ROPA Maus 6 - Machine Maintenance and Service Procedures

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Maintenance and Service

7 Maintenance and Service

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Table of Contents5
Preface13
Name Plate and Important Data17
Serial Number of Diesel Engine18
Declaration of Conformity19
Safety21
General23
Obligations of the Entrepreneur23
General Symbols and Instructions24
Safety Signs25
Proper Use26
Foreseeable Misuse26
Hazard Zone27
Safety Stickers on the Machine29
Safety and Health Protection31
Requirements for Operating and Maintenance Personnel32
Use of the Boarding Steps32
In the Event of Accidents32
Handling and Process Materials33
Residual Risks33
Hazards Caused by Mechanical Influences33
Hazards Caused by Electricity34
Hazards Caused by Process Materials35
Hazards Caused by Noise36
Hazards Caused by the Hydraulic System36
Hazards Caused by Pneumatic System36
Hazards Caused by Hot Substances/Surfaces37
Personal Protective Equipment37
Leakage37
General Notes on Safety When Handling Acid Batteries38
Prohibition of Unauthorised Modifications and Alterations38
General Safety Instructions for the Park Heating System39
Safety and Protective Equipment39
Emergency Exit40
Technical Data and General View41
Technical Data43
Tyre Pressure46
General View47
Transport Draft for Low-Loader Transport53
Lashing Eyes for Transport by Low-Loader/Ship54
General Description57
Function59
Scope of Delivery60
Myropa61
Registration in Myropa61
R-Connect62
Operating Components63
Ladders65
Ladder to Driver's Cabin65
Auxiliary Steps on the Fuel Tank66
Driver's Cabin Cylinder Support67
Driver's Cabin Overview69
Rear Part of Cabin70
Cabin Ceiling71
Steering Column72
Steering Column Switch73
Driver's Seat74
Rotating Driver's Seat79
Driver's Seat Occupancy Identification System80
Folding Left Joystick Console80
Operating Components on the Floor of the Driver's Cabin81
Operating Console R-Concept82
R-Touch Main Terminal83
R-Touch Auxiliary Terminal84
R-Select85
R-Direct88
Keypad I89
Keypad II90
Switches on Operating Console91
Main Steering Switch92
Right Joystick with Multi-Functional Handle93
Left Joystick94
Ignition Lock94
Switches of the Roof Console95
Climate Control97
Engine Housing98
Outlet on Fuel Tank99
Ladder Light100
Battery Emergency Shutdown101
Operation103
First Startup105
Safety Regulations for Operation of the Machine106
Working in the Vicinity of Power Lines108
Behaviour During or after Contact to the Power Lines108
R-Concept109
R-Touch Main Terminal109
Display Areas on the R-Touch Main Terminal110
Fold out Quick Access Window114
R-Touch Cleaning Mode115
Functional Area R-Direct115
HOME Key116
Main Menu116
Main Settings Menu117
Special Functions118
System Menu119
Menu Operating Data122
Scale Menu125
Menu Service126
Water Spray System Menu128
Window Wiper Menu129
Configuration of Window Wiper Program131
Climate Control132
Oil Tank Heating134
Underfloor Heating135
Park Heating137
Light Control139
Configuration of Light Programs141
Ladder Light142
Individual Headlights143
Readjusting Warning Thresholds144
Warning and Status Indications on the R-Touch145
R-Touch Auxiliary Terminal150
Display Areas on the R-Touch Auxiliary Terminal151
Operation of Video System152
Switching between the Different Camera Views152
Configuration of Individual Camera Views153
Deleting an Individual Camera View156
Right Joystick157
Right Joystick - Operating Mode "Turtle157
Right Joystick - Operating Mode "Rabbit161
Left Joystick163
Switching Joystick Left Keys 18+19166
Radio Control167
Diesel Engine168
Start/Shut down Diesel Engine171
Engine Speed Adjustment172
Engine Speed Adjustment in Rabbit Operating Mode172
Engine Speed Adjustment in Turtle Operating Mode173
Power Reduction SCR System (Applicable for C-Diesel Engine and D-Diesel Engine)175
Power Reduction Adblue® Filling Level (Applicable for C-Diesel Engine and D-Diesel Engine)176
Power Reduction Adblue® Quality/System Error (Applicable for C-Diesel Engine and D-Diesel Engine)177
Power Reduction Process178
Diesel Particulate Filter179
(Abbreviated as "DPF", Applicable for D-Diesel Engine)179
Diesel Particulate Filter (DPF) Regeneration Applicable for D-Diesel Engine)182
Amendments or Supplements to the Mercedes-Benz Engine Operating Manual183
Operating Modes "Turtle" and "Rabbit184
Diesel Engine and Traction Drive Overspeed Warning185
Operating Mode Change186
Differential Lock187
Driving189
Driving, "Rabbit" Operating Mode191
Speed Limiting - Diesel Engine too Cold191
Selection of the Driving Direction (Forward/Backward) in Operating Mode "Rabbit192
Cruise Control193
Switching on Cruise Control193
Switching off Cruise Control194
Driving, "Turtle" Operating Mode195
Automatic Feed Switch-On196
Driving Backward in the Operating Mode "Turtle197
Road Traffic198
General198
Additional Axles201
Braking System202
Operating Brake202
Engine Brake203
Parking Brake204
Automatic Parking Brake (Only in the Operating Mode "Rabbit")204
Steering205
Steering in the Operating Mode "Rabbit206
Manual Rear Axle Steering207
All-Wheel Steering208
Put Rear Axle in Central Position209
Quick Description: Steering in the "Rabbit" Operating Mode210
Steering in the Operating Mode "Turtle211
Folding the Machine Out/In212
Folding out Machine with the Help of Automatic Folding in Front212
Folding out Machine with the Help of Automatic Folding at Rear214
Folding in Machine Automatically in Front216
Folding in Machine Automatically at Rear218
Folding out Machine Manually in Front220
Folding out Machine Manually at Rear225
Folding in the Machine Manually at Rear234
Folding in the Machine Manually in Front243
Loading Operation248
General Information Regarding Loading248
Safety Circuits for Loading Operation249
Switching on the Machine Drive249
Pickup Depth Setting251
Relieving the Pickup252
Relieving the Pickup Side Sections252
Relieving the Pickup Central Section253
Clearing Shields254
Beet Path256
Truck Conveyor (Drive A)259
Truck Conveyor Fast Motion260
Recleaner (Drive B)260
Sieve Conveyor Cleaner (Option)262
Fast Speed Sieve Conveyor Cleaning263
8-Set Pinch Roller Cleaning (Option)264
Beet Brake (Only for 8-Set Pinch Roller Cleaner)265
Infeed Conveyor (Drive C)266
Infeed Conveyor Fast Motion267
4-Part Pinch Rollers in the Pickup (Drive D)268
Conveyor Rollers (Drive E)270
Pickup Rollers (Drive F)272
Automatic Reversing Function for All Roller Drives274
Driving into the Beet Pile - Loading Mode START276
Loading a Transport Vehicle277
After-Loading Function277
Special Features During Loading278
Frozen Beet Pile278
Extremely Narrow Beet Pile279
END Load Mode280
Pick up Remaining Beets with Pile Pickup281
Water Spray System (Option)284
Structural Design of the Water Spray System284
Pickup Water Spray Nozzles285
Recleaner Water Spray Nozzles286
Filling Water Tank287
Filling Water Tank with Optional GEKA Coupling288
Operation of Water Spray System289
Setting of the Four Ball Valves in the Four Operating Modes289
Duo Water Spray System (Option)291
Operation of the Water Spray System291
Water-Saving Operation (Timer Control)293
Water-Saving Operation (Pressure Control)294
Configuring Water Spray Programs295
Cleaning of the Water Filter Screen295
Cleaning Filter Screen in the Water Nozzles296
Scales (Option)297
Design and Function297
Operation of Scales298
Scale Display Field and Menu299
Commissioning after Delivery of Machine300
Start/End Weighing301
Amount Limit Scales302
Reset the Currently Loaded Weight303
Run Scale Zeroing304
Scale Calibration307
Continuing Operation of Scales310
Scale Wizard Interface (Option)310
Reset Scale Counter311
Loading Target Weight312
Pump Distributor Gears313
Hydraulic System315
Pneumatic System318
Air Compressor319
Air Dryer319
Compressed Air Reservoir320
Central Lubricating System321
Central Lubricating System Mode AUTO322
Intermediate Lubrication in Central Lubricating System323
Filling up Grease Gun325
Video System326
Back Run Camera327
Central Mark Camera328
Cabin Roof Camera (Option with R-Connect Monitor)329
Recleaner Camera (Option)330
Truck Conveyor Camera (Option)331
R-View Cameras (Option)332
Electrical System333
Voltage Monitoring333
Battery Disconnect Relay334
Battery Main Switch Function334
Battery Emergency Stop Switch335
Shutting down the Machine During the Harvest Season336
Maintenance and Service337
Diesel Engine340
Dry Air Filter341
Changing Engine Oil in the Diesel Engine346
Refuelling with Diesel Fuel349
Fuel System351
Replacing/Draining Water of the Fuel Prefilter Insert at the Electric Pump353
Exchange Fuel Fine Filter and Prefilter on the Diesel Engine354
Bleeding the Fuel System356
Microorganisms in the Fuel System357
Cooling System Diesel Engine357
Cleaning of the Cooling System358
Coolant Check362
Change of Coolant363
Remarks of ROPA on the Coolant (General Information)364
Valve Clearance Adjustment364
SCR Exhaust After-Treatment with Adblue ® (Applicable for C-Diesel Engine and D-Diesel Engine)365
Exchange of Adblue® Filter Insert366
Exchange Diesel Particulate Filter (Applicable for D-Diesel Engine)367
Other Maintenance Work on Diesel Engine367
Pump Distributor Gears (PDG)368
Oil Change/Filter Exchange on Pump Distributor Gears370
Oil Cooler Pump Distributor Gears371
Hydraulic System372
Clean Hydraulic Fluid Cooler372
Hydraulic Oil Tank373
Hydraulic Fluid Change374
Cleaning Intake Sieves377
Exchange Suction Return Filter Element378
Replacing Pressure Filter Element383
Mechanical Drive for Steering Axles384
Cardan Shafts from Gearbox to the Steering Axles385
Maintenance Knuckle Joints of the Axles385
Manual Transmission (4-Gear)386
Axles389
Planetary Gears (Applies to both Axles)389
Differential Gears on Front and Rear Axle391
Pneumatic System393
Pickup394
Central Mark394
Pickup Gears395
Pickup Central Lubrication396
Removing and Installing Rollers397
Removing and Installing Pickup and Cleaning Roller398
Replacing the Fingers of the Pickup Rollers400
Removing and Installing Feed Rollers and Pinch Rollers401
Replacing Wear Flange404
Installing and Adjusting the Bearings of the Pinch Rollers or Conveyor Rollers405
Replacing Radial Shaft Seals (Simmer Rings) on the Gearbox405
Build-Up Welding406
Pile Pickup with Residual Beet Pickup407
Infeed Conveyor408
Tensioning Infeed Conveyor409
Replacing Infeed Conveyor Drive Wheels410
Recleaning411
Sieve Conveyor Cleaner411
8-Set Pinch Roller Cleaning413
Truck Conveyor415
Tensioning the Truck Conveyor415
Scales (Option)417
Settings on the Scale's Mechanics417
Remove Dirt Accumulated on the Scales420
Exchange Weighing Cell421
Rotary Drives for Swivel Arm and Truck Conveyor422
Chassis Energy Ducting Chain to Recleaner Swivel Arm424
Counterweight Arm425
Braking System426
Air Conditioning and Ventilation System427
Condenser Air Conditioning System427
Driver's Cabin Recirculating Filter428
Fresh Air Intake Filter in Driver's Cabin429
Condensate Drain in the Air Conditioner429
Folding down Air Conditioner430
Coolant Circuit433
Battery Maintenance435
Shutdown for a Longer Period of Time435
Mercedes-Benz Regulations for Diesel Engine Shutdown437
Dismantling and Disposal438
Malfunction and Remedies439
Safety Circuits441
Fuses442
Fuses in the Battery Case443
Fuses in the Central Electrics444
Fuses in the Driver's Cabin Seat Console446
Electronic LED Fuses in Wago Pins447
Fuses on Pcbs in the Central Electrics448
Pcb a451
Pcb B453
Pcb C455
List of Relays456
Color Codes for Electric Wiring457
Troubleshooting Via the R-Touch457
Overview of Diagnostic Menus460
Digital Inputs462
Analogue Inputs463
Inputs Speed464
Outputs PWM + SW465
Functions469
Diesel Engine470
Air Conditioning System471
Park Heating472
Control Elements473
Camera479
Pfreundt Scale480
Telematics481
CAN Bus483
Ethernet484
Terminal Exchange485
Jump Starting and Charging the Battery486
Welding on the Machine489
Towing490
Connecting Salvaging Aids492
Jacking up for Wheel Change492
Releasing the Parking Brake Manually494
Hydraulic Valves495
Central Lubricating System - Bleeding and Removal of Blocks495
Emergency Operation Ventilator Drives Emergency Operation496
Adjusting Brake497
Park Heating498
Lists/Tables/Plans/Diagrams/Maintenance Verification499
Lubricating and Operating Supplies501
Maintenance Table503
Lubricating Plan (Lubrication with Grease Gun)507
Lubricant Specification Table508
Product Data Sheetropa Hydrofluid HVLP 46509
Product Data Sheet ROPA Engineoil E9 5W-30510
Product Data Sheet ROPA Engineoil E7+ 10W-40511
Product Data Sheetropa Gearoil GL5 90512
Product Data Sheet ROPA Gearoil GL5 75W-90 Synth513
Product Data Sheet ROPA Gearfluid ATF514
Product Data Sheet ROPA Multi Temperature Grease 2515
Diesel Engine Coolant516
Filter Cartridges, V-Belts518
Lubricating Plans519
Central Lubrication Circle 1 Pickup519
Central Lubrication Circuit 2 Chassis with Sieve Conv. Cleaner520
Central Lubrication Circuit 2 Chassis with 8-Set Pinch Roller Cleaner521
Central Lubrication Circuit 3 8-Set Pinch Roller Cleaner522
Central Lubrication Circuit 2 Chassis with Stone Remover523
Maintenance Verification525
Maintenance Verification Oil Change + Filter Exchange525
Maintenance Confirmation527
Torque Table for Bolts and Nuts (Nm)528
Adblue® Information Sheet529
Confirmation about Instructions Given to the Driver532
Safety Instructions533
Layout Chart for a Beet Pile535
Notes for Beet Harvesting536
Practical Tips536
ROPA Handover Confirmation537
ROPA First Use Record539
Index541

ROPA Maus 6 - Machine Maintenance and Service Procedures

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