PRONAR RC2100-2 Operator'S Manual Download Page 48

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Pronar RC2100-2

SECTION 3

3.8

FIGURE 3.6

Design and diagram of double conduit pneumatic braking system with

ALB regulator

(1) air tank, (2) control valve, (3) automatic braking force regulator, (4) relay valve,

(5) pneumatic cylinder, (6) ALB beam, (7) conduit connector, yellow, (8) conduit connector,

red, (9) air filter, (10) drain valve, (11) air tank control connector

Summary of Contents for RC2100-2

Page 1: ...phone 48 085 681 63 29 48 085 681 64 29 48 085 681 63 81 48 085 681 63 82 fax 48 085 681 63 83 48 085 682 71 10 www pronar pl OPERATOR S MANUAL AGRICULTURAL TRAILER PRONAR RC2100 2 TRANSLATION OF THE ORIGINAL INSTRUCTIONS ISSUE 2A 09 2017 PUBLICATION NO 437N 00000000 UM ...

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Page 3: ...entation Before using the machine the user must carefully read this Operator s Manual and observe all recommendations This guarantees safe operation and ensures malfunction free work of the machine The machine is designed to meet obligatory standards documents and legal regulations currently in force The manual describes the basic safety rules and operation of trailer Pronar RC2100 2 If the inform...

Page 4: ...articularly important information and instructions the observance of which is essential are distinguished in the text by the sign and also preceded by the word ATTENTION Failure to observe the instructions may lead to damage to the machine as a result of improper operation adjustment or use In order to focus the user s attention on the need to perform maintenance the relevant section of the Operat...

Page 5: ...ction of machine s forward travel Right side side to the right hand of the operator facing in the direction of machine s forward travel REQUIRED SERVICE ACTIONS Service actions described in the manual are marked Result of service adjustment actions or comments concerning the performance of actions are marked ...

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Page 7: ...SPORT ON VEHICLE 1 9 1 5 2 INDEPENDENT TRANSPORT BY THE USER 1 11 1 6 ENVIRONMENTAL HAZARDS 1 11 1 7 WITHDRAWAL FROM USE 1 13 2 SAFETY ADVICE 2 1 2 1 BASIC SAFETY RULES 2 2 2 1 1 USE OF TRAILER 2 2 2 1 2 HITCHING AND DISCONNECTING FROM TRACTOR 2 3 2 1 3 HYDRAULIC SYSTEM 2 4 2 1 4 LOADING AND UNLOADING 2 4 2 1 5 TRANSPORTING THE MACHINE 2 6 2 1 6 TYRES 2 9 2 1 7 MAINTENANCE 2 9 2 2 DESCRIPTION OF R...

Page 8: ...FTER DELIVERY 4 2 4 1 2 PREPARE A TRAILER FOR FIRST HITCHING TO TRACTOR 4 2 4 2 HITCHING AND DISCONNECTING FROM TRACTOR 4 4 4 3 TRAILER SUPPORT OPERATION 4 6 4 4 LOADING AND UNLOADING THE TRAILER 4 8 4 4 1 STANDARD SIZE LOADS 4 8 4 4 2 OVERSIZE LOADS 4 10 4 4 3 UNLOADING THE TRAILER 4 10 4 5 RAMPS PROTECTIONS 4 11 4 6 SECURING LOAD 4 12 4 7 TRANSPORTING THE MACHINE 4 14 4 8 PROPER USE AND MAINTENA...

Page 9: ...JUSTMENT OF CABLE TENSION 5 15 5 3 HYDRAULIC SYSTEM OPERATION 5 17 5 3 1 PRELIMINARY INFORMATION 5 17 5 3 2 CHECKING HYDRAULIC SYSTEM TIGHTNESS 5 18 5 3 3 CHECKING TECHNICAL CONDITION OF HYDRAULIC CONNECTIONS AND SOCKETS 5 18 5 3 4 REPLACEMENT OF HYDRAULIC CONDUITS 5 19 5 4 CHECKING DRAWBAR EYE TIGHTNESS 5 19 5 5 OPERATION OF ELECTRICAL SYSTEM AND WARNING ELEMENTS 5 20 5 5 1 PRELIMINARY INFORMATIO...

Page 10: ...5 11 TROUBLESHOOTING 5 31 ...

Page 11: ...SECTION 1 BASIC INFORMATION ...

Page 12: ...er of lower frame The trailer is marked with data plate 1 located on the trailer s front wall and with serial number 2 located on a gold painted rectangle The serial number is stamped on the right longitudinal member of the frame When buying the trailer check that the serial numbers on the machine agree with the number written in the WARRANTY BOOK in the sales documents and in the OPERATOR S MANUA...

Page 13: ... Official certificate number F Tare weight G Maximum gross weight H Carrying capacity I Permissible hitching system loading J Permissible front axle load K Permissible rear axle load 1 1 2 AXLE IDENTIFICATION FIGURE 1 2 Location of the axle data plate 1 data plate 2 wheel axle The factory number of the axle shaft and its type are stamped onto the data plate 2 secured to the axle shaft beam 1 figur...

Page 14: ...ENDED USE The trailer is designed for transporting agricultural and construction machines and the loads which can be properly secured against moving during travel loads placed in boxes containers on pallets etc Transporting people animals bulk and hazardous materials is prohibited and regarded as contrary to the intended purpose of the trailer During the use of the machine comply with all road tra...

Page 15: ...r is designed according to current safety requirements and engineering standards The brake system and the light and indicator system meet the requirements of road traffic regulations The maximum speed of the trailer on public roads in Poland is 30 km h pursuant to Traffic Law Act of June 20th 1997 article 20 In the countries where the trailer is used the limits stipulated by the road traffic legis...

Page 16: ...ety have the required authorisation to drive carrying vehicles and are familiar with the road traffic regulations and transport regulations TABLE 1 3 Requirements for agricultural tractor CONTENTS UNIT REQUIREMENTS Brake system sockets Hydraulic system Double conduit pneumatic system Nominal pressure of the system Hydraulic system Double conduit pneumatic system bar MPa bar KPa sockets compliant w...

Page 17: ...UIPMENT TABLE 1 4 RC2100 2 trailer equipment EQUIPMENT STANDARD ADDITIONAL OPTION THE OPERATOR S MANUAL WARRANTY BOOK Connection lead for the electrical system Floor planks coniferous wood planks Single conduit hydraulic braking system Double conduit pneumatic braking system with ALB regulator Drawbar set with rotating drawbar eye 50 Drawbar set with ball drawbar eye 80 Drawbar set with fixed draw...

Page 18: ...ITIONS OF WARRANTY PRONAR Sp z o o Narew guarantees the reliable operation of the machine when it is used according to its intended purpose as described in the OPERATOR S MANUAL The repair period is specified in the WARRANTY BOOK The warranty does not cover those parts and sub assemblies of the machine which are subject to wear in normal usage conditions regardless of the warranty period Consumabl...

Page 19: ... to warranty service TIP Demand that the seller carefully and precisely fills out the Warranty Book and guarantee repair coupons A missing date of purchase or sale point stamp may make the user ineligible for any warranty repair or refund The user is obliged to report immediately on noticing any wear in the paint coating or traces of corrosion and to have the faults rectified whether they are cove...

Page 20: ...egulations Driver of the vehicle should be particularly careful during travel This is due to the vehicle s centre of gravity shifting upwards when loaded with the machine Use only certified and technically reliable securing measures Carefully read the information contained in the Operator s Manuals for the given securing measures The trailer should be attached firmly to the platform of the vehicle...

Page 21: ... The securing elements must be selected according to the guidelines of the Manufacturer of these elements In case of doubt apply a greater number of securing straps in order to immobilise the trailer If necessary sharp edges of trailer should be protected at the same time protecting the securing straps from breaking during transport During reloading work particular care should be taken not to dama...

Page 22: ...of oxygen values in the water because of lack of direct contact of air with the water An oil leak into water reservoirs may however lead to a reduction of the oxygen content While carrying out maintenance and repair work which involves the risk of an oil leak this work should take place on an oil resistant floor or surface In the event of oil leaking into the environment first of all contain the s...

Page 23: ...ng withdrawal from use and recycling of machines withdrawn from use Before commencing dismantling totally remove the oil from the hydraulic system and reduce air pressure completely in the pneumatic braking system e g using air tank drain valve DANGER During dismantling use the appropriate tools equipment overhead travelling crane crane or hoist etc and use personal protection equipment i e protec...

Page 24: ...PRONAR RC2100 2 SECTION 1 1 14 ...

Page 25: ...SECTION 2 SAFETY ADVICE ...

Page 26: ...nual is dangerous to your health Be aware of the residual risk Use caution when operating this machine and follow all relevant safety instructions The machine must never be used by persons who are not authorised to drive agricultural tractors including children and people under the influence of alcohol drugs or other abusive substances Non compliance with the safety rules of this Operator s Manual...

Page 27: ...e trailer to the tractor use the appropriate hitch After completed hitching of the machines check the safety of the hitch Carefully read the tractor Operator s Manual If the tractor is equipped with an automatic hitch make certain that the coupling operation is completed Be especially careful when hitching the machine to the tractor When hitching there must be nobody between the trailer and the tr...

Page 28: ...ccurrence of irritation consult a doctor In the event of contact of oil with skin wash the area of contact with water and soap Do NOT apply organic solvents petrol kerosene Use the hydraulic oil recommended by the Manufacturer After changing the hydraulic oil the used oil should be properly disposed of Used oil or oil which has lost its properties should be stored in original containers or replace...

Page 29: ...quipment may work on the load platform only if the total weight of the loading equipment and the load does not exceed the maximum carrying capacity of the trailer Be especially careful when opening or closing the ramps because there is a risk of crushing Unfolded ramps must adhere to level surface Unfolded ramps must be at the same height Incorrect load distribution and overloading the machine may...

Page 30: ... against rolling with chocks or other objects without sharp edges placed under the front and back trailer wheels Before driving off check that the parking brake is released The trailer s ramps must be folded and properly secured using ramps interlocks Travelling with ramps which are unfolded and not secured with ramps interlocks is prohibited Before moving off make sure that the support is properl...

Page 31: ...o tip over as a result of loss of stability Prolonged driving across steep ground may lead to loss of braking efficiency While driving on public roads the trailer and the tractor must be fitted with a certified or authorised reflective warning triangle Chocks should be placed only under one wheel one in front of the wheel the other behind the wheel figure 2 1 FIGURE 2 1 Method of placing chocks 1 ...

Page 32: ...ross weight of the trailer exceeding the weight limit causes drastic reduction of basic braking effectiveness FIGURE 2 2 Mounting place for slow moving vehicle warning sign 1 slow moving vehicle warning sign 2 attachment point Before driving on public roads place the triangular slow moving vehicle warning sign on the left folded ramp figure 2 2 The triangular warning sign should be attached using ...

Page 33: ...ned and entitled to do so This work should be carried out using appropriate tools Inspect tightness of wheel nuts after the first use of the trailer every 2 3 hours during first month of work and then every 30 hours of use travel The inspection should be repeated individually if a wheel has been removed from the wheel axle Wheel nuts should be tightened according to recommendations provided in sec...

Page 34: ...king brake and chocks should be placed under the trailer wheels Ensure that unauthorised persons do not have access to the tractor cab Service inspections of the trailer should be carried out according to the frequency specified in this Operator s Manual Regularly check the condition of nut and bolt connections in particular connections of drawbar eye with drawbar and wheel nuts Before beginning r...

Page 35: ...ble material before commencing welding work Before beginning work prepare a CO2 or foam extinguisher In the event of work requiring the trailer to be raised use properly certified hydraulic or mechanical lifts for this purpose After lifting the machine stable and durable supports must also be used Work must not be carried out under a trailer which has only been raised with a lift or jack The trail...

Page 36: ... while the engine is running and when the machine is being attached or hitched to second trailer being on the machine while the engine is running not maintaining safe distance during loading or unloading of trailer operation of the trailer by persons under the influence of alcohol making modifications to the machine without the consent of the Manufacturer cleaning maintenance and technical checks ...

Page 37: ...gure 2 3 Throughout the time it is in use the user of the machine is obliged to take care that notices and warning and information symbols located on the trailer are clear and legible In the event of their destruction they must be replaced with new ones Safety decals are available from your PRONAR dealer or directly from PRONAR customer service New assemblies changed during repair must be labelled...

Page 38: ... Do not place hands between the ramps and the trailer frame 123RPN 00 00 00 04 4 Grease the trailer according to the recommendations in the Operator s Manual 104RPN 00 00 00 04 5 Regularly check if the nuts and bolts fixing the wheels and other components are properly tightened 104RPN 00 00 00 06 6 Air pressure in the tyres standard tyres 208N 00000006 7 Permissible hitching system loading 103RPN ...

Page 39: ...pes chains or other devices for securing load on the platform 123RPN 00 00 00 13 9 Manufacturer s decal 187N 00000016 10 Trailer version 437 20000001 11 Information decal identifying the hydraulic brake connection 29RPN 00 00 028 Numbers in the Item column correspond to labels in figure 2 3 ...

Page 40: ...Pronar RC2100 2 SECTION 2 2 16 FIGURE 2 3 Locations of information and warning decals ...

Page 41: ...SECTION 3 DESIGN AND OPERATION ...

Page 42: ...m mm mm 9 450 2 550 2 450 2 540 1 900 7 020 1 864 1 325 Weights Maximum gross weight Carrying capacity Tare weight kg kg kg 19 000 14 900 4 100 Tyres Tyre dimensions Air pressure in the tyres kPa 215 75R17 5 850 Other parameters Lift of load surface Axle load Hitch load Maximum design speed Nominal voltage of electrical system Noise emission level mm kg kg km h V dB 930 8 000 3 000 60 12 below 70 ...

Page 43: ...s 6 floor insert additional equipment Low chassis trailer is a welded structure made from steel profiles The main support elements are two longitudinal members connected with crossbars Two ramps 1 equipped with springs 5 are installed in the rear part of the frame Springs assist in manual lowering and raising the ramps In the transport position ramps are secured using locking pins 4 and ...

Page 44: ...lanks 1 figure 3 2 with a thickness of 45 mm Load placed on the platform is secured with belts ropes or chains which are attached to fixing lugs 2 located along the whole platform on both sides of the trailer The fixing lugs are marked with information decals 8 table 2 1 On the front side the load platform is limited by wall 3 to which spare wheels 4 optional equipment are attached On the left sid...

Page 45: ...of the drawbar there is a holder for installing bracket for conduit connectors 5 FIGURE 3 3 RC2100 2 trailer drawbar 1 drawbar 2 spring 3 rotating drawbar with a 50 eye 4 parking stand 5 bracket for conduit connectors 3 2 3 SUSPENSION Axles 1 figure 3 4 in a tandem arrangement are attached to parabolic leaf springs 3 using an absorber plate and U bolts The parabolic leaf springs are connected toge...

Page 46: ...xle 2 rocker arm 3 parabolic leaf spring 4 rocker arm pin 5 lubricated leaf spring pin 6 smooth leaf spring pin 7 twin wheels 3 2 4 MAIN BRAKE The trailer can be equipped with one of the main brake systems figure 3 5 3 6 3 7 The main brake is activated from the tractor driver s cab by pressing on the brake pedal The system is designed to activate the trailer s brakes when the brake pedal is presse...

Page 47: ...l axles Oil supplied to cylinder moves the piston rod and rotates axle expander lever Return of cylinder to neutral position is assisted by draw back springs 4 During normal work it does not require service Connecting line of the brake system is marked with decal 3 In the pneumatic cylinders air supplied to cylinder exerts pressure on membrane which in turn moves cylinder piston and rotates to axl...

Page 48: ... conduit pneumatic braking system with ALB regulator 1 air tank 2 control valve 3 automatic braking force regulator 4 relay valve 5 pneumatic cylinder 6 ALB beam 7 conduit connector yellow 8 conduit connector red 9 air filter 10 drain valve 11 air tank control connector ...

Page 49: ... 6 hydraulic cylinder 7 conduit connector yellow 8 conduit connector red 9 air filter 10 hydraulic quick coupler 11 drain valve 12 air tank control connector 13 spring H hydraulics In the trailer equipped with pneumatic brake system in case of an inadvertent disconnection of the conduit between the trailer and the tractor the control valve will automatically activate trailer s brakes Valve used in...

Page 50: ...l valve 2 braking force regulator 3 push button for applying the trailer brakes while standing motionless 4 regulator working position selection lever A NO LOAD position B HALF LOAD position C FULL LOAD position Manual three step braking force regulator 2 figure 3 8 adjusts braking force depending on setting Switching to a suitable working mode is done manually by the machine operator using the le...

Page 51: ...for immobilising the trailer while parking The brake crank mechanism 1 is attached to the right longitudinal member of the lower frame Steel cable 4 routed through guide rollers 5 is connected with expanded levers 3 of front axle 2 Tightening the cable causes tilting of the expander arms which part the brake shoes immobilising the trailer while standing motionless ...

Page 52: ...trailer s electrical system should be connected to the tractor using an appropriate connection lead that is a part of the trailer s standard equipment FIGURE 3 10 Electrical system design 1 rear left lamp assembly 2 rear right lamp assembly 3 license plate light 4 7 pin socket 5 rear clearance lamp 6 side clearance lamp 7 front clearance lamp 8 connecting line ...

Page 53: ...C2100 2 3 13 3 3 HYDRAULIC SYSTEM OF THE SUPPORT OPTION FIGURE 3 11 Design and diagram of hydraulic support system 1 straight hydraulic support 2 cut off valve 3 hydraulic coupler 4 information decal 5 information decal ...

Page 54: ... of double acting cylinders through a single section hydraulic distributor 1 located in the rear part of the frame on the right side of the trailer The system is supplied from the external hydraulic system of the tractor To ensure correct connection the supply conduit and the return conduit are marked with information decals 7 and 8 Hydraulic distributor 9 option has a floating section that enforc...

Page 55: ...mps hydraulic system 1 hydraulic distributor 2 flow divider 3 ramp cylinder 4 hydraulic pipe 5 quick coupler plug supply 6 quick coupler plug with return valve return 7 information decal 8 information decal 9 hydraulic distributor with floating position option ...

Page 56: ...efore unfolding the ramps remove the transport straps and unlock spring catches Travelling with ramps which are unfolded and not secured with spring catches and straps is prohibited When loading or unloading the platform the ramp legs and lower supporting elements must adhere tightly to level ground Lower the ramps until they fully rest on the ground Switch the hydraulic distributor to floating po...

Page 57: ...ans of connection conduit terminated with quick coupler 2 and marked with decal 13 The main brake is activated from the tractor driver s cab by pressing on the brake pedal Return of hydraulic brake cylinders 1 to neutral position is assisted by springs installed in cylinders The emergency brake immediately stops the trailer in case of its disconnection from the tractor Attach the cable thimble 5 t...

Page 58: ...Pronar RC2100 2 SECTION 3 3 18 ATTENTION Connect the cable 5 to tractor in such a manner as not to activate the trailer s brakes ...

Page 59: ...SECTION 4 CORRECT USE ...

Page 60: ... must carefully read this Operator s Manual and observe all recommendations understand the design and the principle of machine operation ATTENTION Before hitching to tractor and using the trailer the user must carefully read this Operator s Manual and observe all recommendations External inspection Check completeness of machine standard and optional equipment Check condition of protective paint co...

Page 61: ...and there is no doubt as to the trailer s good technical condition it can be connected to tractor Start the tractor check all systems and conduct test run of trailer without load no load in load box It is recommended that the inspection is conducted by two people one of which should always remain in the tractor cab Test drive should be conducted according to the sequence shown below Connect the tr...

Page 62: ... HITCHING AND UNHITCHING THE TRAILER FROM TRACTOR Ensure that all connections electric hydraulic and the hitch of agricultural tractor meet the requirements of the low chassis trailer Manufacturer Otherwise the trailer should not be hitched to the tractor In order to hitch the trailer to the tractor perform the actions below in the sequence presented Machine must be immobilised by parking brake Hi...

Page 63: ... that the hitching operation is completed and that drawbar eye is secured Raise support foot turn it to transport position and secure it with pin and cotter pin Read subsection 4 3 4 4 Set hydraulic valve 5 to Z position hydraulic support Turn off tractor engine Ensure that unauthorised persons do not have access to the tractor cab Connect the braking system conduits Connect pneumatic conduit mark...

Page 64: ...ng the trailer In order to unhitch the trailer from the tractor follow these steps Immobilise tractor and trailer with parking brake Lower the support to parking position Read subsection 4 3 Turn off tractor engine Ensure that unauthorised persons do not have access to the tractor cab Possibly disconnect the conduits of the hydraulic system of the support and the ramps from the tractor Disconnect ...

Page 65: ...tractor cab and secure it against access by unauthorised persons 4 3 SUPPORT LEG OPERATION DANGER While placing the support in driving position exercise caution and do not place fingers between the support mounting socket and the support Danger of severing or crushing FIGURE 4 1 Support operation 1 support in parking position 2 support in driving position 3 safety pin in parking position 4 cotter ...

Page 66: ...NTION Do NOT move off or drive with the support in parking position Be sure to change support to the driving position Do NOT travel with the trailer if the support securing elements are damaged or lost safety pin 3 and R clip 4 Setting the support to rest position Immobilise tractor and trailer with parking brake Unlock the cotter pin 4 and remove the safety pin from the driving position 5 figure ...

Page 67: ... Operate selective control valve in the tractor in order to raise the support foot The tractor must be connected with the trailer before the support foot is raised Hydraulic conduit marked with decal 7 figure 4 1 must be connected to the hydraulic socket in tractor The trailer must be hitched to the tractor Close valve 5 Shift valve lever to Z position decal 6 Remove R clip 4 from safety pin remov...

Page 68: ...in 5 cut off valve 6 information decal O Z 7 information decal A B safety pin sockets Turn support foot to position 2 DANGER While placing the support in driving position exercise caution and do not place fingers between the support mounting socket and the support Danger of severing or crushing Insert safety pin 3 to socket B and secure it with R clip 4 ...

Page 69: ...socket A and secure it with R clip 4 Set cut off valve 5 to O position Operate selective control valve in the tractor in order to lower the support foot Drawbar hitching eye should be slightly raised with regard to the tractor hitch in order to facilitate unhitching the trailer Set valve 5 to Z position DANGER Danger of crushing Be especially careful when lowering the support this refers to bystan...

Page 70: ...the transport straps of the ramps Unlock the spring catches and lower the ramps to the ground manually or using the hydraulic system distributor depending on trailer equipment Place the load on the trailer platform Fold the ramps Install transport straps and lock locking pins Secure the load Hoisting crane or overhead crane of proper lifting capacity or additional agricultural tractor may be used ...

Page 71: ...e dimensions exceed allowable dimensions specified by the road traffic regulations in force in the country where the trailer is used Oversize loads may be transported on public roads only if the requirements specified by the road traffic regulations are met and a travel permit is obtained from a competent office Driving on non public roads is not limited by road traffic regulations DANGER Do NOT e...

Page 72: ...se damage to the tractor hitch or drawbar If unloading takes place on soft ground place planks plates or other materials under the ramps to prevent them from sinking into the ground 4 6 RAMPS PROTECTIONS The trailer s ramps are protected by means of transport straps and a spring catch The transport strap 1 figure 4 3 is attached to the ramp element on the outside and to the transport lug 2 located...

Page 73: ...interlock the ramps can be lowered to working position After finishing work and folding the ramps check whether the spring catches have automatically returned to locking position Otherwise set the levers to correct position position 1 Figure 4 4 ATTENTION After finishing ramps folding make sure that spring catches are in ramp locking position FIGURE 4 4 Spring catch 1 catch lever in ramp locking p...

Page 74: ...es of load securing Important instructions are only given concerning correct load fixing methods and risks are indicated which may occur if proper procedures are not followed Properly secured load must not have a tendency to tilt on the load platform when making turns and must not slide on the trailer floor planks For this reason sufficient securing measures should be applied to prevent these unfa...

Page 75: ...ion and the load This person should be visible all the time to the tractor driver as well as be especially careful and keep a safe distance from danger zones The trailer must not be overloaded loads must be uniformly distributed so that the maximum permissible axle and drawbar loads are not exceeded The trailer s maximum carrying capacity must not be exceeded as this can damage the machine and pos...

Page 76: ...g reversing one should use the assistance of another person who gives directions standing clear of the danger zone 4 9 PROPER USE AND MAINTENANCE OF TYRES When working on the tyres chocks or other objects without sharp edges should be placed under the wheels of the trailer to prevent it from rolling Wheels can be taken off the trailer axle only when the trailer is not loaded Repair work on the whe...

Page 77: ... intensive work Please note that higher temperatures could raise tyre pressure by as much as 1 bar At high temperatures and pressure reduce load or speed Do not release air from warm tyres to adjust the pressure or the tyres will be underinflated when temperatures return to normal Protect tyre valves using suitable caps to avoid soiling Do not exceed the trailer s maximum design speed Avoid pothol...

Page 78: ...Pronar RC2100 2 SECTION 4 4 20 ...

Page 79: ...SECTION 5 MAINTENANCE ...

Page 80: ...rded as possible for the trailer operator to perform the user shall invalidate the warranty 5 2 SERVICING BRAKES AND AXLES 5 2 1 PRELIMINARY INFORMATION Work connected with the repair change or regeneration of axle and brakes elements should be entrusted to specialist establishments having the appropriate technology and qualifications for this type of work The responsibilities of the user are limi...

Page 81: ... parking brake Main brake and parking brake should be engaged and released without great resistance and severity Check cylinder movement and correct return of piston to start position The help of a second person is required who shall engage trailer brake Check if axle elements are in place cotter pins in castellated nuts expansion rings etc Inspect tightness of the hydraulic cylinders see section ...

Page 82: ...erheat if brake cylinder piston stroke is significantly longer if there are unusual noises from the drum of wheel axle FIGURE 5 1 Checking brake shoe linings 1 wheel axle drum 2 inspection opening for checking wear of brake shoe linings G brake shoe lining thickness attention The minimum thickness of brake shoe lining for A90TN8QCN002 axle is 2 mm The minimum thickness of brake shoe lining for A90...

Page 83: ...el ground Immobilise tractor with parking brake Place the wheel chocks under the wheel opposite to the lifted wheel Ensure that trailer shall not move during inspection Raise the wheel opposite to the side where chocks are placed The lifting jack should be placed between U bolts 1 figure 5 2 securing axle to leaf spring or as near as possible to axle mounting Recommended support point is marked wi...

Page 84: ...ry to detect slackness You may use a lever placed under the wheel supporting the other end of the lever on the floor Repeat the procedure for each wheel individually remembering that the jack must be on the side opposite to the chocks TIP If hub cover is damaged or missing contamination and dampness enter the hub which causes significantly faster wear of bearings and hub seals Life of bearings is ...

Page 85: ...axle Ensure that trailer shall not move during inspection of axle bearing slackness 5 2 5 ADJUSTMENT OF AXLE BEARING SLACKNESS Preparation procedures Prepare tractor and trailer for adjustment procedures according to description provided in section 5 2 3 Adjustment of axle bearing slackness Take off hub cover 1 figure 5 3 Take out cotter pin 3 securing castellated nut 2 Tighten castellated nut in ...

Page 86: ...iffness or detectable resistance not originating from abrasion of brake shoes in brake drum Adjustment of bearing play may only be conducted when the trailer is hitched to tractor and it is not loaded TIP If the wheels are removed bearing play is easy to check and adjust 5 2 6 MOUNTING AND DISMOUNTING WHEELS INSPECTION OF WHEEL NUT TIGHTENING Wheel removal Immobilise trailer with parking brake Pla...

Page 87: ... twin wheels 1 external wheel 2 internal wheel 3 tyre valve extension 4 nut 5 external ring 6 internal ring Loosen wheel nuts 4 Sequence of nut tightening and loosening is shown in figure 5 5 Place lifting jack and lift the trailer Undo and remove nuts remove external rings 5 Remove external wheel 1 Remove internal wheel 2 Remove internal rings 6 ...

Page 88: ... until the wheels are completely set on the drums Lower trailer tighten nuts according to recommended torque 380Nm and given sequence TIP Wheel nuts should be tightened using the torque of 380 Nm M22x1 5 nuts Tightening nuts Nuts should be tightened gradually diagonally in several stages until obtaining the required tightening torque using a torque spanner If a torque spanner is not available one ...

Page 89: ...er the first use of trailer one time inspection Every 2 3 hours of trailer travel during the first month of trailer use Every 30 hours of trailer travel The above actions should be repeated individually if a wheel has been removed from the wheel axle TABLE 5 1 Spanner arm WHEEL TIGHTENING TORQUE BODY WEIGHT F ARM LENGTH L Nm kg m 86 0 45 77 0 50 70 0 55 380 65 0 60 ...

Page 90: ... more frequently During this time the trailer must be unloaded Checking should be done before travelling when tyres are not heated or after an extended period of parking TIP pressure values are specified in information decal placed on wheel or on upper frame above trailer wheel DANGER Damaged tyres or wheels may be the cause of a serious accident While checking pressure pay attention to technical ...

Page 91: ...neously Brakes adjustment involves changing the position of the expander arm 1 figure 5 6 in relation to expander shaft 2 To do this rotate adjustment screw 4 in appropriate direction to displace the expander lever in direction B if brake brakes too late in direction A if braking is too early Adjustment should be conducted separately for each wheel After proper brake adjustment at full braking the...

Page 92: ...r axle The cylinder fork mounting position is selected by the Manufacturer and may not be changed TABLE 5 2 Position of fork pin in expander arm Type of system Pneumatic system Figure 3 6 Hydraulic system Figure 3 5 Combined system Figure 3 7 Front axle Rear axle Front axle Rear axle Front axle Rear axle Pin position mm 175 175 150 175 175 175 Checking and adjustment of main brake every 12 months ...

Page 93: ... the setting of expander arms 5 2 9 REPLACEMENT OF PARKING BRAKE CABLE AND ADJUSTMENT OF CABLE TENSION Proper operation of the parking brake is dependent on the effectiveness of the axle brake and the correct brake cable tension FIGURE 5 7 Adjustment of parking brake cable tension 1 brake crank mechanism 2 hand brake cable 3 shackle 4 u shaped clamp 5 clamp nuts 6 guide rollers Replacing the parki...

Page 94: ...e check the condition of cable ends correct if necessary FIGURE 5 8 Installation of steel cable 1 steel cable 2 clamp jaw 3 thimble 4 nut 5 heat shrink tubing Installation of steel cable Secure cable ends by means of heat shrink tubing 5 Install thimble 3 on cable 1 Install clamp jaws 2 and tighten nuts 4 The distance between the clamps should be at least 15 mm Clamp jaws must be placed on the sid...

Page 95: ...ts of handbrake cable clamps located near expander lever Tighten cable and tighten clamps Length of parking brake cable should be so selected that at total release of working and parking brake the cable would be loose and hanging by 1 2 cm compared to fully tensioned cables Adjustment of parking brake cable tension should be conducted in the event of stretching of cable loosening of parking brake ...

Page 96: ...use the trailer with out of order hydraulic brake system 5 3 2 CHECKING HYDRAULIC SYSTEM TIGHTNESS Scope of maintenance activities Hitch trailer to tractor Connect all hydraulic system conduits according to maintenance instructions Clean connectors and cylinders Press tractor brake pedal several times Check hydraulic cylinders and conduits for tightness If oil leak is detected on hydraulic cylinde...

Page 97: ...tion of hydraulic couplers and sockets each time before hitching trailer to tractor 5 3 4 REPLACEMENT OF HYDRAULIC CONDUITS Rubber hydraulic conduits must be replaced every 4 years regardless of their technical condition This should be done in specialised workshops Replacement of hydraulic conduits every 4 years 5 4 PNEUMATIC SYSTEM MAINTENANCE 5 4 1 PRELIMINARY INFORMATION During the guarantee pe...

Page 98: ...actor in order to supplement air in trailer brake system tank In single conduit systems air pressure should be between 5 8 6 5 bar In double conduit systems air pressure should amount to approx 6 5 bar Turn off tractor engine Check system components by releasing brake pedal in tractor Pay particular attention to conduit connections and brake cylinders Repeat the system check with depressed tractor...

Page 99: ...king repairs or changing system components annually Visual inspection of the system During tightness inspection attention should additionally be given to technical condition and degree of cleanness of the system components Contact of pneumatic conduit seals etc with oil grease petrol etc may cause damage and accelerate the ageing process Bent permanently deformed cut or worn conduits should be rep...

Page 100: ...tical direction Depending on trailer working conditions but not less than once in three months take out and clean air filter elements which are located in pneumatic system connection conduits Filter elements are used many times and are not subject to change unless they are mechanically damaged Scope of maintenance activities Reduce pressure in supply conduit Pressure in conduit can be reduced by p...

Page 101: ...eaning the air filter filters every 3 months of use 5 4 4 DRAINING WATER FROM AIR TANK Scope of maintenance activities Tilt drain valve stem 1 located in the lower part of tank 1 figure 5 9 The compressed air in the tank causes the removal of water to the exterior After releasing the valve stem the valve should automatically close and stop airflow from the tank If the valve stem resists returning ...

Page 102: ...GURE 5 10 Draining water from air tank 1 air tank 2 drain valve 3 control connector Draining water from air tank after each week of use 5 4 5 CLEANING THE DRAIN VALVE DANGER Release air from the air tank before dismantling drain valve ...

Page 103: ...ulty functioning of braking system Damaged connection body or socket for connecting the second trailer should be replaced In the event of damage to cover or seal change these elements for new reliable elements Contact of pneumatic connector seals with oils grease petrol etc may cause damage and accelerate ageing process If the trailer is unhitched from the tractor connections should be protected b...

Page 104: ...y deformed cut or frayed Push in fittings are used for connecting conduits with pneumatic system components The fittings enable simple fast and tight connection by pushing the conduits in If leaks appear at connections the user may tighten the fitting by himself using a tightening torque according to table 5 3 If air continues to escape replace fittings with new ones FIGURE 5 11 Installation of pn...

Page 105: ...el nut tightness checking Drawbar eye retaining bolts M20X80 DIN127 should be tightened diagonally using a torque spanner with torque of 100Nm and then retightened using torque of 396Nm Bolts and nuts should be in good technical condition Corroded parts or those with damaged threads should be replaced Checking drawbar eye tightness after first use after first travel with load after 6 months of tra...

Page 106: ...d reflectors must be replaced The responsibilities of the user are limited to technical inspection of electrical system and reflectors changing bulbs Scope of maintenance activities Connect trailer to tractor with appropriate connection lead Check if the connection lead is reliable Check connection sockets in tractor and trailer Check completeness and technical condition of trailer lights Check co...

Page 107: ...cured by screws and it is not necessary to dismantle whole lamp or trailer subassemblies TABLE 5 4 List of bulbs LAMP BULB TYPE BULB 12V P21W BA15S 3pcs Rear right lamp assembly W21P Rear left lamp assembly W21L 12V R10W BA15S 1pc License plate light W71 12V R10W BA15S 1pc 5 7 TRAILER LUBRICATION TABLE 5 5 Trailer lubrication schedule ITEM LUBRICATION POINT NUMBER OF LUBRICATION POINTS TYPE OF GRE...

Page 108: ...6M 6 Spring sliding surface 4 B 3M 7 Rocker arm pin 2 B 3M 8 Leaf spring pin 4 B 3M 9 Parking brake mechanism 1 A 6M 10 Pin of parking brake cable guide roller 5 A 6M 11 Drawbar side surface 2 B 1M 12 Rotary drawbar 1 B 1M 13 Pin of ramp interlock lever 2 A 6M 14 Pin of plank holder flap 2 A 6M 15 Upper spring securing pin 2 A 6M 16 Lower spring securing pin 2 A 6M 17 Drawbar sleeve 1 B 1M ...

Page 109: ...ON A machine general purpose grease lithium calcium grease B permanent grease for heavily loaded elements with addition of MoS2 or graphite C ordinary machine oil silicon grease in aerosol Trailer lubrication should be performed with the aid of a manually or foot operated grease gun filled with recommended grease Before commencing work insofar as is possible remove old grease and other contaminati...

Page 110: ...Pronar RC2100 2 SECTION 5 5 32 FIGURE 5 12 Lubrication points part 1 ...

Page 111: ...SECTION 5 Pronar RC2100 2 5 33 FIGURE 5 13 Lubrication points part 2 ...

Page 112: ...er During trailer operation the user is obliged to observe lubrication instructions according to attached lubrication schedule 5 8 CONSUMABLES 5 8 1 HYDRAULIC OIL Always adhere to the principle that the oil in the trailer hydraulic system and in the tractor hydraulic system are of the same type In the event of application of different types of oil make certain that both hydraulic substances may be...

Page 113: ...ratory tract A hazard only occurs when oil is strongly atomised oil vapour or in the case of fire during which toxic compounds may be released Oil fires should be quenched with the use of carbon dioxide foam or steam extinguishers Do not use water to quench oil fires 5 8 2 LUBRICANTS For heavily loaded parts it is recommended to apply lithium greases with addition of molybdenum disulphide MOS2 or ...

Page 114: ... the surface being cleaned Water temperature should not exceed 55 0 C Do not direct water stream directly at system elements and equipment of the trailer i e brake cylinders hydraulic cylinders lights electrical connections information and warning decals identification plate conduit connections lubrication points etc Great water jet pressure may damage these elements During washing try not to wet ...

Page 115: ...nts should be maintained with the aid of special preparations after previous thorough washing After completed washing wait until the trailer is dry and then grease all inspection points according to recommendations Remove excess oil or grease with a dry cloth Observe environmental protection principles and wash trailer in a place designed for this purpose Cleaning and drying of the trailer must ta...

Page 116: ...the place of contact of tyres with ground is changed The tyres will not be deformed and maintain proper geometry Also air pressure in tyres should be inspected from time to time and if necessary pressure should be increased to appropriate value 5 11 TIGHTENING TORQUE FOR NUT AND BOLT CONNECTIONS Unless other tightening parameters are given during maintenance repair work apply appropriate torque to...

Page 117: ...METRIC THREAD Md Nm M27 820 1 150 1 650 M30 1 050 1 450 2 100 1 strength class according to DIN ISO 898 standard TIP Hydraulic conduits should be tightened using torque of 50 70 Nm FIGURE 5 14 Bolt with metric thread 1 strength class d thread diameter ...

Page 118: ... arms Poor efficiency of braking system Excessive heating of axle hubs Worn brake linings Change brake shoes Improper hydraulic oil viscosity Check oil quality make sure that the oil in both machines is of the same type If necessary change oil in tractor or in trailer Insufficient tractor hydraulic pump output damaged tractor hydraulic pump Check tractor hydraulic pump Damaged or contaminated cyli...

Page 119: ...NOTES ...

Page 120: ... ...

Page 121: ...ANNEX A Tyre dimensions LP TYRES WHEEL RIM 1 215 75 R17 5 135 133 J 17 5x6 75 ...

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PRONAR RC2100-2, Operator'S Manual

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