12-15 - Fors MW
Contents
1. 4 5N Q Figure 45 Cylinder description Table 15 Pos Description Note Spec order Spec order 4 Piston Included in sealing kit 6 Sealing Included in sealing kit Included in sealing kit 8 Seaing Included in sealing kit 9 Orig Included in sealing kit Included in sealing kit Included in sealing kit Included in sealing kit Included in sealing kit Included in sealing kit 2009 Ver 3 Fors MW Ltd www forsmw com 45 HOOK LIFT SYSTEM 5 3 8 Frame lock Figure 46 Frame lock Table 14 Po Art No Tile 3910141215 Hydr frame lock system 6 37121535 Suppen 14 37121527 Pin 00 15 37121532 mn o Pin 22 90810 Split4x45DIN94 2009 Ver 3 Fors MW Ltd www forsmw com 46 HOOK LIFT SYSTEM 5 3 9 Electrical system For electrical scheme see chapter 3 4 Pos 5 8 concerning spare parts table 1s not shown in electrical scheme Figure 47 Rear lamp Electrical spare parts Table 16 Pos ArtNo Description Rear lamp Rear light with reversing light special MEE Border light 111x40 orange special MEI 3 920715 Cable terminal 4 920695 Cable Connector 7 pools male lt Cable Connector 7 pools female special 6 920723 Lampl2V 5 o 7 9274 Lam V 8 920725 JjLampl2V W 9 J O 22. 850 500 M22x15 450 650 Screwed connection Flat discs disc rim on track Screw Class 8 8 adjustable wheels 5 260 330 Figure 30 Lubricate points AlI of the hydraulic hoses of the trailer are marked with coloured labels See table below for more detailed information Functions depend of the hydraulic system configuration O 2009 Ver 3 Fors MW Ltd www forsmw com 17 HOOK LIFT SYSTEM PABIGAB 12 15 Hose label colours Figure 31 Hydraulic hose label example tipping cylinder e Red oil from pump e Blue oil to tank e Yellow Brake Marking for hydraulic hoses Table 4 1 no MIRMI M MIMI IMI M a mm sch zl VO IO OO PO G 00 N D GI ON O Colourmark Function Red Doping ot up Tower front Red Tower back Red Telescope in Telescope out Frame lock for tipping Red Frame lock for hooking Red Bogie block on Bogie block off Red Bogie lift on Bogie lift off Red Extra port a Extra port b Rear tailgate a Red 7 Rear tailgate b Red Steering control p Steering control t 28 otraight steering control t 2009 Ver 3 Fors MW Ltd www forsmw com 18 HOOK LIFT SYSTEM NSBIGAB 12 15 2 INSTALLATION 2 1 UNPACKING Before unpacking check visually that the trailer is not damaged during transportation If th
3. 4 BA k 1 70 60 50 40 30 20 10 TH L4 Hra ie 1 70 60 50 40 30 20 10 4 5 ES SE 1 pool connection to pulling vehicle Note For complete connection schedule see the following page Figure 34 Electrical diagram Electrical components Table 3 Po ArtNo Title 1 920765 Rear light 920766 Rear light with reversing light special 2 92710 Border light 111x40 orange special mx 920715 Cable terminal 04 920695 Cable Connector 7 pools male S 920180 Cable Connector 7 pools female special 2009 Ver 3 Fors MW Ltd www forsmw com 26 HOOK LIFT SYSTEM Connections of the cables and lamps Table 6 1 Ra ies m 2 Brown Reversing light DV2IW L2 Brown Spare without reversing igh 3 Yeaw ES 4 Bue Feis man TS Brown Side marking NSW 2009 Ver 3 Fors MW Ltd Www forsmw com 27 HOOK LIFT SYSTEM 3 6 HYDRAULICAL SYSTEM The trailer 1s 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 1s filled up with hydraulic oil VMGZ or SAE100R 16 It is applied as a working fluid of the hydraulic systems for operating in the open air at temperatures ranging from 50 C up to 60 C
4. 0 00 00000 y O 4 37204110 Axe 0 0 000000 o y O 37211115 Axle o o 6 37211120 Taste 37211180 Distance gung 2009 Ver 3 Fors MW Ltd www forsmw com 40 Kate HOOK LIFT SYSTEM 3 3 2 Bogie Bogie spare parts Table 10 Pos ArtNo Description Bogie comp Left side Bogie comp Right side Bogie axle 4 9I6I3R Stubaxle d 5 O9I6I37L j Stbade 6 909125 Slide bearings 980 7 916478 RingnutM20 le 5 3 3 Bogie block Figure 42 Bogie block 2009 Ver 3 Fors MW Ltd www forsmw com 41 HOOK LIFT SYSTEM Bogie block spare parts Table 11 Pos Art No Description Note 37203084 Bogie block manual set EE 37203083 Pin S o 37203082 Innertube oS o 920230 Pim 37203081 Outertubecomp o oo 5 3 4 Steering rollers 1 3 1 3 Figure 43 Steering roller spare parts Rollers spare parts Table 12 Pos Art No Description Note 320340 320341 Roller comp left right mo 37203045 Axle S 909115 Slide bearings 0100 d 320360 Tipper axle dd 2009 Ver 3 Fors MW Ltd www forsmw com 42 HOOK LIFT SYSTEM 5 3 5 Changing operating unit 1 Figure 44 Changing operation unit Changing operating unit spare parts Description Changing unit comp 37203060 JA poo 37203065 Console 0 00 37203070 Slider plate 00
5. 37203075 Coupling rod 0 37203080 Stopper handle kit O 2009 Ver 3 Fors MW Ltd www forsmw com 43 HOOK LIFT SYSTEM 5 3 6 Hydraulic components For hydraulic diagram see chapter 3 5 Hydraulic components spare parts Table 14 Po ArtNo Description Note 1 mmus E eme TT with pilot operated valve 37913256 Front bush for hydraulic cyl 160 80 37913258 Piston for hydraulic cyl 160 80 2 913238 Tower cylinder 12563250 37913241 Front bush for hydraulic cyl 125 63 37913243 Daten for hydraulic cyl 125 63 34 313155 Bogie block lift 100 60 125 37313162 Front bush for hydraulic cyl 100 60 37313163 Piston for hydraulic cyl 100 60 5 913210 Brake cylinder 40 20 60 TI 37913212 Front bush for hydraulic cyl 40 20 37913213 Piston for hydrauliceyl 4020 7 913230 Operation changing cylinder 50 32 70 __ 37913232 Front bush for hydraulic cyl 50 32 37913233 Piston for hydraulic cyl 50 32 9 913640 Endofstrokevave LI 10 915200 Pilot operated check valve 110 915201 Pilot operated double check valve 0 Brake quick coupling Vs _ 2009 Ver 3 Fors MW Ltd www forsmw com 44 HOOK LIFT SYSTEM
6. 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 1s locked in the correct position before driving 4 d IMPORTANT When tipping use the brakes to ensure that the machine does s not roll away when the load slides off 4 M Ki K W r 1 n in e S Peon y Do 2009 Ver 3 Fors MW Ltd www forsmw com 22 HOOK LIFT SYSTEM 1 2 m 1 5 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 S 600 5600kg 11 11 200 16 800 800 21 21 600 Rye water content 15 i E 250 LIx m 500 m 750 NE 250 Barley water content 1596 4 160 kg 9 520 14 280 18 360 Oats water content 1596 3 920 kg 7 840 11 760 15 120 Silage newly harvested 5 950 kg 11 900 17 850 22 950 Macadam 1400 9 800 kg 19 600 29 400 37 800 Gravel 1550 10 850 kg 21 700 32 550 41 850 Wood chips 5096 moisture conte
7. 2009 Ver 3 Fors MW Ltd www forsmw com 15 12 15 40 50 km 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 HERSTELLUNGSNUMMER TOTALVIKT TOT AL 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 AXEL TRYCK AXLE LOAD 2UL ACHSLAST MAX KROKTRYCK ADMISSIBLE SUPPORTING LOAD ZUL STUTZLAST C AS FORS MW TULE 30 76505 SAUE ESTONIA Figure 29 Data plate 2009 Ver 3 Fors MW Ltd Www forsmw com 16 dc Nut tightening torque Table 3 HOOK LIFT SYSTEM Dished discs Flat discs st 37 Flat discs St52 Screw Class Screw Class Nuts with spherical 8 8 10 9 Ee O V lt EE M18x1 5 spherical collar preme SE Se x15 490 M22x1 5 630 74 Flat collar nut with LUS har M20x1 5 M20x1 5 0 00 360 450 lock washer M22x1 5 460 550 Nut with flat seat MILI 20 360 captive washer M2 15
8. The eround 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 25 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 3 Fors MW Ltd www forsmw com 14 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 is intended to handle This can result in danger to you and your surroundings V Figure 26 Max pressure on towing eyelet 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 1s largely determined by the way the load is distributed on the container bridge and it is the user s responsibility to ensure that this is not exceeded Ensure that you do not load in such a way that the pressure on the
9. 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 1s the right way round 1 e the lip against the pressure NB Never operate the hydraulic system with the level of oil dropping below lower mark 5 2 3 Maintenance of the pneumatic units e Clean and lubricate piston rods of pneumatic cylinders e Emptying the water collector 2009 Ver 3 Fors MW Ltd www forsmw com 35 HOOK LIFT SYSTEM Condensed water 1s removed from the air tank located 1n 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 1t e Check the operation of the device 5 2 4 Maintenance of the electrical components The trailer is manufactured with 12V electrical system Electrical system 1s shown in chapter 3 4 The wires to the electric
10. 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 O 2009 Ver 3 Fors MW Ltd www forsmw com 49
11. 009 Ver 3 Fors MW Ltd Www forsmw com 47 HOOK LIFT SYSTEM 5 3 10 Other parts 7 7 Other spare parts Table 17 Pos Art No 930105 920111 37221002 37203068 37203067 6 37203085 920160 8 920150 9 920155 A Ob V i P Figure 47 Other spare parts Description Grease nipple dO Towing eyelet Kl Hook po Support leg OO Pin Security post SSS o y y mmm NENNEN NNNM Reflector 94 44 orange LBF board Reflector 3 angle red 2009 Ver 3 Fors MW Ltd www forsmw com 48 HOOK LIFT SYSTEM 6 TROUBLESHOOTING These troubleshooting instructions are provided to help you to determine the cause for a malfunction Electrical eguipment troubles Fault symptoms Lights fault Lamp born out Replace lamp OO Check and clean electrical connectors Check and repair wire Hydraulic eguipment 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 ol in pump Replace pump Adjust oil pressure order suction and eliminate defect Distributor safety valve maladjusted Adjust valve Oil leaking Replace ruptured hose or tighten hose connection Oil leaks through final drive labyrinth Rubber packing between track sprockets
12. Elies larmin ni Lenin 21080894 it Tier aur TT EU declaration of conformity with Directive 2006 42 2009 Ver 3 Fors MW Ltd Www forsmw com 2 HOOK LIFT SYSTEM 1 2 TECHNICAL SPECIFICATIONS Technical specifications Table 1 Hook lift trailer 12 15 Hub 1 1 90908boi Oil flow 40 80 L min Hydraulic pressure 22 Mpa Tipp angle 48 degrees 5700 mm 4560 mm Pressure on eyelet depending of length of container and load 1600 2300 kg 40 km h 2009 Ver 3 Fors MW Ltd www forsmw com 3 HOOK LIFT SYSTEM 1 3 DESIGN OF THE DEVICE The Trailer 1s 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 strong pendulum bogie that has been eguipped with brakes on all wheels Foldable tower Rollers Back frame Hook frame mb Chassis Support leg Towing eyelet Tipping position Figure 1 Design of the device O 2009 Ver 3 Fors MW Ltd www forsmw com 4 OD OC BIGAB 12 15 HOOK LIFT SYSTEM 1 4 MAIN MODULES The trailer consists of the following subassemblies and functional devices 1 4 1 Chassis Chassis 1s constructed out of cold hollow steel sections Guide a Towing eyelet 27 Bracket for hydraulic
13. OOK LIFT SYSTEM BIGAB warning information labels 12 15 14 17 15 19 17 20 NOBBE Figure 16 Location of the decals on the trailer 2009 Ver 3 Fors MW Ltd www forsmw com 12 HOOK LIFT SYSTEM 1 5 3 Presentation of decals Figure 17 Warning triangle and instruction manual decal The trailer is supplied with a warning triangle alongside the instruction manual decal in order to reinforce the requirement 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 is 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 2009 Ver 3 Fors MW Ltd www forsmw com 13 HOOK LIFT SYSTEM Figure 21 Risk of slipping There 1s a risk of slipping as the surfaces of the trailer can be slippery due to precipitation in combination with pre existing oil and or clay on the surface
14. RIATE PLACES THE DRAW EYELET MUST BE CONTROLLED FOR DEFAULTS EVERY TIME BEFORE THE TRAILER IS USED THE DRAW 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 draw eyelet for defaults Check the towing eyelet and the coupling device Control brakes Control the lights Check that the brakes are functioning Check that hydraulic hoses and couplings are intact and free from cracks Check that all hydraulic functions are working Remember that it is not allowed to use this unit for functions not confirmed by producer Be aware that a long container needs enough working space and turning area e Respect the safety distance e Never stand by the drawbar when connecting and disconnecting or when functions between the towing vehicle and trailer are activated e Be sure that nobody 1s 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 e Study safety instruction 2009 Ver 3 Fors MW Ltd www forsmw com 29 HOOK LIFT SYSTEM During maintenance Be sure that the trailer 1s standing on a flat surface Be sure that the trailer can t move When lubrication or servi
15. YSTEM 1 INTRODUCTION 1 1 PURPOSE Bigab hook lift trailers exists 1n 9 different types of modules with a variety of additional extras which all has it s 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 12 15 1s the perfect hook lift trailer for the person in need of a flexible trailer with high hooking and loading capacity The trailer 1s equipped with a foldable hook tower for an even greater hooking capacity For your safety 1t 1s 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 kis Verdikruc om asverematimmszlses red dirckshs iii
16. ZABIGAE HOOK LIFT SYSTEM ly INTRODUCTION a o Ora eo 2 IMEEM sa pes r ee ace A oe ng ee AE va 2 1 2 TECHNICAL CT TTC KE 3 Mee DESIGN OE CTI PEACE o sk ni 4 I MAIN MODULES nok ona Ondra nan ona A oa 5 I SEE DEVICE praga s d tan pana pao 12 Do INSTALLA a EM A ME NEM 19 2 PEE SEE Ub E 19 2 2 ADUS Os Em 19 2 3 WITHDRAWAL FROM USE AND STORAGE 19 Si TBUINGTION Ale RTE RE 20 3 1 HANDLING IN ROLL ON ROLL OFF eee eee eene nn 20 2 2 HANDLING IN TIPPI NU css sense ane 22 3 3 OPERATION WHEN DRIVING eue atol o donee enero donor 23 sa CHANGING OPERATING PUNCTION Sn 24 9 55 cBBBCTRIC ARS ESTEE popu it rni AN nam 26 36 HYDRAULICAL SYSTEM s cecinit root o otca 28 do SAFETY INSIRUCHONS eege 29 dl GENERA E 29 4 2 WORKING AT EXTREME CONDITIONS 31 4 3 ACTING IN DANGEROUS SITUATION ss 32 5 MAINTENANCE SPARE PARTS ea de dre rn ona een 33 Jes PADNTDENANCESCEHBIEDLBDE fun a ka ETE EEE 33 9 2 MAINTENANCE OPERATIONS ote vani vadno vede deja von eoa ona kesa 34 EE eege 40 O TROUBLE HOO TING rm 49 CONTACT INFORMATION Factory Aftermarket AS FORS MW Language spoken is English and Swedish Tule 30 FMW Farma Norden AB 765 05 Saue Hornsv g 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 3 Fors MW Ltd www forsmw com 1 HOOK LIFT S
17. al equipment are of different colours which facilitate the location of the wire leads connecting individual items of the electrical equipment Refer to the electrical diagram figure 3 4 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 only 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 is optional Control the brakes regularly Test the brakes at least once per week while trailer 1s 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 1s the result of such happening In such a case dismantle the brake eliminate the oil leakage wash the greasy disks with gasoline
18. and let them dry out Control always the brake control linkage after the drum being dismantled adjust if needed 2009 Ver 3 Fors MW Ltd www forsmw com 36 HOOK LIFT SYSTEM 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 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 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 5 2 6 Maintenance of wheels 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 maint
19. at a continuous operation service For maintenance of the hydraulic system see chapter 5 G O s 1 42 NA M e TN e TN e J H V1 V2 V1 V2 e Figure 35 Hydraulic system Hydraulic components Table 7 Po AN 9 913640 End of stroke valve Note Ge with pos 7 10 915200 Pilot operated check valve Note only with pos D O at o Ta a OO 13 91570 Brake quick coupling 2 2009 Ver 3 Fors MW Ltd www forsmw com 28 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 LOOSEN DURING TRANSPORTATION MAKE SURE THAT ALL WARNING SIGNS AS WELL AS LABELS AND TAPES ARE IN THE APPROP
20. cing the trailer turn off the vehicle engine Be sure that the trailer can t slip when using support leg jack or similar eguipment e 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 e Never attempt to do maintenance work on the hydraulic system before you are sure there is no pressure e Do not tighten or repair leaking hydraulic couplings while the system 1s 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 1s 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 and immediately contact a doctor Figure 36 Safety Note It is strictly forbidden to lean under the container body without using the security post 2009 Ver 3 Fors MW Ltd www forsmw com 30 NSBIGAB 12 15 HOOK LIFT SYSTEM oA NES Figure 37 Raised container bridge Never drive under obstacles such as bridges electrical cables etc with the container bridge raised When driving Don t forget to lift the support leg up before driving Do not exceed maximum travel speed Never make sharp tu
21. drive as additional equipment Lever Console Back frame Note It is not allowed to change the changing unit unless the frame is in looked position Sliding plate Figure amp Changing operation unit 1 4 8 Towing eyelet The eyelet is used to hitch the trailer to the pulling vehicle It 1s 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 1s the users responsibility to see to that this is done Chassis Towing eyelet Figure 9 Towing eyelet 2009 Ver 3 Fors MW Ltd www forsmw com 8 HOOK LIFT SYSTEM 1 4 9 Coupling hitch The coupling hitch 1s used for coupling other trailed devices to the trailer Coupling hitch is also used for coupling reflector Rear beam Pin NB Maximum load 10 ton Figure 10 Reflector Figure 11 Coupling hitch 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 roller i Steering roller Chassis Figure 12 Steering rollers 2009 Ver 3 Fors MW Ltd www forsmw com 9 HOOK LIFT SYSTEM 1 4 11 Bogie block The bogie block is used for bogie blocking during the handling of roll on roll off Chassis Outer tube Figure 13 Bogie block 1 4 12 Wheels Wheels for different trailer types Table 2 Trailer Standard
22. e 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 3 0 Nm e Check the lights reflectors and bulbs 2009 Ver 3 Fors MW Ltd www forsmw com 33 NSBIGAB 12 15 HOOK LIFT SYSTEM Monthly maintenance Check the air pressure 1n tires Check if there is enough lubricant on glide surfaces Clean and lubricate hydraulic cylinders Check hydraulic hoses for damages Recommended lubricants ESSO BRAND TYPE Energrease LS EP2 L2M Beacon EP2 Multipurpose GR Moly SHELL Alvania EP Grease 2 MOBIL Mobilux EP2 Mobil Grease MP Special UNION TEXACO Marfak Multi Purpose 2 Molytex Grease 2 5 2 MAINTENANCE OPERATIONS IMPORTANT BEFORE MAINTENANCE AND SERVICE OPERATIONS READ AND UNDERSTAND THE SAFETY INSTRUCTION During maintenance Be sure that the trailer 1s 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
23. e trailer is damaged inform about this to the company that transported the trailer and the manufacturer of the product immediately 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 ADJUSTMENTS Quick couplings are used in the operation of connecting the vehicle in use with the trailer These couplings serve to disconnect the hoses without their breakage and to prevent loss of ol under accidental strain and pull 2 3 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 O 2009 Ver 3 Fors MW Ltd www forsmw com 19 HOOK LIFT SYSTEM SP PABIGAB 12 15 3 FUNCTIONAL DESCRIPTION 3 1 HANDLING IN ROLL ON ROLL OFF If your BIGAB is eguipped with suspension there 1s no bogie blocking Exchange and tipping must be operated from the operato
24. enance of tires e Check the threaded joints e Check the pressure of air in the tires Wheel pressure Table 6 Trailer Standard wheel type Alternative Air pressure Speed type wheel type bar km h ws maen 4 am RENE 12 15 ams 2009 Ver 3 Fors MW Ltd www forsmw com 37 HOOK LIFT SYSTEM 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 If the axel for the bogie side 1s at all moving see picture 1 the trailer 1s in danser Stop at once and tighten the bolts showed in picture 2 Weekly Once per week or nor later then 20 hours it is needed to lubricate the grease nipples shown in picture 3 You need to lean under the trailer to be able to grease the glide bearings This will be easier to do 1f the trailer 1s without load s v y Lu d Tex R U I E x L ww gt lt y S Ni a g 4 z 22 Bolts on either side of the bogie Grease nipples 2009 Ver 3 Fors MW Ltd Www forsmw com 38 HOOK LIFT SYSTEM NSBIGAB 12 15 3 2 8 Lubrication Recommended lubrication cycle is once per week or after 20 working hours Lubricate points eguipped with grease nipples by using a grease gun See chapter 5 1 for recommended lubricants e Ensure regularity of lubrication by following the lubricating schedule e Keep flammable material away from heat sparks and open fi
25. lf 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 eround can cause fatal voltage between legs At about 20 meters away you should be safe but this 1s of course a questions of circumstances 2009 Ver 3 Fors MW Ltd Www forsmw com 32 HOOK LIFT SYSTEM NBIGAB 12 15 5 MAINTENANCE SPARE PARTS 5 1 MAINTENANCE SCHEDULE AlI kinds of maintenance work are subdivided into two groups operating preventive and compulsory scheduled The need for operating maintenance 1s determined based on the results of checking General e Maintenance works must be carried out 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 extrem
26. llers When you have passed the rollers always keep the hooklift trailer s frame close to the rollers Off loading Release the brakes on both the towing vehicle and the trailer to make it easier to roll off the load Check the position of the tower during off loading so that the container bridge s frame does not catch on the rollers from above Lock the frame 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 1s a considerable risk of the exchange s lock being damaged if the container frame catches in the rollers 2009 Ver 3 Fors MW Ltd www forsmw com 21 HOOK LIFT SYSTEM NSBIGAB 12 15 3 2 HANDLING IN TIPPING Note For the models mentioned in this instruction manual the maximum container bridge length 1s 4 6 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
27. m 23 HOOK LIFT SYSTEM Max load distributed evenly over the container Max load downwards in kg BIGAB 12 15 2300kg 3 4 CHANGING OPERATING FUNCTION Figure 21 shows the lever for manually changing between the operating functions The lever is located on the left side of the chassis This operating function 1s also available with hydraulic drive Tipping position Ba Draw the lock out Hooking position roll on roll off Push the lock 1n xe Note The bolt needs to be locked within the handles extreme position Figure 32 Changing operating function 2009 Ver 3 Fors MW Ltd www forsmw com 24 HOOK LIFT SYSTEM ABIGAB 12 15 N ote TIPPNING VAXLING TIPPING ROLL ON OFF It is not allowed to der AUF ABROLLEN change the changing unit TATA TAL TOURNER OUVRIR FERMER unless the frame 1s in Ae A looked position Figure 33 Safety 2009 Ver 3 Fors MW Ltd Www forsmw com 25 HOOK LIFT SYSTEM 3 5 ELECTRICAL SYSTEM The trailer 1s manufactured with 12V electrical system Configuration depends of options example reversing light border light or additional cable connector O 626 T e L5 TILJIL2 SA O aT
28. manual bogie lift Coupling hitch Bogie axle brackets Bracket for hydraulic manual Rear beam bogie block Figure 2 Chassis 1 4 2 Back frame Back frame 1s constructed out of cold hollow steel sections Figure 3 Back frame O 2009 Ver 3 Fors MW Ltd www forsmw com 3 HOOK LIFT SYSTEM CEABIGAB 12 15 1 4 3 Hook frame The hook frame 1s constructed from cold hollow steel sections Foldable tower Cylinder Axle Figure 4 Hook frame 1 4 4 Bogie The trailer 1s equipped with a strong pendulum bogie that has been equipped with brakes on all wheels Brake cylinder Body ft Axle with brake Figure 5 Bogie 2009 Ver 3 Fors MW Ltd www forsmw com 6 HOOK LIFT SYSTEM 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 1 4 6 Support leg Support leg is designed to be of supporting use when the trailer 1s under maintenance or when trailer 1s not in use Before driving the support leg must be lifted up and fixed with the pin Support leg Chassis Figure 7 Support leg 2009 Ver 3 Fors MW Ltd www forsmw com 7 HOOK LIFT SYSTEM 1 4 7 Changing operation unit This unit is designed for manual changing operation from rolling on rolling off to tipping Lever 1s located on the left side of the chassis This function 1s also available with hydraulic
29. nt 2 450 kg 4 900 7 350 9 450 The higher the moisture content of the load the heaver the load a fact that the user has to take into consideration This table 1s only an approximate estimate of the weights that can occur and it 1s the responsibility of the user to ensure that the vehicle s limits and the applicable legislation are not being exceeded The specified values are not exact values just examples Figure 32 Example of weight with different types of load For information purposes and for examples of how much different loads can weigh please refer to the above 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 1s recommended that the user observes these load values Max load upwards in kg BIGAB 12 15 3050kg 2009 Ver 3 Fors MW Ltd www forsmw co
30. on the hydraulic system before you are sure there is no pressure Do not tighten or repair leaking hydraulic couplings while the system 1s pressurized Never attempt to localize a leakage from hoses or connections by feeling with hand The high pressure oil jet can penetrate skin and cause serious burns and damages High pressure oil 1s also highly flammable 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 2009 Ver 3 Fors MW Ltd www forsmw com 34 HOOK LIFT SYSTEM NSBIGAB 12 15 3 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 5 2 2 Maintenance of the hydraulic units Hydraulic system is shown in chapter 3 5 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
31. r s seat in the towing vehicle Figure Ensure that the position selector for exchange or tipping 1s in the exchange position not in the tipping position na Fa Figure 2 Place the hooklift trailer on a flat surface The sideways incline may not exceed 5 degrees O 2009 Ver 3 Fors MW Ltd www forsmw com 20 HOOK LIFT SYSTEM 1 2 1 5 Figure 3 STOP Stop if the tractor lifts off the ground Check that the hook hitches around the loop Check that the frame lock and bogie blocking are On loading activated gt Check that the load carrier is inside tne GISCS Kelease te Drakes on DO e 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 gt 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 1n 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 ro
32. re e Do not let oil run into the nature Oil spilled into ground pollutes environment Towing eyelet D S Link bearing 1pcs NE Link bearing 2pcs a Link bearing 1pcs Glide bearing 2pcs Glide bearing 1pcs Glide bearing 1pcs 4 di Glide bearing left 2pcs Se NY Glide bearing right 2pcs Glide bearing Ipos _ 11 Glide bearing 1pcs ee Glide bearing left 1 pcs Glide bearing right 1 pcs Glide bearing left 1 pcs Glide bearing right Ipcs Figure 36 Lubrication points 2009 Ver 3 Fors MW Ltd www forsmw com 39 OD OC HOOK LIFT SYSTEM 5 3 SPARE PARTS 5 3 1 Back and Hook frames Figure 39 Cylinder coupling Figure 40 Back and hook frame coupling Figure 41 Foldable tower Back rolling frame and foldable tower spare parts Table 9 Pos Art No Description Note 1 37203110 Axle 0 0 00 0 O 2 37203115 Distance musl 3 37203140 Axe
33. rns 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 4 2 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 starting 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 2009 Ver 3 Fors MW Ltd www forsmw com 31 HOOK LIFT SYSTEM 4 3 ACTING IN DANGEROUS 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 yourse
34. wheel type Alternative Air pressure i type wheel type ER NN EN 12 15 Wheel 500 50 17 Trailer nT ol CSRS ns 40 2009 Ver 3 Fors MW Ltd www forsmw com 10 exe HOOK LIFT SYSTEM 12 1 5 1 4 13 Frame lock 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 1 4 14 Hydraulic system The trailer is equipped with a hydraulic system for working movements See chapter 3 5 1 4 15 Electrical system The trailer is manufactured with 12V electrical system See chapter 3 4 1 4 16 Brake system The trailer is equipped with hydraulic brake system Also 1s available pneumatic brake system as an additional extra 2009 Ver 3 Fors MW Ltd www forsmw com 11 HOOK LIFT SYSTEM SP PABIGAB 12 15 1 5 SAFETY DEVICES 1 5 1 Security post Always use the safety support when carrying out service work 1n the tipped position The safety support may not be used under any circumstances when the container bridge 1s loaded Security post Chassis Figure 14 Security post 1 5 2 Location of the decals at the trailer The trailer 1s eguipped with a range of signs relating both to safety and information Check that all the signs are in the correct positions PABIGAB H
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