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14-17

© 2009 Ver. 2 Fors MW Ltd

www.forsmw.com

10

1.4.8.

Pushing cylinders

The trailer is equipped with two pushing cylinders to maximize the power of the tip and hooking
capacity.

Figure 9. Pushing cylinders

Cylinders

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Summary of Contents for 14-17

Page 1: ...IVING 26 3 4 ELECTRICAL SYSTEM 27 3 5 HYDRAULICAL SYSTEM 29 4 SAFETY INSTRUCTIONS 31 4 1 GENERAL 31 4 2 WORKING AT EXTREME CONDITIONS 33 4 3 ACTING IN DANGEROUS SITUATION 33 5 MAINTENANCE SPARE PARTS 34 5 1 MAINTENANCE SCHEDULE 34 5 2 MAINTENANCE OPERATIONS 35 5 3 SPARE PARTS 40 6 TROUBLESHOOTING 50 CONTACT INFORMATION Factory AS FORS MW Tule 30 765 05 Saue Estonia Tel 372 679 00 00 Fax 372 679 00...

Page 2: ...h lorry transports For your safety it is extremely important that you follow the instructions presented in this instruction manual for your particular BIGAB model The unique flexible system gives operators the most cost effective and flexible transport system available Behind the Bigab trailers lays more then forty year of knowledge and 25 years of product development We understand that you are an...

Page 3: ...on off 1 single action Tractor oil volume With trailer system filled up 10 L Oil volume cylinders Press 36 L draw 27 L Oil flow 40 100L min Hydraulic pressure 22 Mpa Tipp angle 48 degrees Chassi weight 1 Standart equipped 3500 kg Chassi length 50mm 5700 mm Distance eyelet to centred bogie 20mm 4370 mm Distance eyelet to ground surface 550 mm Height at skid surface 1050 mm excluding the hook frame ...

Page 4: ...s regarding both bending as well as twisting The trailer is steady both in the tip as well as in the changing movement The trailer is equipped with a spring suspension pendulum bogie that has been equipped with brakes on all wheels Figure 1 Design of the device Chassis Hook Wheels Back frame Hook frame Rollers Support leg Towing eyelet Roll on roll off position Tipping position Foldable tower El O...

Page 5: ...ional devices 1 4 1 Chassis Chassis is constructed out of cold hollow steel sections Figure 2 Chassis 1 4 2 Back frame Back frame is constructed out of cold hollow steel sections Figure 3 Back frame Rear beam Towing eyelet Coupling hitch Frame Spring suspension pendulum bogie brackets Guide Brackets for frame locking system ...

Page 6: ...14 17 2009 Ver 2 Fors MW Ltd www forsmw com 6 1 4 3 Hook frame The hook frame is constructed from cold hollow steel sections Figure 4 Hook frame Foldable tower Frame Hook Cylinder Axle ...

Page 7: ...endulum bogie that has been equipped with brakes on all wheels Figure 5 Bogie 1 4 5 Hook The Trailer is equipped with adjustable hook for two different standard heights Standard height 1450 mm Standard height 1570 mm Figure 6 Hook Picture shows Bogie suspension 20t Brake lever Axle with brake Mounting bracket ...

Page 8: ...g disconnecting trailer Before driving the support leg must be lifted up and fixed with the pin Figure 7 Support leg Technical information Art No Type Length mm Weight kg Capacity liter Working pressure 100 Bar Working pressure 150 Bar Max Working pressure 250 Bar 3900295H 3530 85 250 21 1 5 5 67 t 8 5 t Working position Parking position NOTE This parking position is not allowed Connecting disconn...

Page 9: ...it is designed for changing operation from rolling on rolling off to tipping Unit is located on the left side of the trailer Figure 8 Changing operation unit Chassis Hook frame Back frame Pin Hydraulic cylinder Changing operation unit End of stroke valve Pusher 2 pins Adjustment bolts ...

Page 10: ... 2009 Ver 2 Fors MW Ltd www forsmw com 10 1 4 8 Pushing cylinders The trailer is equipped with two pushing cylinders to maximize the power of the tip and hooking capacity Figure 9 Pushing cylinders Cylinders ...

Page 11: ...the trailer is used The towing eyelet needs to be replaced at least once a year It is the users responsibility to see to that this is done Figure 10 Towing eyelet 1 4 10 Coupling hitch The coupling hitch is used for coupling other trailed devices to the trailer Coupling hitch is also used for coupling reflector Figure 11 Reflector Figure 12 Coupling hitch Rear beam Pin NB Maximum load 10 ton Chass...

Page 12: ...lers 1 4 12 Frame locking The hydraulic frame lock is used to lock the frame during the exchange function The manometer is present to indicate the tensile force on the cylinder The manometer is set at 100 bar on delivery but can subsequently be adjusted either up or down according to the size of the tractor Figure 14 Frame lock Steering roller Steering roller Chassis Frame lock hydraulical cylinde...

Page 13: ...hydraulic system for working movements See chapter 3 4 1 4 15 Electrical system The trailer is manufactured with 12V electrical system See chapter 3 3 1 4 16 Brake system The trailer is equipped with hydraulic brake system Also is available pneumatic brake system as an additional extra The hydraulic pressure in the brake line is not allowed to raise over 16 Mpa If using to high of a hydraulic pres...

Page 14: ...trol unit The trailer is equipped with hydraulic system witch valves are controlled with electric remote control unit Control unit Table 3 Nr Function description 1 Tipping Rolling 2 Foldable tower Telescope 3 Changing operation unit 4 Frame Lock 5 Extra 6 Extra 1 2 3 4 5 6 ...

Page 15: ...The safety support may not be used under any circumstances when the container bridge is loaded Figure 15 Security post 1 5 2 Location of the decals of the trailer The trailer is equipped with a range of signs relating both to safety and information Check that all the signs are in the correct positions Figure 16 Location of the decals on the trailer Security post Chassis ...

Page 16: ...Figure 18 Decal for the use of safety equipment These decals challenge the user to employ appropriate safety equipment in order to avoid injury when using the trailer Figure 19 Risk of clamping injuries There is a risk of clamping or crushing injuries during work and maintenance Figure 20 Hazardous area Standing between the trailer and the towing vehicle when the trailer is being operated moved wi...

Page 17: ...ailer can also become slippery as the tyres can tear up the surface and expose clay and soil Figure 22 Hydraulic fluid under pressure Hot hydraulic fluid at high pressure levels can occur in the hydraulic system Take care when connecting and replace poor quality hoses Figure 23 Using the exchange unit The exchange unit may not be operated unless the frame is folded down During transport with the t...

Page 18: ...tely prohibited to load more than the amount your model is intended to handle This can result in danger to you and your surroundings Figure 26 Max pressure on towing eyelet Ensure that you do not load in such a way that the pressure on the towing eyelet exceeds the permitted laws and regulations The trailer is designed for a maximum pressure of 3 500 kg on the towing eyelet The pressure is largely...

Page 19: ...igure 27 Tyre inspection The tyres must be tightened and the brakes checked regularly at a minimum interval of 40 50 kilometres Figure 28 Lubrication This decal is used to show the importance of regular lubrication of the trailer Figure 29 Data plate ...

Page 20: ... lock washer M18x1 5 210 270 360 M20x1 5 360 450 M22x1 5 460 550 Nut with flat seat captive washer M18x1 5 260 360 M20x1 5 350 500 M22x1 5 450 650 Screwed connection disc rim on track adjustable wheels Thread Flat discs Screw Class 8 8 M18x1 5 260 330 Figure 30 Lubricate points All of the hydraulic hoses of the trailer are marked with coloured labels See table below for more detailed information F...

Page 21: ...ow Brake Marking for hydraulic hoses tractor controlled Table 5 No Colour mark Function 1 Yellow Brake 20 Red Bogie lift on 21 Blue Bogie lift off 22 Red Extra port a 23 Blue Extra port b 24 Red Rear tailgate a 25 Blue Rear tailgate b 26 Red Steering control p 27 Blue Steering control t 28 Blue Straight steering control t ...

Page 22: ...s or damage paint or other surface finishes Lift up the trailer from transportation frame Lower the trailer to the floor Be careful when lifting so that cables connectors or other components are not damaged for instance between lift work and trailer frame Weight depends see technical information for data 2 2 ADJUSTMENTS Quick couplings are used in the operation of connecting the vehicle in use wit...

Page 23: ... the exchange position not in the tipping position Place the hooklift trailer on a flat surface The sideways incline may not exceed 5 degrees Under no circumstances may you reverse exert pressure with the towing vehicle in order to facilitate exchange This entails an immediately risk of the trailer or the towing vehicle being damaged which can be potentially fatal The load must be pulled on and th...

Page 24: ...f the tractor lifts off the ground IMPORTANT Follow the movement with the retractable tower so that the front of the hooklift trailer s frame does not catch on the rollers When you have passed the rollers always keep the hooklift trailer s frame close to the rollers Off loading Release the brakes on both the towing vehicle and the trailer to make it easier to roll off the load Check the position o...

Page 25: ... trailer is in the tipping position and not the exchange position before commencing tipping Place the hooklift trailer on a flat surface The sideways incline may not exceed 5 degrees IMPORTANT When tipping use the brakes to ensure that the machine does not roll away when the load slides off At maximum tipping drive slowly forwards until the container bridge is empty Lower the container bridge befo...

Page 26: ...pproximate estimate of the weights that can occur and it is the responsibility of the user to ensure that the vehicle s limits and the applicable legislation are not being exceeded The specified values are not exact values just examples Figure 32 Example of weight with different types of load For information purposes and for examples of how much different loads can weigh please refer to the above ...

Page 27: ...eversing light special left or right 2 920770 Border light 111x40 orange special 3 920715 Cable terminal 4 920695 Cable Connector 7 pools male 5 920180 Cable Connector 7 pools female special Connections of the cables and lamps Table 7 Nr Color Function Lamp 1 Red Flashing left 12V 21W L1 2 Brown Reversing light 12V 21W L5 2 Brown Spare without reversing light 3 Yellow Earth 4 Blue Flashing right 1...

Page 28: ...ctrical on off is manufactured with 12V electrical system Configuration depends of options Figure 34 Electrical diagram Table 8 Pos Art No Title 1 915181E Electric on off control unit 2 91581CS Cable set 3 91581ES Electrical switch 4 91581RP Rubber protection 5 915181CC Cable connector ...

Page 29: ...ir at temperatures ranging from 50 C up to 60 C at a continuous operation service For maintenance of the hydraulic system see chapter 5 Figure 35 Hydraulic system Hydraulic components Table 9 Pos Art No Title 1 940810 Release valve 2 940815 Security valve 3 940820 Logic valve 4 940825 4 way valve 5 940830 Valve block 6 940835 4 way valve 7 913265 Tipping Rolling cylinder with pilot operated valve ...

Page 30: ...tem Hydraulic components for frame lock Table 10 Pos Art No Title 1 313134 Cylinder 90 40 300 37313942 Seal kit for hydraulic cyl 90 40 2 915275 Manometer 3 915271 Pilot operated check valve 4 915266 Pressure reducing relieving valve 6 915265 Manifold 7 914570 Bayonet coupling male 8 9145702 Bayonet coupling female ...

Page 31: ...w eyelet for defaults Control brakes Control the lights Check that the brakes are functioning Check that hydraulic hoses and couplings are intact and free from cracks Check that all hydraulic functions are working Remember that it is not allowed to use this unit for functions not confirmed by producer Be aware that a long container needs enough working space and turning area Respect the safety dis...

Page 32: ...ing hydraulic couplings while the system is pressurized Never attempt to localize a leakage from hoses or connections by feeling with hand The high pressure oil jet can penetrate skin and cause serious burns and damages High pressure oil is also highly flammable Avoid getting oil into eyes Use safety goggles and gloves If oil has got into eyes flush them with cool water and immediately contact a d...

Page 33: ... oil circulate freely through the system a few minutes Slowly work every action through several times so that gaskets come pliable before they receive full pressure At exceptionally warm conditions beware of hydraulic oils excessive heating Too high oil temperature higher 80 C degrades oil and damages gaskets 4 3 ACTING IN DANGEROUS SITUATION If the trailer comes into contact with high voltage ele...

Page 34: ...eeded for installation Valve adjustments and repairs are recommended to be handled by service personnel Daily inspections Examine visually the loader Note defects and failures that might affect safety Repair possible defects and failures Check so there is no leakages on hydraulic system or damaged hoses Work through every function to its extreme position Check the oil level Weekly maintenance Clea...

Page 35: ...draulic system before you are sure there is no pressure Do not tighten or repair leaking hydraulic couplings while the system is pressurized Never attempt to localize a leakage from hoses or connections by feeling with hand The high pressure oil jet can penetrate skin and cause serious burns and damages High pressure oil is also highly flammable Avoid getting oil into eyes Use safety goggles and g...

Page 36: ...way round i e the lip against the pressure NB Never operate the hydraulic system with the level of oil dropping below lower mark 5 2 3 Maintenance of the pneumatic units Clean and lubricate piston rods of pneumatic cylinders Emptying the water collector Condensed water is removed from the air tank located in the side of trailer Check the pneumatic valves Check the pneumatic valves by listening to ...

Page 37: ...control linkage after the drum being dismantled adjust if needed For adjusting the brakes you need to lift up the bogie frame from the ground and adjust the brake levers You do this by spinning the wheel while adjusting The brakes are correctly adjusted when they spin freely without any scraping noises from the wheel After all kinds of adjusting in regards to the brakes always carry out a practica...

Page 38: ...to lubricate the grease nipples You need to lean under the trailer to be able to grease the glide bearings This will be easier to do if the trailer is without load Weekly 5 2 8 Lubrication Recommended lubrication cycle is once per week or after 20 working hours Lubricate points equipped with grease nipples by using a grease gun See chapter 5 1 for recommended lubricants Ensure regularity of lubric...

Page 39: ...nk bearing 1pcs Glide bearing 2pcs Glide bearing right 1pcs Glide bearing right 1pcs Glide bearing right 1pcs Glide bearing left 1pcs Glide bearing left 1pcs Glide bearing left 1pcs Link bearing 2pcs Glide bearing 2pcs Link bearing 3pcs Glide bearing 1pcs Glide bearing 1pcs Glide bearing 1pcs Glide bearing 1pcs ...

Page 40: ...er coupling Figure 41 Back and hook frame coupling Figure 42 Foldable tower Back rolling frame and foldable tower spare parts Table 12 Pos Art No Description Note 1 37203110 Axle 2 37203115 Distance ring 3 37203140 Axle 4 37204110 Axle 5 37211115 Axle 6 37211120 Axle 7 37211180 Distance ring 1 2 3 5 7 6 7 4 ...

Page 41: ...pring suspension bogie Spring suspension bogie spare parts Table 13 Pos Art No Description Note 916827 Spring suspension bogie comp 17t 2 916827 AXLE Axle 3 916827 BOGIE Spring suspension 4 916480 Ring nut M20 5 916466 Brake arm 3 4 5 2 Picture shows Bogie suspension 20t ...

Page 42: ...rt No Title 391014 1215 Hydr frame lock system 3 37121520 Link 4 37121525 Link 5 37121530 Link 6 37121535 Support 12 37121522 Axle 14 37121527 Pin 15 37121532 Pin 17 37024378 Pin 22 908110 Split 4x45 DIN 94 23 911250 Stopper ring 20 DIN 471 24 920230 Locking pin 6x40 DIN 11023 26 920223 Chain 8 link 32 313134 Cylinder 90x40x300 ...

Page 43: ...eering roller spare parts Rollers spare parts Table 15 Pos Art No Description Note 1 320340 320341 Roller comp left right 2 37203045 Axle 3 909115 Slide bearings Ø100 4 320360 Tipper axle 5 3 5 Changing operating unit Figure 46 Changing operation unit 1 3 1 3 2 4 6 1 2 4 5 3 5 7 9 8 ...

Page 44: ...37913256 Front bush for hydraulic cyl 160 80 37913258 Piston for hydraulic cyl 160 80 8 913238 Tower cylinder 125 63 250 37913240 Sealing kit for hydraulic cyl 125 63 37913241 Front bush for hydraulic cyl 125 63 37913243 Piston for hydraulic cyl 125 63 18 913210 Brake cylinder 40 25 55 37913210 Sealing kit for hydraulic cyl 40 20 37913212 Front bush for hydraulic cyl 40 20 37913213 Piston for hydr...

Page 45: ...Cylinder 90 40 300 37313940 Sealing kit for hydraulic cyl 90 40 37313942 Front bush for hydraulic cyl 90 40 37313944 2 Piston for hydraulic cyl 90 40 915275 Manometer 3 915271 Pilot operated check valve 4 915266 Pressure reducing relieving valve 6 915265 Manifold 7 914570 Bayonet coupling male 8 9145702 Bayonet coupling female ...

Page 46: ...der 3 Front bush 4 Piston 5 Scrape ring Included in sealing kit 6 Sealing Included in sealing kit 7 Bush ring Included in sealing kit 8 Sealing Included in sealing kit 9 O ring Included in sealing kit 10 O ring Included in sealing kit 11 Sealing Included in sealing kit 12 Sealing Included in sealing kit 13 Locking ring 14 Locking ring Included in sealing kit 15 Locking ring Included in sealing kit...

Page 47: ...Cable terminal 4 920695 Cable Connector 7 pools male 5 920180 Cable Connector 7 pools female special 6 920723 Bulb 12V 5W 7 920745 Bulb 12V 21W 8 920725 Bulb 12V 10W 5 3 9 Electrical on off system For electrical on off system diagram see chapter 3 3 2 Electrical on off components spare parts see also chapter 5 3 6 Table 21 Pos Art No Title 1 940810 Release valve 2 940815 Security valve 3 940820 Lo...

Page 48: ...14 17 2009 Ver 2 Fors MW Ltd www forsmw com 48 Figure 50 Electrical on off system 7 8 1 2 3 4 5 6 9 10 11 ...

Page 49: ...her spare parts Other spare parts Table 22 Pos Art No Description Note 1 930105 Grease nipple 2 920111 Towing eyelet 3 37221002 Hook 4 920822H Hydraulic Support leg 5 700617 Parking brake BPW 6 37203085 Security post 8 920150 LBF board 9 920155 Reflector 3 angle red 2 4 3 9 8 1 5 ...

Page 50: ...ulic system Locate leaky point and eliminate defect Check oil level Excessive leakage of oil in pump Replace pump Low oil pressure Adjust oil pressure Hydraulic cylinder piston packing out of order Replace packing Hydraulic system noise Air entrapped into system Locate air suction and eliminate defect Distributor safety valve maladjusted Adjust valve Oil leaking Replace ruptured hose or tighten ho...

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