ROPA Tiger 6 Installation instructions

Translation of the
Original Operating Manual
Tiger 6 with RR lifting unit
Software version: 19T0017
Printed in Germany: 07/2019
Edition 3
E901415GB
Translation of the
Original Operating Manual
Tiger 6 with RR lifting unit
Software version: 19T0017
Printed in Germany: 07/2019
Edition 3
E901415GB

2 / 564
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: [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 authorised by ROPA
GmbH forms a violation of current domestic and international copyright law and will be
judicially prosecuted.
Publisher responsible for the content:
ROPA Fahrzeug- und Maschinenbau GmbH

Contents
3 / 564
Contents

Contents
4 / 564

Contents
5 / 564
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............................................................... 30
2.7 Safety and health protection................................................................... 32
2.8 Requirements for operating and maintenance personnel....................... 33
2.9 Use of the boarding steps.......................................................................33
2.10 In the event of accidents.........................................................................33
2.11 Handling and process materials..............................................................33
2.12 Residual risks.......................................................................................... 34
2.13 Hazards caused by mechanical influences............................................. 34
2.14 Hazards caused by electricity................................................................. 34
2.15 Hazards caused by process materials.................................................... 35
2.16 Hazards caused by noise........................................................................35
2.17 Hazards caused by the hydraulic system............................................... 36
2.18 Hazards caused by pneumatic system................................................... 36
2.19 Hazards caused by hot substances/surfaces..........................................36
2.20 Personal protective equipment................................................................37
2.21 Leakage................................................................................................... 37
2.22 General notes on safety when handling acid batteries........................... 38
2.23 Prohibition of unauthorised modifications and alterations....................... 38
2.24 Safety and protective equipment.............................................................39
2.25 Emergency exit........................................................................................40
3 General View and Specifications.............................. 41
3.1 General view............................................................................................43
3.2 Technical data..........................................................................................46
3.3 Tyre pressure...........................................................................................48
3.4 Transport draft for low-loader transport of machine without additional
chassis..................................................................................................... 49
3.5 Transport draft for low-loader transport of machine with additional
chassis..................................................................................................... 50
3.6 Lashing eyes for transport by low-loader/ship.........................................51
4 General Description................................................... 53
4.1 Function................................................................................................... 55
4.2 Scope of delivery.....................................................................................56
5 Operating Components..............................................57
5.1 Ladders.................................................................................................... 59
5.1.1 Ladder driver's cabin............................................................................... 59

Contents
6 / 564
5.1.2 Ladder bunker..........................................................................................61
5.2 Driver's cabin overview............................................................................62
5.3 Steering column.......................................................................................64
5.3.1 Steering column switch........................................................................... 65
5.4 Driver’s seat.............................................................................................66
5.5 Operating components on the floor of the driver‘s cabin.........................72
5.6 Operating console R-Concept................................................................. 73
5.6.1 Colour terminal R-Touch..........................................................................74
5.6.1.1 Positioning R-Touch.................................................................................75
5.6.2 R-Select................................................................................................... 76
5.6.3 R-Direct....................................................................................................79
5.6.4 Keypad I...................................................................................................80
5.6.5 Keypad II..................................................................................................81
5.6.6 Keypad III.................................................................................................82
5.6.7 Switches on operating console............................................................... 83
5.6.8 Main steering switch................................................................................84
5.6.9 Joystick with multi-functional handle....................................................... 85
5.6.10 Ignition lock..............................................................................................87
5.7 Operating panel bunker emptying........................................................... 88
5.8 Switches on roof console........................................................................ 89
5.9 Air conditioning........................................................................................ 91
5.10 Switch ground operation over front wheels.............................................92
5.11 Ground operation lifting unit.................................................................... 94
5.12 Engine compartment................................................................................95
5.13 Battery emergency shutdown..................................................................97
6 Operation..................................................................... 99
6.1 First startup............................................................................................102
6.2 Safety regulations for operation of the machine....................................102
6.2.1 Working in the vicinity of power lines....................................................104
6.2.2 Behaviour during or after contact to the power lines.............................104
6.3 R-Concept..............................................................................................104
6.3.1 Colour terminal R-Touch........................................................................105
6.3.1.1 Display areas on the R-Touch...............................................................106
6.3.2 Functional area R-Direct....................................................................... 112
6.3.2.1 HOME key............................................................................................. 112
6.3.2.2 Main menu.............................................................................................113
6.3.2.2.1 Menu Programmable keys (P1/P2/P3)..................................................113
6.3.2.2.2 Menu Main settings............................................................................... 117
6.3.2.2.3 Menu Autopilot.......................................................................................120
6.3.2.2.4 Menu Light control.................................................................................121
6.3.2.2.5 Menu Special functions......................................................................... 122
6.3.2.2.6 Menu System.........................................................................................123
6.3.2.2.7 Menu Operating data.............................................................................125
6.3.2.2.8 Menu Service.........................................................................................127
6.3.2.3 Order management................................................................................129
6.3.2.3.1 Order data quick overview.................................................................... 130
6.3.2.3.2 Number of rows setting......................................................................... 131
6.3.2.3.3 Hiding fuel consumption........................................................................ 131
6.3.2.3.4 finish order.............................................................................................132
6.3.2.3.4.1 Finish order at standard equipment and R-Transfer Basic....................133
6.3.2.3.4.2 Finish order at R-Transfer Professional................................................ 134
6.3.2.3.5 data export.............................................................................................135
6.3.2.3.6 Data import R-Transfer Professional.....................................................136
6.3.2.3.7 Evaluating orders...................................................................................137
6.3.2.4 Readjusting warning thresholds............................................................ 138
6.3.3 Warning and status indications on the R-Touch....................................139

Contents
7 / 564
6.3.4 Light control........................................................................................... 145
6.3.4.1 Configure light programs....................................................................... 146
6.3.4.2 Ladder light............................................................................................146
6.4 Joystick.................................................................................................. 147
6.5 Diesel engine.........................................................................................154
6.5.1 Start/shut down diesel engine............................................................... 157
6.5.2 Engine speed adjustment......................................................................159
6.5.3 Power reduction SCR system (only at RT6c)........................................161
6.5.3.1 Power reduction AdBlue filling level......................................................162
6.5.3.2 Power reduction AdBlue quality and system error................................ 163
6.5.4 Modifications and additions to the engine operating manual from
Volvo...................................................................................................... 164
6.6 Operating mode "Field" and "Road"......................................................165
6.6.1 Operating mode change........................................................................165
6.6.2 All-wheel switching................................................................................ 166
6.6.3 Differential lock...................................................................................... 166
6.7 Driving....................................................................................................168
6.7.1 Speed limiting - diesel engine too cold................................................. 171
6.7.2 Selection of the driving direction (forward+/backward)..........................172
6.7.3 Drive pedal damping............................................................................. 173
6.7.4 Cruise control.........................................................................................174
6.7.4.1 Switching on cruise control in operating mode "Road"..........................174
6.7.4.2 Switching off cruise control in operating mode "Road"..........................175
6.7.4.3 Quick description: cruise control in operating mode "Road"..................176
6.7.4.4 Switching on cruise control in operating mode "Field".......................... 176
6.7.4.5 Change set speed of cruise control (operating mode "Field")............... 177
6.7.4.6 Switching off cruise control in operating mode "Field".......................... 178
6.7.4.7 Quick description: cruise control in operating mode "Field".................. 179
6.8 Road traffic............................................................................................ 180
6.8.1 General.................................................................................................. 180
6.8.2 Additional chassis (option).................................................................... 183
6.8.2.1 Additional chassis coupling................................................................... 183
6.8.2.1.1 Actuate three-point suspension in the coupling mode...........................183
6.8.2.1.2 Actuate chain hoists in coupling mode..................................................185
6.8.2.2 Road drive with the additional chassis..................................................188
6.8.2.3 Additional chassis uncoupling............................................................... 189
6.9 Braking system...................................................................................... 191
6.9.1 Operating brake.....................................................................................191
6.9.2 Engine brake..........................................................................................191
6.9.3 Parking brake.........................................................................................192
6.9.4 Automatic parking brake........................................................................192
6.10 Steering..................................................................................................193
6.10.1 Steering in operating mode "Road".......................................................196
6.10.1.1 Synchronized steering........................................................................... 196
6.10.1.2 Moving rear axles in central position.....................................................196
6.10.1.3 Synchronise articulation steering...........................................................197
6.10.1.4 U-turn steer in the operating mode "Road"...........................................198
6.10.1.5 Quick description: steering in operating mode "Road".......................... 200
6.10.2 Steering in operating mode "Field"........................................................201
6.10.2.1 Preselect and activate lifting through steer........................................... 201
6.10.2.2 Preselecting offset-steer direction left/right........................................... 202
6.10.2.3 Preselect offset-steer stage...................................................................203
6.10.2.4 Activating offset-steer............................................................................ 204
6.10.2.5 U-turn steer............................................................................................205
6.10.2.6 All-wheel steer....................................................................................... 205
6.10.2.7 Crab steering......................................................................................... 206
6.10.2.8 Steering rear wheels with joystick.........................................................207
6.10.2.9 Manual control....................................................................................... 208

Contents
8 / 564
6.10.2.10 Quick description: steering modes in operating mode "Field"............... 209
6.10.3 Automatic steering (Autopilot)............................................................... 210
6.10.3.1 Activating autopilot front axle steering.................................................. 210
6.10.3.2 Quick description: activating only front axle autopilot............................211
6.10.3.3 Activating rear wheels autopilot............................................................ 212
6.10.3.4 Quick description: manual activation of rear wheels autopilot...............214
6.10.3.5 Quick description: automatic activation of rear wheels autopilot........... 215
6.10.4 Setting steering behaviour.....................................................................216
6.11 Chassis.................................................................................................. 217
6.11.1 Chassis display field on R-Touch.......................................................... 218
6.11.2 Chassis activation..................................................................................218
6.11.3 Menu Chassis control on the R-Touch.................................................. 220
6.11.3.1 Chassis control "Active".........................................................................220
6.11.3.2 Chassis control "Manual".......................................................................221
6.11.3.3 Chassis control "Very top".....................................................................221
6.11.3.4 Chassis control "Bottom"....................................................................... 221
6.11.4 Manual inclination.................................................................................. 222
6.11.5 Automatic inclination (option)................................................................ 222
6.12 Lifting......................................................................................................224
6.12.1 Preparation for lifting............................................................................. 224
6.12.2 Lifting process........................................................................................224
6.13 Defoliator................................................................................................225
6.13.1 Leaf sensor............................................................................................227
6.13.2 Defoliator shaft.......................................................................................229
6.13.2.1 Defoliator shaft rotational speed setting................................................230
6.13.2.2 Monitoring the defoliator shaft...............................................................230
6.13.2.3 Adjust cleaning shaft rpm (RES only)................................................... 231
6.13.2.4 Setting cleaning shaft height (only with RES)....................................... 232
6.13.3 Depth-control wheels............................................................................. 233
6.13.4 Defoliator discharge activity.................................................................. 235
6.13.5 Additional defoliator lifter....................................................................... 237
6.13.6 Leaf auger conveyor (only with RBS/RAS)........................................... 238
6.13.7 Hydraulic defoliator flap (only with RAS)...............................................238
6.13.8 Leaf-spreader.........................................................................................240
6.13.8.1 Fold leaf-spreader..................................................................................240
6.13.8.2 Setting rotational speed of leaf-spreader.............................................. 241
6.13.8.3 Leaf-spreader speed bunker unloading.................................................242
6.13.9 Scalper...................................................................................................243
6.13.9.1 Scalper Micro-Topper 2 (MT2 for short)................................................ 243
6.13.9.2 Adjusting cutting height - MT2.............................................................. 244
6.13.9.3 Basic setting scalper comb................................................................... 246
6.13.9.4 Setting inflow sheet with skid (option)...................................................247
6.13.9.5 Spring loading/cutting angle of the scalper (Micro-Topper 2)................ 249
6.14 Lifter....................................................................................................... 250
6.14.1 Setting depth-control wheel speed........................................................ 252
6.14.2 Depth guide........................................................................................... 253
6.14.3 Setting lifting depth................................................................................255
6.14.4 Setting rollers movement height............................................................256
6.14.5 Setting share depth............................................................................... 259
6.14.6 Lifting shares......................................................................................... 265
6.14.7 Setting shaking share rotational speed................................................. 267
6.14.8 Stone protection.....................................................................................269
6.14.9 Setting the stone protection pressure................................................... 271
6.14.10 Share body guide (linear guide)............................................................272
6.14.11 Share body steering.............................................................................. 273
6.14.12 Setting the lifting rollers rotational speed.............................................. 274
6.14.13 Lifting rollers reverse............................................................................. 276
6.14.14 Setting distance between last lifting roller and the short lifting rollers... 278

Contents
9 / 564
6.14.15 Rotating direction of the last (smooth) lifting roller (pinch roller)........... 279
6.14.16 Short lifting rollers / 2x paddles.............................................................279
6.14.17 Lifting unit side shift.............................................................................. 280
6.14.18 Lifting unit side shift manual..................................................................281
6.14.19 Lifting unit side shift automatic..............................................................282
6.14.20 Setting row distance for the RR-V lifter.................................................284
6.14.21 Side shift rollers movement...................................................................288
6.14.21.1 Adjust rollers movement side shift to row distance (RR-V only)............289
6.15 Infeed conveyor..................................................................................... 290
6.15.1 Setting infeed conveyor rotational speed.............................................. 290
6.15.2 Infeed conveyor reverse........................................................................292
6.15.3 Ground operation infeed conveyor........................................................ 293
6.15.4 Setting infeed conveyor – distance settings..........................................294
6.15.4.1 Setting infeed conveyor distance longitudinally.....................................294
6.15.4.2 Setting infeed conveyor height front......................................................295
6.15.4.3 Setting infeed conveyor height rear...................................................... 296
6.16 Strainer wheels (turbines)..................................................................... 297
6.16.1 Setting the strainer wheel rotational speed...........................................298
6.16.1.1 Adjust strainer wheels individually.........................................................300
6.16.1.2 Switching off strainer wheels.................................................................300
6.16.2 Strainer wheels monitoring....................................................................301
6.16.3 Switching ground operation of strainer wheels..................................... 302
6.16.4 Strainer wheel guide grids.....................................................................303
6.16.5 Offset strainer wheel tines.....................................................................307
6.16.6 Spring tines (option).............................................................................. 308
6.16.7 Wiper......................................................................................................308
6.17 Elevator..................................................................................................309
6.17.1 Fold elevator out/in................................................................................309
6.17.2 Setting elevator rotational speed...........................................................311
6.17.3 Elevator monitoring................................................................................311
6.18 Bunker....................................................................................................312
6.18.1 Folding bunker bars out/in.....................................................................313
6.18.2 Unload conveyor articulation parts folding out/in.................................. 314
6.18.3 Raise/lower bunker auger..................................................................... 315
6.18.4 Switching auger rotating direction......................................................... 316
6.18.5 Switching auger rotating direction manually..........................................318
6.18.5.1 Quick shutdown..................................................................................... 319
6.18.6 Machine automatic folding out/in...........................................................320
6.18.7 Folding the machine manually out/in.....................................................321
6.19 Bunker unloading...................................................................................325
6.19.1 Operating panel bunker emptying......................................................... 326
6.19.2 Adjustment of unloading stage 2 cross conveyor speed.......................333
6.19.3 Setting the unload rotating speed......................................................... 334
6.19.4 Instruction on piles creation (with the ROPA loader).............................335
6.20 Pump distributor gears.......................................................................... 336
6.21 Hydraulic system................................................................................... 337
6.22 Compressed air system.........................................................................341
6.22.1 Compressor............................................................................................342
6.22.2 Compressed air reservoir...................................................................... 342
6.23 Central lubricating system..................................................................... 343
6.23.1 Filling up grease gun.............................................................................344
6.23.2 Intermediate lubrication......................................................................... 345
6.24 Video system......................................................................................... 347
6.24.1 Rear view camera................................................................................. 347
6.24.2 Strainer wheel camera (option)............................................................. 348
6.24.3 Unload conveyor camera (option)......................................................... 348
6.24.4 R-View (option)...................................................................................... 350
6.25 Air conditioning...................................................................................... 353

Contents
10 / 564
6.25.1 Setting fan speed.................................................................................. 353
6.25.2 Adjusting set temperature..................................................................... 353
6.26 Electrics..................................................................................................356
6.26.1 Voltage monitoring................................................................................. 356
6.26.2 Battery disconnect relay........................................................................ 356
6.26.3 Battery emergency shutdown................................................................357
6.27 Printer.....................................................................................................358
6.27.1 Description of the keyboard functions...................................................358
6.27.2 Which thermally-sensitive paper suits?.................................................358
6.28 Shutdown............................................................................................... 360
7 Maintenance and Service........................................ 361
7.1 Diesel engine.........................................................................................363
7.1.1 Dry air filter............................................................................................364
7.1.2 Oil change at diesel engine...................................................................369
7.1.3 Fuel supply............................................................................................ 371
7.1.3.1 Replacing/draining water of the fuel prefilter insert at the electric
pump...................................................................................................... 373
7.1.3.2 Replacing fuel prefilter cartridge and main fuel filter cartridge.............. 374
7.1.3.3 Bleeding the fuel system.......................................................................376
7.1.3.4 Refuelling with diesel fuel......................................................................377
7.1.3.5 Microorganisms in the fuel system........................................................378
7.1.4 Cooling system diesel engine............................................................... 379
7.1.4.1 Cleaning of the cooling system............................................................. 380
7.1.4.2 Checking coolant................................................................................... 383
7.1.4.3 Replacing coolant.................................................................................. 384
7.1.4.4 Remarks of ROPA on the coolant (general information)....................... 385
7.1.5 Valve clearance adjustment...................................................................385
7.1.6 SCR exhaust after-treatment with AdBlue®...........................................386
7.1.6.1 Exchanging the AdBlue® filter insert......................................................386
7.1.7 Other maintenance work on the engine................................................ 388
7.2 Pump distributor gears (PDG)...............................................................388
7.3 Hydraulic system................................................................................... 389
7.3.1 Hydraulic oil tank................................................................................... 392
7.3.1.1 Hydraulic fluid change........................................................................... 393
7.3.1.2 Exchange suction return filter element..................................................395
7.3.2 Exchange of pressure filter element......................................................397
7.3.3 Collective return pipe protective strainer...............................................399
7.4 Mechanical drive for steering axles.......................................................400
7.4.1 Cardan shafts from CVR gearbox to the steering axles........................400
7.4.2 Maintenance knuckle joints of the axles............................................... 401
7.5 CVR gearbox (Traction drive)................................................................402
7.5.1 Oil cooler CVR gearbox........................................................................ 406
7.6 Axles...................................................................................................... 407
7.6.1 Planetary gearing (applies to all 3 axles)..............................................407
7.6.2 Differential gears front axle (portal axle)............................................... 409
7.6.3 Differential gears 1nd rear axle.............................................................410
7.6.4 Differential gears 2nd rear axle.............................................................412
7.6.5 Reduction gears.....................................................................................413
7.6.5.1 Oil cooler reduction gears..................................................................... 415
7.6.6 Portal drives front axle.......................................................................... 416
7.7 Pneumatic system................................................................................. 417
7.8 Defoliator................................................................................................417
7.8.1 Defoliator service position..................................................................... 419
7.8.2 Setting the leaf sensor.......................................................................... 422
7.8.3 Depth-control wheels (not with R*SU)...................................................424
7.8.4 Defoliator shaft.......................................................................................425

Contents
11 / 564
7.8.5 Scalper...................................................................................................427
7.9 Lifter....................................................................................................... 429
7.9.1 Lifting shares......................................................................................... 429
7.9.2 Lifter gears for lifting rollers...................................................................432
7.9.3 Paddle gears..........................................................................................434
7.9.4 RR 6-row depth-control roller drive....................................................... 435
7.9.5 Shaking share gears............................................................................. 436
7.9.6 Shaking share drive only with the "variable row distance" option..........437
7.9.7 Eccentric shaft bearing..........................................................................438
7.9.8 Readjusting eccentric bearing shaking share drive...............................439
7.9.9 Share body guide/suspension............................................................... 440
7.9.10 Lifting rollers.......................................................................................... 441
7.10 Infeed conveyor..................................................................................... 443
7.10.1 Tension...................................................................................................443
7.10.2 Setting synchronism.............................................................................. 444
7.11 Infeed conveyor gears...........................................................................445
7.12 Strainer wheels (turbines)..................................................................... 446
7.13 Elevator..................................................................................................447
7.14 Bunker....................................................................................................454
7.14.1 Bunker auger......................................................................................... 454
7.14.2 Ultrasound sensors................................................................................454
7.14.3 Cross conveyors....................................................................................454
7.14.3.1 Tensioning conveyor chains.................................................................. 456
7.14.3.2 Retensioning longitudinal conveyor.......................................................457
7.14.3.3 Retensioning cross conveyor................................................................ 458
7.14.3.4 Drive chains...........................................................................................459
7.14.3.5 Bearings of the conveyor drive shaft and cleaner roller........................ 460
7.15 Unload elevator......................................................................................462
7.15.1 Tighten the belt......................................................................................464
7.16 Air conditioning and ventilation system................................................. 466
7.16.1 Condenser air conditioning system....................................................... 466
7.16.2 Recirculating filter.................................................................................. 467
7.16.3 Fresh air intake filter..............................................................................468
7.16.4 Condensate drain.................................................................................. 468
7.16.5 Coolant circuit........................................................................................469
7.17 Battery maintenance..............................................................................470
7.18 Printer (option).......................................................................................471
7.19 Shutdown for a longer period of time....................................................472
7.20 Dismantling and disposal...................................................................... 474
8 Malfunction and Remedies......................................475
8.1 Safety circuits........................................................................................ 477
8.2 Fuses..................................................................................................... 478
8.2.1 Fuses..................................................................................................... 478
8.2.2 Electronic fuses..................................................................................... 479
8.2.3 Fuses on the diesel engine................................................................... 480
8.2.4 Fuses in the driver's cabin seat console............................................... 481
8.2.5 Fuses in the central electrical system in the driver's cabin................... 482
8.2.6 Fuses in the central electrical system outside on the driver's cabin...... 484
8.2.7 Fuses in the lifter fuse box....................................................................485
8.2.8 Fuses in the engine fuse box................................................................487
8.3 Relays list.............................................................................................. 489
8.4 Colour codes for electric wiring.............................................................490
8.5 Searching for malfunctions using R-Touch............................................490
8.5.1 Overview of diagnostic menus.............................................................. 492
8.5.1.1 Digital inputs.......................................................................................... 493
8.5.1.2 Analogue inputs.....................................................................................494

Contents
12 / 564
8.5.1.3 Rpm inputs.............................................................................................496
8.5.1.4 Outputs PWM + SW..............................................................................497
8.5.1.5 CAN bus................................................................................................ 499
8.5.1.6 Diesel engine.........................................................................................500
8.5.1.7 Machine error memory.......................................................................... 501
8.5.1.8 Engine error memory.............................................................................502
8.5.1.9 Joystick.................................................................................................. 502
8.5.1.10 Air conditioning control device.............................................................. 503
8.5.1.11 Operating Components..........................................................................504
8.5.1.12 Functions................................................................................................505
8.5.1.13 GPS data............................................................................................... 507
8.5.1.14 Pressure sensors...................................................................................508
8.5.1.15 Camera steering.................................................................................... 508
8.6 Jump starting and charging the battery.................................................509
8.7 Welding on the machine........................................................................512
8.8 Towing....................................................................................................513
8.9 Connecting salvaging aids.................................................................... 514
8.10 Jacking up for wheel change................................................................ 515
8.11 Manual releasing of parking brake........................................................516
8.12 Hydraulic valves.....................................................................................519
8.13 Central lubrication system – bleeding and removal of blocks............... 520
8.14 Emergency operation ventilator drives emergency operation............... 522
8.15 Swinging away the fuel tank................................................................. 523
8.16 Checklist for optimising the lifting quality.............................................. 524
9 Lists/Tables/Plans/Diagrams/Maintenance
Verification.................................................................527
9.1 Lubricating and operating supplies........................................................529
9.2 Maintenance table................................................................................. 531
9.3 Lubrication schedule for RR 6-row lifter................................................535
9.4 Lubricant recoding table........................................................................ 537
9.5 Filter cartridges, V-belts........................................................................ 539
9.6 Torque table for bolts and nuts (Nm).................................................... 541
9.7 Lubricating plans....................................................................................542
9.7.1 Base machine only lubrication plan with 78 lubrication points...............542
9.7.2 Lubrication plan for RR lifter (6-row, 45 cm/50 cm/variable)................. 544
9.7.3 Lubricating plan for RIS defoliator.........................................................545
9.7.4 Lubricating plan for RISU defoliator...................................................... 545
9.7.5 Lubricating plan for RASW defoliator....................................................545
9.7.6 Lubricating plan for RASO defoliator.....................................................545
9.7.7 Lubricating plan for RES-45/-50/-V....................................................... 546
9.8 AdBlue® information sheet....................................................................547
9.9 Maintenance verification........................................................................ 550
9.9.1 Maintenance verification oil change + filter exchange...........................550
9.9.2 Maintenance confirmation......................................................................552
9.9.3 Software updates...................................................................................552
9.10 Confirmation about instructions given to the driver............................... 553
9.11 Safety instructions................................................................................. 554
9.12 ROPA Handover confirmation............................................................... 556
10 Index...........................................................................559

Preface
13 / 564
1 Preface

Preface
14 / 564

Preface
15 / 564
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 01 201
Spare parts telephone + 49 – 87 85 – 96 01 202
Fax + 49 – 87 85 – 566
Internet www.ropa-maschinenbau.de
E-mail Customer Service [email protected]
E-mail 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 unauthorised 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.
WARNING
In rare cases, massive interference of vehicle electronics or malfunctions of the
machine may occur due to operation of improperly installed electronic appliances (e.g.
radios or other appliances emitting electromagnetic radiation). In case of such interfer-
ence, the complete machine may suddenly stop operating or execute unwanted func-
tions.
In such cases, immediately shut off the sources of interference and immediately
shut down the machine.
If needed, notify the company ROPA or the nearest authorised customer service of
ROPA.

Preface
16 / 564
Servicing and specific maintenance work on the engine may only be performed by
companies or persons expressly authorised for this purpose by Volvo. Volvo main-
tenance vouchers must be completed by these persons or companies to confirm
completion of the work. Without these maintenance vouchers properly completed,
any warranty or statutory warranty of the engine manufacturer lapses.
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 for 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.
Employ the decades of experience collected by ROPA in sugar beet harvesting
and loading technology and implemented in this machine, by correct operation of
this machine. Remember that any neglect in maintenance and servicing inevitably
leads to loss of performance and therefore to loss of time.
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.

Preface
Name plate and important data
17 / 564
1.1 Name plate and important data
The name plate (2) of the machine is located on the right side of the vehicle near the
knuckle joint between the front and rear axle on the vehicle chassis near the chassis
number (1).
2
1
Please enter the data of your machine in the following image of the name plate. You
will need this data for ordering spare parts. If you have not yet exchanged the defo-
liator unit and/or lifting unit, these may also be identified by ROPA using the chassis
number.

Preface
Type overview
18 / 564
1.2 Type overview
Classification of the defoliator identification by example of ROPA "RBSO-45":
R→R=ROPA version
B→B=Leaf-spreader defoliator including leaf auger
I=Integrated defoliator
A=All-round defoliator
E=Rubber defoliator
S→S=Defoliator
O→O=Eastern version (4 depth-control wheels)
W=Western version (identical, however only 2 depth-control wheels
foldable)
U=Unwheeled (without depth-control wheels)
-→-= Separating character
45 →45 =45 cm row distance
50 =50 cm row distance
V=variable, adjustable between 45 cm and 50 cm
XL = wider version
9x45 = 9 rows with 45 cm row distance etc.
8x22 = 8 rows with 22 inch row distance etc.
In the operating manual, the above designation is often shown incomplete. In this
case, the description includes all variants of the production model.
Examples:
RIS → applies for all integrated defoliators, applies for all row distances
(45 cm, 50 cm, variable, etc.)
RS → applies to all ROPA defoliators
Classification of the lifter identification by example of ROPA "RR-45":
R→R=ROPA version
R→R=Lifting unit
-→-= Separating character
45 →45 =45 cm row distance
50 =50 cm row distance
V=variable, adjustable between 45 cm and 50 cm
XL = wider version
9x45 = 9 rows with 45 cm row distance etc.
8x22 = 8 rows with 22 inch row distance etc.

Preface
Serial numbers and name plates
19 / 564
1.3 Serial numbers and name plates
1
4
5
The serial number of the engine (1) is located on the engine block. Viewed from the
bunker in the direction of forward movement it can be found on the right on the belt
side of engine under the intake manifold.
The Volvo Penta chassis ID (4), the engine serial number and the engine model (5)
are on the valve cover.
2
The serial number (2) of the öifting unit is located on the rear left part of the main lifter
bracing tube.

Preface
Serial numbers and name plates
20 / 564
The serial number (3) of the defoliator is located on the left side or top of the defoliator
side wall.
3
RIS defoliator
3
RASW/RASO defoliator
3
RES rubber-defoliator