Traileyre Bale Transporters Models 1496 & 1498 Instruction Manual & Operating Guide
EC Declaration of Conformity in accordance with BS EN ISO/IEC 17050-1:2004 David Ritchie (Implements) Ltd., Carseview Road, Forfar, Scotland DD8 3BT declare that: Equipment:... Traileyre Bale Transporter Model No:... 1496 / 1498 Serial No:... in accordance with the following directive: 2006/42/EC Conforms with the essential requirements of the Machinery Directive and its amending directives has been designed and manufactured to the following specifications: BS EN ISO 12100-1: 2003 Safety of Machinery - Basic concepts, general principals for design - Basic terminology, methodology. BS EN ISO 12100-2: 2003 Safety of Machinery - Basic concepts, general principals for design - technical principals and specifications. BS EN 982: 1996 Safety of machinery. Safety requirements for fluid power systems and their components - Hydraulics BS EN ISO 4254-1:2009 Agricultural machinery - Safety - Part 1: General requirements BS EN ISO 13857:2008 Safety of machinery - Safety distances to prevent hazard zones being reached by upper and lower limbs. BS EN ISO 14121-1: 2007 Safety of machinery - Risk assessment - Part 1: Principles Signed:- Robert Ritchie Al agr E Agricultural Sales Director at:- David Ritchie Implements Ltd. Forfar, UK on:- 5th January 2011
Contents Traileyre Bale Transporters - Models 1496 & 1498 Pages Foreword... 4 Warranty... 5 Intended Use... 5 Safety... 6, 7 Machine Specifications... 8 Machine Overview... 9 Attaching to Tractor / Hydraulic and Electrical Connections... 10, 11 Operating Instructions... 12 Bale Loading / Unloading... 13 Arm Extension Kits... 14-16 Arm Extension Kits - Settings for different bale types... 17 Maintenance & Servicing... 18-19 Road Lighting System... 20 Troubleshooting... 20 Traileyre Bale Transporter - Typical Applications... 21, 22 Rev A - May 2009 3
Foreword The Ritchie Traileyre Bale Transporter has been designed for the transportation of bales and is not intended for any other use. David Ritchie Implements shall not be liable for damage resulting from misappropriate use of the machine. The user shall bear all responsibility. Intended use also comprises adherence to the operating, maintenance and servicing instructions contained in this manual. The machine must only be used in perfect working condition. Any functional disorders, especially those which affect the health and safety of personnel must be rectified immediately. The Traileyre Bale Transporter must only be used by an experienced, competent operator who has been trained in the safe use of the machine, who has read the operator s instruction manual and who is aware of the potential risks involved in working with the machine. Following the setting up, operating and maintenance instructions contained in the manual should allow the operator to achieve the best performance from the machine, resulting in increased reliability. Operators should read carefully all safety notes contained within the manual prior to using the machine in order to help avoid dangerous situations, expensive repairs and prolonged downtime. In addition operator s should also read any relevant legislation regarding health and safety and accident prevention applicable to the country in which the machine is to be used. The right to alter specifications, equipment and maintenance instructions at any time, without notice is reserved as part of our policy of continuous development and improvement. No liability can be accepted for inaccuracies or omissions in this manual, although every possible care has been taken to make it as complete and accurate as possible. Owners who encounter a problem not covered in this manual should contact David Ritchie Implements Ltd at the address given on the rear cover of the manual, or consult their local Ritchie dealership. 4
Warranty The machine should be checked over at time of delivery for transport damage. Check also that the specification is complete and that the data plate contains the serial number of the machine. All claims must be delivered to the manufacturer in written form within 48 hours. David Ritchie Implements Ltd. guarantee subject to certain conditions that the goods supplied will be free of defects both in material and workmanship. The following conditions apply:- The machine should only be used for the purpose indicated in this manual. Service and warranty work is carried out only by authorised Ritchie dealers. The original specification of the machine has not been subject to unauthorised modification. Correct operation of the machine and regular maintenance will help to prevent breakdowns. If however operating trouble is experienced during the warranty period the following actions should be adopted:- Notify the dealer immediately from whom the machine was purchased, quoting the model and serial number. Do not operated the machine. Damage resulting from failure to report a fault may not be covered by warranty. The manufacturer cannot accept liability for damage to machines or third party through operational negligence. Intended Use The Ritchie Traileyre Bale Transporter model 1496, is designed to transport 6 round silage, hay or straw bales up to a maximum of 1.25m in width and 1.25m in diameter. It may also be used to transport 6 high density square bales or 12 straw bales when the specially designed extension arm kit is fitted. The Ritchie Traileyre Bale Transporter model 1498, is similar in design to the 1496 model mentioned above but with the capacity to transport 8 round silage, hay or straw bales up to a maximum of 1.25m in width and 1.25m in diameter. It may also be used to transport 8 high density square bales or 16 straw bales with the arm extension kit fitted. The Traileyre is designed to be towed on a 4 wheel drive tractor with a minumum of 80 horsepower (model 1496) or 100 horsepower (model 1498) and must be capable of delivering a minimum hydraulic flow rate of 40 litres per minute at a pressure of 160 bar (2400 psi). The machine is designed to be used by a single operator only (tractor driver). The Traileyre Bale Transporter is equipped with a self loading system which enables the operator to load a bale into the machine from his position in the tractor seat. Bales are then transported to the place where they are to be stored. The machine should be used on firm ground. Sloping ground exceeding 8 in inclination should be avoided to minimise the risk of toppling over. Inappropriate Use The machine must not be used for purposes other than those indicated in this manual. The machine must not be used for loading or transportation of other materials other than those mentioned in this manual. 5
Safety Information Please read these instructions carefully. Ignoring these instructions could result in serious personal injury or damage to the machine. These instructions apply to all personnel involved with the operation, maintenance and servicing of the machine. General The machine must only be used by an experienced, competent operator who has been trained in the safe use of the machine. The operator should consult the tractor handbook for information and instruction on mounting implements and other safety issues. Only operate this machine from the tractor seat (work station). Never allow personnel to ride on the machine. Do not modify any part of the machine which could affect safety. Any modifications or additions to the machine should be approved by the manufacturer. This also applies to welding work. Always test the machine prior to operation to ensure services function correctly. Do not use the machine if a malfunction occurs. Do not stand in the area between tractor and implement or allow others to enter this area, especially when the machine is operational. Warn bystanders to keep clear of the machine whilst operational. Hay and Straw are flammable - so always keep the machine in a clean condition away from open fires and smoking materials. Keep a fire extinguisher in the tractor cab! Before and During Operation Never leave the tractor cab while the machine is running. Always switch off the tractor engine, remove the ignition key and apply the tractor handbrake before approaching the working zone of the machine. The same applies for downtime and standstills. Take particular care when mounting the implement to the tractor. Always position the machine on flat level concrete or tarmac. Never work on ground exceeding 8 in inclination. Take care when coupling / uncoupling the hydraulic hoses to the tractor. Hydraulic oil under pressure can damage your skin. Always seek immediate medical advice in such circumstances. Warning: Hydraulic fluid under pressure can penetrate the skin or eyes and cause serious personal injury or blindness. Fluid leaks, under pressure, may not be visible. Use a piece of cardboard or wood to find leaks. DO NOT use your bare hand. Wear safety goggles for eye protection. If any fluid is injected into the skin, it MUST be surgically removed within a few hours by a doctor familiar with this type of injury. 6
Servicing and Maintenance Only use suitably qualified engineers working to the relevent standards and codes of practice when repair work to the hydraulic or braking systems is to be undertaken. Never attempt maintenance or servicing work on the machine when the tractor engine is running. Release any residual hydraulic pressure to the system by operating the spool valves in both directions. Switch off the tractor engine and remove the ignition key! If the Bale Transporter is to be unhitched from the tractor for maintenance or storage, select even level ground and always engage the handbrake. Use wheel chocks before releasing the handbrake for maintenance. After cleaning the machine check all hydraulic hoses for leaking or operational damage. Damaged hoses should be replaced immediately. Adhere to replacement intervals noted in the manual even if signs of wear to component parts is not evident. After servicing is complete check all nuts and bolts have been tightened satisfactorily. Transportation Before travelling on public roads ensure the machine is free of loose material and equipment. Check also that the braking system is properly connected and fully operational. Road speed should not exceed 20 mph (30 km/h). When turning or at bends take the width and load of the machine into consideration. Take extra care when reversing the machine. When stopped, always use the parking brake. Storage When storing the machine- clean thoroughly. Raise the bale lifting arms into the upright position. Affix the end of the brake hose to the holder provided. Place the feed and return hose ends, road lighting plug, 12V lead and solenoid control box in the manifold housing for protection. Position the machine indoors on flat level concrete or tarmac where it presents no hazard to people or animals. Dispose of used oils carefully with due consideration to the environment. Road Light System Fold out the front marker lights at both sides and check the lighting system especially before travelling on public roads. Replace bulbs if necessary. Clean lens covers and reflectors periodically. 7
Machine Specifications 1496 1498 Overall Length 6.182 m 7.700 m Overall Width 2.270 m 2.270 m Overall Height 1.760 m 1.800 m Unladen Mass 1600 kg 2300 kg Gross Weight 6000 kg 8000 kg Maximum Drawbar Load 1000 kg 1000 kg Maximum Axle Weight 5000 kg 7000 kg Axle Single Tandem Wheels 15.0/55-17 10 ply 11.5 x 15 12 ply Tyre Pressure 3.5 bar 3.5 bar Max. cont. 'A' weighted Sound Pressure does not exceed 70 db(a) Tractor Power Requirement 80 hp 100 hp Transmission Minimum Hydraulic Oil Flow Maximum Oil Pressure Tractor Coupling Bale Width Bale Length 4 Wheel Drive 40 litres / min 160 bar Hydraulic Pick-up hitch 1.250 m (4ft) 1.250 m (4ft) Bale Capacity 6 Round Bales 8 Round Bales Bale Capacity (with Extension Arms) 12 Bales (Straw only) 16 Bales (Straw only) High Density Square Bale Capacity (with Extension Arms fitted) 6 Bales 8 Bales Tractors should be equipped with a hydraulic trailer brake coupling, 1 double acting spool valve and a 12V DC power socket from cigar lighter or jackplug. 8
Machine Overview 5 4 3 2 1 7 OFF ON Fig 1 Model 1498 illustrated 6 1. Manifold Housing 2. Lifting Ram 3. Bale Lifting Arm 4. Bale Spike 5. Central Barrier 6. Drawbar 7. Handbrake 9
Attaching to the Tractor The machine is fitted with a drawbar eye for quick and easy attachment to the tractor hydraulic pick up hitch. Consult the Tractor Operator s manual for instructions on mounting implements and for pick up hitch adjustments.! During hitching operations do not allow persons to stand in the area between tractor and implement. Carefully reverse the tractor toward the machine until the hydraulic pick up hitch is in position below the drawbar eye. Use tractor lift controls to raise the drawbar clear of the ground. Apply the tractor handbrake, stop engine and remove the ignition key! If extra drawbar clearance is required during operations or for road transportation the parking stool can be detached from the underside of the drawbar and relocated on top. See Position 1 & 2, fig 2. Position 2 Position 1 Fig 2 10
Hydraulic and Electrical Connections The machine is fitted with hydraulic feed and return hoses which are stored in the manifold housing, Fig 3. Check the quick release couplings and plugs are clean before connecting to the two double acting hydraulic outlets on the tractor spool block. Remove the trailer brake coupling from the holder on the side of the manifold housing and attach to the trailer brake socket. Attach the road light plug to the tractor auxiliary socket. Pass the control box through the tractor rear window and situate in a position where it cannot be activated inadvertently. The back of the control box has a magnetised pad which can be used to fix the control box to a metal surface if required. Connect the 12V lead to the cigar lighter socket or jackplug. Check all bystanders are clear of the machine. Slowly operate the spool lever to check spool valve direction and change hose positions if required. Hydraulic Quick Release Couplings 12V lead Holder for Trailer Brake Coupling Control Box (stowed position) Road Light Plug Fig 3 When not in use, store the control box, hydraulic quick release couplings, road light plug, and 12V lead - inside the manifold housing. Fit the trailer brake coupling to the holder on the side of the housing. 11
Operating Instructions Fig 4 Model 1496 Model 1498 Control Boxes Before starting the machine check the drawbar connection to the tractor pick up hitch is secure and that the traileyre handbrake is off. (see fig 1) Check also to ensure no bystanders are in the vicinity of tractor and machine. Note:- Model 1496 can handle 6 round silage, hay or straw bales. Fitting the extension arm kit allows the machine to handle 12 round bales (straw only) or 6 high density square bales. Start up the machine to check all functions operate as intended. Each lift arm operates via its own solenoid valve. Therefore the operator must select the appropriate switch on the control panel, Fig 4, before activating the spool valve lever. The switches are marked to identify each individual lift arm. Note: References to right and left are taken from a position behind the machine and facing in the direction of travel. Model 1498 can handle 8 round silage, hay or straw bales. Fitting the extension arm kit allows the machine to handle 16 round bales (straw only) or 8 high density square bales. 12
Bale Loading! On steep ground always load bales from the top side of the machine. To increase stability, the opposite lift arm can be lowered temporarily. Ensure also that tyres are fully inflated when working on sloping ground. Begin loading at the rear to ensure good vision and retain maximum stability. Lower a rear lift arm to a height which allows the spike to enter the bale slightly above the centre of the bale. Drive alongside the bale ensuring the spike penetrates completely into the bale and then raise the lift arm until the bale has rested onto the Traileyre. Next load the opposite rear lift arm repeating the process loading towards the front of the machine, Fig 5. Bale Unloading Position the tractor with sufficient space either side of the Traileyre. Unload only from the front to the rear. Lower the front 2 arms in turn allowing the bales to swing centrally to the ground, then reverse to unload. Raise the arms to the vertical position and repeat the sequence till the machine is empty. Fig 5 13
Arm Extension Kits When lifting round straw bales (only) the capacity of the traileyre can be doubled by fitting the specially designed extension arm kit. The kit is also used when lifting high density square bales. The following pages give installation details for Extension Arms, Gantry and Braces. (4) M16 x 45 Set Screws, plated c/w M16 Nyloc Nut & Plated Washer Model 1496 (2) M16 x 55 Set Screws, plated c/w M16 Nyloc Nut & Plated Washer Fig 6 14 Gantry Central Barrier (2) M12 x 100 Plated Bolts c/w Nyloc Nuts & Plated Washers in (3) positions Brace Position Brace Position Traileyre Front 1400 1650 1660
(2) M16 x 55 Set Screws, plated c/w M16 Nyloc Nut & Plated Washer Model 1498 (6) M16 x 45 Set Screws, plated c/w M16 Nyloc Nut & Plated Washer (2) M12 x 100 Plated Bolts c/w Nyloc Nuts & Plated Washers in (4) positions Gantry Central Barrier Brace Position 1400 1650 1650 1660 Brace Position Fig 7 Traileyre Front 15
Models 1496 & 1498 Braces to be assembled as shown in rear and front arm positions. (See pages 14 & 15). M16 bolts in clamping plates to be fitted with the bolt head towards the bale. (2) M16 x 45 Plated Set Screws c/w Nyloc Nuts and Plated Washers (2) M16 x 55 on Front Braces (7) M16 x 150 Plated Bolts c/w Nyloc Nuts and Washers (Typical in each position). Braces M16 x 65 Plated Bolts c/w Nyloc Nut and Washer (already available this position). Fig 8 Rear View 16
Arm Extension Kits - Settings for different Bale Types Reposition the traileyre extension arms as shown below to suit bale type to be handled. Position 1 For handling Round Bales Note To achieve Position 2 Remove Bolts 1 & 3 and reposition Bolt 1 into Slot 2. Position 2 For handling Large Square Bales 1 2 3 Fig 9 17
Maintenance and Servicing General! Never attempt maintenance or servicing work on the machine when the tractor engine is running. Release any residual hydraulic pressure to the system by operating the spool valves in both directions. Switch off the tractor engine and remove the ignition key! Fig 10 If service is required to the underside of the machine ensure adequate supporting devices are in place to prevent sudden lowering of the machine. When replacing equipment on the machine always use original spare parts. Important Fig 11 Check tightness of all bolts after the 1st hour in use including wheel nuts. Wheel nut torque setting = 185 lbs/ft. Re-check tightness of all bolts after every 10 hours of work including wheel nuts. Lubrication Model 1498 only Grease Nipples are provided at various points on the machine to aid lubrication. Grease daily when the machine is in use, as shown Figures 10-13. Fig 12 Cleaning Use a high pressure water jet to remove residue from the machine at the end of each working day. Take care to avoid water ingress to Manifold Housing! 18 Fig 13 Model 1498 only
Hydraulic System The hydraulic system should be checked for leaks or damage prior to each use of the machine. Read safety instructions on (page 6 and 7). The hoses on the machine must be replaced every 5 years even if signs of wear or damage is not apparent. Always use suitable replacements available from Ritchie dealerships according to the rating below:- Hose Rating - SAE 100 R2 AT DIN EN 853 2SN Working Pressure - 330 bar (4800 psi) Min. Burst Pressure - 1320 bar (19150 psi) Hose Replacement It is advisable to wear eye protection when replacing hoses or when working on the hydraulic system. Before replacing hoses - release any residual pressure in the hydraulic system by operating the tractor spool valves in both directions. Place a suitable container below the hose to allow the hydraulic oil to be drained. Detach and drain the first hose end followed by the opposite end to ensure any remaining oil is drained completely. Repeat procedure for all hoses to be replaced. Braking System The traileyre hydraulic brake system should be checked and adjusted regularly when the machine is in use. To adjust brakes:- Using suitable jacking devices raise the axle clear of the ground until wheels are free to rotate. Rotate wheel in forward direction as if the traileyre was travelling forward on the road whilst at the same time turning the adjuster screw (Fig 14), in a clockwise direction until the brake shoes start to engage the side of the wheel drum. Turn the screw in an anticlockwise direction a little at a time while turning the wheel in a forward direction. Continue until the wheel rotates with little effort. Repeat this procedure for each wheel. When adjustments are complete - lower the traileyre to the ground and remove jacks. Start up tractor and test braking efficiency on concrete or tarmac. With hose ends reconnected, charge the system with oil via the tractor spool valves putting the service through a few cycles to allow the tractor hydraulic system to bleed out any trapped air. Fig 14 Adjuster Screw Always dispose of oil responsibly with due consideration to the environment. Brake Shoes If brake shoes are to be replaced consult a specialist contractor familiar with this type of work. 19
Road Light System Always fold out the front marker lights at both sides of the machine before travelling on public roads, Fig 15. Before moving off - connect the road light plug to the tractor auxiliary socket and check the system. Replace bulbs if required. Clean lens covers and reflectors periodically. Fig 15 Troubleshooting Bale Lifting arm not operating as expected:- Cause Inadequate system pressure. Incorrect hydraulic connection between tractor and machine. Fault with valve or lifting ram Remedy Increase the hydraulic oil output to provide 40 l/min at a system pressure of 160 bar. Check the hydraulic quick release connectors at the tractor spool block. With the relevant control panel switch in the operative position - check the corresponding solenoid by placing a small screwdriver in the centre of the nut as shown in Fig 16. A slight magnetism should be felt which would indicate the electrical signal to the solenoid is in order. This may point to faulty valve or problem with the ram in question. Operator s should consult their Ritchie dealership. Fig 16 Disassembly (at end of service life) Careful maintenance and adherence to the instructions contained in this manual should ensure many years of trouble free service. At the time of decommissioning the machine however or replacing parts on the machine - all waste metals, rubber, plastics and used oils should be delivered to suitable recycling centres. 20
Traileyre Bale Transporter - Typical Applications Fig 17 Model 1496 loading from rear to front to ensure good vision Fig 18 Model 1498 fully laden. Fig 19 Model 1496 unloading from front to rear. 21
Fig 20 - shows the 1496 model fitted with arm extensions for handling 12 straw bales. Note the bolt positions in the clamping plates (circled) are set up for handling round bales as described on page 17. Fig 20 Fig 21 - shows the traileyre fitted with arm extensions for handling high density square bales The bolts in the clamping plates (circled) are set up in position 2 for handling square bales as described on page 17. Fig 21 22
David Ritchie (Implements) Ltd, Carseview Road, Forfar, Scotland, DD8 3BT Tel: 01307 462271 fax: 01307 464081 e-mail: agrisales@ritchie-uk.com www.ritchie-uk.com