
2-134
SL11
Original operating instructions
201703 en
BTA_SL11_CAREX+SHUTTLE_201703_en
SHUTTLE 370 S SHUTTLE 410 S SHUTTLE 450 S SHUTTLE 490 S
SHUTTLE 390 K SHUTTLE 430 K SHUTTLE 470 K SHUTTLE 510 K
CAREX 370 S CAREX 410 S CAREX 450 S CAREX 490 S
CAREX 390 K CAREX 430 K CAREX 470 K CAREX 510 K
Silage trailers
Operating Instructions

General
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1 General
1.1 Identification
☐CAREX 370 S
☐CAREX 390 K
☐CAREX 410 S
☐CAREX 430 K
☐CAREX 450 S
☐CAREX 470 K
☐CAREX 490 S
☐CAREX 510 K
☐SHUTTLE 370 S
☐SHUTTLE 390 K
☐SHUTTLE 410 S
☐SHUTTLE 430 K
☐SHUTTLE 450 S
☐SHUTTLE 470 K
☐SHUTTLE 490 S
☐SHUTTLE 510 K
Type:
Vehicle identification number
(VIN):
Delivery date:
1.2 Manufacturer
Ludwig Bergmann GmbH
Maschinenfabrik
+49 (0)4444 - 2008-0
+49 (0)4444 - 2008-88
-
Hauptstraße 64-66
49424 Goldenstedt
[e-mail]
www.Bergmann-Goldenstedt.de
1.3 Spare Parts Stock
Ersatzteillager
+49 (0)4444 - 2008-16
+49 (0)4444 - 2008-25
-
Hauptstraße 64-66
49424 Goldenstedt
[e-mail]
www.Bergmann-Goldenstedt.de
1.4 Customer Service Management
Jörg Kammacher
+49 (0)4444 - 2008-15
+49 (0)4444 - 2008-43
-
Hauptstraße 64-66
49424 Goldenstedt
[e-mail]
www.Bergmann-Goldenstedt.de

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1.5 Preface
Dear customer,
You have made a good choice. We would like to thank you for placing your trust in us by purchasing a
Bergmann vehicle. As a supplier of agricultural machinery, we offer you efficient machinery at high quality
standards with the service to match.
These operating instructions provide a detailed technical description, general and special explanations with
regards to correct use and operation as well as tips for troubleshooting. Please read these operating instructions
carefully before operating the vehicle for the first time. Please follow the recommendations for proper preventive
maintenance and service for your trailer, which will ensure a long operating life and a continuous operational
readiness. Also observe the safety notices listed in these operating instructions.
Modifications that are not in accordance with or allowed by these operating instructions may only be carried out
with written permission from Bergmann.
Due to the fact that our products and technical standards are constantly being developed, these operating
instructions are subject to change without notice.
If the vehicle is transferred by the customer to a third party, the operating instructions must be
passed on to the new owner.
1.5.1 Instructions for work safety
All sections in the operating instructions which concern personal safety have been marked
with this symbol. Pass all safety instructions on to other users.
Particularly useful information for the user
Important!
Important!

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1.6 Table of Contents
1General.................................................................................................................... 2
1.1 Identification ...................................................................................................................... 2
1.2 Manufacturer...................................................................................................................... 2
1.3 Spare Parts Stock.............................................................................................................. 2
1.4 Customer Service Management........................................................................................ 2
1.5 Preface................................................................................................................................ 3
1.5.1 Instructions for work safety................................................................................................................3
1.6 Table of Contents .............................................................................................................. 4
2Notices for the User............................................................................................. 10
2.1 Product Liability, Obligation to Inform........................................................................... 10
2.2 Product Transfer Instructions......................................................................................... 12
2.3 General Information......................................................................................................... 13
2.3.1 Intended Use ...................................................................................................................................13
2.4 Designation...................................................................................................................... 14
2.4.1 Vehicle Identification Number (VIN) ................................................................................................14
2.4.2 CE Symbol.......................................................................................................................................14
2.4.3 Identification Plate - Vehicle............................................................................................................15
2.4.3.1 Position of identification plate......................................................................................................15
2.4.4 Identification Plate - Drawbar ..........................................................................................................16
2.5 Technical data.................................................................................................................. 16
2.5.1 CAREX 370 S / 390 K / 410 S / 430 K / 450 S / 470 K / 490 S / 510 K ..........................................17
2.5.1.1 Dimensions..................................................................................................................................17
2.5.1.2 Weights .......................................................................................................................................17
2.5.1.3 Pick-Up........................................................................................................................................18
2.5.1.4 Chassis........................................................................................................................................18
2.5.1.5 Supply .........................................................................................................................................18
2.5.1.6 Airborne acoustical noise emissions...........................................................................................18
2.5.1.7 Ambient temperature...................................................................................................................18
2.5.2 SHUTTLE 370 S / 390 K / 410 S / 430 K / 450 S / 470 K / 490 S / 510 K ......................................19
2.5.2.1 Dimensions..................................................................................................................................19
2.5.2.2 Weights .......................................................................................................................................19
2.5.2.3 Pick-Up........................................................................................................................................20
2.5.2.4 Chassis........................................................................................................................................20
2.5.2.5 Supply .........................................................................................................................................20
2.5.2.6 Airborne acoustical noise emissions...........................................................................................20
2.5.2.7 Ambient temperature...................................................................................................................20
2.6 Warning Symbols and Notice Stickers........................................................................... 21
2.6.1 Definition of the Warning Symbols and Notice Stickers..................................................................21
2.6.1.1 General........................................................................................................................................21
2.6.1.2 Drive............................................................................................................................................25
2.6.1.3 Hydraulic .....................................................................................................................................26
2.6.1.4 Scraper floor................................................................................................................................26
2.6.1.5 Tailgate........................................................................................................................................26
2.6.1.6 Chassis- Tandem axle unit..........................................................................................................27
2.6.1.7 Chassis - with Hydraulic Axle Compensation .............................................................................27
2.6.1.8 Lift axle........................................................................................................................................28
2.6.1.9 Forced Steering...........................................................................................................................29
2.6.1.10 Silage Trailer...........................................................................................................................31
2.7 Safety and Accident Prevention Requirements............................................................. 32
2.7.1 Basic rules.......................................................................................................................................32
2.7.2 Driving..............................................................................................................................................32

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2.7.3 Road traffic regulations....................................................................................................................33
2.7.4 Coupling, loading, transport.............................................................................................................33
2.7.5 PTO Shaft Operation.......................................................................................................................34
2.7.6 Hydraulic system .............................................................................................................................35
2.7.7 Brakes and Tires .............................................................................................................................36
2.7.8 Maintenance....................................................................................................................................36
2.8 Important Information for Vehicle Operation................................................................. 37
2.9 Other Hazards.................................................................................................................. 38
2.10 Safety Notice.................................................................................................................... 38
3Initial Start-up and Functions ............................................................................. 39
3.1 Vehicle Functions............................................................................................................ 39
3.2 After Delivery ................................................................................................................... 39
3.3 Coupling to the Tractor ................................................................................................... 40
3.3.1 Preparation......................................................................................................................................40
3.3.2 Coupling the Hydraulic ....................................................................................................................40
3.3.3 Coupling the Controller....................................................................................................................40
3.4 Jack Stand........................................................................................................................ 41
3.4.1 Mechanical Jack Stand....................................................................................................................41
3.4.1.1 Couple the Vehicle......................................................................................................................41
3.4.1.2 Coupling the Vehicle ...................................................................................................................41
3.5 Drawbar............................................................................................................................ 42
3.5.1 Drawbar Adjustment (Hydraulic) .....................................................................................................42
3.5.1.1 E-controls (operated using terminal)...........................................................................................42
3.5.1.2 Vehicle controls...........................................................................................................................43
3.6 PTO shaft.......................................................................................................................... 44
3.7 Pick-up.............................................................................................................................. 46
3.7.1 Locking / Unlocking the Pick-up......................................................................................................47
3.7.2 Raising / Lowering the Pick-up........................................................................................................48
3.7.3 Switching the Pick-up On / Off ........................................................................................................49
3.7.4 Setting the Pick-up Working Height.................................................................................................50
3.7.5 Guide Wheels..................................................................................................................................52
3.7.6 Guide roller......................................................................................................................................53
3.7.7 Guide Comb and Swath Roller........................................................................................................54
3.7.7.1 Adjusting the height.....................................................................................................................54
3.7.7.2 Setting the angle of inclination....................................................................................................54
3.8 Conveyor Unit.................................................................................................................. 55
3.8.1 Switching Conveyor Unit On / Off....................................................................................................55
3.8.2 Conveyor Unit Cover .......................................................................................................................56
3.9 Cutting Unit...................................................................................................................... 57
3.9.1 Cutting Unit......................................................................................................................................57
3.9.1.1 Procedure:...................................................................................................................................57
3.9.2 Sharpening the Knives ....................................................................................................................58
3.9.3 Cleaning...........................................................................................................................................58
3.10 Chassis (hydraulic Axle Balance)................................................................................... 59
3.10.1 Setting the Clearance......................................................................................................................59
3.10.2 Position of the ball valves:...............................................................................................................59
3.10.3 Setting..............................................................................................................................................60
3.11 Follow up Steering........................................................................................................... 61
3.12 Forced Steering ............................................................................................................... 62
3.12.1 Safety Notice ...................................................................................................................................62
3.12.2 Adapting the Tractor to the Trailer...................................................................................................63
3.12.3 Coupling...........................................................................................................................................64
3.12.4 Uncoupling:......................................................................................................................................64
3.12.5 Adjusting the Steering .....................................................................................................................65
3.12.6 Steering Variations ..........................................................................................................................65
3.13 Cargo Space..................................................................................................................... 67
3.13.1 Access to Cargo Space...................................................................................................................67

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3.13.2 Ladder and Access Door.................................................................................................................68
3.13.3 Front Wall - Hydraulic Swivel Mechanism.......................................................................................69
3.13.3.1 Front wall elements.................................................................................................................69
3.13.3.2 Front Wall Positions................................................................................................................70
3.13.3.3 Raising and lowering the front wall.........................................................................................71
3.13.4Front Wall Sensor, Bottom (Right) ..................................................................................................72
3.13.4.1 Angle sensor...........................................................................................................................73
3.13.5 Front Wall Sensor, Middle...............................................................................................................74
3.13.5.1 Inductive sensor “Opener” & “Closer” .....................................................................................75
3.13.6Tailgate Sensor, Top (Left & Right).................................................................................................76
3.13.6.1 Inductive sensor “Opener” & “Closer” .....................................................................................77
3.13.7 Cargo Space, Rear..........................................................................................................................78
3.13.8 Extension Walls...............................................................................................................................79
3.13.9 Cargo Space Cover.........................................................................................................................80
3.13.9.1 Opening / Closing the Cargo Space Cover ............................................................................80
3.13.10 Cargo Space Cover Sensor, Right..............................................................................................81
3.13.10.1 Inductive sensor “Opener” & “Closer” .....................................................................................82
3.14 Scraper Floor ................................................................................................................... 83
3.14.1 Scraper floor chains.........................................................................................................................83
3.14.2 Scraper Floor Chain Tensioning System.........................................................................................83
3.14.3 Scraper Floor Drive .........................................................................................................................83
3.15 Dosing Unit ...................................................................................................................... 84
3.15.1 Dosing Unit Sensor Left...................................................................................................................84
3.15.1.1 Inductive sensor “Opener” & “Closer” .....................................................................................85
3.16 Tailgate............................................................................................................................. 86
3.16.1 Locking and Unlocking the Tailgate ................................................................................................87
3.16.2 Tailgate Sensor, Bottom (Left & Right)............................................................................................88
3.16.2.1 Inductive sensor “Opener” & “Closer” .....................................................................................89
3.16.3 Tailgate Sensor, Top (Right) ...........................................................................................................90
3.16.3.1 Angle sensor...........................................................................................................................91
3.16.4 Tailgate Positions ............................................................................................................................92
3.17 Hydraulics........................................................................................................................ 93
3.17.1 Storing the Supply Lines..................................................................................................................93
3.17.2 Hydraulic Supply Line Markings......................................................................................................94
3.17.3 Hydraulic System “E-Control” ..........................................................................................................95
3.17.3.1 Control block...........................................................................................................................95
3.17.3.1.1 Control block emergency operation.................................................................................95
3.17.3.2 Hydraulic System Supply Line “E-Control“ .............................................................................97
3.17.3.3 Supply System with E-control.................................................................................................99
3.17.3.4 Coupling the hydraulic supply lines with E-control ...............................................................102
3.17.3.5 Uncoupling the hydraulic supply lines with “E-control” .........................................................103
3.18 Terminal.......................................................................................................................... 104
3.18.1 Terminal BCT 20 ...........................................................................................................................104
3.18.1.1 User Interface .......................................................................................................................104
3.18.1.2 Quick Start............................................................................................................................105
3.18.1.3 Menu Structure .....................................................................................................................105
3.18.1.4 Menu Examples –Transport Trailer .....................................................................................105
4Operating the Vehicle........................................................................................ 107
4.1 Loading Procedure........................................................................................................ 107
4.1.1.1 Start the loading procedure.......................................................................................................107
4.1.1.2 Loading Procedure....................................................................................................................107
4.2 Unloading Procedure..................................................................................................... 108
4.2.1.1 Unloading without dosing rollers...............................................................................................108
4.2.1.2 Unloading with dosing rollers....................................................................................................108
4.3 Driving on Roads........................................................................................................... 109
4.3.1 Set Vehicle Parts in Driving Position.............................................................................................109

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4.3.2 Locking the Steering Axle..............................................................................................................109
4.3.3 Driving............................................................................................................................................110
4.4 Weights and Capacity Information ............................................................................... 110
5Care and Maintenance....................................................................................... 111
5.1 General:.......................................................................................................................... 111
5.2 Cleaning and Maintenance in the Cargo Space........................................................... 111
5.3 Maintenance Schedule .................................................................................................. 112
5.4 Screw torques................................................................................................................ 114
5.5 Cleaning the machine.................................................................................................... 115
5.6 Suspension .................................................................................................................... 115
5.7 Tires and Wheels ........................................................................................................... 116
5.7.1 Wheel nuts and wheel bolts...........................................................................................................116
5.7.1.1 Maximum Wheel Nuts Torque...................................................................................................116
5.7.2 Tire Pressure.................................................................................................................................117
5.8 Axles............................................................................................................................... 118
5.8.1 Maintenance..................................................................................................................................118
5.8.2 Check wheel hub for play..............................................................................................................118
5.8.3 Changing the grease in the wheel hub bearing.............................................................................119
5.8.4 Follow-up Axles .............................................................................................................................120
5.8.5 Forced Steering.............................................................................................................................120
5.9 Air Brake System........................................................................................................... 121
5.9.1 Trailer Brake Effect Regulator (Manual Adjustment) (If Available)................................................121
5.9.2 ALB –Automatic load sensing brake effect regulator (if available)...............................................121
5.9.3 De-watering the air tank ................................................................................................................121
5.9.4 Cleaning the Line Filter..................................................................................................................122
5.9.4.1 Tightness test............................................................................................................................122
5.9.5 Check Pressure in Reserve Tank..................................................................................................122
5.9.6 Check Brake Cylinder Pressure ....................................................................................................122
5.9.7 Check Brake Cylinder Stroke ........................................................................................................123
5.9.8 Adjusting the Brake Lever .............................................................................................................123
5.9.9 Adjusting the Linkage Control Element.........................................................................................123
5.10 Parking brake................................................................................................................. 124
5.11 Drive ............................................................................................................................... 125
5.11.1 PTO shaft.......................................................................................................................................125
5.11.1.1 General: ................................................................................................................................125
5.11.1.2 Lubrication of Walterscheid PTO shaft.................................................................................125
5.11.1.3 Lubrication Points and Grease Quantities............................................................................125
5.11.1.4 Maintenance Intervals...........................................................................................................126
5.11.2 Gearboxes.....................................................................................................................................127
5.11.2.1 General: ................................................................................................................................127
5.11.2.2 Gearbox Allocation and Oil Fill Quantities............................................................................127
5.11.2.3 Rotor- planetary gearbox - Draining gearbox oil...................................................................128
5.11.2.4 Rotor- planetary gearbox - Adding gearbox oil.....................................................................130
5.11.3 Roller Chains.................................................................................................................................131
5.11.4 Clutches.........................................................................................................................................132
5.12 Scraper Floor Chains..................................................................................................... 133
5.12.1 Tensioning Scraper Floor Chains..................................................................................................133
5.12.2 Shortening the Scraper Floor Chain..............................................................................................133
5.12.3 Shorten scraper floor chain if chains are different lengths............................................................133
5.13 Cutting Unit.................................................................................................................... 134
5.13.1 Knife Adjustment ...........................................................................................................................134
5.13.2 Cutting Unit Adjustment.................................................................................................................134
5.13.3 Sensor Adjustments ......................................................................................................................135
5.13.3.1 Top Sensor: Indicator "Cutting unit off".................................................................................135
5.13.3.2 Bottom Sensor: Knife Position..............................................................................................135
5.14 Conveyor Unit................................................................................................................ 136

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5.14.1 Scraper..........................................................................................................................................136
5.15 Hydraulics...................................................................................................................... 136
5.15.1 Hydraulic Oil Filter (Pilot box / Comfort Control) ...........................................................................136
5.16 Circuit Diagrams............................................................................................................ 137
5.16.1 Hydraulics......................................................................................................................................137
5.16.2 Electric...........................................................................................................................................139
5.16.2.1 Terminal –BCT 20................................................................................................................139
5.16.2.2 Terminal –CCI 200...............................................................................................................139
5.16.2.3 Terminal –ISOBUS ..............................................................................................................140
5.16.2.4 Wiring harness BCT / CCI / ISOBUS....................................................................................141
5.16.2.4.1 Wiring harness legend...................................................................................................142
5.16.2.5 Wiring harness BCT / CCI / ISOBUS - expansion unit.........................................................144
5.16.2.5.1 Wiring harness legend...................................................................................................145
5.16.3 Brake System ................................................................................................................................146
5.16.3.1 Air Brake - Tandem...............................................................................................................146
5.16.3.2 Air Brake - Tridem.................................................................................................................148
5.17 Lubrication..................................................................................................................... 150
5.17.1 Lubrication diagram.......................................................................................................................151
5.17.1.1 Lubrication diagram vehicle type "S"....................................................................................152
5.17.1.2 Lubrication diagram vehicle type "S"....................................................................................153
5.17.1.3 Lubrication diagram axle.......................................................................................................154
5.17.1.4 Lubrication diagram drawbar (Forced steering hydraulic / normal).....................................155
5.18 Malfunctions................................................................................................................... 156
6Declaration of Conformity................................................................................. 157
6.1 CAREX............................................................................................................................ 157
6.2 SHUTTLE........................................................................................................................ 158
7Contact Details & Contact Persons.................................................................. 159
7.1 Manufacturer.................................................................................................................. 159
7.2 Authorized officer / Sale................................................................................................ 159
7.3 Sales management Export West................................................................................... 159
7.4 Sales management Export East.................................................................................... 159
7.5 Spare parts warehouse ................................................................................................. 160
7.6 Customer service management.................................................................................... 160
7.7 Emergency service........................................................................................................ 160
7.8 Worldwide Sales Partners............................................................................................. 160

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Notices for the User
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2 Notices for the User
2.1 Product Liability, Obligation to Inform
Product liability requires the manufacturer and dealer to go through the operating instructions and to instruct the
customer at the time of transfer, paying particular attention to operational, safety and maintenance
requirements.
In order to prove that the vehicle and the operating instructions were transferred properly, written confirmation is
needed.
You will find a transfer statement below which must be filled out and returned to Bergmann after transfer.
According to the German product liability law, every farmer is the owner of a business.
According to the German product liability law, property damage is damage which is caused by a vehicle, but not
damage caused to a vehicle. The liability includes a 500 Euro excess. In accordance with the German product
liability law, damages to the business are not covered.
Attention!
If the vehicle is transferred by the customer to a third party, the operating instructions must also be given to the
new owner and the new owner must be made aware of the requirements.
Attention!
Be advised that the right to make claims under guarantee only exists after this transfer statement has been filled
out, signed and returned to Bergmann.
We reserve the right to process personal information, received within the framework of this business relationship
in accordance with the federal privacy act.