ROPA KS 475 Operational manual

Translation of the Orig-
inal Operating Manual
Haulm topper
Printed in Germany: 10/2021Edition 1
E901450GB

Imprint
All rights reserved
©Copyright by
ROPA Fahrzeug- und Maschinenbau GmbH
Sittelsdorf 24
D-84097 Herrngiersdorf
Phone: + 49 – 87 85 – 96 01 0
Fax: + 49 – 87 85 – 56 6
Internet www.ropa-maschinenbau.de
Email: [email protected]
This operating manual may only be reprinted or otherwise reproduced – even in
excerpts – 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 authorized by ROPA
GmbH forms a violation of current domestic and international copyright law and will be
judicially prosecuted.
Publisher responsible for content:
ROPA Fahrzeug- und Maschinenbau GmbH
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Contents
Contents
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Contents
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Contents
1 Preface........................................................................... 7
1.1 Name plate and important data...............................................................11
1.2 Declaration of Conformity........................................................................ 12
1.3 Extended documentation......................................................................... 13
1.3.1 Supplier documentation and purchased parts operating manual............ 13
2 Safety........................................................................... 15
2.1 General.................................................................................................... 17
2.2 Obligations of the entrepreneur...............................................................17
2.3 General symbols and instructions........................................................... 18
2.3.1 Safety signs............................................................................................. 19
2.4 Proper use............................................................................................... 20
2.4.1 Foreseeable misuse................................................................................ 20
2.5 Hazard zone............................................................................................ 21
2.6 Safety stickers on the machine............................................................... 23
2.7 Safety and health protection................................................................... 26
2.8 Requirements for operating and maintenance personnel....................... 27
2.9 In the event of accidents.........................................................................27
2.10 Handling and process materials..............................................................27
2.11 Residual risks.......................................................................................... 28
2.12 Hazards caused by mechanical influences............................................. 28
2.13 Hazards caused by process materials.................................................... 29
2.14 Hazards caused by noise........................................................................29
2.15 Hazards from gear oil..............................................................................30
2.16 Hazards caused by hot substances/surfaces..........................................30
2.17 Risks due to drive shafts.........................................................................30
2.18 Personal protective equipment................................................................31
2.19 Leakage................................................................................................... 31
2.20 Prohibition of unauthorised modifications and alterations....................... 31
2.21 Safety and protective equipment.............................................................32
3 General View and Specifications.............................. 33
3.1 General overview.....................................................................................35
3.2 Technical data..........................................................................................37
3.3 Tyre pressure...........................................................................................38
3.4 Transport draft for truck transport of the machine...................................39
3.5 Transport draft for road travel................................................................. 41
3.6 Lashing eyes for truck transport/ship transport....................................... 43
4 General Description................................................... 45
4.1 Function................................................................................................... 47
4.2 Scope of delivery.....................................................................................48
5 Operating Components..............................................49
5.1 Overview of machine controls................................................................. 51
6 Operation..................................................................... 53
6.1 First startup..............................................................................................56
6.2 Safety regulations during operation of the machine................................57
6.3 Support foot............................................................................................. 58
6.4 Coupling and uncoupling the machine....................................................59
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Contents
6.4.1 Coupling the machine..............................................................................59
6.4.2 Uncoupling the machine..........................................................................59
6.5 Attachment/detachment of the machine..................................................60
6.5.1 Attachment of the machine..................................................................... 60
6.5.2 Detachment of the machine.................................................................... 65
6.6 Road travel.............................................................................................. 67
6.6.1 General.................................................................................................... 67
6.7 Chassis.................................................................................................... 69
6.7.1 Support wheels........................................................................................ 69
6.7.2 Drawbar....................................................................................................70
6.8 Firming wheels.........................................................................................71
6.9 Angular gear............................................................................................ 72
6.10 Shutdown................................................................................................. 73
7 Maintenance and service...........................................75
7.1 Angular gear............................................................................................ 78
7.2 Cardan shaft above topper shaft.............................................................79
7.3 V-belts and V-belt pulleys....................................................................... 81
7.3.1 V-belt tension...........................................................................................81
7.3.2 Replacement of V-belt pulleys................................................................ 82
7.4 Topper shaft and flails............................................................................. 86
7.5 Shutdown for an extended period........................................................... 87
7.6 Dismantling and disposal........................................................................ 87
8 Malfunction and remedies......................................... 89
8.1 Safety circuits.......................................................................................... 91
8.2 Colour codes for electric wiring...............................................................91
8.3 Welding on the machine..........................................................................91
9 Lists/Tables/Plans/Diagrams/Maintenance
Verification...................................................................93
9.1 Lubricating and operating supplies......................................................... 95
9.2 Maintenance table................................................................................... 95
9.3 Lubricating plan (lubrication with grease gun).........................................96
9.4 Lubricant recoding table.......................................................................... 97
9.5 Torque table for screws and nuts (Nm)...................................................98
9.6 Maintenance verification.......................................................................... 99
9.6.1 Maintenance verification oil change........................................................ 99
9.6.2 Maintenance confirmation........................................................................99
9.7 Confirmation about instructions given to the driver............................... 100
9.8 Safety instructions................................................................................. 101
9.9 ROPA Handover confirmation............................................................... 103
9.10 ROPA First Use Record........................................................................ 105
10 Index...........................................................................107
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Preface
1 Preface
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Preface
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Preface
We congratulate you on the purchase of your new ROPA machine. Please take the
time and read thoroughly the operating manual. The operating manual is primarily
intended for the machine operator. It contains all information required for safe oper-
ation of this machine, informs about safe handling and gives hints on practical use
as well as for self-help and servicing. The respective safety information is based on
the safety, work and health protection regulations applicable at the time of printing of
this operating manual. In case of questions about the machine, on operation of the
machine or on ordering of spare parts, please contact the dealer in your vicinity or the
manufacturer directly:
ROPA Fahrzeug- und Maschinenbau GmbH
Sittelsdorf 24
D-84097 Herrngiersdorf
Phone Customer Service + 49 – 87 85 – 96 01 203
Phone Spare Parts + 49 – 87 85 – 96 01 202
Fax + 49 – 87 85 – 566
Internet www.ropa-maschinenbau.de
Email Customer Service [email protected]
Email Spare Parts [email protected]
Important information
Original ROPA spare parts have been especially developed for your machine.
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. We cannot assume any responsibility for such installations, additions or
reconstructions. In case of unauthorized modifications to the machine, any war-
ranty claim lapses! Furthermore, the Declaration of Conformity (CE Marking) or
regulatory approvals can be declared ineffective. This also applies if seals or seal-
ing wax applied by the factory are removed.
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Preface
We expressly reserve the right to make technical modifications for the purpose of
improving our machines or increasing the safety standards – even without specific
notification.
All information about directions given in this operating manual (front, rear, right,
left) are in relation to the driving direction forward. Please always state the chassis
number of the machine for any orders of spare parts and technical inquiries. You
will find the chassis number on the name plate and on the vehicle chassis above
the name plate.
Please have the machine serviced according to regulations. Comply with the infor-
mation given in this operating manual and have parts subject to wear replaced in
due time respectively ensure timely repairs. Have the machine respectively main-
tained or repaired according to regulations.
Listen for suddenly occurring, unusual noises and have their cause remedied
before the machine is operated further, since otherwise heavy damage or costly
repairs to the machine may be caused.
Generally comply with the respective applicable regulations for road traffic and the
applicable regulations on occupational health and safety.
A copy of this manual must be accessible to authorised personnel any time for
the entire lifetime of the machine. Make sure that the manual is supplied with the
machine, e.g. in the event of an onward sale.
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.
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Preface
Name plate and important data
1.1 Name plate and important data
The name plate (1) of the machine is located on the right side of the three-point for
rear attachment to the tractor.
Please enter the data of your machine in the following image of the name plate. You
will need this data for ordering spare parts.
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Preface
Declaration of Conformity
1.2 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.
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Preface
Extended documentation
1.3 Extended documentation
Additional documents in addition to this operating manual also apply, e.g.
Supplier documentation
Wiring diagrams
1.3.1 Supplier documentation and purchased parts operating manual
The operating manuals for the purchased parts must be followed and they are
attached to the technical documentation as separate sections. Optional components
are also listed.
Supplier Component Description
Walterscheid Cardan shafts Operating manual for car-
dan shaft
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Safety
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Safety
2 Safety
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Safety
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Safety
Obligations of the entrepreneur
2.1 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.
Modifications to this machine may only be performed with the express approval of the
manufacturer, since otherwise the manufacturer's warranty lapses. In addition, the
road traffic registration may lapse and other registrations of the machine may become
invalid. The operating manual supplied must be strictly observed. The manufacturer
shall not be liable for damage caused by incorrect handling, inappropriate application
or incorrect repairs respectively missing maintenance and service carried out by the
customer. The machine may only be operated in a technically perfect condition, for its
intended purpose and with due consideration of the risks involved.
2.2 Obligations of the entrepreneur
The entrepreneur employing the machine, respectively his agent, is obliged:
to observe the applicable European and national work and safety regulations.
to instruct the machine operators about their special obligation for safe driving of
the machine. These instructions must be given anew before the start of each sea-
son. Records must be prepared about giving of these instructions, which must be
signed by the entrepreneur and the instructed machine operator. These records
must be kept for at least one year by the entrepreneur.
before first use of the machine, to instruct the machine operators about operation
respectively about safe handling of the machine.
Forms for these instructions may be found in Chapter 9 of this operating manual (doc-
umentation of instructions given to the driver). When needed, please copy these forms
before completing them.
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Safety
General symbols and instructions
2.3 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. This haz-
ard may always occur if the operating or working instructions are not or only impre-
cisely observed.
WARNING
This signal word warns you of a possibly dangerous situation which may lead to
serious injury or to death. This hazard may always occur if the operating or working
instructions are not or only imprecisely observed.
CAUTION
This signal word warns you of a possibly dangerous situation which may lead to seri-
ous injury or to death and damage to the machine or other serious property dam-
age. Non-observance of these instructions may lead to loss of warranty. This hazard
may always occur if the operating or working instructions are not or only imprecisely
observed.
ATTENTION
This signal word warns you of a possible severe damage to the machine or other
severe property damage. Non-observance of these instructions may lead to loss of
warranty. This hazard may always occur if the operating or working instructions are
not or only imprecisely observed.
ADVICE
This symbol draws your attention to some special aspects. This helps to facilitate
work.
(1)
Item numbers
The item numbers used in drawings are put in text in parentheses (1) and marked in
bold.
-
Operational activities
The defined sequence of operational activities facilitates the correct and safe use of
the device.
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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.
Warning against open running belt
This warning symbol stands for activities during which the hazards of open running belt
or chains with possible deadly consequences exist.
Warning against hot surfaces/hot liquids
This warning symbol stands for activities during which the hazards of hot surfaces/hot
liquids with possible deadly consequences exist.
Warning against explosion hazard, battery area
This warning symbol stands for activities during which the hazards of corrosive liquid
and gases exist.
Warning against falling hazard
This warning symbol stands for activities during which the hazards of falling with possi-
ble deadly consequences exist.
Warning of electromagnetic fields
This warning symbol stands for activities during which the hazards of electromagnetic
fields respectively disorders exist.
Warning against crushing hazard
This warning symbol stands for activities during which the crush hazards with possible
deadly consequences exist.
Warning against crushing hazard
This warning symbol stands for activities during which the crush hazards with possible
deadly consequences exist.
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Safety
Proper use
2.4 Proper use
This machine is exclusively meant for:
removal of potato haulm or haulm of 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. Any other use of the machine is deemed improper and is therefore prohibited.
2.4.1 Foreseeable misuse
We would like expressly to point out that this machine is not be used for hilling of
potato ridges.
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