Fliegl ASW 110 Operating Instructions Manual Download

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Operating instructions

ASW push-off trailer

We are Fliegl.

Translation of original operating instructions

Summary of Contents for ASW 110

Page 1: ...Operating instructions ASW push off trailer GB We are Fliegl Translation of original operating instructions...

Page 2: ...Read these operating instructions prior to first time start up and observe them at all times Retain for future reference...

Page 3: ...n or maintenance of the GIGANT trailer These operating instructions must therefore also be passed on to the operating personnel Before putting the Fliegl GIGANT push off trailer into operation every o...

Page 4: ......

Page 5: ...fe of the machine 20 2 4 Risks when working with the machine 20 2 5 Residual risks 20 2 6 Obligations of the operator 20 2 7 Obligations of personnel 21 2 8 Qualification of operating personnel 21 2 9...

Page 6: ...ir supply 36 4 2 4 Establishing hydraulic connections 37 5 Start up 39 5 1 First time start up 39 5 2 Check before start up 39 5 3 Returning to service 39 6 Preparation and setup 40 6 1 Draw gear 40 6...

Page 7: ...0 6 10 Electrical systems 60 7 Use and operation 61 7 1 Trailer operation 61 7 1 1 Before operation 61 7 1 2 Setting up the trailer coupling on the towing vehicle 61 7 1 3 Coupling the trailer 62 7 1...

Page 8: ...2 Lights 78 9 2 1 Marker lights 78 9 2 2 Warning lamp 78 9 2 3 Beacon light 78 9 2 4 Working light 78 9 3 Potentiometer optional 79 9 4 Cardan shaft drive for auxiliary devices 79 9 5 Underride guard...

Page 9: ...nance of the compressed air brake system 100 10 5 2 Maintenance of the air suspension 101 10 6 Checking the seals on the moving panel and sliding floor 102 10 7 Maintenance of the tyre pressure contro...

Page 10: ...sion 111 15 1 7 Gigant tridem assembly 112 15 1 8 Gigant Plus tridem assembly 112 15 1 9 Tridem hydraulic suspension 112 15 1 10 Tridem air suspension 112 15 2 Axle maintenance work 112 16 Appendix 11...

Page 11: ...hird party parts without our knowledge or prior agreement especially if improper modifications were made 5 The warranty will also be invalidated if a defect is not rectified completely and correctly i...

Page 12: ...liegl com Internet www fliegl com Formal details of operating instructions Document no Version revision Creation date Last revision 1 002B06203 1 3 1 13 03 2015 04 08 2020 Language of original operati...

Page 13: ...281 ASW 381 ASW 391 ASW 3101 ASW D 378 ASW D 388 ASW 271 GreenTec ASW 281 GreenTec ASW 381 GreenTec ASW 391 GreenTec ASW 160 FOX ASW 256 Compact FOX ASW 261 Compact FOX ASW 271 Compact FOX ASW 281 FOX...

Page 14: ...and malfunctions resulting from failure to comply with the operating instructions This information is required to ensure a smooth replacement parts ordering process Copy the relevant information from...

Page 15: ...followed in the correct order The system response to each operator action is marked with an arrow Example Operator action step 1 System response to operator action step 1 1 4 Cross references Cross r...

Page 16: ...d safety at work as well as accident prevention Based on the specifications in these operating instructions Fliegl Agrartechnik GmbH assumes no liability for direct or consequential damage attributabl...

Page 17: ...rawbar and trailer loads dictated by EU or national law are not exceeded The support gear must be completely raised Lighting equipment must be connected A functional check of the lighting equipment mu...

Page 18: ...to be fitted with ballast weights in order to ensure steering and braking capability at least 20 of the vehicles empty weight on the front axle The drive shaft must be switched off Carrying persons o...

Page 19: ...ed securely before performing any adjustments repairs maintenance or cleaning Handling the mechanical supporting stand Couple the ASW to the tractor coupling height can be adjusted slightly via the hy...

Page 20: ...use and must only be used if All safety equipment specified in the operating instruction is present and in the safety position All safety instructions in the operating instructions are observed and co...

Page 21: ...ith the ground Overloading can result in axle or spring breakage Prohibited causes vehicle damage Fig 3 Model may vary The illustration serves as an example Caution when reversing Because the area beh...

Page 22: ...ine requires knowledge of the safety and user instructions set out in this manual Always store the operating instructions at the usage location of the machine The operating instructions must be availa...

Page 23: ...lteration conversion extension repairs retrofits is performed incorrectly this can lead to serious injury or death To avoid accidents any person performing work in accordance with these operating inst...

Page 24: ...involving personal injury All maintenance and adjustment work must be performed as described in the relevant sections Shut down and secure the machine before performing any maintenance and adjustment...

Page 25: ...ective devices The following safety devices are installed on the machine Service brake system Parking brake PB Pipe break protection on the hydraulic rear panel Pipe break protection on the hydraulic...

Page 26: ...fety distance must be observed If this safety distance is not maintained this can result in accidents involving personal injury Only switch on the machine if there are no persons within the danger zon...

Page 27: ...the machine that continue to run after it is switched off this can result in accidents involving personal injury After turning off the drives the following machine parts continue to run Drive shaft Sp...

Page 28: ...ine Danger due to crushing or entanglement Warning against automatic restart Caution Exercise special caution when handling or touching Information in operating instructions Read contents of operating...

Page 29: ...ng such as turning and transport directions CE identification number Indicates conformity with applicable EU directives related to the product which also require a CE marking Located on type plate Typ...

Page 30: ...000 kg ASW 256 Compact FOX tandem 20 000 kg ASW 381 tridem 29 000 kg ASW 261 Compact FOX tandem 20 000 kg ASW 391 tridem 29 000 kg ASW 271 Compact FOX tandem 20 000 kg ASW 3101 tridem 29 000 kg ASW 2...

Page 31: ...29 3 4 Layout of the machine The following figure provides an overview of the most important components and assemblies and shows where they are installed on the machine Fig 8 Layout and components 8 1...

Page 32: ...separate sliding floor cylinder exists its size and installation length depends on the vehicle length Fig 9 Assembly item 1 Item 2 moving panel Depending on the truck type different moving panel unit...

Page 33: ...ange coupling Flange couplings are available in different standards and designs Fig 16 Assembly item 8 Item 9 body The bridge is self supporting and thus forms the main frame of the vehicle Fig 17 Ass...

Page 34: ...1 500 1 500 2 000 2 000 2 000 2 000 Type ASW 391 tridem ASW 3101 tridem ASW D 378 three axle ASW D 388 three axle ASW 271 GreenTec ASW 281 GreenTec ASW 381 GreenTec ASW 391 GreenTec ASW 281 TAURUS FOX...

Page 35: ...e ASW 381 GreenTec Type ASW 391 GreenTec Type ASW 160 FOX Version Tridem Version Tridem Version Tandem Total weight 29 000 kg Total weight 29 000 kg Total weight 16 000 kg Drawbar load laden 2 000 kg...

Page 36: ...owing vehicle and of the machine itself Before travelling on public roads ensure that The machine is fully and correctly coupled to a suitable tractor All safety devices are locked and secured The tyr...

Page 37: ...unctions of the vehicle electronics or other components Lighting connection Procedure Power is supplied by the towing vehicle via plug connection s 12 V plug connection for lighting 7 pin connector IS...

Page 38: ...eservoir before your first journey of the day Do not set off with the coupled machine until the pressure gauge on the tractor shows a pressure of 5 0 bar Disconnection procedure Secure the machine to...

Page 39: ...control device to neutral position Ensure that the couplings are clean Constant flow 1 Pressure connection 2 Return connection Load sensing A Pressure connection B Return connection C Load sensing co...

Page 40: ...6 Check hydraulic hoses and couplings regularly and replace them if they are damaged or old at least every 6 years 7 The replacement hoses must meet the requirements of the machine manufacturer 8 When...

Page 41: ...l are responsible for observing the legal provisions of national road traffic regulations Observe the safety instructions that are affixed to the trailer An explanation of the individual warning symbo...

Page 42: ...ose a hole pattern is provided on the traction bar support The trailer must be as horizontal as possible when coupled Prerequisites Suitable spanners torque wrenches Means of supporting and protecting...

Page 43: ...sting the drawbar height 6 1 4 Ball head coupling The ball head coupling must only be coupled with an approved coupling ball 80 ball diameter 80 mm that is suitable for ensuring safe attachment and lo...

Page 44: ...tractor with 250 mm clearance 5 mm Fig 31 Installation layout for forced steering The towing vehicle requires a suitable coupling mechanism At maximum steering angle the tyres must not touch the frame...

Page 45: ...at the end of the forced steering cylinders by lifting up the lever The cylinder can now move freely and can be easily connected to the towing vehicle Fold the lock lever back down again Drive the tra...

Page 46: ...as well as L3 and L4 on tridem models must be opened before travel to avoid damaging the hydraulic cylinders 5 Open stopcocks 1 2 and 3 as well as 4 and 5 on tridem models Apply a pressure of 50 bar t...

Page 47: ...re commencing travel to prevent damage to the hydraulic cylinders Tridem Fig 36 Tridem steering axle L1 steering axle stopcock L2 steering axle stopcock L3 steering axle stopcock L4 steering axle stop...

Page 48: ...r is delivered with the stopcocks closed Stopcocks L1 L2 L3 L4 must be opened before commencing travel to prevent damage to the hydraulic cylinders At maximum steering angle the tyres must not touch t...

Page 49: ...must be no persons in the danger area during raising and lowering Lever position of the air suspension system Stop Position the lever vertically and push it in Raise lower Move the lever to the right...

Page 50: ...valve Select from operating mode Empty Half load or Full load depending on the trailer load Release operating mode for moving the uncoupled trailer is triggered via the trailer release valve The butt...

Page 51: ...he setting dimension of the automatic load dependent brake force regulator The setting dimension must match the value specified on the ALB plate 6 4 3 Brake system release valve The release valve allo...

Page 52: ...brake system to the reservoir which builds up the pressure in the spring loaded brake system resulting in the parking brake being released The spring loaded brake system must always be released manual...

Page 53: ...to decline the connections are vented simultaneously resulting in automatic actuation of the spring loaded brake system to prevent the trailer from rolling away Automatic emergency braking Push in th...

Page 54: ...nt valve When hydraulic brake systems are connected to the tractor s hydraulic brake system the trailer must be braked via the tractor s brake system The brake pressure must not exceed 120 bar 12 000...

Page 55: ...nti clockwise until the tension on the brake cable is released The cable must sag slightly Fig 46 Crank 6 6 2 Farmer stop parking brake Applying the brake To activate the parking brake pull the actuat...

Page 56: ...vehicle as in the case of the single action control device 6 7 2 Additional load sensing LS version also known as power beyond Connection with load sensing LS Procedure The towing vehicle must be par...

Page 57: ...1 to 2 seconds The LS line of the towing vehicle is connected at position The connection at position must be closed Turn the screw at position anti clockwise up to the stop Turn the screw at position...

Page 58: ...ion amount Objective The moving panel travels towards the spreading roller with a constant working pressure 1 Adjusting screw for pressure sequence valve 2 Adjusting wheel for flow rate of push off cy...

Page 59: ...of push off cylinder 3 Electrical flow control valve for push off cylinder Fig 54 Electrical flow control valve The flow control valve is correctly set in the factory and must not be changed For obje...

Page 60: ...operation of the hydraulic control The rear panel can be closed in manual emergency mode This returns the push off trailer to normal travel position Single action control unit Lowering To lower the re...

Page 61: ...ning the crank The length of the crank handle can be adjusted to facilitate this process To do so remove the splint and adjust the crank handle as necessary Secure the handle with the splint again whe...

Page 62: ...You must also read the drive shaft operating manual carefully and follow the contained instructions Fig 61 Drive shaft Shorten the drive shaft and the corresponding protective tubes on both sides Oth...

Page 63: ...and the tools Check the fill levels of lubricants and auxiliary materials Unlock all devices used for stopping in an emergency The hydraulic connections should always be connected to the same ports o...

Page 64: ...onnection points see the stickers on the vehicle and on the couplings See section 16 1 Hydraulic connections Connect all hydraulic lines to the towing vehicle in pairs double action For labelling to i...

Page 65: ...movement in all operating conditions 7 Verify that there is sufficient space around the drive shaft in all operating conditions A lack of space will result in damage to the drive shaft 8 Rectify any l...

Page 66: ...intentional start up or rolling away 4 Detach the drive shaft fastener from the tractor PTO When detaching the drive shaft observe the supplied instructions for the drive shaft 5 Place the drive shaft...

Page 67: ...ll the safety precautions listed in these sections Procedure Turn on the machine as specified Perform all functions of the machine individually Correct the settings e g potentiometer if necessary Cond...

Page 68: ...p children away 9 When coupling make sure that the trailer coupling pin is secured In the area around the tractor three point linkage there is a risk of injury at crushing or shearing points 10 The dr...

Page 69: ...an be compressed by means of a pressure valve to accommodate more material The valve must be activated via the control unit before the compression process During this process the sliding floor remains...

Page 70: ...wings open to the rear Extend the moving panel and sliding floor hydraulically the load is then pushed off Retract the moving panel and sliding floor again Close the rear panel Emptying through the gr...

Page 71: ...d M 24 730 Nm Never travel with non secured bodies When travelling with non secured chassis locks the body can slip or topple while moving 7 3 2 Chassis lock Twistlock optional For vehicles with swap...

Page 72: ...ting device can be retrofitted to the trailer In this case the disassembly process is the same as for trailers with air suspension The optional hydraulic lifting device is intended for the disassembly...

Page 73: ...d wear and trip hazards Fig 69 Low wear support surface The load bearing capacity of asphalt surfaces varies significantly according to the temperature frost or sun exposure and composition of the asp...

Page 74: ...ders Step 3 Connect the hydraulic line to the lifting cylinder Step 4 Bleed the hydraulic system Fig 71 Attaching the lifting cylinder Fig 72 Connecting the hydraulic line 7 4 3 Using the supporting f...

Page 75: ...wly retract the hydraulic cylinders into their initial position Close the 4 stopcocks again You can drive the chassis out from underneath the swap body Loading the swap body Procedure Drive the chassi...

Page 76: ...machine workstation Fig 79 Traction bar suspension 8 1 3 Drawbar The drawbar is only available for the three axle ASW models Versions Fixed drawbar Extendible drawbar Fixed Extendible Fig 80 Drawbar 8...

Page 77: ...Every ASW type has a specially designed moving panel and sliding floor unit These differ in their length number of hydraulic cylinders on the sliding wall as well as the length and size of the thrust...

Page 78: ...e drawbar load 7 Move the axle assembly forwards reduces the drawbar load Note the max drawbar load on the tractor 8 7 2 Hydraulic axle adjustment optional Hydraulic axle adjustment is available as an...

Page 79: ...With a fully laden trailer the distance between the tyres and frame must be at least 100 mm The measurement must be performed on both sides of the trailer for all steering axles If the distance is to...

Page 80: ...low Clearance lights rear white red Position lights front white Fig 90 Marker lights 9 2 2 Warning lamp The warning lamp lights up to indicate that the rear panel is open This warning is triggered by...

Page 81: ...talled in the chassis frame This allows rear mounted auxiliary devices e g spreader to be powered via the cardan shaft drive of the towing vehicle Fig 94 Through drive 9 5 Underride guard 9 5 1 Rear u...

Page 82: ...re made from plastic or rubber Plastic mudguards Plastic rear apron Lateral profile fillers rubber on side panels Fig 97 Protect package 9 7 Folding side panel mechanical The mechanical folding mechan...

Page 83: ...using the tarpaulin for the first time fully retract it and verify that it assumes the shape shown in the figure below Then leave the tarpaulin in this folded position for a few hours so that it reta...

Page 84: ...l the way to the front of the vehicle Secure the bar with the spring bolt back in its retainer Secure the tieback at the designated fastening point on the front left side of the vehicle A loose rope p...

Page 85: ...e that you keep the tieback under tension A loose rope poses a safety risk as it could catch and injure persons when travelling on public roads Secure the bar with the spring bolt back in its retainer...

Page 86: ...lateral springs When closed the roll net rapidly moves towards the rear of the trailer under tension Safety is assured by the limit switches for the hydraulic system as well as a stop for the arms Fi...

Page 87: ...n the folding roof is fully open Otherwise the cover system may be damaged The folding roof must be fully closed when travelling on public roads This will prevent any of the load from falling out 9 8...

Page 88: ...urised system is not possible take the recommended safety precautions and wear the prescribed personal protective equipment PPE Keep other persons away from the danger zone The product must only be us...

Page 89: ...ol 2 line system The system is connected to the compressed air brake system via a safety valve to ensure a constant supply pressure of 6 5 bar in the brake reservoir Due to the high volume tyres on th...

Page 90: ...o the saved road value Fill selected axles to the saved field value Select and deselect axles ON OFF Display brightness Note the LUG on the socket when connecting Press both buttons simultaneously to...

Page 91: ...ompressor cuts in automatically and supplies air until the desired tyre pressure is reached It then switches itself back off again This is enabled by an electro pneumatic compressor switch which is pn...

Page 92: ...ing sensors and weighing system components must be fitted to the ASW You also require an ISOBUS display and or ISOBUS control system in your towing vehicle You configure the operation in your ISOBUS c...

Page 93: ...ion 10 1 Fig 117 Beacon 9 13 ISOBUS universal terminal The universal terminal can be used to operate the ISOBUS control systems The operating instructions are supplied separately See section 10 1 Fig...

Page 94: ...r Boch Stra e 1 84453 M hldorf am Inn Germany Telephone 49 0 8631 307 461 Fax 49 0 8631 307 550 E mail service fliegl com Internet www fliegl com 10 2 Replacement parts For a detailed list of all rele...

Page 95: ...e class 3 EU type approval number 4 Vehicle ID number VIN 5 Total weight axle load 6 Drawbar load 7 Axle load of 1st axle 8 Axle load of 2nd axle 9 Axle load of 3rd axle 10 Vehicle type 11 Trade name...

Page 96: ...raw gear bearing is securely fastened x Vent the forced steering x Check all screw connections on the chassis and body x Clean the trailer Body Check the seals of the moving panel and sliding floor x...

Page 97: ...rts when cleaning work is performed with the trailer coupled When performing cleaning tasks turn off the towing vehicle engine apply the parking brake and remove the ignition key Empty the trailer com...

Page 98: ...ir and hydraulic lines in particular for corrosion on a regular basis Have damaged corrosion protection restored by a specialist workshop Have a specialist workshop remove any corrosion and apply corr...

Page 99: ...cturer See section 15 2 Fig 121 Central lubrication points model may vary Lubrication schedule The lubrication schedule applies to all Fliegl push off trailers Dispose of old oil and grease in the cor...

Page 100: ...00 55 22 5 16 PR 2 60 x x x x x x x x 650 50 R22 5 4 00 x x x x x x x x x 650 55 R26 5 4 00 x x x x x x x x 700 50 R22 5 16 PR 2 80 x x x x x x x 710 50 R26 5 4 00 x x x x x x x x 750 45 R26 5 4 00 x...

Page 101: ...deformed or modified wheels are fitted Tyres are fitted with a speed symbol and load capacity index that does not match the vehicle Tyres are stored incorrectly Environmental influences Temperature ex...

Page 102: ...amaged filter inserts The filter housing 1 contains a sieve insert 3 If the filter inserts in the line air filters are clogged air flows around them without being filtered As a result there is no filt...

Page 103: ...plate on the vehicle 10 5 2 Maintenance of the air suspension Check all components for damage and wear every 200 operating hours Check air bellows for external damage cracks abrasion creasing trapped...

Page 104: ...ents are depressurised If working on a depressurised system is not possible take the recommended safety precautions and wear the prescribed personal protective equipment PPE Keep other persons away fr...

Page 105: ...brake farmer stop Braking effect too low Identify the cause of lacking brake force Adjust the cable pull or Visit a specialist workshop Vibration on the push off trailer operation with spreader Speed...

Page 106: ...nections Check the coupling and replace if necessary Check the tractor hydraulics Hydraulic cylinders extend but then do not retract The piston seal in the cylinder is faulty meaning that the piston a...

Page 107: ...r with a tarpaulin to protect it against dust etc 4 Deactivate the pneumatic hydraulic and electrical supplies to the machine Protect connections 5 Lubricate the Fliegl push off trailer see lubricatio...

Page 108: ...334 055 2 1 Coupling head brake 334 054 3 2 Pipe filter 310 005 011 4 1 Trailer brake valve with release valve 350 026 7 1 Compressed air tank EN 030 09 8 1 Drain valve manual 315 019 001 9 1 ALB reg...

Page 109: ...ke light Left rear light 1 2 3 4 5 6 7 L 54g 31 R 58R 54 58L 7 pin connector ISO DIS 1724 Yellow Blue White Green Brown Red Black The three earth wires must not be electrically connected to the traile...

Page 110: ...ate for ASW assembly M24 250 Nm Axle stop M24 650 Nm Bearing for traction bar M24 400 Nm Bearing for traction bar M24 400 Nm Axle plate M24 650 Nm Lagerbuchse M24 300 Nm Traction bar M30 750 Nm Drawba...

Page 111: ...m 14 1 Electro pneumatic diagram tandem Control unit Manometer Digital box RDS switch box Data cable 5 pin Current signal 3 pin To SV of compressor drive Blue Blue Black Red Yellow Auxiliary reservoir...

Page 112: ...tic diagram tridem Control unit Digital box RDS switch box Manometer Auxiliary reservoir Compressed air brake reservoir Overflow valve 6 5 bar Compressor RDS control unit To SV of compressor drive Cur...

Page 113: ...2 Titan Plus tandem assembly Fig 130 Titan Plus tandem assembly 15 1 3 Gigant tandem assembly Fig 131 Gigant assembly 15 1 4 Gigant Plus tandem assembly Fig 132 Gigant Plus assembly 15 1 5 Tandem hydr...

Page 114: ...idem air suspension 15 2 Axle maintenance work For information on the required maintenance work for the relevant axles please contact the manufacturer of the installed axles The necessary data is prov...

Page 115: ...dix 113 16 Appendix 16 1 Designation of the hydraulic connections A supply B return Supporting foot Push off process Lock steered trailing axle Drawbar suspension Overloading auger sliding gate Rear p...

Page 116: ...Appendix 114 Axle adjustment TopLift or SpeedCover Lifting device Transfer auger Forced steering Hydraulic suspension Hydraulic front grid Double changeover valve...

Page 117: ...he operating manual supplied with the drive shaft The stickers and operating instructions are available in different versions depending on the country of destination of the drive shaft Before commenci...

Page 118: ...nal spare parts or have them correctly retrofitted Fig 141 Drive shaft attachment Before entering the work area and before carrying out maintenance work always switch off the engine remove the ignitio...

Page 119: ...ctive tube SIMPLE CARDAN SHAFTS Work with limited and uniform angles 1 2 On tight bends joint angles can be very wide but must not exceed the maximum articulation angle of 45 even if they are uniform...

Page 120: ...id long slip phases Do not touch Do not use the chains for handling or hanging up the drive shaft when work is completed Instead use a support that is suitable for this purpose Fig 154 Handling To pre...

Page 121: ...s an adjustable axle assembly as standard Depending on the towing vehicle the customer must adjust the axle to the correct tongue load 5 If the trailer is parked when loaded the tongue load must not e...

Page 122: ...m 3 2808 Foot ft Power Kilowatt kW 1 3410 Horse power hp Pressure Kilopascal kPa 0 1450 Pounds per square inch psi Megapascal MPa 145 0377 Bar non SI bar 14 5038 Torque Newton metre Nm 0 7376 Pound f...

Page 123: ...allation 34 L Layout of the machine 29 M Maintenance 93 95 Misuse 18 N Notes on operation 67 O Obligations of personnel 20 Obligations of the operator 20 Operation 62 P Personal protective equipment 2...

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Page 128: ...Fliegl Agrartechnik GmbH B rgermeister Boch Str 1 D 84453 M hldorf a Inn Tel 49 0 86 31 307 0 Fax 49 0 86 31 307 550 e Mail info fliegl com 1 002B06203 1...

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Fliegl ASW 110, Operating Instructions Manual

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