Strautmann Giga-Trailer 1840, Giga-Trailer 1840 DO, Giga-Trailer 2246, Giga-Trailer 2246 DO, Mega Trailer II DO Operating Instructions Manual
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Ausgabe 540 00 903/3
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Landmaschinenfabrik • Bielefelder Straße 53 • D-49196 Bad Laer
Tel.: 05424/802-0 • Fax: 05424/80264 • E-Mail: kontakt@strautmann.com • www.strautmann.com
Operating Instructions
/06
According to EC Directive 89/392/EWG
We, the company B. Strautmann & Söhne GmbH & Co. KG
To comply with the safety and health requirements of the named EC Directive, the following
2006
Dipl. Kfm. W. Strautmann R. Kleine – Niesse
Managing Director Senior Manager, Construction
Vehicle Technology
Dr. K.-P. Strautmann D. Werries
Managing Director Senior Manager,
Quality Control
1. Foreword ......................................................................................................... 2
2. Proper Use ....................................................................................................... 3
3. Accident Prevention Information ......................................................................... 4
3.1 General and Hazard warning Pictograms ........................................................... 4
3.2 Linkage and Traction Mode ............................................................................... 7
3.3 P.T.O. Shaft Operation ...................................................................................... 9
3.4 Wheels, Tyres, Brakes ....................................................................................... 10
3.5 Hydraulics ....................................................................................................... 10
3.6
Maintenance - General ..................................................................................... 11
3.7 Road Traffic Regulations .................................................................................... 11
4. Technical Data ................................................................................................. 12
5. Tyre Pressure Chart ........................................................................................... 13
6. Hydraulic System .............................................................................................. 14
6.1 Regulating the floor conveyor ............................................................................. 14
6.2 Electro-hydraulics (special feature) ...................................................................... 15
6.3 LS Connection .................................................................................................. 15
7. Operation ....................................................................................................... 16
7.1 Electric Control Box (standard) ........................................................................... 16
7.2 Electric Control Box (special feature) ................................................................... 17
8. Technical Data and Notes on practical Usage ...................................................... 18
9. Hitching to Tractor ............................................................................................ 19
9.1 Universal Drive Shaft Adjustment ........................................................................ 20
9.2 Forced Steering ................................................................................................ 21
10. Practical Usage (loading/unloading) .................................................................. 23
11. Maintenance and Care ..................................................................................... 23
11.1 Floor Conveyor Chains ...................................................................................... 23
11.2 Shredder drum – drive chains ............................................................................ 23
11.3 Hydraulic Oil Filter (for electro-hydr.) ................................................................... 24
11.4 Axles .............................................................................................................. 24
11.5 Tyres ............................................................................................................... 25
11.6 Torques for metric screws ................................................................................... 26
12. Compressed Air Brake System ............................................................................ 27
12.1 Coupling to Tractor ........................................................................................... 27
12.2 Brake System Components ................................................................................. 28
12.3 Brake Plan ....................................................................................................... 29
13. Lubrication ....................................................................................................... 30
13.1 Lubrication Chart ............................................................................................. 31
14. Circuit Diagrams .............................................................................................. 32
14.1 Hydraulic Circuit Diagram ................................................................................. 32
14.2 Electro-hydraulic Circuit Diagram ........................................................................ 33
14.3 Wiring Diagram (standard) ................................................................................ 34
14.4 Wiring Diagram (special feature) ....................................................................... 35
15. List of Malfunctions – Hydraulics ......................................................................... 36
16. List of Malfunctions – Electric .............................................................................. 37
Contents Page
OPERATING INSTRUCTIONS
Page 2 Giga-Trailer
1. Foreword
Dear Customer
We thank you for the confidence you have shown in us.
You have purchased a top-quality technical product which will enable you to improve your operating results.
Strautmann’s many years of experience guarantee you optimum performance, quality and ease of operation.
Safety
Before putting the machine into operation, please read these operating instructions and observe the regulations
and advice on safety.
Throughout these operating instructions all points which relate to your
safety have been marked by a warning triangle. Please pass all safety
instructions on to other users.
The hazard-warning and safety-advice signs provide important information on safe operation. Observing them is
in the interests of your own safety.
Due to the many different types of machines and special features available, not every variation described here is
to be found on your machine.
Should you have any further questions, please do not hesitate to contact your Strautmann representative or the
factory.
Machine References: This information should always be to hand. Please quote when ordering
spare parts.
Therefore please copy down the machine ref. from the vehicle ident. plate
of your new trailer into the space provided below:
Vehicle – ID.-No: Model Year of Manufacture
OPERATING INSTRUCTIONS
Giga-Trailer Page 3
2. Proper Use
The Strautmann chopper trailer has been designed for exclusive use in agricultural work. Its intended function is
the transport and spreading of chopped forage material.
Any use beyond this will be considered as improper.
The manufacturer will not be held responsible for any damage
resulting thereof. The user will solely bear the risk.
Adherence to all operating, servicing and maintenance conditions specified by the manufacturer will also be part
of ‘proper use’.
The vehicle may only be operated, maintained and serviced by people who are acquainted with the said vehicle
and its equipment and have been instructed as to the dangers involved.
Any unauthorized modifications carried out on the machine will invalidate the product liability and the
manufacturer’s liability for any damage resulting thereof.
Any costs arising from modifications or malfunctions due to peculiarities of the tractor or carelessness on the part
of the operator will not borne by the Strautmann Company.
Only genuine Strautmann spare parts may be used!
OPERATING INSTRUCTIONS
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3. Accident Prevention Information
For your safety and accident prevention
Most farming accidents are caused by non-observance of the simplest safety rules. Careful observance of the
following suggestions and rules helps prevent accidents from the very outset.
3.1 General and hazard warning pictograms
Fig. 1
Attention: Torn-off or unreadable signs or pictograms must be replaced immediately
by new ones.
Pictograms or signs can be procured from specialist stores or directly from Strautmann’s
spare-parts warehouse (Tel.:+49(0)5424/ 802-31)
on both sides
on both sides
on both sides
on both sides
OPERATING INSTRUCTIONS
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Please observe the general accident prevention regulations in addition to the information given in these operating instructions; any other generally recognized safety,
industrial medicine and traffic regulations are to be complied with.
Familiarize yourself with all the equipment, actuating elements and their functions
before beginning work on the unit.
When you have already started work it will be too late!
The machine is designed for single-handed operation. The operator may only operate the machine and actuate its functions when there are no other persons in the
danger zone (please pay particular attention to children).
Foreign objects in the forage can be slung out during discharge by the spreader
drums.
All safety guards must be properly mounted at all times.
Never open or remove safety guards while the motor is running.
Do not enter the loading area while the P.T.O. shaft/hydraulic system is connected
and the motor is running.
870 07 101
870 07 119
870 07 116
870 07 117
OPERATING INSTRUCTIONS
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Do not reach into the discharge opening while the P.T.O. shaft is connected and the
motor is running.
Never try to clear blockages while the motor is running.
Never take hold of the moving floor conveyor rails (risk of fingers/hand being crushed).
Before every machine start-up, put the hydraulic controls and electro-hydraulic switches to
zero position.
Before carrying out any work (e.g. maintenance and repairs) on the machine, switch off
the motor and remove the ignition key.
870 07 113
870 07 115
870 07 120
OPERATING INSTRUCTIONS
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3.2 Linkage and Traction Mode
Vehicle brake system:
The trailer can be equipped with various types of brake system (acc. to the relevant
national regulations).
a) Compressed air brake (two-line air brake system)
b) Hydraulically operated brake system
The tractor brake system must match the relevant trailer brake system.
Before starting up, make sure that all road safety and operating safety regulations
have been complied with and that the brake system and lighting function correctly.
Where compressed air brake systems are used, check that the brake power control is
correctly positioned. (see note 19.2)
Hitch the vehicle to the tractor in the prescribed manner. Be particularly careful during
hitching and unhitching!
Ensure that the tractor hitch has been approved to take the hitch eye fitted to the trailer.
If a ball hitch 80 is being used take particular care that the crop guard to ball clearance is adequate when driving on stacks.
To attain greater freedom of movement on the tractor-side “Scharmüller ball head
hitch”, use the shorter crop guard 1 (Scharmüller order no. 02481316).
Damaged or bent hitching equipment is a threat to safety and should not be used
again.
Before every start-up or drive make sure that there is no-one in the danger zone. Watch
out in particular for children.
When reversing make sure you have a good all-round view. You may need an additional person to guide you.
After hitching or unhitching is completed, adjust the support stand as required and
secure.
Before loading check that the back panel and/or inspection door is/are closed. Fold
up the inspection ladder.
Do not put down loaded vehicles onto supports.
Before unhitching make sure the support stand is in a stable position. Secure vehicle
against rolling (parking brake, chocks).
870 07 126
OPERATING INSTRUCTIONS
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Independent braking must be prevented (lock pedals) on all runs with trailers.
Do not go between tractor and trailer while the engine is running.
Observe permitted axle loads, tongue loads and laden weights, in particular the maximum
tongue load which the trailer hitch can take on.
It is forbidden to go within the chute rotation range of the hydraulically swivelled back panel.
When maintenance and repair work is being carried out with the back panel open, the latter
must be secured by closing the stop cock.
Keep an eye on the reactions of your tractor on the road when the load is unevenly distributed
due to loading and auxiliary parts.
Always adapt your driving speed to the prevailing local conditions. When driving up and
down steep hills as well as across hills avoid sudden cornering.
Ensure adequate steering and braking performance.
Single and tandem axle vehicles with tongue load are in danger of tipping over if they have
been unevenly loaded, especially during hitching or in uncoupled condition. Ensure sufficient
tongue load!
Please take care during driving and unloading on the stack that the vehicle is kept stable
(danger of tipping over).
When driving over stacks with soft sides keep to the middle as the danger of tipping over is
particularly high. Take care to stay at a safe distance from anyone in the vicinity!
Lock the steering axle when driving across slopes and over stacks.
This is recommended for driving on public roads.
If the steering axle is not locked, cornering at high speeds is not permitted.
870 07 104
870 07 119
870 07 130
OPERATING INSTRUCTIONS
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3.3 P.T.O. Operation (only with discharge unit)
Observe the operating instructions of the drive shaft manufacturer.
Only use the drive shafts specified by the manufacturer.
Mount and dismount the drive shaft only when the engine has been switched off and the ignition key removed.
Only use the drive shaft with the proper safety guard and in good condition and with the protective tubes secured against twisting.
Ensure sufficient tube overlapping of the drive shaft.
When cornering and with overrunning brake, keep to the permitted bending range and ensure
adequate drive shaft leeway.
Before switching on the P.T.O. shaft make sure that the selected speed and sense of rotation of
the tractor P.T.O. corresponds to the permitted speed and sense of rotation of the machine.
Before every drive shaft start-up check that the locking mechanisms have locked into place
properly.
Never switch on the drive shaft with the engine switched off.
If drive shafts with overload or free wheel clutch are used, these types of clutch must be
mounted on the trailer side.
After the P.T.O. shaft has been switched off, the unit driven by it can run on.
Stay out of the danger zone until all the equipment has come to a standstill.
870 07 131
OPERATING INSTRUCTIONS
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3.4 Wheels, Tyres, Brakes
To ensure operation safety, wheels, tyres and brakes are subject to special checks.
Retighten wheel nuts after a short period of use and after every 50 hours of operation (see note 11.3)
Check air pressure regularly (see note 5)
Check tyres as well as wheels and brakes regularly for wear and tear. Check brake lines regularly for leaks and
good general condition.
Connect brake system properly before start-up.
Adjustments and repairs to the brake system are only to be carried out by authorized brake service centres or
qualified personnel.
Fitting tyres and wheels requires specialist knowledge and equipment.
If you wish to use a different tyre size, please consult the vehicle manufacturer first.
3.5 Hydraulics
Check the hydraulic lines and hose as well as fittings and parts for damage and leaks regularly. Hydraulic hoses
should be replaced every 6 years. Only use spare parts that meet the manufacturer’s requirements.
Ensure that the hydraulic hoses never bend or rub.
When connecting to tractor, make sure the hydraulic system is depressurised both on the tractor and machine side
and make sure the hydraulic connections do not get mixed up (accident risk due to reversed functions). Keep the
hydraulic couplings clean.
Attention: The hydraulic system is under high pressure. Before carrying out any
maintenance or repair work, always depressurise the system.
Liquids (hydraulic oil) escaping under pressure can penetrate the skin causing serious injuries
and infections.
Never try to block leaks with your fingers.
If injuries occur, consult a doctor or medical services immediately.
870 07 123
OPERATING INSTRUCTIONS
Giga-Trailer Page 11
3.6 Maintenance – General
Any repair, maintenance, cleaning and conversion work and the clearing of malfunc
tions is only to be carried out with the drive system switched off, the hydraulic system
depressurised, the electrical system de-energised and the tractor engine stopped!
Remove the ignition key!
Check regularly that nuts and bolts have not loosened and retighten if necessary.
Observe and maintain the correct torque settings!
Check and mount safety guards!
Dispose of oils, greases and filters according to regulations.
Ensure adequate, safe support and stability.
Attention!
If work is being carried out under the hydraulic back panel, the latter must additionally
be protected by the stopcock on the vehicle front panel.
3.7 Road Traffic Regulations for Germany
In the case of exported vehicles, the road traffic regulations in force in the relevant country shall apply.
1. Registration (§ 18)
Trailers running at a speed of over 25 km/h are always subject to registration.
2. TÜV – Re-examination (§ 29)
Trailers with an admissible maximum speed of 40 km/h are subject to this examination by the TÜV every 24
months.
Trailers with an admissible maximum speed of over 40 km/h are subject to this examination every 12 months.
Trailers with an admissible gross weight of over 10 tons must also undergo a safety test every 6 months or, in the
case of vehicles on the road for the first time, starting with the initial test after 24 months.
3. Brakes (§ 41)
The chopper trailer is fitted ex-works with a properly functioning brake system (two-line air brake system). Please
have any readjustment or initial adjustment of brakes done by a renowned brake service centre
870 07 120
OPERATING INSTRUCTIONS
Page 12 Giga-Trailer
4. Registration Number Plate (§ 18)
Trailers over 25 km/h require their own registration number plate.
5. Obligatory Insurance (§ 29)
Trailers over 25 km/h require a third-party insurance.
6. Driving Licence (§ 4 and 5 or driving permit – ordinance – FeV)
Lof vehicles and vehicle combinations up to a maximum speed of 60 km/h may be driven with a class T driving
license. However over 40 km/h a minimum age of 18 years is required.
(If the vehicle is to be driven with a licence class L, a sign showing 25 km/h (§ 58, STVZO traffic regulations)
must be displayed on the rear of the vehicle.
4. Technical Data
fig. 2
OPERATING INSTRUCTIONS
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5. Tyre Pressure Chart
up to 40 km/h Axle load
2,55 m 16 to 18 to max.
600/50 - 22.5 12PR bar 2,0 - 2,7
600/55 - 22.5 12PR bar 1,5 1,8 2,7
700/45 - 22.5 12PR bar 1,5 1,7 2,3
700/50 - 22.5 12PR bar 1,5 1,5 2,5
600/55 - 26.5 12PR bar 1,5 1,7 2,7
600/55 - R 26.5 165D bar 1,5 1,8 4,0
650/55 - R 26,5 175A8 bar 1,5 1,9 4,8
680/55 - R 26,5 165D bar 1,4 1,7 3,2
700/50 - 26.5 12PR bar 1,5 1,5 2,5
710/45 - 26.5 169A8 bar 1,5 1,8 2,4
710/50 - R 26.5 170D bar 1,3 1,5 4,0
750/45 - R 26.5 178A8 bar 1,3 1,5 4,8
800/40 - R 26.5 172D bar 1,5 1,8 4,0 1 bar = 14,5 psi
Machine Type 1840 1840 DO 2246 2246 DO
Perm.veh.gross weight, acc. to tyres used* to 18 / 20 18 / 20 18 / 20 18 / 20
perm.axle load, acc. to tyres used* to 16 / 18 16 / 18 16 / 18 16 / 18
perm.tongue load kg 2000 2000 2000 2000
unladen weight kg 6700 7100 7800 8200
A = overall length m 8,58 8,58 9,64 9,64
B = overall width m 2,63 - 2,76 2,63 - 2,76 2,65 - 2,80 2,65 - 2,80
C = extension width m 2,55 2,55 2,55 2,55
D = overall height m 3,95 3,95 4,00 4,00
E = loading area length m 6,76 6,76 7,71 7,71
F = loading area width (conical) m 2,34 - 2,38 2,34 - 2,38 2,34 - 2,38 2,34 - 2,38
G = loading area height m 2,32 2,32 2,32 2,32
H = track width m 2,03 2,03 2,05 2,05
I = Axle spacing m 1,50 1,50 1,60 1,60
J = drawbar height top hitch m 1,00 1,00 1,00 1,00
K = drawbar height bottom hitch m 0,55 0,55 0,55 0,55
load capacity m³ 37,0 37,0 42,5 42,5
max. hydraulic pressure bar 210 210 210 210
oil flow rate l/min 40 - 70 40 - 70 40 - 70 40 - 70
min. power requirement KW (PS) 96 / 130 96 / 130 110 / 150 110 / 150
min. weight of towing vehicle kg 5000 5000 5500 5500
P.T.O.shaft speed (for discharge unit) rpm - 1000 - 1000
voltage supply Volt 12 VDC 12 VDC 12 VDC 12 VDC
noise level dBA 79,3 82,2 79,3 82,2
*If drawbar bottom hitch and Scharmüller ball hitch eye or Scharmüller ring hitch eye are used, the tongue load and the
overall gross weight will increase in each case by 2000 kg. This does not apply to flanged Scharmüller ring or ball hitch
couplings and only up to 40 km/h.
*see typeplate
Diagrams, technical data and weights may be altered from time to time due to technical advancement and are therefore not
binding for every delivery
If the vehicle width exceeds 2.55 m.
due to wide tyres, the German traffic
(StVZO) regulations permit a max.
1.5 bar tyre inner pressure.
OPERATING INSTRUCTIONS
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6. Hydraulic System
Every hydraulic function is directly connected with and controlled from the tractor.
The tractor requires a double- or single-acting control valve with free return (red = supply; blue = return) for
the floor conveyor drive.
A free return direct to the hydraulic oil tank is preferable as it involves less tailback pressure.
A double-acting control valve on the tractor is required for each of the following functions: Tailgate, steering
axle, hydr.upper front panel or hydr. stand. The control valve requires a floating position for the steering
axle.
As a special feature, an electro-hydraulic remote control is available for controlling. The hydraulic block is
constructed in modular design so that optional equipment can be fitted at a later date by simply extending
the hydraulic block. The flow regulator for the neutral circuit, the pressure relief valve and the floor conveyor
valve are to be found in the pump inlet plate. Speed adjustment for consumers other than the floor conveyor
is regulated from the adjusting screw on the intermediate plate.
6.1 Regulating the floor conveyor
All Giga Trailers (with or without discharge unit) are equipped
with hydraulic floor conveyor drive. The floor conveyor speed
can be variably adjusted infinitely by turning knob 4 fig.3
(on the left, vehicle rear).
The floor conveyor return can be actuated by pressing button 8.
Fig. 3
Attention: Only reverse floor conveyor briefly
The fast run floor conveyor speed (special feature) can be switched
on from the toggle switch on the control box.
OPERATING INSTRUCTIONS
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6.2 Electro-hydraulics (special feature)
The hydraulic system can be driven as an open system with max. 80 l. /min. The tractor requires a double- and a
single-acting control valve with free return (red=supply;blue( thick hose)=return for the hydraulic connection.
A free return directly to the hydraulic oil tank is preferable as it involves less tailback pressure. The flow regulator
for the neutral circuit and the speed adjuster for the small consumers such as pick-up, the articulated drawbar,
tailgate etc. are to be found in the pump inlet plate. The speed adjustment for consumers other than floor conveyor
and cross conveyor is regulated from the adjusting screw (1). The flow rate can be set from 1 – 16 l. / minute.
If the tractor control valve is actuated, oil flows through the
hydraulic system.
(Attention: Always ensure correct flow direction!)
The tractor control valve lever should always be locked in
place so that it does not have to be held onto constantly.
The functions required can now be selected directly from
the control box using the toggle switches.
Attention: Before depressurising the hydraulic system again
via the tractor control valve, the toggle switches on the
electrical control box must be put to zero position.
High accident risk!
Fig.3.1
6.3 LS – Connection
The self-loading trailer hydraulic system can be regulated with the tractor LS system. (The hydraulic pump’s pressure and delivery rates are adjusted to current need).
For this purpose the LS connection on the tractor is connected up to the LS connection (2) fig. 3.1 on the self-loading trailer control valve.
The supply is connected directly to the hydraulic pump.(Not via the tractor control valve).
Attention: Never use the pressure connection without the LS connection.
The pressure regulator must be blocked by screwing in the bolt (3) fig. 3.1 as far as it will go. The regulating
current cut-off must be set to open system.
Attention: If connecting via the tractor control valve, the bolt (3) will have to be screwed out again as far as it will
go.
Tractor Trailer
OPERATING INSTRUCTIONS
Page 16 Giga-Trailer
7.1 Electric Control Box (standard)
1. Control: on
2. Control: off
3. Check light: control on
4. Floor conveyor speed: level I
5. Floor conveyor speed: level II
6. Work lights: on (not permitted
on public roads)
7. Work lights: off
8. Check light: tailgate open
9. Check light: work lights: on
Fig. 4
7. Operation
The Strautmann “Giga Trailer” chopper is equipped with an electric control box.
In this electric control box, which is mounted in full view of the driver, you will find the switches and check
lights (acc. to model) which the tractor driver has to operate and/or control.
Wherever necessary the toggle switches are fitted with a ‘locked’ position so that they do not have to be
continually held.
OPERATING INSTRUCTIONS
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7.2 Electric Control Box (optional equipment)
Fig. 5
1. Control: on 12. Hydr. stand: down
2. Control: off 13. Hydr. stand: up
3. Check light: control on 14. Front panel grid: open
4. Floor conv. speed: level I 15. Front panel grid: closed
5. Floor conv. speed: level II 16. Work lights: on
6. Floor conveyor: on (not permitted on public roads)
7. Floor conveyor: off 17. Work lights: off
8. Tailgate: open 18. Check light: tailgate open
9. Tailgate: closed 19. Check light: work lights on
10. Steering axle: locked 20. Check light: speed control
11. Steering axle: free
In case of power failure, it is possible to actuate the control
valve by pressing the starter (7) on the solenoid.
OPERATING INSTRUCTIONS
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8. Technical Data and Notes on practical Usage
1. The system can only be operated at 12 volts
2. Connecting terminal 15 / 30 – plus; 31 – minus
3. Hydraulic system maximum flow rate 70 l/min.
4. Hydraulic system maximum pressure 210 bar
5. Supply (marked red)
6. Return (marked blue)
7. Tailback pressure at tractor must not exceed 10 bar
8. Hydraulic block torque setting 25 – 28 Nm.
9. Every unit must possess an emergency hand-operated actuator. If the electrical system breaks down,
the magnets can be actuated with a sharp object.
10. When hitching, make sure that the hydraulic couplings are perfectly clean. If dirt gets into the hydraulic
system, malfunctioning is likely to occur.
11. The hydraulic couplings on the trailer must match those of the self-loading or discharge trailer. On
certain types of trailer, for example, John Deere, Ford or Fiat, the hydraulic couplings are fitted with
a ball. If this kind of coupling is used, tailback pressure or complete closure of the coupling can occur.
12. Protect the control box against humidity.
13. When driving for longer periods on the road, it is advisable to switch off the tractor hydraulic system.
This prevents the system from heating up unnecessarily.
14. During long downtimes the self-loading and discharge trailer electrical systems should be switched
off as otherwise the consumers connected up to it will cause the tractor battery to discharge completely.
OPERATING INSTRUCTIONS
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9. Hitching to Trailer
Install electric switch box on the trailer and plug into socket.
If it is not already fitted, a 3-pin socket must be mounted for the electrical remote control.
If it is not already fitted, a 3-pole socket must be mounted for the electrical remote control.
- Connect hydraulic hoses (supply and return) correctly.
- Connect up lighting to tractor socket and test correct functioning
- Hitch up vehicle to tractor properly.
- Check that the hitch to hitch eye combination (drawbar) complies with the relevant national road traffic
regulations/laws.(do not forget tongue load)
- Push on drive shaft and adjust lengths if necessary. Mount the drive shaft slip clutch on the machine side.
Attention: Even if the position is unfavourable, a minimum overlap of 1/3 of the lemon tubes must be reached.
Please follow the operating instructions of the drive shaft manufacturer.
Fig. 6
The height of the drawbar can be adjusted by removing the modules dia. 150 on the rubber buffers.
The support winch can be adjusted by means of the 4 screws (2). The support winch is fitted with a two-speed
transmission.
Crank (3) pushed in = 1st gear, pulled out = 2nd gear
Please note:
Always depressurise the hydraulic system before unhitching the trailer. When the trailer is unhitched, put all the plugs with quick release couplings in the holders provided.
Close compressed air hose coupling heads and place in blank couplings.
OPERATING INSTRUCTIONS
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9.1 Universal Drive Shaft Adjustment
For length adjustment slip on the drive shaft halves on both sides in the
shortest operating position. Hold them side by side and mark them.
A=approx. 110-120 mm.
Shorten the inner and outer tubes equally.
Shorten the inner and outer slide-in sections by the same length as the protective
tube.
Deburr the cutting edges and remove the filings carefully.
Fig.7
OPERATING INSTRUCTIONS
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9.2 Forced Steering (only with bottom hitch)
Fig. 8
7
Fig. 9 1 2 3 closed Fig. 10
Installing Forced Steering
- Ball-, hitch hook- or piton-fix towing mechanisms are all suitable for use with forced steering. To ensure that the
forced steering functions properly the hitch eye must be positioned over the bolt with as little play as possible.
- Attach the coupling ball (1/fig.8) for the steering rod (2) to the tractor securely at a distance of 245 mm from
the hitch eye.
cyl.left cyl.right
drawbar
pressure
gauge
diaphragm tank 60bar
test connection
3-way valve
hand-operated
pump
cyl. left steering axle cyl.right
OPERATING INSTRUCTIONS
Page 22 Giga-Trailer
- The coupling ball is to be attached at the same height and at right angles to the towing mechanism.
Misalignment of levels can result in different steering angles.
- After the steering rod has been fitted, swing round the tractor steering to its limit until the tractor wheels touch
the collision guard (3). The swing limit (4) must not restrict the axle. At the maximum steering angle, the
cylinders should still have at least another 10 mm way remaining. If this is not the case, the collision guards
will have to be adjusted by the customer.
Check all free space and possible steering angles for collision.
After fitting is completed, open the stopcocks 1-3 fig. 9 under the vehicle completely for track-adjustment of
steering. Pump up the steering system to 60 bar with the pump (7) which is mounted on the vehicle.
After driving 20 metres straight ahead, close the cocks. The system is now ready for operation.
Check the pressure in the system regularly. If there is any deviation, repeat the above procedure.
Use the bolt (5) to secure the steering rod before manoeuvring the machine.
The towing mechanism shown here is only one example of the many types of hitch to be found on tractors so
that in everyday practice a different method of mounting the towing device can be used to suit the situation.
However to ensure correct functioning of the steering, the main points given in the above description should be
taken into consideration.
Bleeding the Forced Steering
1. Check the oil level in the pump container and refill as needed (Hydr.-oil VG 46)
2. Two persons are required to bleed the forced steering.
3. Uncouple the steering rod from the tractor. Do not lock.
4. Screw out all the sealing plugs on all the hydraulic cylinders. Two master cylinders on the drawbar and
two steering cylinders on the steering axle.
5. Open ball cock no. 1
6. Pump oil into the system with the pump until bubble-free oil emerges from the openings on the piston
crown side of the cylinder mounted on the left in direction of travel on the steering axle and the righthand cylinder on the drawbar.
7. Screw in the sealing plugs again on the piston crown side of the cylinders and open ball cock no. 1.
ATTENTION: Continue to pump while the screws are being closed.
8. Open ball cock no. 2
9. Pump oil into the system with the pump until bubble-free oil emerges from the openings on the piston
crown side of the cylinder mounted on the right in direction of travel on the steering axle and the lefthand cylinder on the drawbar.
10. Screw in the sealing plugs again on the piston crown side of the cylinder and then close ball cock no. 2.
ATTENTION: Continue to pump while the screws are being closed.
11. Open ball cock no. 3.
12. Pump oil into the system with the pump until bubble-free oil emerges from the openings on the connecting
rod side of all four mounted cylinders.
13. Screw in sealing plugs again on the connecting rod side of the cylinders and then close ball cock no. 3.
ATTENTION: Continue to pump while the screws are being closed.
14. Raise the steering axle until the wheels no longer touch the ground.
15. Bring the steering cylinder to the same level and drop the axle again.
16. Check that the master cylinders have been run out to the same degree. If this is not the case, continue
with step no. 17.
17. To adjust the master cylinders, open the ball cock which releases the oil supply to the piston side of the
shorter master cylinder and open the sealing plug on the steering cylinder on the piston crown side (do
not completely unscrew) which is connected to the piston crown of the second master cylinder.
18. Pump slowly until both master cylinders reach the same length. Close ball cock and sealing plugs again.
19. Open all the ball cocks, preload system to 60 bar and close the ball cocks again.
OPERATING INSTRUCTIONS
Giga-Trailer Page 23
10. Practical Usage
Loading
To front-load onto the vehicle during forage harvesting, the upper part of the front panel can be swivelled down
hydraulically.
Unloading
- Fully open hydraulic tailgate.
- Switch on hydraulic floor conveyor.
- Do not switch to floor conveyor level 2 before the vehicle has half emptied.
- In the case of Mega-Trailer DO, switch on the shredder drums via the tractor P.T.O. shaft.
Switch on the hydraulic floor conveyor.
- Adjust your driving over the stack so that forage does not pile up behind the trailer.
Practical Tip
To discharge the last forage remaining in the vehicle, we recommend switching off the drive shaft together with the
shredder drums and running the trailer empty on the hydraulic floor conveyor.
11. Maintenance and Care
Check all nuts and bolts regularly and re-tighten as required.
11.1 Floor Conveyor Chains
The floor conveyor chains are self-tensioning. If the maximum tension way of this automatic system has become
overstretched after long periods of use, 2 or 4 links will have to be removed from each round steel chain.
The spring tension should be set to 3 - 10 mm (see fig. 11) with the adjusting screw (5).
5
Fig. 11
To shorten floor conveyor chains
Shorten the floor conveyor chains as follow:
1. Let the floor conveyor run on until the chain connecting links reach the upper platform area.
2. Loosen the adjusting screw completely (see fig. 11)
3. Shorten chain lengths by an equal amount (2 or 4 chain links from each one)
4. Re-tension floor conveyor as described in 11.1.
11.2 Shredder drum – drive chains
Attention: Only open shredder-drum-drive protective hood when the tractor is switched off.
The shredder drum drive chains are fitted with automatic chain tensioners.
If the max. tension way is used up, the chain tensioner has to be loosened and readjusted in the slotted hole.
OPERATING INSTRUCTIONS
Page 24 Giga-Trailer
11.3 Hydraulic Oil Filter (for electro-hydraulic system)
The filter element (1) must be replaced after approx. 250 hours of operation.
Thereafter as required, but at least every 1000 hours of operation.
Check the O-ring (2) for damage.
Clean the filter hood (3). The filter element cannot be cleaned.
Soiled filters cause the oil to overheat.
Filter element order no. 870 01 773 (for filter HD 069 – 168)
O – ring dia. 53.6 x 3.5 order no. 870 08 702
11.4 Axles
Never overload axles. Overloading shortens the service life of the bearings and causes damage to the axles. In
addition the following may cause unnecessary wear etc. and should be avoided: Hitting kerbs, driving too fast.
Wheel brakes must always be set correctly to maintain operational safety.
Maintenance Schedule: Axles
After first working runs: Check state of wheel nuts. If necessary, retighten wheel nuts (M 22 x
1.5 = Md 630Nm). Check leeway of wheel hub bearing.
After 50 service hours: Check leeway of wheel hub bearing.
Every 100 service hours: Grease brake camshaft bearing (not applicable with nylon
bushings). Check brake lever setting and adjust if necessary.
Every 500 service hours: Check leeway of wheel hub bearing: remove dust cap and
split pin, tighten axle nut until hub run almost stops and loosen
up again to next split pin hole. Fix the nut by split pin and test run.
Every 1000 service hours: Lubricate wheel hub bearing with roller bearing grease. Check
brake linings for wear. If necessary fit new brake linings.
This maintenance schedule has been designed for medium axle loading and brake wear. With heavier use, and
in particular higher demands on the brakes, shorten the maintenance intervals accordingly.
Check air pressure regularly. (see note 5)
Fig. 12
OPERATING INSTRUCTIONS
Giga-Trailer Page 25
11.5 Tyres
Good tyre economics is a question of regular checks and driving with the correct tyre pressure. If you follow the
advice given below, your will gain the most benefit from your investment.
1. Check the tyre pressure every 2 weeks at least. If the machine hasn’t been used for a longer period of
time, check the tyre pressure before driving off. Always make sure that the tyre pressure is correct and
adapted to the load and type of work, which the vehicle in question generally carries out.
2. Never overstrain the tyres.
3. Make sure the caps are on the valves and have been tightened.
4. It is best to check the tyres during operation for “folds” or other abnormal deformation. Remove any
stones, gravel, nails and other foreign objects caught up in the tyres before they work themselves further
in. Deep tears should be repaired as soon as possible.
5. If the tyres are not to be used for a longer period of time, remove load to prevent deformation. ‘Loose’
tyres should be kept in a dark place, out of the way of oil and other chemicals. Do not put tyres near
electric motors otherwise the ozone generated by this equipment will dry out the rubber.
Effects of different Tyre Pressures in use on Farm and Meadow Land
The power required to draw a wheel over a field is called ‘rolling resistance’. This increases considerably if the
tyres burrow or sink into the ground. Low tyre pressures increase the contact surface of the tyres in comparison to
high pressures. By using wide tyres with low tyre pressure the tyres stay on the surface better and the rolling re
sistance decreases. Drawing the vehicle or equipment then requires less power, fuel consumption falls and time is
saved. In addition less wheel imprints are left, thus avoiding destructive soil compaction. A larger contact surface
enables more effective power transfer. Unnecessary damage to ground structure is avoided and fuel consumption
reduced. The load is carried by the air in the tyres. This is why it is very important to choose the right size of tyres
and the right tyre pressure for each vehicle and job. A tyre with low pressure is softer and therefore causes less
damage to the ground surface. The softness also makes driving more comfortable. The wear on tyres varies according to the tyre pressure and the type of surface driven on. A simple rule is: soft tyres for soft surfaces and hard
tyres for hard surfaces. A quick look at a tyre will soon tell you how the tyre has been used. If the tyre is worn
mainly on the shoulder, then it was most probably used at too low a pressure – the side walls of the tyre then carry
too much of the weight of the load. If the tyres are worn mainly in the middle of the driving surface, they most
probably have been used with tyre pressures that are too high.
Effects of different tyre pressures on roads
If the vehicle is mainly used on tarred roads, and yard surfaces, the tyres can be run at max. permissible pressure.
Tyre wear is then at its lowest.
OPERATING INSTRUCTIONS
Page 26 Giga-Trailer
class. 4.8 class. 8.8 class. 10.9 class. 12.9
size lubric.* dry° lubric.* dry° lubric.* dry° lubric.* dry°
Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft
M 6 4,8 3,5 6 4,5 9 6,5 11 8,5 13 9,5 17 12 15 11,5 19 14,5
M 8 12 8,5 15 11 22 16 28 20 32 24 40 30 37 28 47 35
M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70
M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 190
M16 100 73 125 92 190 140 240 175 275 200 350 255 320 240 400 300
M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410
M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580
M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800
M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000
M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500
M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000
M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500
The torque values shown in this chart are guide values and do NOT apply when a different torque is quoted
in this manual for particular screws and nuts. Check that screws and bolts fit tightly regularly. Shear bolts are
designed to shear off at a certain load level. Shear bolts must be replaced with bolts of the same standard. When
replacing nuts and bolts make sure that replacements are always of the same standard or higher. Torque nuts and
bolts of a higher standard to the same value used for the original parts.
Check that the threads are clean and the bolts correctly inserted. This will prevent damage when they are being
tightened.
Tighten lock nuts (not the screws) with plastic inserts and flared steel lock nuts with approx. 50% of the “dry” value
shown in the chart. Tighten toothed and castellated nuts with the full torque value.
* “lubricated” means that the bolts are lubricated with, for example, engine oil or that phosphate coated or oiled bolts are
being used.
° ”Dry” means that normal or galvanised bolts without any lubrication are being used.
11.6 Torque values for metric screws
classification
and marking
of screw
heads
classification
and marking
of nuts
OPERATING INSTRUCTIONS
Giga-Trailer Page 27
12. Compressed Air Brake System
The most important components of the twin-circuit – compressed air brake system(see fig. 14)
1. Service line hose coupler (supply) red
2. Service line hose coupler (brake) yellow
3. Air filter
4. Trailer brake valve with brake pressure regula
-
tor
5. Trailer brake valve with release valve (ALB)
6. Piston brake cylinder (for 25 km/h)
7. Diaphragm brake cylinder
8. Compressed air vessel
9. Drain valve
10. Test connection compressed air vessel
11. Test connection front axle
12. Test connection rear axle
13. Test connection ALB
14. ALB regulator
15. Pressure differential valve
16. Parking brake
17. Release valve (ALB)
Fig. 13
12.1 Coupling to Tractor
- The compressed air brake system of the tractor must be compatible with that of the trailer.
- Couple the two service line hose couplers to the tractor as follows
Red coupler = Supply
Yellow coupler = Brake
- Take care that the hoses are correctly positioned and the couplers correctly fitted
- Stopcock for compressed air system on the tractor must be open
- Carry out brake test
OPERATING INSTRUCTIONS
Page 28 Giga-Trailer
12.2 Brake System Components
- Both service line hose couplers must be correctly connected and close tightly.
- The air filters, i.e. the filter elements (1) fig. 13 in both pipelines must be cleaned at regular intervals. If this is
not carried out, the correct functioning of the components (valves) down-line has no protection. The pipelines
must be depressurised before cleaning the air filters. Push in the floor cover (2) and release the retaining slide
(3), then the filter element can be removed and cleaned. The system remains in working condition even if the
filter element is blocked.
- The trailer brake valve (5) is protected against impurities by the air filter and requires no special maintenance.
- The trailer brake valve is controlled via the brake line (yellow hose coupler) with the aid of regulated pressure
from the trailer control valve on the tractor side. The trailer compressed air vessel (8) is filled via the supply line
(red hose coupler). The brake pressure regulator (4) flanged to the trailer brake valve can be manually adjusted
to the respective load situation on the trailer.
The adjustment data for the ALB regulator (14) can be found next to the type plate on the front right-hand side of
the vehicle.
The brake pressure regulator can be set to Full Load, Half Load, Empty and Release. The Release position enables
the uncoupled vehicle to be manoeuvred into place.
Graphic symbols on hand lever of brake pressure regulator
On self-loading trailers with ALB regulators, the brake is released by pressing the release valve fig. 14.
The compressed air vessel (8) (capacity 30 l.) is design-tested. Modifying or welding any part is not permitted. The drain valve (9) on the underside of the vessel must be activated after approx. 20 operating hours.
The brake cylinder (6) piston must pull back completely when the brakes are released, i.e. the piston rod must
make contact with the piston bottom.
= Full Load
= Half Load
= Release
= Empty
}
OPERATING INSTRUCTIONS
Giga-Trailer Page 29
12.3 Brake Plan (General)
Fig. 14
Only with steering axle
OPERATING INSTRUCTIONS
Page 30 Giga-Trailer
13. Lubrication
Attention: Do not use lubricants with graphite additives!
Where lubricants could penetrate fodder or soil, only use biodegradable oils and greases.
Check with your agricultural supplies dealer for further information!
Lubricate all bearing points in accordance with the lubrication chart. Before you start, remove the dirt from the
lubrication nipples
Oil filling capacity for gearbox
Fill the spur drive gearbox with 0.75 l liquid grease.
Fill the angular gear for the shredder drum drive with 1.2 l. gear oil VG 320.
Check oil levels once a year.
After long Downtimes
Clean vehicle thoroughly, lubricate, oil and grease. Touch up damaged paintwork.
Take special care when using high-pressure cleaning
units right
1. Minimum distance of spraying nozzle to vehicle 30 cm
2. Minimum spraying angle to vehicle at least 25°
3. Maximum spraying pressure 80 bar
4. Maximum water temperature 60°
5. No chemical additives allowed
Attention: Grease vehicle before and after each wash
OPERATING INSTRUCTIONS
Giga-Trailer Page 31
13.1 Lubrication Chart
OPERATING INSTRUCTIONS
Page 32 Giga-Trailer
14. Circuit Diagrams
14.1 Hydraulic Circuit Diagrams
floor conveyor shaft floor conveyor shaft
OPERATING INSTRUCTIONS
Giga-Trailer Page 33
14.2 Electro – Hydraulic Circuit Diagram
(hydr. stand)
(front grid)
(steering axle)
(BPW)
(Tailgate)
Floor conveyor floor conveyor 2–speed
standard (optional)
Floor conveyor 2 – speed with integrated
hydraulics (optional)
OPERATING INSTRUCTIONS
Page 34 Giga-Trailer
14.3 Electric Circuit Diagram (standard)
green/yellow
signal loading
area lighting
loading area lighting
(step switching)
signal/ tailgate open
Standard loading
area
Special loading
area
Standard
tailgate
Special tailgate
OPERATING INSTRUCTIONS
Giga-Trailer Page 35
14.4 Electric Circuit diagram (special feature/optional)
free
straight
Alternative
with BPW
vsteering axle
BPW
indicator tailgate open
(only Giga Trailer)
loading area lighting
loading area lighting
hydr. stand
front grid
steering axle
tailgate
floor conveyor 2nd level
floor conveyor on
off
up
closed
open
free
straight
closed
open
green yellow
OPERATING INSTRUCTIONS
Page 36 Giga-Trailer
15. List of malfunctions – Hydraulics
Malfunction Cause Remedy
No silo-trailer break in oil flow Check quick-release coupling. Switch
Functions tractor control unit to pressure.
All functions run out no return to tractor Check control unit on tractor
back in hydraulic plug worn replace hydraulic plug
forward drive only control piston (floor Clean control piston and check play
running occasionally conveyor valve) sticking during installation
pilot piston (floor clean pilot piston and check play
conveyor valve) sticking
during installation
Tailgate closes, but leaky cylinder re-seal cylinder
opens a little again
during loading piston in cylinder leaking re-seal cylinder piston
oil pre-stressing too low actuate toggle switch a little longer
tailgate sags during cylinder leaking Seal cylinder
operation
Control block leaking O-rings defective Replace O-rings
connecting bar not tight Tighten connecting bar to 25 – 28 Nm
Screw plugs leaky Seal screw plugs with Loctite or
sealing tape.
OPERATING INSTRUCTIONS
Giga-Trailer Page 37
16. List of malfunctions – Electric
Malfunction Cause Remedy
No function working no 12 V voltage at control Ensure 12 V voltage at tractor
box.
fuse defective Replace fuse
loose connection in socket repair loose connection
ON – OFF switch not Set switch to ON
switched to ON
Fuse often defective fuse too weak install 10 A fuse
Fuse constantly defective cable damaged replace cable
switch defective replace switch
terminal strip defective replace terminal strip
forward drive cannot be no 12 V voltage at tractor Ensure 12 V voltage
regulated or trailer
Cable cross-section of supply select larger cable cross-section
line too small
forward drive not running forward drive magnet replace magnet
defective
2 or more functions Cable damaged, 2 magnets replace cable
operating at same time activated at same time
terminal strip defective replace term. Strip
function not operating magnet defective replace magnet
although 12 V voltage
available at magnet
Green signal lamp not light signal defective replace light signal
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