ROPA Tiger 5 Operational manual

Translation of the
Original Operating Manual
Tiger 5
Software version: 15T0052
Printed in Germany: 10/2015
Edition 1.2
E901160-GB
Translation of the
Original Operating Manual
Tiger 5
Software version: 15T0052
Printed in Germany: 10/2015
Edition 1.2
E901160-GB

2 / 530
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
E-mail: T[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

Contents
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Contents

Contents
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Contents
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1 Preface......................................................................... 13
1.1 Name plate and important data...............................................................17
1.2 Type overview..........................................................................................18
1.3 Serial numbers and name plates............................................................ 19
1.4 Declaration of Conformity........................................................................21
2 Safety........................................................................... 23
2.1 General.................................................................................................... 25
2.2 Obligations of the entrepreneur...............................................................25
2.3 General symbols and instructions........................................................... 25
2.3.1 Safety signs............................................................................................. 26
2.4 Proper use............................................................................................... 27
2.4.1 Foreseeable misuse................................................................................ 27
2.5 Hazard zone............................................................................................ 28
2.6 Safety stickers on the machine............................................................... 29
2.7 Safety and health protection................................................................... 31
2.8 Requirements for operating and maintenance personnel....................... 32
2.9 Use of the boarding steps.......................................................................32
2.10 In the event of accidents.........................................................................32
2.11 Handling and process materials..............................................................32
2.12 Residual risks.......................................................................................... 33
2.13 Hazards caused by mechanical influences............................................. 33
2.14 Hazards caused by electricity................................................................. 33
2.15 Hazards caused by process materials.................................................... 34
2.16 Hazards caused by noise........................................................................34
2.17 Hazards caused by the hydraulic system............................................... 35
2.18 Hazards caused by pneumatic system................................................... 35
2.19 Hazards caused by hot substances/surfaces..........................................35
2.20 Personal protective equipment................................................................36
2.21 Leakage................................................................................................... 36
2.22 General notes on safety when handling acid batteries........................... 37
2.23 Prohibition of unauthorized modifications and alterations....................... 37
2.24 Safety and protective equipment.............................................................37
2.25 Emergency exit........................................................................................38
3 General View and Specifications.............................. 39
3.1 General view............................................................................................41
3.2 Technical data..........................................................................................43
3.3 Tyres pressure.........................................................................................45
3.4 Transport draft for low-loader transport of machine with additional
chassis..................................................................................................... 46
3.5 Transport draft for low-loader transport of machine without additional
chassis..................................................................................................... 47
3.6 Lashing eyes for transport by low-loader/ship.........................................48
4 General Description................................................... 51
4.1 Function................................................................................................... 53
4.2 Scope of delivery.....................................................................................54
5 Operating Components..............................................55
5.1 Ladders.................................................................................................... 57
5.1.1 Ladder driver's cabin............................................................................... 57

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5.1.2 Ladder bunker..........................................................................................58
5.2 Driver's cabin overview............................................................................59
5.3 Steering column.......................................................................................60
5.3.1 Steering column switch........................................................................... 61
5.4 Driver’s seat.............................................................................................62
5.5 Operating components on the floor of the driver‘s cabin.........................66
5.6 Operating console R-Concept................................................................. 67
5.6.1 Colour terminal R-Touch..........................................................................68
5.6.1.1 Positioning R-Touch.................................................................................69
5.6.2 R-Select................................................................................................... 70
5.6.3 R-Direct....................................................................................................73
5.6.4 Keypad I...................................................................................................74
5.6.5 Keypad II..................................................................................................75
5.6.6 Keypad III.................................................................................................76
5.6.7 Switches on operating console............................................................... 77
5.6.8 Main steering switch................................................................................78
5.6.9 Joystick with multi-functional handle....................................................... 79
5.6.10 Ignition lock..............................................................................................81
5.7 Operating panel bunker emptying........................................................... 82
5.8 Switches on roof console........................................................................ 83
5.9 Air conditioning........................................................................................ 84
5.10 Switch ground operation over front wheels.............................................85
5.11 Ground operation lifting unit.................................................................... 87
5.12 Engine compartment................................................................................88
5.13 Battery emergency shutdown..................................................................89
6 Operation..................................................................... 91
6.1 First startup..............................................................................................93
6.2 Safety regulations for operation of the machine..................................... 93
6.2.1 Working in the vicinity of power lines......................................................95
6.2.2 Behaviour during or after contact to the power lines...............................95
6.3 R-Concept................................................................................................96
6.3.1 Colour terminal R-Touch..........................................................................96
6.3.1.1 Display areas on the R-Touch.................................................................97
6.3.2 Functional area R-Direct....................................................................... 102
6.3.2.1 HOME key............................................................................................. 103
6.3.2.2 Main menu.............................................................................................103
6.3.2.2.1 Menu Programmable keys (P1/P2/P3)..................................................104
6.3.2.2.2 Menu Main settings............................................................................... 107
6.3.2.2.3 Menu Autopilot.......................................................................................110
6.3.2.2.4 Menu Light control.................................................................................111
6.3.2.2.5 Menu Special functions......................................................................... 111
6.3.2.2.6 Menu System.........................................................................................112
6.3.2.2.7 Menu Operating data.............................................................................114
6.3.2.2.8 Menu Service.........................................................................................116
6.3.2.3 Order management................................................................................118
6.3.2.3.1 Order data quick overview.................................................................... 119
6.3.2.3.2 Number of rows setting......................................................................... 120
6.3.2.3.3 Hiding fuel consumption........................................................................ 120
6.3.2.3.4 Finish order............................................................................................121
6.3.2.3.4.1 Finish order at standard equipment and R-Transfer Basic....................122
6.3.2.3.4.2 Finish order at R-Transfer Professional................................................ 123
6.3.2.3.5 Data export............................................................................................ 124
6.3.2.3.6 Data import R-Transfer Professional.....................................................125
6.3.2.3.7 Evaluating orders...................................................................................126
6.3.2.4 Readjusting warning thresholds............................................................ 127
6.3.3 Warning and status indications on the R-Touch....................................128

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6.3.4 Light control........................................................................................... 134
6.3.4.1 Configure light programs....................................................................... 135
6.3.4.2 Ladder light............................................................................................135
6.4 Joystick.................................................................................................. 136
6.5 Diesel engine.........................................................................................143
6.5.1 Start diesel engine.................................................................................146
6.5.2 Shut down diesel engine.......................................................................147
6.5.3 Engine speed adjustment......................................................................147
6.5.4 Power reduction SCR system............................................................... 149
6.5.4.1 Power reduction AdBlue filling level......................................................150
6.5.4.2 Power reduction AdBlue quality/system error....................................... 151
6.5.4.3 Power reduction process.......................................................................152
6.5.5 Modifications respectively additions to the engine operating manual from
Mercedes-Benz......................................................................................152
6.6 Operating mode "Field" and "Road"......................................................154
6.6.1 Operating mode change........................................................................154
6.6.2 All-wheel switching................................................................................ 155
6.6.3 Differential lock...................................................................................... 155
6.7 Driving....................................................................................................157
6.7.1 Selection of the driving direction (forward+/backward)..........................158
6.7.2 Gas pedal damping............................................................................... 159
6.7.3 Speed limiting - diesel engine too cold................................................. 159
6.7.4 Cruise control.........................................................................................160
6.7.4.1 Switching on cruise control in operating mode "Road"..........................160
6.7.4.2 Switching off cruise control in operating mode "Road"..........................161
6.7.4.3 Quick description: cruise control in operating mode "Road"..................161
6.7.4.4 Switching on cruise control in operating mode "Field".......................... 162
6.7.4.5 Change set speed of cruise control (operating mode "Field")............... 163
6.7.4.6 Switching off cruise control in operating mode "Field".......................... 163
6.7.4.7 Quick description: cruise control in operating mode "Field".................. 164
6.8 Road traffic............................................................................................ 165
6.8.1 General.................................................................................................. 165
6.8.2 Additional chassis (option).................................................................... 167
6.8.2.1 Additional chassis coupling................................................................... 168
6.8.2.2 Additional chassis: road drive............................................................... 171
6.8.2.3 Additional chassis uncoupling............................................................... 172
6.9 Braking system...................................................................................... 174
6.9.1 Operating brake.....................................................................................174
6.9.2 Engine brake..........................................................................................174
6.9.3 Parking brake.........................................................................................175
6.9.4 Automatic parking brake........................................................................175
6.10 Steering..................................................................................................176
6.10.1 Steering in operating mode "Road".......................................................178
6.10.1.1 Synchronized steering........................................................................... 178
6.10.1.2 Moving rear axles in central position.....................................................178
6.10.1.3 Synchronizing articulation (only for machines with synchronized
steering)................................................................................................. 179
6.10.1.4 U-turn steer in the operating mode "Road"...........................................180
6.10.1.5 Quick description: steering in operating mode "Road".......................... 182
6.10.2 Steering in operating mode "Field"........................................................183
6.10.2.1 Preselect and activate lifting through steer........................................... 183
6.10.2.2 Preselecting offset-steer 0-1-2 direction left/right..................................184
6.10.2.3 Preselect offset-steer stage...................................................................184
6.10.2.4 Activating offset-steer............................................................................ 185
6.10.2.5 U-turn steer............................................................................................186
6.10.2.6 All-wheel steer....................................................................................... 186
6.10.2.7 Crab steering......................................................................................... 187
6.10.2.8 Steering rear wheels with joystick.........................................................188

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6.10.2.9 Manual control....................................................................................... 189
6.10.2.10 Quick description: steering modes in operating mode "Field"............... 190
6.10.3 Automatic steering (Autopilot)............................................................... 191
6.10.3.1 Activating autopilot front axle steering.................................................. 191
6.10.3.2 Quick description: activating only front axle autopilot............................193
6.10.3.3 Activating rear wheels autopilot............................................................ 194
6.10.3.4 Quick description: manual activation of rear wheels autopilot...............196
6.10.3.5 Quick description: automatic activation of rear wheels autopilot........... 197
6.10.4 Setting steering behaviour.....................................................................198
6.11 Chassis.................................................................................................. 199
6.11.1 Display field Chassis on R-Touch......................................................... 199
6.11.2 Chassis activation..................................................................................200
6.11.3 Menu Chassis control on the R-Touch.................................................. 200
6.11.3.1 Chassis control "Active".........................................................................201
6.11.3.2 Chassis control "Manual".......................................................................202
6.11.3.3 Chassis control "Very top".....................................................................202
6.11.3.4 Chassis control "Bottom".......................................................................202
6.11.4 Manual inclination.................................................................................. 203
6.11.5 Automatic inclination (option)................................................................ 203
6.12 Lifting......................................................................................................205
6.12.1 Preparation for lifting............................................................................. 205
6.12.2 Lifting process........................................................................................205
6.13 Defoliator................................................................................................206
6.13.1 Leaf sensor............................................................................................208
6.13.2 Defoliator shaft.......................................................................................210
6.13.2.1 Defoliator shaft rotational speed setting................................................211
6.13.2.2 Monitoring the defoliator shaft...............................................................211
6.13.2.3 Cleaning shaft rotational speed setting (only at PESh).........................212
6.13.2.4 Setting cleaning shaft height (only at PESh).........................................213
6.13.3 Depth-control wheels............................................................................. 214
6.13.4 Defoliator discharge activity.................................................................. 216
6.13.5 Additional defoliator lifter....................................................................... 218
6.13.6 Defoliator relief when driving on the road............................................. 219
6.13.7 Leaf worm conveyor (only at PBS*h/PASh).......................................... 219
6.13.8 Hydraulic defoliator flap (PASh only).....................................................220
6.13.9 Leaf-spreader.........................................................................................222
6.13.9.1 Fold spreader.........................................................................................222
6.13.9.2 Setting rotational speed of leaf-spreader.............................................. 223
6.13.9.3 Leaf-spreader speed bunker unloading.................................................224
6.13.10 Scalper...................................................................................................225
6.13.10.1 Scalper Micro-Topper 2 (MT2 for short)................................................ 225
6.13.10.2 Adjusting cutting depth – MT2.............................................................. 226
6.13.10.3 Basic setting scalper comb................................................................... 228
6.13.10.4 Setting inflow sheet with skid (option)...................................................228
6.13.10.5 Spring loading/cutting angle of the scalper (Micro-Topper 2)................ 230
6.14 Lifter....................................................................................................... 231
6.14.1 Setting depth-control shaft speed..........................................................232
6.14.2 Depth guide........................................................................................... 233
6.14.3 Setting lifting depth................................................................................234
6.14.4 Setting rollers movement height............................................................236
6.14.5 Setting share beam height.................................................................... 238
6.14.6 Lifting shares......................................................................................... 239
6.14.7 Setting shaking share rotational speed................................................. 240
6.14.8 Stone protection.....................................................................................242
6.14.9 Setting the stone protection pressure................................................... 243
6.14.10 Share body guide (linear guide)............................................................244
6.14.11 Share body steering.............................................................................. 244
6.14.12 Installing/uninstalling guide rod holders................................................ 245

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6.14.13 Setting the lifting rollers rotational speed.............................................. 246
6.14.14 Lifting rollers reverse............................................................................. 247
6.14.15 Setting the distance between the 4th and 5th lifting rollers...................248
6.14.16 Rotating direction of the smooth lifting roller (pinch roller).................... 249
6.14.17 Paddle rotational speed.........................................................................250
6.14.18 Side shift................................................................................................250
6.14.19 Manual side shift................................................................................... 251
6.14.20 Automatic side shift............................................................................... 251
6.14.21 Setting row distance for the lifter PR2h-V.............................................252
6.15 Infeed conveyor..................................................................................... 257
6.15.1 Setting infeed conveyor rotational speed.............................................. 257
6.15.2 Infeed conveyor reverse........................................................................258
6.15.3 Ground operation infeed conveyor........................................................259
6.16 Setting infeed conveyor – distance settings..........................................260
6.16.1 Setting infeed conveyor distance longitudinally.....................................260
6.16.2 Setting infeed conveyor height front......................................................260
6.16.3 Setting infeed conveyor height rear...................................................... 262
6.17 Strainer wheels (turbines)..................................................................... 263
6.17.1 Setting the strainer wheel rotational speed...........................................264
6.17.2 Strainer wheels monitoring....................................................................266
6.17.3 Switching ground operation of strainer wheels..................................... 267
6.17.4 Strainer wheel guide grids.....................................................................268
6.17.5 Scraper...................................................................................................272
6.17.6 Spring tines (option).............................................................................. 273
6.17.7 Wiper......................................................................................................274
6.18 Elevator..................................................................................................275
6.18.1 Fold elevator out/in................................................................................275
6.18.2 Setting elevator rotational speed...........................................................277
6.18.3 Elevator monitoring................................................................................277
6.19 Bunker....................................................................................................278
6.19.1 Folding bunker bars out/in.....................................................................279
6.19.2 Unloading conveyor articulation parts folding out/in..............................280
6.19.3 Raise/lower bunker auger..................................................................... 281
6.19.4 Switching auger rotating direction......................................................... 282
6.19.5 Switching auger rotating direction manually..........................................284
6.19.6 Machine automatic folding out/in...........................................................286
6.19.7 Folding the machine manually out/in.....................................................287
6.20 Bunker unloading...................................................................................291
6.20.1 Operating panel bunker emptying......................................................... 292
6.20.2 Setting the unload rotating speed......................................................... 300
6.20.3 Instruction on piles creation (with the ROPA loader).............................301
6.21 Pump distributor gears.......................................................................... 302
6.22 Hydraulic system................................................................................... 303
6.23 Compressed air system.........................................................................307
6.23.1 Compressor............................................................................................307
6.23.2 Compressed air reservoir...................................................................... 308
6.24 Central lubricating system..................................................................... 309
6.24.1 Filling up grease gun.............................................................................310
6.24.2 Intermediate lubrication......................................................................... 311
6.25 Distance Controll Assistant (DCA), option (not possible by R-View)..... 312
6.26 Video system......................................................................................... 314
6.26.1 Rear view camera................................................................................. 314
6.26.2 Strainer wheel camera (option)............................................................. 315
6.26.3 Unload conveyor camera (option)......................................................... 315
6.26.4 R-View (option)...................................................................................... 317
6.27 Air conditioning...................................................................................... 320
6.27.1 Setting fan speed.................................................................................. 320
6.27.2 Adjusting set temperature..................................................................... 320

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6.28 Electrics..................................................................................................323
6.28.1 Voltage monitoring................................................................................. 323
6.28.2 Battery disconnect relay........................................................................ 323
6.28.3 Battery emergency shutdown................................................................324
6.29 Printer.....................................................................................................325
6.29.1 Description of the keyboard functions...................................................325
6.29.2 Which thermally-sensitive paper suits?.................................................326
6.30 Shutdown............................................................................................... 328
7 Maintenance and Service........................................ 329
7.1 Diesel engine.........................................................................................331
7.1.1 Dry air filter............................................................................................332
7.1.2 Oil change at diesel engine...................................................................337
7.1.3 Fuel supply............................................................................................ 338
7.1.3.1 Replacing/draining water of the fuel prefilter insert at the electric
pump...................................................................................................... 340
7.1.3.2 Exchange fuel fine filter and prefilter at the engine...............................340
7.1.3.3 Bleeding the fuel system.......................................................................342
7.1.3.4 Microorganisms in the fuel system........................................................343
7.1.4 Cooling system diesel engine............................................................... 343
7.1.4.1 Cleaning of the cooling system.............................................................345
7.1.4.2 Checking coolant................................................................................... 348
7.1.4.3 Replacing coolant.................................................................................. 350
7.1.4.4 Remarks of Mercedes-Benz on the cooling agent (general
information)............................................................................................ 351
7.1.5 Valve clearance adjustment...................................................................351
7.1.6 SCR exhaust after-treatment with AdBlue®...........................................352
7.1.6.1 Exchanging the AdBlue® filter insert......................................................353
7.1.7 Other maintenance work on the engine................................................ 354
7.2 Pump distributor gears (PDG)...............................................................355
7.3 Hydraulic system................................................................................... 357
7.3.1 Hydraulic oil tank................................................................................... 360
7.3.1.1 Hydraulic fluid change........................................................................... 361
7.3.1.2 Exchange suction return filter element..................................................363
7.3.2 Exchange of pressure filter element......................................................365
7.3.3 Collective return pipe protective strainer...............................................367
7.4 Mechanical drive for steering axles.......................................................368
7.4.1 Cardan shafts from CVR gearbox to the steering axles........................368
7.4.2 Maintenance knuckle joints of the axles............................................... 369
7.5 CVR gearbox (Traction drive)................................................................370
7.5.1 Oil cooler CVR gearbox........................................................................ 373
7.6 Axles...................................................................................................... 374
7.6.1 Planetary gearing (applies to all 3 axles)..............................................374
7.6.2 Differential gears front axle (portal axle)............................................... 375
7.6.3 Differential gears 1st rear axle.............................................................. 376
7.6.4 Differential gears 2nd rear axle.............................................................377
7.6.5 Reduction gears.....................................................................................379
7.6.5.1 Oil cooler reduction gears..................................................................... 382
7.6.6 Portal drives front axle.......................................................................... 383
7.7 Pneumatic system................................................................................. 384
7.8 Defoliator................................................................................................385
7.8.1 Defoliator maintenance position............................................................ 386
7.8.2 Moving defoliator from maintenance into operating position................. 388
7.8.3 Setting the leaf sensor.......................................................................... 389
7.8.4 Depth-control wheels............................................................................. 391
7.8.5 Defoliator shaft.......................................................................................392
7.8.6 Scalper...................................................................................................393