Great Britain 17-20
Contents
1. VIXLINE TELE Zug pee e RA POWER SUPPLY a 2 3 5 6 7 8 9 10 1l 12 13 9 LI LLL tt tt tf 6 6 6 o 6 JE ei S3 L e d d OBS OW dU E de 19 JA 14 13 2 3 4 5 6 7 8 9 0 l T8 2 4 A 5 6 7 8 9 10 11 12 13 14 rE TPT i u o ID r ODO BD oe iH Qu O DI DVD bi DH od vd DUDU OD OD Figure 33 Electrical diagram Pos Art No Tile 0 LX o 915181E Electric on off control unit 91581CS 91581ES Electrical switch 9T58IRP Rubber protection 5 915181CC 2009 Ver 2 Fors MW Ltd www forsmw com 27 BIGAB HOOK LIFT SYSTEM opa 3 5 HYDRAULICAL SYSTEM 17 20 3 5 1 Main hydraulic system The trailer is delivered with filled up and tested hydraulic system The hydraulic system consists of the functional components showed in the figure below Technical data and configuration depends on the type of trailer see table 1 The hydraulic system is filled up with hydraulic oil VMGZ or SAEIOOR16 It is applied as a working fluid of the hydraulic sy2. EN L4 L4 p O 60 50 40 30 20 10 I C9 Gy Re 7 pool connection to pulling vehicle Figure 32 Electrical diagram Electrical components Table 6 Po ArtNo Title Rear light Rear light with reversing light special Border light 111x40 orange special Cable terminal Cable Connector 7 pools male Cable Connector 7 pools female special Connections of the cables and lamps Table 7 1 Red JPlahingeft 12V2IW LD 2 Brown Revesinglght 12V2IW L 2 Brown Spare without reversing Uh 3 Yellow Eath S O 4 Bhue JjPlahingrgh LNW 5 Grey Rer gt jDV21W 2 3 Brown Side marking DVSW 4 6 Black Bmkelgh IVIOW 3 2009 Ver 2 Fors MW Ltd www forsmw com 26 opa 3 4 2 Electrical on off system BIGAB 17 20 HOOK LIFT SYSTEM The electrical on off is manufactured with 12V electrical system Configuration depends of n m VU TIPP KROK RAMLAS BOGGIE VAXLING TELESKAP AV P D O D AF VIPPUR EXTRA EXTRA
3. 930105 Greasenippe 0 0 0 0 00 2 92020 fong oct 3 372102 Hok 0 y 4 92082H Jj HydmulcSupprtleg o o OO 6 3720085 Securitypst L4 amp 8 37203181 Rearlampcompl with bracket Right 8 37203183 Rearlampcompl with bracket Let 9 920155 _ Reflector 3 angle ell 2009 Ver 2 Fors MW Ltd www forsmw com 47 opa 6 TROUBLESHOOTING BIGAB 17 20 HOOK LIFT SYSTEM These troubleshooting instructions are provided to help you to determine the cause for a malfunction Electrical equipment troubles Fault symptoms Reason and action Lights fault Lamp born out Replace lamp Check and clean electrical connectors Check and repair wire Hydraulic equipment troubles Fault symptoms Too slow lift of implement or cylinders Valve stuck Clean valve parts Valve will not return from working position to should move freely without seizure neutral Ingress air into hydraulic system Locate leaky point and eliminate defect Check oil level Excessive leakage of oil in pump Replace pump Adjust oil pressure Hydraulic cylinder piston packing out of Replace packing order 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 hose connection Oil leaks through final dr
4. Bigab hook lift trailers exist in 11 different types of modules with a variety of additional extras which all has its own purpose but with the same unique flexibility The flexibility lays in its ability to handle different kinds of loads on one and the same chassed This allows the Bigab to be used at a wide range of different user applications Bigab 17 20 is the hook lift trailer for the farmer and or entrepreneur with varying transport needs The trailer is fully equipped to handle long and hard working hours in the most convenient way The trailer is possible to combine with 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 anxious to get to work the trailer but stop for a bit and take time to carefully read through this instruction book The Bigab trailer is unique which also if not used properly could turn out to be dangerous A few moments reading through the instruction book might save you time and money in the future We congratulate you at your chose of trailer and wish you and your Bigab all the best for the future Ki Vardikruc am dizrrna immrla red dirobih IKC Elidas larmin
5. 14 the brake show distance to the drum needs to be adjusted through loosening and by doing so adjusting the brake control linkage BIGAB models 12 15 15 19 17 20 and 20 24 the brake show distance to the drum on the brake cylinder needs to be adjusted through loosening or vice versa tightening the adaptable screw on the brake 2009 Ver 2 Fors MW Ltd www forsmw com 36 opa 5 2 6 Maintenance of wheels BIGAB 17 20 HOOK LIFT SYSTEM The maintenance of the wheels before proceeding to work consists in watching over the condition of the threaded joints and timely tightening there of and in observance of the rules for use and maintenance of tires e Check the threaded joints e Check the pressure of air in the tires Wheels pressures see table 2 Tightening torque for nuts see table 4 5 2 7 Maintenance undercarriage Every day It is necessary to visually check the nuts on the bogie side each time the customer uses the trailer Weekly Once per week or nor later then 20 hours it is needed 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 2009 Ver 2 Fors MW Ltd www forsmw com 37 sb PRBIGAB HOOK LIFT SYSTEM 5 2 8 Lubrication 17 20 lubricants points eguipped with grease nipples by using a grease gun See chapter 5 1 for recommended e Ensure regularity of l
6. 16 Greasenipple 5 3 8 Electrical system For electrical scheme see chapter 3 3 Pos 5 8 concerning spare parts table is not shown in electrical scheme Figure 47 Rear lamp Electrical spare parts Table 19 Po Art No Description 1 Note 1 920764L R Rearlam le 1 920766 Rear light with reversing light special 1 2 920770 Border light 111x40 orange special 1 3 920715 Cabletermnal 0 4 920695 Cable Connector 7 pools male 1 5 920180 Cable Connector 7 pools female speci 6 920723 Lamp NW 7 92745 j Lampl2V2IW le 8 920725 Lamp 12V 10W 2009 Ver 2 Fors MW Ltd www forsmw com 45 Re 5 3 9 Electrical on off system BIGAB 17 20 HOOK LIFT 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 16 Po Art No Tile 6 940835 J4wayvalee gt S 8 23918 Lake 9 9OI58IES Electrical switch Rubber protection Cable connector Ri Ww Dp A EE TTT x v S Y a Dar s nb 9 4 y e aN e 9 AM z Figure 48 Electrical on off system O 2009 Ver 2 Fors MW Ltd www forsmw com 46 opa 3 3 10 Other parts BIGAB 17 20 HOOK LIFT SYSTEM Figure 49 Other spare parts Other spare parts Table 20 Pos ArtNo Description Note 1
7. HOOK LIFT SYSTEM Hydraulic system is shown in chapter 3 4 e Clean and lubricate piston rods of hydraulic cylinders e Check the hydraulic valves Check visually hydraulic valves In case of leaking replace the damaged valve e Check hydraulic hoses Check visually hydraulic hoses and union pipe connections Replace a hose in case of leaking or if there are ruptures or slashes on it e Check the level of oil add and replace oil e Check the operation of the device When replacing hydraulic components such as hoses gaskets etc make sure they correspond with original parts To avoid malfunctions and ensure safe operation use original spare parts Changing the seals Change all cylinder seals at the same time The piston cannot be split The seals must be slipped over the piston edge Be careful not to break the seals when fitting them in place e After removing the old seals clean the grooves carefully before fitting the new seals into place Lubricate the new seals with hydraulic oil Open the pistons lock nut Screw the piston off Withdraw the guide piece from the rod Change the guide piece seals make sure that the piston rod seal is the right way round 1 e the lip against the pressure NB Never operate the hydraulic system with the level of oil dropping below the lower mark 5 2 3 Maintenance of the pneumatic units e Clean and lubricate piston rods of pneumatic cylinders e Emptying the water collector Condensed w
8. washer M20x1 5 360 450 M22x15 Il 46 M18x1 5 26 nua M20x15 835 captive washer M20x1 5 390 500 M22x15 450 65 Screwed connection Flat discs disc rim on track Screw Class 8 8 adjustable wheels PEERS Eo 260 330 Figure 30 Lubricate points All of the hydraulic hoses of the trailer are marked with colored labels See table below for more detailed information Functions depend of the hydraulic system configuration Figure 31 Hydraulic hose label example tipping cylinder 2009 Ver 2 Fors MW Ltd www forsmw com 19 opa Hose label colors e Red oil from pump e Blue oil to tank e Yellow Brake BIGAB 17 20 HOOK LIFT SYSTEM Marking for hydraulic hoses Table 5 No Colormark Function 10 Red jTippingoy up amp Tower front B B B Red Bogie block on 19 Red Bogie lift on 22 X Red Exrapot a 24 Red Reartailgate a 26 Red Steeringcontrol p Straight steering control t DO O CO lt I O AIIN C C 2009 Ver 2 Fors MW Ltd www forsmw com opa 2 INSTALLATION 2 1 UNPACKING BIGAB 17 20 HOOK LIFT SYSTEM Before unpacking check visually that the trailer 1s not damaged during transportation If the trailer is damaged inform about this to the company that transported the trailer and the manufacturer of the product immedia
9. ensure that this is not exceeded Ensure that you do not load in such a way that the pressure on the towing eyelet 2009 Ver 2 Fors MW Ltd www forsmw com 17 HOOK LIFT SYSTEM 17 20 40 50 km H CONTROL WHEELS AND BRAKES Figure 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 GOD ZABIGAE HOOK LIFT SYSTEM PRODUKT TYP PRODUCT TYPE FAHRZEUG TYP TILLVERKNINGSAR YEAR OF PRODUCTION BAUJAHR TILLVERKNINGSNUMMER SERIAL NUMBER HERSTELLUNGSNUMIAER TOTALVIKT TOTAL WEIGHT ZUL GESAMTGEWICHT MAX LAST INKL FLAK TIPPNING MAX LOAD INCL BOOY TIPPING MAX GEWICHT INKL AUFBAU KIPPEN MAX LAST INKL FLAK FLAKVAXLING MAX LOAD INCL BODY ROLLON ROLLOF MAX GEWICHT INKL AUFBAU AUF ABROLLEN KP TRYCK LE LOAD M ACHSLAST MAX KROKTRYCK EE INE ING LOAD ZUL STUT AS FORS MW TULE 30 76505 SAUE ESTONIA Figure 29 Data plate 2009 Ver 2 Fors MW Ltd www forsmw com 18 ER Tightening torque for nuts Table 4 BIGAB 17 20 HOOK LIFT SYSTEM Flat discs Flat discs Thread Dished discs St37 St52 collar conical nuts 8 8 10 9 Screws with spherical UN collar M18x1 5 M20x15 490 630 M22x15 630 4 Flat collar nut with lock M1815 360 ena o7 wans Z 836 450
10. that this is done Chassis Towing eyelet Figure 9 Towing eyelet 1 4 9 Coupling hitch The coupling hitch is used for coupling other trailed devices to the trailer Coupling hitch is also used for coupling reflector Rear beam Pin NB Max load 10 ton Figure 10 Reflector Figure 11 Coupling hitch 2009 Ver 2 Fors MW Ltd www forsmw com 10 BIGAB 17 20 HOOK LIFT SYSTEM opa 1 4 10 Steering rollers The steering rollers are designed to guide the container During handling roll on roll off the container frame must be inside the rollers Steering Steering roller roller Chassis Figure 12 Steering rollers 1 4 11 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 Manometer Frame lock hydraulical cylinder Chain to the tractor Figure 13 Frame lock 2009 Ver 2 Fors MW Ltd www forsmw com 11 1 4 12 Wheels Wheels for different trailer types Table 2 Trailer type Standard wheel type Alternative wheel Air pressure Speed e SCC E M 17 20 600 50R 22 5 Ha ME T SERES 445 65R 22 5 Lo Z85 6SR 22 5 DNE 600 55 22 5 I2PR 40 40 1 4 13 Hydraulic system The trailer is equipped with a hy
11. 3640 Endofstroke valve po 10 915201 Pilot operated double check valve il 913230 Operationchangingcylinder 50 32 70 37913232 Front bush for hydraulic cyl 50 32 37913235 Piston for hydraulic cyl 50 32 12 913210 Brake cylinder 40 20 60 TI 37913212 Dot bush for hydraulic cyl 40 20 2009 Ver 2 Fors MW Ltd www forsmw com 43 opa For frame lock hydraulic diagram see chapter 3 4 2 BIGAB 17 20 HOOK LIFT SYSTEM Frame lock hydraulic components spare parts Table 17 Po ArtNo Die 373139442 Front bush for hydraulic cyl 90 40 37313944 Piston for hydraulic cyl 90 40 2 915275 Manometer 3 91527 Pilot operated check valve 4 915266 Pressure reducing relieving valve 5 915280 Hydro pneumatic accumulator 6 915265 Manifold Bayonet coupling male 8 91570 Bayonet coupling female 5 3 7 Cylinder description Figure 46 Cylinder description Table 18 Frontbush A Piston 1 Sealing Included in sealing kit Included in sealing kit 2009 Ver 2 Fors MW Ltd www forsmw com 44 7 Included in sealing kit opa BIGAB 17 20 HOOK LIFT SYSTEM I3 Lockingring
12. 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 doctor Figure 36 Safety Note It is strictly forbidden to lean under the container body without using the security post Figure 37 Raised container bridge Never drive under obstacles such as bridges electrical cables etc with the container bridge raised 2009 Ver 2 Fors MW Ltd www forsmw com 31 Re Driving HOOK LIFT SYSTEM BIGAB 17 20 Don t forget to lift the support leg up before driving Do not exceed maximum travel speed Never make sharp turns at great travel speed Long container needs enough working space and turning area Do not exceed maximum loading values Be sure that the container is firmly fixed before driving Recommended load placement symmetrical 42 WORKING AT EXTREME CONDITIONS Recommended working temperature range for a Bigab trailer is 30 C up to 40 C Note that working at low temperatures accelerates hydraulic gaskets wearing and increases hydraulic hoses exposure to damages and steel constructions exposure to brittle fracture When working at lower temperature than recommended lift lighter loads than usual Before start
13. SBIGAB 17 20 1 4 6 Parking support leg Hydraulic support leg is designed to be of supporting use when the trailer 1s under maintenance when trailer is not in use or when connecting disconnecting trailer Before driving the support leg must be lifted up and fixed with the pin NOTE This parking position is not allowed Connecting disconnecting trailer Parking position ga E Figure 7 Support leg Working position Technical information Working Working M Capacity pressure pressure W K Type mm liter 100 Bar 150 Bar orang pressure 250 Bar 3900295H 3530 85 5 67 t 2009 Ver 2 Fors MW Ltd www forsmw com 8 HOOK LIFT SYSTEM GSPIABIGAB 17 20 1 4 7 Changing operation unit This unit is designed for changing operation from rolling on rolling off to tipping Unit is located on the left side of the trailer Hook frame Changing operation unit Back frame 2 pins Chassis Pin Hydraulic cylinder Adjustment bolts Pusher End of stroke valve Figure 6 Changing operation unit 2009 Ver 2 Fors MW Ltd www forsmw com 9 opa 1 4 8 Towing eyelet BIGAB 17 20 HOOK LIFT SYSTEM The eyelet is used to hitch the trailer to the pulling vehicle It is extremely important that the towing eyelet is checked for defaults every time the trailer is used The towing eyelet needs to be replaced at least once a year It is up to the users responsibility to see to
14. acks 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 distance Never stand by the drawbar when connecting and disconnecting or when functions between the towing vehicle and trailer are activated Be sure that nobody is in the working area of the trailer Do not exceed maximum loading values Always engage the base machines parking brakes before loading If necessary put some obstacles in front of wheels Study safety instruction During maintenance Be sure that the trailer is standing on a flat surface Be sure that the trailer can t move When lubrication or servicing the trailer turn off the vehicle engine Be sure that the trailer can t slip when using support leg jack or similar equipment 2009 Ver 2 Fors MW Ltd www forsmw com 30 opa BIGAB 17 20 HOOK LIFT SYSTEM Always use the security post in tipping position when servicing The safety support must always be used when carrying out service work in the tipped position There must not be any load on the trailer when carrying out service work in the tipped position See figure below Never attempt to do maintenance work on the hydraulic system before you are sure there is no pressure Do not tighten or repair leaking hydraulic couplings while the system is pressurized
15. ame lock OFF Frame lock ON Traktor hydraulic 7 i system HXH Figure 35 Frame lock hydraulic system Hydraulic components for frame lock Table 10 Po Art No Til A 6 91565 Manifold 8 9145702 Bayonetcouplingfemdle 0 2009 Ver 2 Fors MW Ltd www forsmw com 29 opa BIGAB 17 20 HOOK LIFT SYSTEM 4 SAFETY INSTRUCTIONS IMPORTANT READ AND UNDERSTAND THE USER MANUAL CAREFULLY BEFORE USING THE DEVICE CONSULT THE USER MANUAL TO SOLVE YOUR PROBLEMS THE DEVICE HAS AN IDENTIFICATION LABEL ON IT BEFORE USING THE TRAILER ENSURE THAT FACTORY SETTINGS HAVE NOT CHANGED AND THERE ARE NO PARTS BECOME LOOSE DURING TRANSPORTATION MAKE SURE THAT ALL WARNING SIGNS LABELS AND TAPES ARE IN THE APPROPRIATE PLACES THE TOWING EYELET MUST BE CONTROLLED FOR DEFAULTS EVERY TIME BEFORE THE TRAILER IS USED THE TOWING EYELET NEEDS TO BE CHANGED AT LEAST ONCE A YEAR IT IS UP TO THE USER OF THE TRAILER TO SEE IT THAT THIS IS DONE 4 1 GENERAL Before you start to work Carefully examine the trailer Check that all joints are connected tightly Check that the trailer is located on hitch hook Check the towing 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 cr
16. ater is removed from the air tank located in the side of trailer e Check the pneumatic valves Check the pneumatic valves by listening to the working sound In case of leaking replace the damaged valve e Check pneumatic hoses Check visually pneumatic hoses and union pipe connections Replace a hose if there are ruptures or slashes on it e Check the operation of the device 2009 Ver 2 Fors MW Ltd www forsmw com 35 opa 5 2 4 Maintenance of the electrical components BIGAB 17 20 HOOK LIFT SYSTEM The trailer is manufactured with 12V electrical system Electrical system is shown in chapter 3 3 The wires to the electrical equipment are of different colors which facilitate the location of the wire leads connecting individual items of the electrical equipment Refer to the electrical diagram figure 23 to ensure a correct subsequent reconnection of the electrical units and also when checking the operation of the equipments and individual electric circuits e Clean and check the lights In case of fault replace the lamp If the lamp keeps on braking repeatedly find out the case of the matter e Check electrical connectors Clean them of dirt and dust e Check wires insulation Check wire insulation wire joints and protection of insulation against rubbing during jolting and contacting the trailer parts Protect the wires from oil and fuel which ruin insulation Wipe dirty wires NB Join and disjoin plug connectors onl
17. ct positions HOOK LIFT SYSTEM gt PABI GAB BIGAB warning information labels 12 15 14 17 15 19 17 20 ze Re pg ZG O FORS MW Figure 16 Location of the decals on the trailer 2009 Ver 2 Fors MW Ltd www forsmw com 14 opa 1 5 3 Presentation of decals Figure 17 Warning triangle and instruction manual decal The trailer 1s supplied with a warning triangle alongside the instruction manual decal in order to reinforce the reguirement for the user to read the entire instruction manual carefully before starting to use the trailer Ignoring this can entail a danger to life 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 1s being operated moved with frame steering or when other functions are activated between trailer and tractor can be potentially fatal As the driver you must always ensure that the area around the machine is free of people BIGAB 17 20 HOOK LIFT SYSTEM 2009 Ver 2 Fors MW Ltd www forsmw com 15 opa BIGAB 17 20 HOOK LIFT SYSTEM Figure 21 Risk of slipping There is a risk of slipping as the surfaces of th
18. draulic system for working movements See chapter 3 5 1 4 14 Electrical system The trailer is manufactured with 12V electrical system See chapter 3 4 1 4 15 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 1s not allowed to raise over 16 Mpa If using to high of a hydraulic pressure the tappet of the brake arm might go from centum and lock the brakes 2009 Ver 2 Fors MW Ltd www forsmw com 12 Re 1 4 16 Electric on off control unit BIGAB 17 20 HOOK LIFT SYSTEM The trailer is equipped with hydraulic system witch valves are controlled with electric remote control unit v VAMLING TEL OA m RAMLA m S KAP SY S Y 1 j Figure 14 Control unit Table 3 Function description Tipping Rolling Foldable tower Telescope Changing operation unit Bogie lift Extra 2009 Ver 2 Fors MW Ltd www forsmw com 13 OCSBIGAB 17 20 1 5 SAFETY DEVICES 1 5 1 Security post Always use the safety support when carrying out service work in the tipped position The safety support may not be used under any circumstances when the container bridge is loaded Security post Figure 15 Security post 1 5 2 Location on decals on 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 corre
19. e and activate bogie blocking between the towing vehicle and trailer 1 Raise the hooklift frame slightly so that the container bridge does not scrape against the frame when off loading the container bridge 2 Then retract the tower so that the locking rails wings on the container bridge frame move freely and cannot be damaged 3 Adjust the tower upwards continually so that the container frame does not catch on the rollers at the back of the trailer during off loading 4 If the tower is not adjusted upwards during off loading there is a considerable risk of the exchange s lock being damaged if the container frame catches in the rollers 2009 Ver 2 Fors MW Ltd www forsmw com 23 opa 3 2 HANDLING IN TIPPING BIGAB 17 20 HOOK LIFT SYSTEM Note For the models mentioned in this instruction manual the maximum container bridge length is 6 0 m during tipping Ensure that the towing vehicle and the trailer are securely coupled before tipping Figure 1 Ensure that the 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 Figure 3 At maximum tipping drive slowly forwards until the container bridge is empty Lower the container bridge before continuing to drive Important Ensure that the container bridge is locked in the correct position before driving IMPORTANT When tippi
20. e trailer can be slippery due to precipitation in combination with pre existing oil and or clay on the surface The ground around the trailer 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 trailer the hook must be folded down in the parking position 2009 Ver 2 Fors MW Ltd www forsmw com 16 opa BIGAB 17 20 HOOK LIFT SYSTEM Figure 24 Use the safety support during all service Leaning under the raised frame is absolutely prohibited unless it is blocked with the safety support Under no circumstances may the trailer be carrying either a load or a container when using the safety support Figure 25 Max load It is absolutely prohibited to load more than the amount your model ts intended to handle This can result in danger to you and your surroundings Figure 26 Max pressure on 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 determined by the way the load is distributed on the container bridge and it is the user s responsibility to
21. f unit Chassis Support leg Towing eyelet Roll on roll off position Tipping position Figure 1 Design of the device 2009 Ver 2 Fors MW Ltd www forsmw com 4 opa 1 4 MAIN MODULES BIGAB 17 20 HOOK LIFT SYSTEM The trailer consists of the following subassemblies and functional devices 1 4 1 Chassis Chassis is constructed out of cold hollow steel sections Guide fe Towing eyelet Spring suspension pendulum bogie brackets P ud Rear beam Coupling hitch Brackets for frame locking system Figure 2 Chassis with frame locking system 2009 Ver 2 Fors MW Ltd www forsmw com 5 opa 1 4 2 Back frame BIGAB 17 20 HOOK LIFT SYSTEM Back frame is constructed out of cold hollow steel sections Figure 3 Back frame 1 4 3 Hook frame The hooking frame is constructed from cold hollow steel sections Hook Flexible tower Cylinder Figure 4 Hooking frame O 2009 Ver 2 Fors MW Ltd www forsmw com 6 1 4 4 Bogie The trailer 1s equipped with a spring suspension pendulum bogie that has been equipped with brakes on all wheels Mounting bracket Brake lever Axle with brake 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 2009 Ver 2 Fors MW Ltd www forsmw com 7 OC
22. ing to work in cold conditions let the 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 INDANGEROUS SITUATION If the trailer comes into contact with high voltage electric wires comply with the following instructions IF YOU ARE OUTSIDE THE MACHINE Do not attempt to get into the machine Keep everybody out from the machines vicinity Do not touch any part of machine IF YOU ARE INSIDE THE MACHINE Get out of it by JUMPING Avoid touching any conducting parts Do not make yourself a wire through which electricity may flow Get away from the machine by JUMPING so that both feet do not touch the ground at the same time Electric field at ground can cause fatal voltage between legs At about 20 meters away you should be safe but this is of course a question of circumstances 2009 Ver 2 Fors MW Ltd www forsmw com 32 opa o MAINTENANCE SPARE PARTS BIGAB 17 20 HOOK LIFT SYSTEM 5 1 MAINTENANCE SCHEDULE All kinds of maintenance work are subdivided into two groups operating preventive and compulsory scheduled The need for operating maintenance is determined based on the results of checking General e Maintenance works must be carried ou
23. ive labyrinth Rubber packing between track sprockets seals and hub or labyrinth seals worn Replace rubber rings Brake system troubles Fault symptoms Poor operation of brakes Wash linings with gasoline or replace from Greasy or worn out drive disk linings spares Maladjustment of brake control linkage Adjust brake control linkage 2009 Ver 2 Fors MW Ltd www forsmw com 48
24. ng use the brakes to ensure that the machine does not roll away when the load slides off 2009 Ver 2 Fors MW Ltd www forsmw com 24 3 3 OPERATION WHEN DRIVING It is the responsibility of the user to ensure that a sufficiently powerful and heavy towing vehicle is coupled to the trailer in all situations The use of a towing vehicle that is too small and insufficiently powerful can entails risks for the user and the surrounding environment as well as leading to damage to the vehicle and trailer Load excl the container s dead weight 7 m3 Peas Wheat water content 15 80 A 600 5600kg 11 11200 16800 800 21 21000 Rye water content 1596 ea 250 e a 500 LN 750 Ec 250 Barley water content 1596 4 760 kg 9 520 14 280 18 360 Oats water content 1596 560 o 3 920 kg 7 840 11 760 15 120 Silage newly harvested 5 950 kg 11 900 17 850 22 950 1400 380kg 1060 2940 37 800 Wood chips 50 moisture content 2 450 kg 4 900 7 350 Se 450 The higher the moisture content of the load the heaver the load a fact that the user has to take into consideration This table is only an approximate 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 p
25. ni Lenin 2108908642 T l Ubserkaare ae EU declaration of conformity with Directive 2006 42 EC 1 2 TECHNICAL SPECIFICATIONS 2009 Ver 2 Fors MW Ltd www forsmw com 2 opa Technical specifications Table I BIGAB 17 20 HOOK LIFT SYSTEM Hooklift trailer 17 20 Frame Hollow sections Axle distance between wheels Wheels 600 50 22 5 Brake Hydraulic drum 400 120 on 4 wheels Depending on market Towing eyelet Type for hitch hook Support leg Manual Hydraulic Light system 12 volt yes Tractor hydraulic equipped with For brakes El on off 1 single action Tractor oil volume OL With trailer system filled up Chassi weight 1 Standart equipped ME Max load including container c1 40 Pressure on eyelet depending of lenght of 2600 3500 kg container and load Max tipping capacity 18000 kg 40 km h 2009 Ver 2 Fors MW Ltd www forsmw com opa 1 3 DESIGN OF THE DEVICE BIGAB 17 20 HOOK LIFT SYSTEM The Trailer is constructed out of cold hollow steel sections Through this construction the trailer receives maximum endurance and stiffness 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 Hook Rollers Back frame Hook frame Flexible tower Frame lock Wheels Z El On of
26. nts BIGAB 17 20 HOOK LIFT SYSTEM BRAND BP ESSO MOBIL SHELL UNION TEXACO 5 2 MAINTENANCE OPERATIONS IMPORTANT BEFORE MAINTENANCE AND SERVICE OPERATIONS READ AND UNDERSTAND THE SAFETY INSTRUCTION During maintenance Be sure that the trailer is standing on a flat surface Be sure that the trailer can t move When lubrication or servicing the trailer turn off the vehicle engine Be sure that the trailer can t slip when you using support leg jack or similar equipment Always use the security post in tipping position when servicing Never attempt to do maintenance works on the hydraulic system before you are sure there is no pressure Do not tighten or repair leaking hydraulic couplings while the system is pressurized e 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 e Avoid getting oil into eyes Use safety goggles and gloves If oil has got into eyes flush them with cool water after contact the doctor 5 2 1 Surface cleaning Remove accumulated dust and dirt Painted outer surfaces should be cleaned regularly with sponge and soap When cleaning never use hot water under high pressure it will remove the grease from bearings 2009 Ver 2 Fors MW Ltd www forsmw com 34 opa 5 2 2 Maintenance of the hydraulic units BIGAB 17 20
27. opa Table of contents BIGAB 17 20 HOOK LIFT SYSTEM TP INTRODUC ION eee reer HE Ld E 1 2 DEGPENICASE AS ds Gils WK ho eee ner sonet mer errr renner un euer PEE o rab rere USER vade L3 DESIGN OF THE DEVICE M MH I MEC ILS EE cs E eet E eee L5 ARETY DEVY E an E ee ee E 2 IN ACEA R e WEE P UNPA NG mr 2 23 WITHDRAWAL FROM USE AND STORAGE Oy PING ULP DESCRIP TION P RM 3 1 HANDLING IN ROLL ON ROLL OFF ee EE 32 HANDLING IN KI TE D OPERA TOWN WHEN DRIVING icenen AEn a E AER aE GE PEPR IRICAL Y TENE e E iets 3 92 HMYDRAULICAL SY STEM erea EE E EE d SAFETY IN EINE ON enere e EE EA ee dE GENERA E 4 2 WORKING AT EXTREME CONDITIONS 4 3 ACTING IN DANGEROUS SITUATION RE 5 MAINTENANCE SPARE KE Sl MYINTENANCE SCHEDULE EE 3 2 MAINTENANCE OPERATIONS EE S Ec qu O TROUBERSHOO TING c o ei an okej Me oken CONTACT INFORMATION Factory Aftermarket AS FORS MW Language spoken is English and Swedish Tule 30 FMW Farma Norden AB 765 05 Saue Hornsvig 2 Estonia 605 97 Norrk ping Sweden Tel 372 679 00 00 Tel 46 0 165 770 Fax 372 679 00 01 Fax 46 0 128 370 E mail info forsmw ee E mail aftermarket forsmw ee 2009 Ver 2 Fors MW Ltd www forsmw com opa 1 INTRODUCTION 1 1 PURPOSE BIGAB 17 20 HOOK LIFT SYSTEM
28. ractor lifts off the ground Check that the hook hitches around the loop Check that the frame lock and bogie blocking are On loading activated Check that the load carrier is inside the discs Release the brakes on both the towing vehicle and the trailer to make it easier to roll on the load Check the position of the tower during on loading so that the container bridge s frame does not catch on the rollers from behind The tower must be fully retracted when rolling on the container bridge in order to increase lifting force and reduce the strain on the towing eyelet Ensure that the container frame does not catch in the rollers at the back of the trailer Adjust the tower upwards continually during exchange in order to move past the rollers If the tower is not adjusted upwards during on loading there is a considerable risk of the exchange s lock being damaged if the container frame catches in the rollers 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 Figure 4 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 of the tower during off loading so that the container bridge s frame does not catch on the rollers from above Lock the fram
29. stems for operating in the open air at temperatures ranging from 50 C up to 60 C at a continuous operation service For hydraulic system maintenance see chapter 5 n OH H H whl Lom atr 4 P Less 2 e e H p E d X XTRA XTRA XTRA 9 Jo 2 wi O D d Figure 34 Hydraulic system Hydraulic components Table 9 Po Art Ne Die 6 940835 Away valve 8 91340 Towercylinder O 9 913640 End of stroke valve Note only with pos 11 Pilot operated double check valve Note only with pos 11 Operation changing cylinder 2009 Ver 2 Fors MW Ltd www forsmw com 28 BIGAB PABIGAI 17 20 3 5 2 Frame lock hydraulic system Fr
30. t 2 9 Figure 45 Changing operation unit 2009 Ver 2 Fors MW Ltd www forsmw com 42 Changing operating unit spare parts Table 15 Pos Art No Description _ X Note 3711007 Changingunitcomp 1 _913230__ Operation changing cylinder O 2 37211787 Pin J J J o 3 3711788 Pin 4 0 y 4 37211789 Axle 0 0 00 0 0 5 37211790 Levr 9 J 6 37211791 Pusher S O 7 913640 1 Endofstroke valve 8 37211792 JAxe 2 1 9 37211793 Axe 5 3 6 Hydraulic components For hydraulic diagram see chapter 3 5 1 Hydraulic components spare parts Table 16 Po Art No Description 1 Note 1 940810 Relasevalve Z 0 0 0 00 000 2 94085 Securityvalve 00000 00 3 2940820 Logicvalve 0 0 S 4 940825 4wayvave 0 Le 5 94080 Valvblock o Z o 0 6 94083 Jj4wayvalvee 0 po 4 wayvalee S o KANIN 07 with pilot operated valve 37913265 Sealing kit for hydraulic cyl 200 100 37913266 Dot bush for hydraulic cyl 200 100 8 913240 Tower cylinder 125 63 450 TI 37913241 Front bush for hydraulic cyl 125 63 _ 37913243 Piston for hydraulic cyl 125 63 9 91
31. t regularly to ensure safe and malfunction free operations e Maintenance works does not require any special tools The user can perform most of the operations e Use correct tools e Attempt to localize the defects as clearly as possible you should have to avoid opening the system unnecessarily e Keep disassembled parts and repair area protected from dirt e Keep spare parts in their packages until needed for installation e Valve adjustments and repairs are recommended to be handled by service personnel Daily inspections e Examine visually the loader Note defects and failures that might affect safety Repair possible defects and failures e Check so there is no leakages on hydraulic system or damaged hoses e Work through every function to its extreme position e Check the oil level Weekly maintenance e Clean the trailer regularly with sponge and soap When cleaning never use hot water under high pressure it will remove the grease from bearings Check the operation of the device Check hydraulic pressure Check the brake condition Control wheel nut tightness When tightening the locking force must be 330 370 Nm Check the lights reflectors and bulbs Monthly maintenance Check the air pressure in tires Check if there is enough lubricant on glide surfaces Clean and lubricate hydraulic cylinders Check hydraulic hoses for damages 2009 Ver 2 Fors MW Ltd www forsmw com 33 opa Recommended lubrica
32. tely e Usage of the trailer is strictly forbidden if safety devices of the trailer are damaged For more detailed information about safety devices see 1 5 e When you are unpacking the trailer be careful do not damage sensitive components do not change factory settings or damage paint or other surface finishes e Lift up the trailer from transportation frame e Lower the trailer to the floor e Be careful when lifting so that cables connectors or other components are not damaged for instance between lift work and trailer frame e Weight depends see technical information for data 2 2 WITHDRAWAL FROM USE AND STORAGE e tis not allowed to store the trailer in a cold and or damp environment for a long period e All metal parts are recyclable and should when time comes be handed over to a recycler 2009 Ver 2 Fors MW Ltd www forsmw com 21 UP PRBIGAB 17 20 3 FUNCTIONAL DESCRIPTION 3 1 HANDLING IN ROLL ON ROLL OFF If your BIGAB is equipped with suspension there is no bogie blocking Exchange and tipping must be operated from the operator s seat in the towing vehicle Figure 1 Ensure that the position selector for exchange or tipping is in the exchange position not in the tipping position Figure 2 Place the hooklift trailer on a flat surface The sideways incline may not exceed 5 degrees 2009 Ver 2 Fors MW Ltd www forsmw com 22 BIGAB HOOK LIFT SYSTEM 1 7 20 Figure 3 STOP Stop if the t
33. ubrication by following the lubricating schedule Keep flammable material away from heat sparks and open fire Do not let oil run into the nature Oil spilled into ground pollutes environment J amp Towing eyelet f Link bearing 2pcs Link bearing 3pcs Link bearing I pcs Glide bearing 2pcs Link bearing I pcs Glide bearing 2pcs Glide bearing I pcs cen NE Glide bearing 1pcs Glide bearing left Ipcs Glide bearing l pcs Glide bearing right 1 pcs 4 gt Glide bearing 1pcs VE y Glide bearing left Ipcs VU Glide bearing left Ipcs Glide bearing right 1 pcs Glide bearing right 1 pcs 2009 Ver 2 Fors MW Ltd Figure 38 Lubrication points www forsmw com 38 Recommended lubrication cycle is once per week or after 20 working hours Lubricate 5 3 SPARE PARTS 5 3 1 Back and Hook frames Figure 39 Cylinder coupling Figure 40 Back and hook frame coupling Fig
34. ure 41 Flexible tower 2009 Ver 2 Fors MW Ltd www forsmw com 39 opa Back and rolling frame spare parts Table 11 Po ArtNo Description Noe 1 sar Ade 2 3DMIS3 Ditamerng V 3 3DMMO ae 4 amin Ad fee pa 6 37211120 Axe Distance ring cj BIGAB 17 20 HOOK LIFT SYSTEM 5 3 2 Bogie Figure 42 Spring suspension bogie Spring suspension bogie spare parts Table 12 Po Art No Description Note 916831 Spring suspension bogie comp BEEN UO 916831 A Axle o o 916831 S Spring suspension po 916480 Ring nut M20 OH 916466 Brake am 2009 Ver 2 Fors MW Ltd www forsmw com 40 HOOK LIFT SYSTEM opa 3 3 3 Frame locking BIGAB 17 20 424 2405 1 122 4 Stroke 300 a pe si x F Figure 45 Frame lock Frame locking spare parts Table 13 Pos Art No Title 391519 M Hydrframelocksystem 5 12 14 15 Pin 16 Pin 17 Pin 22 23 24 26 28 29 30 2009 Ver 2 Fors MW Ltd www forsmw com 41 GPPIABIGAB 17 20 HOOK LIFT SYSTEM 5 3 4 Steering rollers Figure 44 Steering roller spare parts Rollers spare parts Table 14 Po Art No Description Note 1 320340 320341 Roller comp left right Le 2 37203045 Axle gt JS lo O 3 90015 Slide bearings OI 5 3 5 Changing operating uni
35. urposes and for examples of how much different loads can weigh please refer to the above table This table should only be viewed as guidance and information The manufacturer cannot be held responsible for dimensions or volumes specified in the table and the table may only be viewed as a recommendation 3 3 1 Load on towing eyelet and coupling Always adapt your driving to the load road conditions and your level of experience Do not exceed the maximum speed specified for the trailer Ensure that you have the correct pressure on the tow hook when you are driving Ensure that you do not exceed the intended upwards and downwards pressures on the trailer s towing eyelet and the coupling to the hook device The given ideal conditions and theoretical calculations indicate the following maximum load values and it is recommended that the user observes these load values Max load upwards in kg BIGAB 17 20 4150kg Max load distributed evenly over the container Max load downwards in kg BIGAB 17 20 3500kg 2009 Ver 2 Fors MW Ltd www forsmw com 23 opa 3 4 ELECTRICAL SYSTEM BIGAB 17 20 HOOK LIFT SYSTEM 3 4 1 Basic electrical system The trailer is manufactured with 12V electrical system Configuration depends of options example reversing light border light or additional cable connector obo E obo IS a a aaa ILS IL TIL SIL L2 L3 L1 OOOO Z
36. y with dead circuits 5 2 5 Maintenance of the brake system The trailer is manufactured with a hydraulically functioned brake system Air brake system with negative or positive action 1s optional Control the brakes regularly Test the brakes at least once per week while trailer is working See to it that no lubricant penetrates into the brakes Any lubricant which has penetrated the brake causes greasing of the disks thereby reducing friction between their working surfaces A poor operation of the brakes is the result of such happening In such a case dismantle the brake eliminate the oil leakage wash the greasy disks with gasoline and let them dry out Control always the brake control linkage after the drum being dismantled adjust 1f 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 practical brake test before driving away If the brakes seems to work grainy found the brakes pull the trailer maintaining low speed for a couple of hundred meters try again through braking the vehicle while driving in a normal speed Keep on reiterate until the brakes functional normally If necessary contact our service department BIGAB models 7 10 8 12 and 10
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