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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