Operation and Maintenance Manual

Operation and Maintenance Manual
Operation and Maintenance Manual
Delilah Spreaders
FBS Manure Spreaders
SDS Manure Spreaders
Make a Note of the Machine serial number in this
box for future reference and when ordering
replacement parts.
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Original Instructions
It is the responsibility of the operator to read and
understand the contents of this manual before
operating the machine for the first time.
The Operators manual must accompany the machine
at all times. If the machine is resold the Operators
manual must be given with the machine to the new
owners.
Pages containing information about the Manufacturer,
Agent, Use of the machine and its Disposal.
Preface
Identification Plate.
Operating on Public Roads
How to use the Manual
Safety Warnings
Warranty
:2
:3
:4
:5
:6
Delilah Manure Spreaders.
FBS Manure Spreaders.
SDS Manure Spreaders.
:2
:3
:4
Location of Safety Decals
Manure Spreaders
:1
:2
Overview
Safety Decals
General Safety
Pages promoting General Hazard perception and Safety
Awareness for the Operator.
Specifications
General
Delilah Manure Spreaders.
FBS Manure Spreaders.
SDS Manure Spreaders.
Axles & Tyres
:2
:3
:4
:5
:6
1 Transportation & Handling
PTO Drive Shaft
1:2
2 Before Operation
Checks
Coupling to Towing vehicle - Hitch
Coupling to Towing vehicle - Air Brakes
Coupling to Towing vehicle - Hydraulic Brakes
ABS Connections
Coupling to Towing vehicle - Steering Axle
Coupling to Towing vehicle - Hydraulic Connections
Coupling to Towing vehicle - Drive Shaft
Adjusting Sprung Drawbar
Adjustments before Towing Trailer
2:1-2:2
2:3
2:4
2:5
2:5
2:5
2:6
2:7
2:7
2:8
Index
Introduction
3 Operation
Loading the Trailer
Moving Off
Spreading Delilah & FBS
Slurry Gate
Spreading SDS
Slurry Gate
Unblocking Delilah & FBS
Troubleshooting
Examples of Foreseen Misuse
3:2
3:2
3:3
3:3
3:4
3:4
3:5
3:6
3:7
4 Maintenance & Service Schedules
Service Schedules
Grease Points
Delilah & FBS
Power Take Off
Service Checks
Delilah & FBS
Grease Points
SDS
Service Checks
SDS
Axles Brakes & Suspension
Tightening Wheel Nuts
Checking Hubcaps & Wheel Bearings
Lubricating Wheel Bearings
Brake Maintenance & Adjustment
Suspension Maintenance
Drawbar Maintenance
Tyre Pressures
Recommended Lubricants
Laying Up & Long Term Storage
4:2-4:5
4:6
4:9
4 : 10
4 : 12
4 : 15
4 : 17
4 : 18
4 : 19
4 : 20
4 : 22
4 : 25
4 : 27
4 : 28
4 : 29
4 : 32
5 Braking System
Two Line Schematic
Two Line Air or Air Hydraulic with ABS
Brake Electrical Schematic
ISO 7638 Connections
General Description
Operation
Brake Application
Air/Hyd Actuators
Basic Checks
RELSV Setting
ABS General Description
Testing
Troubleshooting
Eurosafe Brake Equipment
Set-up
Operation
Troubleshooting
5:2
5:4
5:6
5:7
5:8
5:9
5 : 10
5 : 11
5 : 12
5 : 14
5 : 17
5 : 18
5 : 22
5 : 25
5 : 26
5 : 27
5 : 30
Introduction
INTRODUCTION
This manual provides information on the use,
adjustment and servicing of the
RICHARD WESTERN range of spreaders
Models covered are:Delilah Spreaders
FBS Manure Spreaders
SDS Manure Spreaders
Following the advice on the correct maintenance
and servicing procedures will ensure maximum
performance and a long service life for your
machine.
Failure to carry out maintenance work correctly, or
incorrect operation will result in poor machine
efficiency and loss of valuable time.
By ensuring the correct operation, and by carrying
out maintenance and service work with care, you
will be able to make full use of the technical
knowledge and the experience with which your
trailer was originally designed.
Introduction : 1
Introduction
RICHARD WESTERN
Introduction
continued
The Richard Western range of machines covered in
this manual are trailed agricultural implements
designed and constructed for the sole purpose of
carrying and redistributing agricultural crops and
associated materials.
This is their intended use.
The machines may contain, additional equipment
which may function under the direct control of the
operator of a towing vehicle., or in certain
circumstances automatically and autonomously.
Use of the machine in any other way is considered by
the manufacturer to be contrary to the intended use.
Consequently the manufacturer does not accept any
liability for such use and the user therefore accepts
all risks arising from such use.
Intended use also includes the observation of the
service, maintenance and repair conditions and
routines as prescribed by the manufacturer.
Within this manual is the information required by an
operator to assemble and put the machines to work,
operate and maintain them and lay them up for
storage.
Additionally comprehensive information relating to the
machines safe use and the responsibilities of the
operator is also given.
The Operator and User must read this manual fully
before commencing work with or transporting the
machine. If the Operator or User does not
understand any part of this manual further help and
advice is available from the manufacturer or from
the manufacturers agent shown on the following
pages of this manual.
Introduction : 2
Introduction
RICHARD WESTERN
Manufacturer
Manufacturers Name :
Richard Western Ltd
Manufacturers Address :
D'Urbans,
Framlingham,
Suffolk,
ENGLAND
IP13 9RP
Introduction : 3
Agent
Agents Stamp :
Introduction : 4
Disposal
Upon completion of the useful life of the machine,
all parts can be disposed of at a suitable waste
disposal facility.
Care must be taken if oxy-acetylene cutting
equipment is to be used.
The wheels and tyres , hydraulic & pneumatic
cylinders, valves and hoses must be removed
before using cutting equipment.
Oil must be drained collected and disposed of in
accordance with current legislation.
Electrical components must be disposed of in
accordance with the relevant legislation.
Introduction : 5
Introduction
RICHARD WESTERN
THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK
Preface
Note that the Richard Western Range of Trailers
may also be referred to simply as the machine(s) in
the following sections.
The instructions set forth in this manual must be
read carefully and followed by all persons
concerned with the operation, maintenance, repair
or inspection of this machine in order to prevent
accidents.
Read especially sections relating to Safety and
Before Operation.
The use of spare parts, accessories and additional
equipment which is not originally manufactured,
checked and released by Richard Western Ltd can
have a negative effect on specific design features
of the machine and on its operability.
This may impair its operating safety, as well as
safety at work for the operator.
Richard Western Ltd will in no way be liable for
damage or personal injury caused by the use of
other than original Richard Western Ltd parts,
accessories and additional equipment.
Technical specifications, dimensions and weights
are given with the usual tolerances.
Front, rear, right and left refer to the direction of
forward travel as viewed from the operators seat of
the towing vehicle.
Fitment of Parts or accessories or modifications not
approved in writing by Richard Western Ltd may
compromise the effective and safe operation of the
machines and could invalidate the warranty.
Richard Western Ltd operates a policy of continual
improvement, as such some items in this manual
may differ slightly from that of your machine.
Richard Western Ltd reserve the right to make
changes to the machine or this manual without
notice.
If in any doubt regarding any aspect of the design
or operation of this machine contact Richard
Western Ltd or your Richard Western Ltd agent for
clarification.
Preface : 1
Preface
RICHARD WESTERN
IDENTIFICATION PLATE
The machine number (VIN) ), the model are
required with all orders for spare parts and
technical enquiries. This is necessary in order to
ensure correct delivery of spare parts.
The identification plate with the machine
Number (VIN) is attached to the front right side of
the machine frame (1) on all machines
Additionally an identification number is located on
the forward crossbrace of the main chassis (2)
1
2
ROAD TRANSPORT
Observe the applicable road regulations in your
country.
Information
It is the duty of the operator to ensure
that the machine is maintained and
operated in accordance with all Local
and National regulations.
Preface : 2
Operating on public roads
Before operating on public roads the trailer must be
correctly connected to the towing vehicle, the lights
must be connected and function of the lighting
equipment must be checked.
The trailers are equipped with hydraulic and/or
Pneumatic braking systems. These must be
correctly connected to the Towing Vehicle and
checked for correct operation.
If the trailer has an air brake system the brake lines
and any breakaway rope (breakaway brake) must
be connected.
Number plate
To 15 m.p.h. (25 km/h) : Trailers must be fitted with
a number plate issued to the vehicle owner for one
of his vehicles
Over 15 m.p.h. (25 km/h) : Trailers must be fitted
with a duplicate of the number plate fitted to the
Towing Vehicle.
Preface : 3
Preface
RICHARD WESTERN
How to use this manual
The manual contains sections that cover all of the
following, Safety , before and during operation,
Assembly, Using the machine, Maintenance,
Specifications and Technical data. Refer to the
contents pages for the relevant page number.
Before use of the machine familiarise yourself with
the manual and its contents.
The machine may only be operated, serviced and
repaired by persons who are familiar with the
machine and who have read and understood this
manual, and are informed of the risks.
Observation of the relevant accident prevention
regulations and other generally acknowledged
regulations regarding safety, and occupational
health is critical, as is conformance with local and
nationally enforced standards relevant to motor
vehicles and road traffic law.
Modifications to the machine without the specific
approval of the manufacturer, exclude the
manufacturer from any liability or damage resulting
from the modifications.
Failure to follow the procedures given in this
manual could invalidate the warranty given.
Preface : 4
Safety Warnings
Identification of Warnings and Danger
All parts of the manual to do with the safety of the
operator, or the safe operation of the machine, are
marked with the following symbols.
Warning
This symbol identifies that hazard exists.
If proper precautions are not taken, it is
highly probable that the operator (or
others) could be killed or seriously
injured
Caution
This symbol identifies a reminder of
safety practices. Failure to observe
these safety practices could result in
injury to the operator (or others) and
possible damage to the machine.
Information
This symbol identifies instructions that
make it easier to use the machine
effectively and economically
Preface : 5
Preface
RICHARD WESTERN
Warranty
The Richard Western range of machines are
supplied with a full One Year warranty.
There are some exclusions, namely :Wheels and Tyres
Damage caused by misuse and abuse
Damage caused by overloading
Damage to ground engaging or suspension parts
For full details refer to the manufacturers
documentation.
If you have a claim under warranty contact the
manufacturer or the manufacturers agent.
Electrical
Equipment
Your machine may be supplied with electrical
control equipment for some of its functions.
To ensure correct operation care should be taken
to ensure that these controllers are correctly
connected when in use.
Ensure any damage howsoever caused is repaired
immediately.
When not in use the controllers should be removed
from the machine and stored in a suitable dry
container on the towing vehicle or alternatively in
the workshop.
If the machine is to be unused for a prolonged
period of time, the open connections should
covered and protected against water ingress and
corrosion.
Controllers damaged by the ingress of water, water
damage to electronic components or corrosion to
electrical or electronic components will not be
covered by the warranty agreement.
Preface : 6
The information contained within this section
identifies the major assemblies and component
parts within each machine model.
Overview : 1
Overview
RICHARD WESTERN
Delilah Manure Spreaders
5
4
8
7
3
1
Key
1
2
3
4
5
6
7
8
Drawbar
PTO
Hose Storage
Hydraulic & Brake Connectors
Discharge Rotors
Rotor Gearbox
Ladder
Slurry Gate
Overview : 2
6
2
Overview
Overview
RICHARD WESTERN
FBS Manure Spreaders
4
5
8
3
2
7
1
6
Key
1
2
3
4
5
6
7
8
Drawbar
PTO
Hose Storage
Hydraulic & Brake Connectors
Ladder
Rotor Gearbox
Rotor
Slurry Door
Overview : 3
SDS Manure Spreaders
4
5
7
Key
1
2
3
4
5
6
7
Drawbar
PTO
Hose Storage
Hydraulic & Brake Connectors
Discharge Rotors
Rotor Gearbox
Rear Step
Overview : 4
6
3
1
2
LOCATION OF
SAFETY DECALS
Safety decals & warning symbols are placed in
danger areas of the machine to help identify risks
of injury.
The decals fixed to a machine do not make the
machine safe they are there as a guide and to
direct appropriate behaviour when using the
machine.
The operator is ultimately responsible for his own
safety and that of other persons around the
machine. Never permit anyone to ride on the trailer
or to approach the trailer or any of its components
whilst operating.
The information in these decals show how to avoid
injury and accidents by appropriate behaviour.
The location of the decals on the machine and their
wording is shown on the following pages.
Over time the manufacturer may change the type
and quantity of decals. A machine may therefore
contain a mixture of all of the decals shown.
The numbers against the explanation correspond to
those showing the location on the illustrations
Immediately replace damaged or illegible
safety decals with new replacements.
When replacing parts with decals affixed to
them, make sure you affix new decals again
to the new parts.
Safety Decals : 1
Safety Decals
RICHARD WESTERN
Manure Spreaders
Typical
12
1
2
3
4
5
7
6
8
9
11
12
1
Overhead Power Lines
2
Warns the operator not to
raise the body or any lifting
device in the proximity of
Overhead Power lines or
obstructions
3
Refer to Operators Manual
Warns the operator to
disable the Towing Vehicle
and Isolate the trailer from
any energy sources when
undertaking maintenance
Overview : 2
Refer to Operators Manual
Reminds the operator to
refer to the operators
manual for Technical
information and data
4
Hydraulic & Pneumatic
Pressure
Warns the operator of the
danger of trapped residual
pressures when coupling
and de-coupling the trailer
Overview
RICHARD WESTERN
10
5
Crush Prevention
6
Warns the operator of the
potential for crushing injuries
in the area between the
Trailer and Towing vehicle
7
9
Maximum Allowable
Speed
Reminds the operator of
the maximum permissible
towing speed
Service Checks
Reminds the operator of the
need to raise the slurry door
before operating the floor
chains
8
Power Take Off
Reminds the operator to
refer to the Operators Manual
for information on Power
Take Off Connection and
permissible rotation Speed
Service Checks
Reminds the operator to
refer to the Operators Manual
for information on Tyre
Pressures
10
Reminds the operator to
refer to the Operators Manual
for information on Wheel Nut
Torques
11
Crush Prevention
Rotating Shafts
Warns the operator to
refer to the Operators Manual
for information related to
fitting and using the rotating
driveshaft and its guards
12
Rotating Shafts
Warns the operator of the
danger in this area due to
rotating machinery
Overview : 3
THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK
General Hazards
Introduction
Machine operators must be aware of
the correct hand signals and those
personnel authorised to give them.
Warnings or Cautions for hazards that may be
present when operating the machine, or during
maintenance of the machine, are shown in the
following sections
Operators must accept hand signals
only from a single and authorised
person.
Before Operation
Make sure that all fluids used during
maintenance of the machine are stored
in the correct containers.
Operation
The following Warnings and Cautions are of a
General nature and are not task specific.
All personnel operating or maintaining this machine
must be fully aware of these warnings.
Never store these fluids in other types,
such as glass containers.
General
Make sure the location of high voltage
power lines and buried power cables
are known. Serious injury or death, by
electrocution, can occur if the
machine contacts these hazards.
Do not wear loose clothing or
Jewellery, which can snag on the
controls or machine structure, causing
personal injury.
Make sure that all protective guards and
covers are secured in place on the
machine. If guards and covers are
removed, a hazard to personnel will
exist.
Make sure that all foreign objects and
materials, such as oil, tools, debris and
other items, are kept clear from
equipment, walkways and steps on the
machine. Failure to do this can cause
personal injury.
Make sure that all fluids are disposed
of correctly and in accordance with
Local Health and Safety Regulations.
Make sure that all cleaning fluids are
used with care and that any necessary
repairs are reported immediately.
Unauthorised personnel must not be
permitted to operate or maintain this
machine.
Make sure the size of the machine,
including any load, is known. This will
ensure a correct and safe clearance is
maintained, when operating the machine
in confined spaces or near obstacles.
Make sure that all loose items, such
as tools, lunch boxes and other items,
which are not part of the equipment,
are secured correctly before operating
the machine. Failure to do this can
cause personal injury.
Always wear the correct protective
equipment, including a hard hat and
protective glasses, as required.
General Safety : 1
General Safety
RICHARD WESTERN
GENERAL HAZARDS
Pressurised air and water
If released, air or water in pressurised
machine systems can cause debris or
hot water to be ejected. This can cause
personal injury. Care must be taken
when working on pressurised machine
systems.
Operators using pressurized air or
water for cleaning purposes must wear
the correct protective equipment. This
includes protective clothing, shoes/
boots and goggles or face shield.
Operators using pressurised air or
water for cleaning purposes must not
exceed the following maximum
operating pressures:
Air - 205 kPa (30 psi)
Water - 275 kPa (40 psi).
Residual hydraulic pressure
Refer to the Service Manual before
releasing hydraulic pressure.
Non-operating hydraulic systems can
retain residual hydraulic pressure. If
released, this residual pressure can
cause:
Sudden movement of the machine or
machine attachments.
Disconnected hoses to whip.
Hydraulic fluid to be sprayed, causing a
personal hazard through direct contact
or ingestion.
.Fluid
penetration
Residual hydraulic pressure must be
released before any hydraulic
maintenance, disconnection or
component removal is done. Refer to
the Service Manual before releasing
hydraulic pressure. Non-operating
hydraulic systems can retain residual
hydraulic pressure. If not released
correctly, personal injury can occur.
Leaking fluid, even from a pin hole leak,
can penetrate the skin, causing serious
injury or death. Always use cardboard or
a board to check fluid leaks. If fluid
penetration of the skin occurs, you must
seek medical help immediately,
preferably from experienced medical
staff.
General Safety : 2
Fluid spillage
Care must be taken to avoid fluid
spillage during machine maintenance,
testing, adjusting and repair. Before any
possible fluid spillage can occur, a suit
able container must be positioned to
collect the fluid.
Disposal of waste material
The disposal of waste materials,
including potentially harmful fluids, must
be in accordance with local Health and
Safety Regulations.
Improper disposal procedures can be
harmful to personnel and the environment.
Always use the correct and leakproof type
of container for the storage of waste fluids.
Do not dispose of these fluids by pouring
onto the ground, into water sources or into
drains. Improper disposal procedures can
be harmful to personnel and the
environment.
Asbestos hazards
Contact with asbestos must be
avoided, particularly inhalation of
airborne dust,which can cause serious
Injury or death.
If it becomes necessary to come into
contact with asbestos, you must use the
guidelines that follow:
Avoid creating dust if handling debris or
components that may contain asbestos,
such as brake pads and bands, liner
material, clutch plates and some gaskets.
Never use compressed air for
cleaning purposes.
Avoid machining or brushing materials
that may contain asbestos.
Before disposal, use a wet, damping
down method to concentrate material
dust and debris.
If possible, a vacuum cleaner fitted
with a high particle air filter (HEPA),
should be used to collect debris and dust.
Use exhaust ventilation on permanent
machining work.
Wear an approved respirator if there is no
other way to control any dust produced.
Always comply with the applicable
environmental regulations for the disposal
of asbestos.
Stay away from areas that may contain
airborne asbestos particles.
Always comply with the applicable rules
and regulations for the work place.
Use genuine Richard Western equipment,
components and parts, which are supplied
asbestos free.
GENERAL HAZARDS
Crushing or cutting prevention
Fire and Explosion prevention
Support equipment correctly before you
do any work or maintenance from
beneath that equipment.
If a Fire extinguisher is fitted , make sure
It is available and in a fully charged and
serviceable condition.
Unless instructed otherwise, never
attempt to do adjustments whilst the
machine is moving or the engine or
other power source is running.
Make sure you are fully aware of the
operating instructions for the fire
extinguisher.
Clearances in machine control
linkages will change with control
operation or machine movement.
Always keep clear of controls or areas
that may experience clearance changes.
Always keep clear of rotating or moving
parts of the machine.
Always re-install any guard or cover that
has temporarily removed.
When handling cables, always wear
protective gloves. Never use kinked or
frayed cables.
Striking any object can cause debris
chips to fly off, causing personal injury.
Always wear protective glasses/goggles
before striking an object and make sure
that the area is clear of other personnel.
If a retaining pin is struck with force, it
may be ejected and cause personal
injury. Always wear protective glasses/
goggles before striking a retaining pin
and make sure that the area is clear of
other personnel.
Burn prevention
Some components will get hot during
operation, causing a potential burn
hazard to personnel. Before you do
any maintenance on these parts, you
must:
Always allow these parts to fully cool
before you do any maintenance work.
Always release residual pressure in the
air, hydraulic and lubrication systems
and associated pipe lines/hoses, before
you do any maintenance work.
Hot fluids and surfaces can cause
personal injury. Avoid direct contact
with hot fluid or surfaces.
Inspect and service the fire extinguisher
at regular intervals or in accordance
with the manufacturers instructions.
All fuels, most lubricants and some
coolant mixtures are flammable and if
leaking onto a hot surface or electrical
components, can create a fire. Fire can
cause severe personal injury or death.
Do not operate the machine close a
naked flame or heat source.
Always clean pipes and thoroughly with
a non-flammable solvent first.
Examine all electrical wires daily and
check and tighten all electrical
connections. If necessary, repair loose
or frayed wires before you operate the
machine.
Dust produced from repairs to
Non-metallic components, such as
hoods or fenders, can be flammable.
Always repair such components in a well
ventilated area, away from naked flame
and heat sources.
Leaking pipes and hoses can cause a
fire. Examine all pipes, hoses and
associated supports for wear,
deterioration and damage and ensure
hat pipe and hose clamps are secure.
Make sure pipe and hose connections
are correctly torqued.
Remove all flammable materials such as
fuel, oil and debris from the machine. Do
not allow the accumulation of flammable
materials on or around the machine.
Always store fuels and lubricants in the
correct and properly marked containers
and away from unauthorised personnel.
General Safety : 3
General Safety
RICHARD WESTERN
Fire and Explosion prevention (contd)
Always store soiled oily rags and other
flammable materials in protective
containers.
Do not smoke in areas that are used
for the storage of flammable materials.
Do not operate the machine close to
naked flames.
Make sure that heat shields, installed
to prevent fluids or fluid spray from
igniting, are fitted correctly.
Do not weld or flame cut any pipes or
tanks that contain flammable fluids or
gases. Always clean such pipes and
tanks thoroughly with a non-flammable
solvent first.
Tyre hazards
An air inflated tyre can expand and
explode if excessive heat is applied
through welding, heating rim compo
nents, external fire or excessive use of
the brakes. An exploding tyre can eject
axle and wheel debris 500 m (1500 ft) or
more from the vehicle, causing damage
and possibly personal injury or death.
All personnel must be aware of the
hazards of overheating tyres.
An over-inflated tyre can blow out or
cause a rim failure. This can cause
damage or personal injury. Inflation of
tyres must only be done by trained
personnel.
When you inflate a tyre, you must stand
behind the tyre tread and use a selfattaching inflator.
Do not approach a warm or hot tyre.
Keep the minimum distances away
from the tyre and stay outside the
shaded areas (refer to illustration above).
Pipes, tubes and hoses
Leaks from loose or damaged pipes,
tubes or hoses can cause a system
failure or a fire. Examine pipes, tubes
and hoses regularly, particularly for
signs of damage, leaks or being loose.
Never use bare hands to check for leaks
from pipes, tubes or hoses.
Always use cardboard or a board and
if necessary, torque connections to the
recommended value.
Do not bend or strike high pressure
pipes or install a bent or damaged
high pressure pipe.
You must replace any pipe, tube or hose
if:
End fittings are damaged or leaking.
Outer coverings are chafed or cut.
Wires are exposed.
Outer covering is blistered or ballooning.
Flexible portion of a hose is kinked.
Outer covers have embedded armouring.
End fittings are damaged or displaced.
Clamps, guards and heat shields are
installed to prevent vibration, contact
between components and excessive
heat. Make sure that all clamps,
guards and heat shields are installed
correctly.
General Safety : 4
Maintenance on tyres and rims can be
hazardous. The use of incorrect
procedures can result in a tyre exploding.
An exploding tyre can eject axle and wheel
debris 500 m (1500 ft) or more from the
vehicle, causing damage and possibly
personal injury or death. Maintenance on
tyres and rims must be done only by
trained personnel, using the correct tools
and procedures. The tyre dealer or
manufacturers instructions must be
followed.
GENERAL HAZARDS
Mounting and dismounting
You must never attempt to mount,
dismount or jump from a machine that is
moving.
Always mount or dismount the machine
at the recognised locations, which have
steps and/or hand holds.
Make sure the steps and/or hand hold
are clean and examined regularly.
Make any necessary repairs.
When you mount or dismount the
machine, always keep a three -point
contact with the steps and hand holds.
Three-point contact can be two feet/one
hand or two hands/one foot.
When you mount or dismount the
machine, always face the machine and
never attempt to carry tools or supplies.
Tools and supplies should be raised or
lowered from the machine using a hand
line or other suitable method.
Before operating the machine
This machine must be operated only by
correctly trained and authorised
personnel. Certain local operating
conditions may require the machine
operator to obtain an operators licence
or a certificate.
The machine operator must be fully
aware of the machines capabilities and
limitations. The operator must also be
familiar with the local working area or
site and in particular:
Check the area for vertical and horizontal
clearances.
Check for overhead obstructions.
Check for electrical power lines and make
sure the machine keeps at least
8 m (25 ft) away.
Check the work area or site for changes
in the stability of the ground surface, back
filled trenches and structural integrity of
buildings, roofs etc.
Make sure that all protective guards and
covers are correctly installed on the
vehicle.
Make sure that if the machine is equipped
with a fully working lighting system that is
adequate for the working conditions, and is
compliant with local or national road traffic
regulations
Make sure that the machine reverse
alarm and other warning devices are in full
working order.
Make sure that all obstacles are cleared
from the intended path or route of the
machine.
Make sure that before the machine is
moved, there are no personnel on, under
or near the machine.
General Safety : 5
General Safety
RICHARD WESTERN
GENERAL HAZARDS
Collision of high speed road traffic and
slow moving machines can cause
personal injury or death. When on a
public road, use a flashing beacon and
other lights according to local laws.
Use a Slow Moving Vehicle (SMV)
emblem displayed at the rear of the
machine where this is a national
requirement. Pull over to let faster traffic
pass. Signal and slow down before
turning off the road.
Use warning devices (flags, SMV
emblem, lights, etc.) which are
approved for use by your local
government agencies, when using
equipment on public roads. Keep these
devices clean and in good working
order.
General Safety : 6
GENERAL SAFETY INSTRUCTIONS
5.
A risk of injury due to crushing exists in the
vicinity of the Towing vehicle 3-point linkage!
Check that the machine is roadworthy and safe to
operate every time it is put into operation!
6.
Couple and uncouple the machine to the
towing vehicle only as specified in the
instructions.
7.
The performance of the towing vehicle can
be influenced by the machine, ensure the
towing vehicle has sufficient steering and
braking capacity..
8.
Make sure no one is between the machine
and the towing vehicle unless both are
secured and prevented from moving.
9.
The travel speed must always be matched to
the under wheel conditions. Avoid sudden
turns and braking when driving up or down
hill or across a slope.
10.
Observe the maximum permissible axle
loads and total weights!
11.
Operate the machine only when all guards
are fitted and in the correct position!
12
Ensure that the machine is stable when
parked.
13.
Ensure all equipment is placed in the
transport position before driving on the road.
14.
Always switch off the engine of the towing
vehicle before carrying out troubleshooting,
and for repair, maintenance and cleaning
work. Remove the towing vehicle ignition
key.
15.
When working under raised covers ensure
that they are sufficiently supported.
16.
When handling sharp-edged parts, wear
appropriate protection (gloves, shoes etc.).
17 .
Do not stand near hinged covers.
1.
Observe the current regulations regarding
safety and accident prevention as well as the
information in the operator's manual.
2.
When using public roads observe all traffic
regulations.
3.
Make yourself familiar with all equipment and
controls and their functions before starting
work as it will be too late once you have set
off.
4.
Make sure that there is no one in close
proximity to the machine before putting it into
operation (Be especially aware of children!).
Check that visibility is good, particularly when
reversing (have someone direct you if
necessary).
5.
Clothing worn by the operator must be closefitting. Avoid wearing loose fitting clothing
when operating or maintaining the machine
6.
Keep the machine clean to prevent fire.
7
If it is necessary to access the machine, the
Engine of the towing vehicle must be
switched off. The ignition key of the towing
vehicle must be removed.
9.
Any safety guards must be checked regularly
for wear and replaced if necessary.
10.
Any safety decals that are missing must be
replaced immediately.
General
1.
Use only the recommended fastenings on
the machine!
2.
Do not exceed the maximum load on the
trailer drawbar
3.
Use extreme caution when coupling and
uncoupling the machine from the towing
vehicle to avoid risk of injury.
4.
During maintenance or after use prevent the
machine from rolling away by use of the
parking brake or wheel chocks.
General Safety : 7
General Safety
RICHARD WESTERN
GENERAL SAFETY INSTRUCTIONS contd
BRAKES
WHEELS AND TYRES
1.
Check the brakes before every journey.
1.
Repair work to the tyres must be carried out
by qualified technicians using suitable tools.
2.
Check the brake system thoroughly at
regular intervals.
2.
If the brake system malfunctions, do not use
the machine, stop the towing vehicle
immediately. Repair faults immediately.
When working on the wheels make sure that
the trailer is secured and that wheels are
chocked to prevent it from moving.
3.
Tighten the wheel nuts after the first trip with
a load.
4.
After replacing the wheels retighten the
wheel nuts or bolts after the first 10 operating
hours, then check them every 50 hours.
3.
4
Any adjustments and repairs to the brake
System must be carried out by your Richard
Western agent or approved specialist work
shop.
5
Engage a lower gear before going downhill.
5.
Make sure that the jack used has sufficient
load capacity.
6.
Engage the parking brake before coupling or
uncoupling the towing vehicle
6.
Avoid excessive inflation pressure.
7.
The specified tyre pressure must be
maintained.
8.
Stand clear of the tyre when inflating.
9.
Check the pressure regularly.
10.
Regularly check nuts and screws for
tightness and retighten them, if necessary.
11.
All mounting bolts and nuts must be
tightened to the torque specified by the
manufacturer.
7
The brakes must always be correctly
adjusted. No liability can be accepted for
normal wear or unauthorised modifications.
HYDRAULIC SYSTEM
1.
The hydraulic system is under high pressure!
2.
When connecting the hydraulic hoses to the
towing vehicle hydraulics, make sure that the
hydraulic systems are depressurised on the
tractor side and on the machine side.
4.
The female and male couplings between the
tractor and the machine should be labelled to
prevent incorrect connections. If connections
are reversed (e.g. lifting/lowering), there is a
risk of accident.
MAINTENANCE
1.
Always switch off the towing vehicle engine
before carrying out any troubleshooting, and
before all repair, maintenance and cleaning
work. Remove the ignition key!
5.
Keep the hydraulic plugs clean.
6.
Check hydraulic lines at regular intervals,
and replace them if they are damaged
2.
Use suitable tools and wear safety gloves
when replacing working parts!
7.
Any replaced hydraulic lines must meet the
technical requirements of the manufacturer!
3.
Always disconnect the power supply before
working on the electrical system!
10.
The towing vehicle engine must be switched
off and the system depressurised before
starting work on the hydraulic system.
4.
Protection devices that are subjected to wear
must be checked at regular intervals
and replaced as necessary.
11.
Repair work on the hydraulic system must be
carried out by approved specialised work
shops only.
General Safety : 8
Specifications
INTRODUCTION
This section contains tables covering the general
specification of the machine , dimensions ,
weights and capacities.
All information given is subject to alteration
without notice and is subject to manufacturing
tolerances.
If in doubt contact the manufacturer or the
manufacturers agent for further information or
advice.
A number of factors may cause the overall
dimensions to change EG Tyre pressures ,etc
Always check actual dimensions before
entering confined areas buildings and vehicles.
Specifications: 1
Specifications
RICHARD WESTERN
General Specification
Model
Delilah
FBS
SDS
Electric System
Voltage
V
12 V DC
12 V DC
12 V DC
Current (cont)
A
10 A
10 A
10 A
Current (max)
A
15 A
15 A
15 A
Braking System
Single line hydraulic brakes
Standard
Option
1
Eurosafe (TM) Hydraulic Failsafe with Load Sensing & ABS options
2
Dual line airbrakes
Speed
kmh
32
32
32
1
kmh
32
32
32
2
kmh
Max towing vehicle
speed
Max towing vehicle
speed
Max towing vehicle
speed
As towing vehicle
As towing vehicle
As towing vehicle
Standard braking system
Option
Hydraulic System
Supply
Hyd working pressure
bar
As towing vehicle
As towing vehicle
As towing vehicle
Max hydraulic pressure
bar
200
200
200
Max hydraulic flowrate
l/min
75
75
75
Noise
dB(A)
< 70
< 70
< 70
Overview : 2
Data
Delilah
Model
Dimensions
Width (Overall)
Height (Overall)
Length (Overall)
Body Length
Loading Height
Body Depth
Body Width
Capacities
Capacity
Weights
Unladen Weight
Misc
A
B
C
D
E
F
D7c
D8
D10
D12
D18T
m
m
m
m
m
m
m
2.53
2.73
6.31
3.41
1.97
0.90
1.49
2.76
2.91
6.28
3.61
2.30
1.24
1.50
2.87
2.99
7.28
4.61
2.40
1.24
1.50
2.87
2.99
8.28
5.61
2.40
1.24
1.50
3.10
3.30
9.50
7.07
2.96
1.24
1.50
m3
4.80
7.15
9.18
11.22
18.30
4895
5530
5825
6250
kg
Floor Chains
mm
2 X 16
4 X 14
4 X 14
4 X 14
4 X 16
PTO Speed
r/min
1000
1000
1000
1000
1000
Rotor Speed
r/min
420
420
420
420
420
24 X 2
30 X 2
30 X 2
30 X 2
30 X 2
1
1
1
1
1
Rotor Tips
Number of Axles
Specifications: 3
Specifications
RICHARD WESTERN
FBS Manure Spreaders
Model
Dimensions
Width (Overall)
Height (Overall)
Length (Overall)
Body Length
Loading Height
Body Depth
Body Width
Capacities
Capacity
Weights
Unladen Weight
Misc
A
B
C
D
E
F
FBS12
FBS16
FBS20
m
m
m
m
m
m
m
2.50
3.52
7.64
4.68
2.59
1.20
2.00
2.50
3.52
8.45
5.49
2.59
1.20
2.00
2.50
3.52
10.59
7.63
2.59
2.00
1.50
m3
12.00
14.00
19.00
kg
6250
6750
7250
4 X 14
4 X 14
4 X 16
Floor Chains
PTO Speed
r/min
1000
1000
1000
Rotor Speed
r/min
420
420
420
24 X 2
24 X 2
24 X 2
2
2
3
Rotor Tips
Number of Axles
Specifications : 4
Specifications
RICHARD WESTERN
SDS Manure Spreaders
Model
Dimensions
Width (Overall)
Height (Overall)
Length (Overall)
Body Length
Loading Height
Body Width
Capacities
Capacity
Weights
Unladen Weight
Misc
PTO Speed
Number of Axles
A
B
C
D
E
SDS 1600
SDS 2000
SDS 2400
SDS 24T
m
m
m
m
m
m
2.39
2.57
5.30
3.72
2.42
2.12
2.68
2.87
6.12
4.54
2.71
2.12
2.68
2.87
7.26
5.68
2.71
2.12
2.39
2.75
7.26
5.68
2.60
2.12
l
7264
9080
10896
10896
kg
4500
5125
5750
6000
r/min
540
540
540
540
1
1
1
2
Specifications: 5
Axles & Tyres
Delilah
D7c
D8
D10
D12
D18T
mm
100
10
127
10
127
10
150
10
150
10
mm
400X80
Axles
Axle Beam
Axle Studs
Brakes
Brake Drum
420X180
Tyres &Rims
Tyre Size
16.9X34
FBS
18.4X34
650/75 X 32
FBS 12
FBS 16
FBS 20
100
127
127
10
10
10
650/75
X32+B20
Axles
Axle Beam
mm
Axle Studs
Brakes
Brake Drum
400X80
420X180 420X180
Tyre Size
20.5 X 22.5
560/60 X 22.5
SDS
SDS 1600 SDS 2000
mm
Tyres &Rims
SDS 2400
SDS 24T
Axles
Axle Beam
Axle Studs
mm
127
10
127
10
127
10
100
10
mm
420X180
420X180
420X180
400X80
Brakes
Brake Drum
Tyres &Rims
Tyre Size
Specifications : 6
23.1X26
600/65X23
560/60X22.5
RICHARD WESTERN
Transportation &
Handling
Richard Western Trailers are generally
delivered ready for use.
However in some circumstances it is necessary to
remove certain components for shipment and/or
storage, these will need to be fitted before use.
General instructions for the fitting of these
components are given in the following pages, for
further information refer to your Richard Western
agent.
Assembling the machine should only be
undertaken by a competent person. If in
doubt about any procedure refer to the
manufacturer or the manufacturers
agent for further information.
When working on the machine always
ensure that the Towing vehicle engine is
turned off and the Key removed.
Section 1: 1
1
PTO Driveshaft
The PTO Driveshaft is supplied loose with the
machine. Ensure it is removed before use.
Section 1 : 2
RICHARD WESTERN
Before Operation
When working on the machine always
ensure that the Towing vehicle engine is
turned off and the Key removed.
Dirty Quick release couplings can cause
increased wear in Hydraulic pumps and
Air Compressors. Incorrectly connected
couplings can cause failure within the
system. Always clean the couplings
before connecting them
BEFORE OPERATION CHECK THE FOLLOWING
1
The towing vehicle must be equipped for
operation hydraulically with at least one feed
and one free flow return.
2
Trailer Braking System
The machines can be fitted with one of the two
different types of brake systems (this may
differ and be dependant on locally or nationally
enforced traffic regulations
– Air brake system (dual-circuit system)
– Hydraulically operated brake system.
The towing vehicle brake system must be the
same as that of the machine
Machines to be towed at speeds above
32 km/h (20 mph) are to be equipped
with an ABS air brake system.
3
Check the brakes before every journey.
4
Check safety equipment for function and
correct position.
5
Thoroughly lubricate the machine before
operation.
6
Check all Bolts and Nuts are tight.
7
Couple the towing vehicle to the trailer at
idle speed only.
8
Before connecting Air and Hydraulic lines
turn off the engine of the towing vehicle and
ensure the connections are clean.
Section 2: 1
2
Section 2 : 2
9
Check the wheel nuts for tightness
(see Specification section)
10
Check tyres for correct inflation pressures.
Correct if necessary
(see Specification section)
11
If a wheel is changed check the wheel nut
torques after 10 hrs of operation, and every
10 hours until the torque is maintained.
(see Specification section)
12
Wheels must be changed using a jack with
sufficient lifting capacity for the weight of the
machine.
13
Make sure that there are no loose parts on
the machine and the towing vehicle before
moving off. Secure or cover parts which
could fall off during travel.
14
Make sure no persons are in the danger
areas before moving off or raising the body.
If any person approaches the danger areas
turn off the Towing vehicles engine
immediately and make safe.
15
When connecting the Air, Electric and
hydraulic lines to the Towing vehicle, ensure
they are fixed in a way which allows their full
articulation as the machine steers.
16
Ensure the Air, Electric and hydraulic lines
cannot be trapped or chaffed by moving
parts during operation.
RICHARD WESTERN
Coupling to the Towing Vehicle - Hitch
Reverse the towing vehicle until the tow hitch (1) is
located beneath the Eye (2)
2
Raise the tow hitch (1) and lock into the raised
position.
Uncoupling from the Towing Vehicle - Hitch
Ensure the tipping body is lowered fully.
Ensure the drawbar is in the tow position.
1
Lower the trailer onto the drawbar foot or Skid
Decouple all hoses and electrical connections.
Apply the parking brake.
Unhitch the trailer.
Ensure all personnel are outside of the
danger area between the Towing Vehicle
and Trailer before reversing
Check that the trailer is properly and
securely attached to the Towing Vehicle
before moving off
Always park the trailer on firm level
ground
Check the Eye periodically for signs of
damage or wear. Replace as required
Section 2: 3
2
Coupling to the Towing Vehicle
Air Braking Connections
1
Connect Seven Pin Trailer Electric connector (1) to
towing vehicle trailer lighting socket.
Connect Yellow Control Line Braking Connector (2)
to the relevant connection on the Towing Vehicle
Connect Red Air Service Line Braking Connector
(3) to the relevant connection on the Towing
Vehicle
Always connect the Yellow line first when
coupling and Disconnect the Red line first when
uncoupling.
Note! The trailer will also be equipped
with the standard hydraulic brake
connections, it is not necessary to
connect these when the Air service is
used.
2
When working in the danger area
between the trailer and the Towing
Vehicle always ensure that the Towing
vehicle engine is turned off and the Key
removed.
When working in the danger area
between the trailer and the Towing
Vehicle always ensure that the hydraulic
and Pneumatic controls are in Neutral.
3
Release residual Pneumatic & Hydraulic
pressure before connecting or
disconnecting Air & Hydraulic lines.
Ensure all personnel are outside of the
danger area between the Towing Vehicle
and Trailer before reversing.
Check that the trailer is properly and
securely attached to the Towing Vehicle
before moving off.
Check the Ring Hitch periodically for
signs of damage or wear. Replace as
required.
Dirty Quick release couplings can cause
increased wear in Hydraulic pumps and
Air Compressors. Incorrectly connected
couplings can cause failure within the
system. Always clean the couplings
before connecting them.
When coupling to a tractor connect the
Yellow line first when connecting and
remove the Red line first when
disconnecting.
Section 2 : 4
RICHARD WESTERN
4
2
Coupling to the Towing Vehicle
Hydraulic Braking Connections
For trailers that are equipped with Hydraulic Brakes
connect the Hydraulic Service Line (4) to the
correct connection on the Towing vehicle.
Note! The trailer will also be equipped with the
standard hydraulic brake connections, it is not
necessary to connect these when the Air service is
used.
Note! The trailer will also be equipped
with the Optional Air brake
connections, it is not necessary to
connect these when the Hydraulic
service is used.
ABS Brake Connections
Some trailers are fitted with ABS braking, if
applicable connect the ABS system plug to the
relevant socket on the towing vehicle.
For connection information see page 5:7
Illo
Coupling to the Towing Vehicle
Steering Axle Connections
Some trailers are fitted with a self steering axle, this
allows easier turning with less damage to tyres and
to the road surface.
A Dual hydraulic connection from the towing
vehicle is used for this.
When travelling forwards the spool valve should be
moved to Power Cylinders this allows the pressure
in the cylinders to be released , and the steering
axle will follow the lead axle.
When reversing the trailer the spool position must
be moved to extend the cylinders. The trailer
wheels will then stay in line.
Section 2: 5
Coupling to the Towing Vehicle
Hydraulic Connections
1
2
Connect the Hydraulic floor drive (Delilah & FBS
models) service lines (1) and (2) to a spool valve
connection on the towing vehicle
3
Connect Hydraulic slurry gate (Optional ) service
lines (3) and (4) to double acting spool valve
connections on the towing vehicle
Coupling to the Towing Vehicle
Lighting Connections
5
Connect the electrical seven pin connector (5) to the
vehicle lighting socket
When working in the danger area
between the trailer and the Towing
Vehicle always ensure that the Towing
vehicle engine is turned off and the Key
removed.
When working in the danger area
between the trailer and the Towing
Vehicle always ensure that the hydraulic
and Pneumatic controls are in Neutral
and that the Control Panel switch is off
Release residual Pneumatic & Hydraulic
pressure before connecting or
disconnecting Air & Hydraulic lines.
Section 2 : 6
RICHARD WESTERN
Coupling the Drive shaft to the Towing Vehicle
Ensure the Tractor and Trailer PTO shafts are
clean and suitably greased.
Ensure the driveshaft is of the correct length
(Refer to the driveshaft manufacturers
documentation for further information)
Ensure the correct orientation of the driveshaft (IE
The tractor symbol on the guard indicates the
Tractor end connection).
Slide back the guard sleeve and slide the shaft onto
the trailer PTO , then repeat and fit to the Towing
vehicle PTO.
Fit safety chains where applicable
When not in use remove the driveshaft from the
machine.
For normal operation the skid should be moved to
its stowed position at the rear of the drawbar.
The correct skid must always be used when
parking the machine.
Adjusting Sprung Drawbar Height
3
The trailer chassis should run level when
connected to the towing vehicle.
Remove any load from the trailer, lower the body
apply the parking brake and disconnect from the
Towing Vehicle.
1
2
Support the front of the trailer chassis on suitable
supports and remove all weight from the drawbar.
Using a suitable jack under the front of the
drawbar , take the load and remove the Pin (1).
Using the jack raise or lower the drawbar to the
required height.
Insert the Pin (1) in the Lower hole (2) to increase
the drawbar height , or in the Upper hole (3) to
reduce it.
Remove jack and supports and check operation.
Never work beneath any unsupported
vehicle
Section 2: 7
2
Adjustments before Towing the Trailer
A
Adjust the drawbar and/or the hitch of the towing vehicle so that when towing the Spreader body is
parallel to the road surface.
B
Hitching too high will cause unnecessary wear to the suspension and brake components of the rear axle,
and reduce the braking efficiency. It can also cause stability problems for the Spreader and towing vehicle
C
Hitching too low will cause unnecessary wear to the suspension and brake components of the front axle,
and reduce the braking efficiency. It can also cause additional loading to be placed on the towing
vehicle, possibly causing damage to rear axle and brake components.
Section 2 : 8
RICHARD WESTERN
3
Operation
Never exceed the trailers maximum
permitted capacity as stated on the
manufacturers plate
Dirty Quick release couplings can cause
increased wear in Hydraulic pumps and
Air Compressors. Incorrectly connected
couplings can cause failure within the
system. Always clean the couplings
before connecting them
Section 3: 1
Loading the Trailer
The capacity of the trailer is shown on the
Manufacturers plate on the chassis.
Do not overload the trailer
Always load by weight not volume.
Loading Method
a
Commence loading the Spreader from the rear of
the machine and progress towards the front..
Avoid packing the material down into the body with
the loader bucket., this will minimise the start up
power requirements
For Deliliah and FBS models do not load higher
than the beaters. (a)
Moving Off
Ensure all Hydraulic connections are made and that
services are functioning correctly
Ensure all Air connections are made and that the
brakes are functioning correctly
Ensure all electrical connections are made and that
all lighting systems and the Eurosafe braking
(option) are functioning correctly.
1
When the Air Braking system is fitted allow air
pressure from the towing vehicle to build to the
required level.
Release the manual Parking brake lever (1).
If only using the hydraulic brakes or when shunting
the trailer push the Air release valve (2) before
moving off.
Check all around the trailer before
moving away, especially in confined
areas and when reversing.
2
Section 3 : 2
Be especially careful when reversing,
use a banksman if visibility is limited.
RICHARD WESTERN
Spreading (Delilah & FBS Models)
The Beaters are driven directly by the towing
vehicles Power Take Off.
The maximum spreading width is approximately
4 Meters (dependant on material density), this will
be achieved with an appropriately powered Towing
vehicle driving the PTO at 1000 rev/min.
Allow the beaters to reach full operating speed
before engaging the floor drive.
The floor drive is operated by an appropriately
configured double acting spool on the Towing
Vehicle.
Ensure the spool valve is connected so
the floor moves towards the beaters
before spreading . Failure to do this will
result in severe damage to the machine.
The floor drive speed should be adjusted by the in
line spool valve to provide a suitable flow of material
to the beaters. Overfeeding the beaters may lead to
premature damage of the floor and beaters, aswell
as increasing fuel consumption.
Spread Density
Variation of spreading density is controlled by
varying the floor speed of the spreader and varying
the forward speed of the towing vehicle.
Experience with the machine and different loads will
ensure an equal spread pattern can be achieved.
Operators should take account of varying ground and
weather conditions and for example work with the
wind when spreading rather than against it.
Slurry Gate
A gate controlled by a double acting spool on the
Towing Vehicle can be supplied as option. The
purpose of the gate is to hold semi solid material in
the hopper and to limit the flow of material to the
beaters.
This is essential when the material being spread is a
semi solid slurry and light material such as poultry
litter.
Using the gate will allow the fine control of material
flow so that the a very fine spread can be achieved,
however the gate should be fully opened spreading
heavier materials.
Ensure the Slurry gate is raised to the
required height before engaging the floor
drive..
Failure to do this will result in severe
damage to the machine
Section 3: 3
3
Spreading (SDS Models)
The Auger and side discharge rotors are driven
mechanically from the Towing vehicle PTO
The maximum spreading pattern is approximately
16 Meters (dependant on material density), this will
be achieved with an appropriately powered Towing
vehicle driving the PTO at 540 rev/min.
When commencing spreading the Slurry door should
be opened as the PTO is engaged. The PTO should
not be engaged whilst the door is closed.
After use and when turning on the headland the door
should be closed and the PTO disengaged.
Leaving the door open and the PTO disengaged may
lead to blocking of the spreading rotor.
When restarting this will place additional loads on the
rotor and may lead to breakage of the shear bolts.
Spread Density
Variation of spreading density is best controlled by
varying the forward speed of the towing vehicle.
Experience with the machine and different loads will
ensure an equal spread pattern can be achieved.
Operators should take account of varying ground and
weather conditions and for example work with the
wind when spreading rather than against it.
Slurry Gate
A gate controlled by a double acting spool on the
Towing Vehicle Seals the Hopper and can be used to
meter light material to the rotors.
This is essential when the material being spread is a
semi solid slurry and light material such as poultry
litter.
Using the gate will allow the fine control of material
flow so that the a very fine spread can be achieved.
The gate should be fully opened when spreading
heavy material.
Section 3 : 4
RICHARD WESTERN
Unblocking the spreader (Delilah & FBS Models)
In the event of a blockage the floor direction can be
reversed momentarily by using the appropriate
double acting spool of the towing vehicle.
Never attempt spread whilst in this configuration, as
serious damage will occur.
Return the floor direction to the correct direction
when the blockage has been cleared.
Unblocking the spreader (SDS Models)
In the event of a blockage the auger direction can be
reversed
Stop the towing vehicle and turn off the engine.
Remove the PTO drive shaft from the Spreader.
Remove the Guard (1) and turn it to expose the
offset drive input. (2)
1
Replace the PTO Driveshaft
Start the machine and run the spreader, the auger
will now turn in reverse to clear the blockage.
2
Only run the auger in reverse for a short
period of time as it could result in
damage to the machine.
Never operate the machine whilst stood
in the vicinity of rotating shafts or with
the guards removed.
If the above procedure does not remove the
blockage it may be necessary to intervene manually.
Fully open the Slurry gate and block in the raised
position.
Stop the machine and turn off the engine.
Open the Hydraulic Stone trap to allow access to the
blockage .
The stone trap is fitted to the Left side of the machine
and is designed to catch larger stones and solids.
During use this should be opened at least twice a
day to allow any accumulation to clear.
Section 3: 5
3
Troubleshooting
Problem
Possible Cause
Towing Vehicle Stalls
Excessive material packed into body
Foreign Body jamming Auger / Beaters
Shear Bolts broken
Insufficient power from Towing vehicle PTO
Auger / Beaters Fail to Start
Excessive material packed into body
Foreign Body jamming Auger / Beaters
Shear Bolts broken
Incorrect PTO speed
PTO Clutch incorrectly adjusted
Material Not Shredded properly
Floor advance too fast
PTO speed too low
Insufficient power from Towing vehicle PTO
Floor Fails to move
Spool Valve incorrectly adjusted
Hydraulic Hoses incorrectly fitted to rear of Towing
Vehicle
Driveshaft Shear Bolts
The PTO Driveshafts are equipped with shear bolts
which will fail and cut the drive in the event of a
severe blockage, and therefore prevent mechanical
damage.
1
Spare Shear bolts (1) are provided, conveniently
located adjacent to the Drive input.
Always replace shear bolts after use.
On SDS machines additional shear bolts are
located under the front cover.
All Shear bolts are Grade 8.8. Higher grade bolts
must not be used if severe damage to the machine
is to be prevented.
Section 3 : 6
RICHARD WESTERN
3
Load and travel on Level Ground as far as practical. Avoid Traversing slopes
Always load on firm Ground, avoid trenches and submerged services
Section 3: 7
THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK
RICHARD WESTERN
Maintenance &
Service Schedules
The service and maintenance schedule must be
adhered to ensure the optimum availability and
efficiency of the machine is maintained.
Failure to adhere to these schedules may cause
damage to the machine and possibly endanger the
operator and others.
The warranty given for the machine will become
void if the maintenance schedule is not followed.
Ensure all personnel are outside of the
danger area between the Towing Vehicle
and Trailer before use.
When working in the danger area
between the trailer and the Towing
Vehicle always ensure that the Towing
vehicle engine is turned off and the Key
removed.
When working in the danger area
between the trailer and the Towing
Vehicle always ensure that the hydraulic
and Pneumatic controls are in Neutral
and that the Control Panel switch is off.
Ensure the control panel or Joystick
power is in the off position before
maintaining the machine.
Ensure the Cylinder locks are installed
before working under the raised bed.
Wear the correct personal protective
clothing. The brake linings may contain
asbestos, a respirator should be worn
whilst handling brake components.
Ensure tyre pressures are correct.
Incorrect tyre pressures can cause
stability and handling problems for the
trailer and Towing vehicle
Release residual Pneumatic & Hydraulic
pressure before connecting or
disconnecting Air & Hydraulic lines.
Ensure that decals are clearly visible.
Replace damaged or missing decals
immediately.
Carry out all maintenance at the correct
intervals and in accordance with the
instructions in this manual.
Section 4: 1
4
Delilah
Manure Spreaders
FBS
Manure Spreaders
SDS
Manure Spreaders
Service Schedule
Inspect for damage due to the load or loading machine
□
□
□
Check Brake operation
□
□
□
Check Park brake operation
□
□
□
Drain Water from Air reservoir (if fitted)
■
■
■
Grease Rocking Beam Pivots (if fitted)
■
■
■
Grease Floor chain Tensioner Bearings
■
Grease Drive Shaft support bearings
■
Grease Floor drive shaft bearings
■
Grease Rotor Top Bearings
■
Check Floor Drive Gearbox Oil level
■
Check Rotor gearbox Oil level
■
Grease PTO Shaft
■
■
■
■
□
Perform task
Check
Maintenance Task
Daily
Grease Rotor PTO Shaft
■
Grease Main Rotor Bearings
■
Grease Chain Drives
■
Grease Rear Thrust bearing
■
Grease All Support Bearings
■
Section 4 : 2
RICHARD WESTERN
FBS
Manure Spreaders
SDS
Manure Spreaders
Delilah
Manure Spreaders
4
□
□
□
□
□
□
□
□
□
■
□
■
□
□
□
□
□
□
□
□
□
■
□
■
□
□
□
□
□
□
□
□
□
■
□
■
■
■
■
■
■
Weekly
Check Lights
Check Wheel nut torque
Check for Oil leaks
Check Hydraulic hose condition
Check air line condition
Check connections to Towing Vehicle
Check Towing Eye condition
Check Tyre Pressures
Check Tyre condition
Grease all nipples on running gear
Inspect the machine for loose Nuts and Bolts
Adjust Floor Chain Tension
Every Month
Lubricate PTO
Every 3 Months
Check Brake clearance & wear
Adjust Brakes
Section 4: 3
FBS
Manure Spreaders
SDS
Manure Spreaders
Delilah
Manure Spreaders
Service Schedule contd
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
Every 6 Months
Check the Axle Hubcaps
Check Wheel bearing wear
Tighten All Suspension U-Bolts
Tighten All Spring Drawbar U-Bolts
Every Year
Check Suspension
Every 2 Years
Lubricate Wheel Bearings
Laying Up Protection
Protect all Electrical Connections
Clean down machine
Repaint any areas where paint has been removed
Replace worn or damaged parts
Replace missing or damaged decals
Grease all bright parts
Cover ends of all Quick release connectors
Section 4 : 4
RICHARD WESTERN
SDS
Manure Spreaders
additional requirements
FBS
Manure Spreaders
Delilah
Manure Spreaders
ABS Brakes
□
■
□
■
□
■
□
□
■
□
□
■
□
□
■
■
■
■
□
□
□
Every 3 Months
Check all system components for signs of damage
Test whole system for air leakage
Every Year
Check Electrical wiring for damage
Check piping for damage & security)
Check Sensor for Wear & Readjust as required
Every 2 Years
Replace Modulator & Solenoid
When Hubs removed
Check and readjust Exciter & Sensor
Section 4: 5
4
Lubrication Points
(Deliilah & FBS Types)
Every 8 hrs or daily unless specified
9
7
13
1
4
8
2
3
6
5
10
1
Remove Cover and grease Chain Tensioner Pivots
and Jockey wheel bearings (4 Off)
Section 4 : 6
2
Grease Parking Brake Mechanism
RICHARD WESTERN
4
3
Grease Suspension & Rocking Beam Pivots
(Tandem Axle Machines)
5
Grease Drive shaft Support Bearings
7
Grease Floor Drive Gearbox Centre Shaft
4
Grease Drive shaft Support Bearings
6
Grease Drive shaft Support Bearings
8
Grease Floor Drive Shaft bearings (2 off)
Section 4: 7
9
Grease Rotor Top Nipples (2 off)
11
Check Floor Drive Gearbox oil level & top up as
required
13
Grease Light cluster pivots
Section 4 : 8
10
Grease Brake Actuators (Weekly)
12
Check Rotor Drive Gearbox oil level & top up as
required
RICHARD WESTERN
4
Power Take Off
Ensure the tubes are well greased and free from
debris before coupling
Regularly lubricate and check the movement of the
spring couplings at both ends of the shaft
Grease the Joints daily and before laying up the
machine for extended periods
Clean the guards and grease the bearings regularly
especially in arduous conditions
Avoid use at extreme angles, declutch on turning.
20Hrs
Daily
20Hrs
Daily
20Hrs
Section 4: 9
Service Checks
1
5
2
1
Check All Air and Hydraulic Lines for signs of Damage
Check Connections to Towing Vehicle
Section 4 : 10
4
3
2
Check the condition of the Towing eye for signs of
wear or damage
RICHARD WESTERN
4
3
Check Wheel Nut Torque
4
Check Tyre Pressure & Tyre condition
5
Adjust Floor chains. To give equal tension on each
chain.
When lifted in the centre of the body there should
approx. 100mm free play.
Section 4: 11
Lubrication Points
(SDS Types)
Every 8 hrs or daily unless specified
5
4
3
1
2
6
5
6
1
Grease PTO Support Bearings
Section 4 : 12
22
Grease Rotor PTO shaft
RICHARD WESTERN
4
3
4
Grease All support bearings
4a
Grease Chain Drives
4b
Grease All support bearings
Grease All support bearings
5
Grease Mainshaft support bearings Front and Rear
Section 4: 13
THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK
RICHARD WESTERN
4
Service Checks
5
1
6
2
3
4
1
Check All Air and Hydraulic Lines for signs of Damage
Check Connections to Towing Vehicle
2
Check the condition of the Towing eye for signs of
wear or damage
Section 4: 15
3
Check Wheel Nut Torque
5
Check Lights & Reflectors for Correct operation &
Damage
4
Check Tyre Pressure & Tyre condition
6
Replace the rotor blades when they become worn to
prevent damage to auger See procedure below.
Rotor Blade Replacement
Remove all of the old blades from the machine.
It is important to maintain the rotors balance and
clearance when replacing blades.
Start from the bottom of the flighting and work
upwards.
All blades should be placed on top of the flighting.
Note the leading edge of the flight is plain and the
trailing edge is chamfered.
If using mixed flails (IE Straight and Twisted), like flails
should be fitted opposing each other on the rotor to
maintain balance.
Always use new nuts and bolts
Section 4 : 16
RICHARD WESTERN
Axles Brakes &
Suspension
This section contains information that must be
followed to ensure the correct functioning of the
axles and wheel brakes.
If in doubt contact the manufacturer or the
manufacturers agent for further information or
advice.
Failure to adhere to these instructions may
affect the performance of the brakes and
axles and could therefore lead to injury
For additional Information refer to the
manufacturers documentation
Section 4: 17
4
TIGHTENING WHEEL NUTS
Before Use
After Refitting
Every 6 Months
On wheels that have been replaced or refitted, the
nuts can loosen after short periods of operation.
It is therefore necessary to check the tightness of the
nuts after the first loaded run, after refitting and again
after approx 1000 km (620 Miles)
Do not use Impact Tools to tighten the Wheel
Nuts
To tighten the nuts, to use a suitable wheel brace,
and tighten the progressively and diagonally.
Check the torque using a Torque Wrench, or if not
available use a suitable spring balance and refer to
the table above.
DO NOT OVERTIGHTEN
Various Wheel Nut and Stud combinations
may be used. Always select the correct Nut
Type from the table before checking Wheel
Nut Tightness.
Section 4 : 18
RICHARD WESTERN
4
CHECKING THE HUBCAPS
Every 6 Months
1
Missing or damaged hubcaps must be replaced
immediately to avoid dirt penetrating into the hub
which might result in damage to the bearings.
Check that the hub caps (1) are in place and in
perfect condition.
For press fit hubcaps, check visually that they are
fully home.
For hubcaps attached using screws, fit a new gasket
if necessary when the hubcap is removed and
retighten the screws regularly
CHECKING THE WHEEL BEARING PLAY
Every 6 Months
.
Wheel bearings are subject to wear: their lifetime
depends on the operating conditions, the load, the
speed, the adjustment and lubrication, etc.
To check the wheel bearings:
Use a suitable Jack and lift the wheel off the
ground.
Turn the wheel in both directions slowly to
check for any rough points or friction.
Turn the wheel at high speed to check for
unusual noises, such as grating or knocking.
If the bearing is damaged or worn, the bearing
and seals should all be replaced
It is advisable to Check Hub Caps and Wheel
bearing play after the first 1000km (620
miles)
Section 4: 19
LUBRICATING THE WHEEL BEARINGS
Every 2 Years
In normal operating conditions, lubricate the bearings every 2 years or every 50,000 km and when the brake
shoes are replaced.
In harsh conditions the bearings should be lubricated more frequently.
Use a general purpose EP grease formulated for lubricating plain, ball and roller bearings, subject to heavy
loads and impacts typical of HGV, agricultural vehicle hubs, etc.
All parts (hub, spindle, bearings, seals, castle nuts, hubcap, cotter pin) should be degreased and
Perfectly clean before reassembly.
The work should be carried out in a clean environment with appropriate tools as the slightest bit of dirt can
Damage the bearings or even the spindle.
When carrying out maintenance on the bearings, check the brake linings, drum and return springs, clean the
brakes,clean and lubricate the brake cam shaft.
Section 4 : 20
RICHARD WESTERN
4
METHOD - DISASSEMBLY
Slacken the wheel nuts.(12) Lift the axle until the wheel is off the ground, and remove the wheel
Ensure the trailer cannot move by chocking the remaining wheels or suitably supporting the trailer.
Release the brakes
Remove the hubcap (11) and Gasket (10). Remove the split pin or pin (9) from the spindle and remove the
castle nut.(8)
Remove the drum/hub assembly.(5) using a hub puller if necessary: the outer ring, the grease retaining
plates inside the hub (depending on the model), the small bearing cone and cage come away with the hub.
The bearing cups and grease retaining plates can be left inside the hub for cleaning.
Remove the large bearing cage and cone (3) from the spindle (1) using a bearing puller if necessary.
Check the oil seal (2) between the spindle and the large bearing (or the wheel bearing seal depending on the
model), and replace these parts if necessary. A puller may be required to remove the wheel bearing seal.
Note the orientation of the oil seal for reassembly.
Check the contact surfaces on the spindle for the bearing and seal and the threaded end of the spindle and
remove any bumps or scratches.
Check the hub surfaces and the bearing face of the castle nut in the same way.
Clean and degrease all parts with a suitable cleaning fluid.
REASSEMBLY & LUBRICATION
Grease the spindle lightly.
Refit the oil seal or wheel bearing seal (2) ensure that the seal is the right way round), use a tube of the
correct size to fit the wheel bearing seal to avoid damaging the seal.
Apply a generous coating of grease to the large bearing cage and rollers (3), making sure that the grease
penetrates all round the rollers and under the cage. Fit Bearing Cone of the large bearing onto the spindle (1),
take care not to damage the cage of the bearing, use a tube of the correct size to tap the bearing onto the
spindle.
Apply a 15 - 20 mm layer of grease all around the large and small bearing cups that are still in the hub (5).
If the hub does not have grease retaining plates (2 & 6), put a large amount of grease in the centre of the hub
to act as a reservoir.
Slide the hub/drum (5) assembly over the spindle and the brake shoes keeping the hub perfectly straight and
aligned until it is in contact with the oil seal at the back of the spindle.
Apply a generous layer of grease to the small bearing cage and rollers (7) and fit the assembly to the spindle.
Tighten the castle nut (8) (right-hand thread) to take up the internal play (the roller bearings should then be
firmly held between the hub seatings). Rotate the hub whilst tapping it gently with a mallet
Slacken the castle nut until there is no longer any friction between the castle nut and the outer bearing and the
hole for the pin is aligned with a notch in the castle nut. Check that the hub rotates freely.
Lock the castle nut with a new split cotter pin as appropriate.
For hubs without grease retaining plates, fill the hubcap with grease, then refit the Hubcap (12) and
Gasket (11)
Section 4: 21
BRAKE MAINTENANCE & ADJUSTMENT
Initial checks
The brakes should be tested before using for the first time and after the first laden journey:
Check the actuator and return spring mountings, check the actuator stroke and return travel and check that
the road and parking brakes operate and release correctly.
Tighten the screws and nuts (covers, fulcrum, etc), check the cotter pins, pins, circlips, etc.
Check for hydraulic fluid and air leaks.
Checking brake clearance and wear
Every 3 Months
Check and test the brakes before intensive use
and every 3 months:
Check the brake wear and the clearance between
the brake linings and the drum visually.
It is probable that the linings are worn when the
actuator travel has increased significantly.
Check the thickness of the brake linings
(See table opposite)
The brake shoes should be replaced as soon
as the minimum lining thickness is reached.
Check that the brakes are clean and clean them if
necessary.
Section 4 : 22
RICHARD WESTERN
4
ADJUSTING BRAKES (WITH FIXED LEVERS)
Every 3 Months
Take up the slack when the actuator stroke reaches about two thirds of the maximum travel.
To adjust, turn the lever by one or more splines, ensuring that the brakes are not touching when released
(to prevent overheating the brakes).
Never change the linkage position for the
actuator on the lever. Always use the
original hole
For braking systems which use a yoke, the yoke
must remain parallel with the axle especially when
the brakes are fully applied
This means that the stroke of the levers on the
brakes at each side must be identical. Otherwise, the
brake slack must be adjusted.
ADJUSTING BRAKES (WITH ADJUSTABLE LEVERS)
Every 3 Months
Take up the slack when the actuator stroke reaches about two thirds of the maximum stroke
To take up the slack, turn the adjustment screw on
the lever to adjust the relative position of the cam
and the lever
NB. The actuator brakes by pushing the
lever to turn it in a particular direction. The
screw must be adjusted so that the cam
moves in this direction to take up the slack.
The direction in which the screw must be
turned depends on the configuration of the
axle.
Never change the linkage position for the
actuator on the lever. Always use the
original hole
Ensure that the brakes are not touching when
released (to prevent overheating the brakes).
For braking systems which use a yoke, the yoke
must remain parallel with the axle especially when
the brakes are fully applied
This means that the stroke of the levers on the
brakes at each side must be identical. Otherwise, the
brake slack must be adjusted.
Section 4: 23
ADJUSTMENTS FOR STEERING AXLES
Every 3 Months
Steering axles should be maintained in the same way as standard axles. The following additional maintenance
is required for steering axles
4
2
3
3
4
Lubricate the kingpins.(1)
1
Tighten all screws and nuts and parts mounted to the
axle
Tighten the blind nut and lock nut on the locking
cylinders (2)
Tighten the lock nuts (3) at the end of the adjustable
tie rod or the clamping screw (4) for the flexible
bushing (For fixed Tie rods) depending on the
model.
Check the flexible bushings on the tie rod and
damper and change them if necessary.
When maintaining hydraulic components
Always release trapped hydraulic
pressure
Check that the tie rod has not been accidentally bent
as this adversely affects the steer axle, in particular
the wheel alignment.
.
For further Information and detailed
servicing instructions refer to the
manufacturers documentation or
to your dealer.
Section 4 : 24
RICHARD WESTERN
4
BASIC TANDEM SUSPENSION
Every 6 Months
After the first laden journey, before intensive use.
Tighten all the centre clamping bolts and axle U-bolts to the recommended torque. (See Table Below)
Tighten the nuts diagonally
Retighten all the nuts and screws on the suspension (spring shackles, rocker, equaliser bearings, spring bolts,
springs)
Lubricate the rocker bearings and the spring bolts.
Section 4: 25
Every year
Check the play between the bushings (2) and the rocker shafts (1) and, if there is excessive play, replace the
worn parts.
Check the rocker (3) and the spring shackles (4) for wear (spring bearing surface) and replace these parts if
they are very worn.
Check the general condition of the springs (5), clean them thoroughly and brush the sides of the springs to
check for cracks.
If there is any play between the springs and the axles, check the whole of the clamping system: clamping plates
(8), spring alignment (9), bridges (10)
Maintenance of half-tandem suspensions without rocker bars is the same as for simple tandem suspensions
with rocker.
Section 4 : 26
RICHARD WESTERN
4
SPRING DRAWBAR
Every 6 Months
After the first laden journey, and before intensive use.
Retighten all the mounting U-bolt nuts (2) to the recommended torque
Lubricate the attachment shaft (3)
Under harsh or intensive operating
conditions, maintenance should be
carried out more frequently.
Every year
Check the play between the bushing (4) and the spring drawbar shaft (1) and, if there is excessive play, replace
the worn parts.
Check the general condition of the spring (5) clean it thoroughly and brush the sides of the springs to check for
cracks.
Check the condition of the clamps (6).
Section 4: 27
Tyre Pressures
Pressure
Tyre Size
In Bar
Bar
PSI
12.5/80 X 15 PR14
5.75
83.4
15 X 22.5 X 18 PR Rem
5.5
79.8
385 / 65 R 22.5
5.5
79.8
20.5 X 22.5 Rem
4.5
65.3
560 / 60 X 22.5 Cross Ply
4.5
65.3
560 / 60 X 22.5 FP
4.0
58.0
560 / 45 X 22.5 FP
4.0
58.0
650 / 50 X 22.5 FP
4.0
58.0
650 / 75 X 32
2.5
36.3
710 / 50 X 26.5 FP
4.0
58.0
800 / 45 X 26.5
4.0
58.0
23.1 X 26
2.4
34.8
16.9 X 34
2.5
36.3
18.4 X 34
2.5
36.3
Section 4 : 28
RICHARD WESTERN
4
Recommended Lubricants
Energrease Marfak All
LS / LS2 Purpose 2
Multifak
EP2
Agricastrol
Multi Use
Spheerol
AP2
Castrol LM
Oil
Floor Drive
Gearbox
Energear
Hypoid
80w-90
EPX
80w - 90
Oil
Rotor Drive
Gearbox
Energear
Hypoid
80w-90
EPX
80w - 90
Grease
Esso
Mobilux 2
MultiPurpos Mobigrease
e
MP
Beacon 2
Farm
Grease
Universal
Retinax A
Multifak
EP2
Totalfarm
Multis 2
Mobilube 1
SHC
75W-90
Spirax A
80w-90
Geartex
EP-C
80w-90
Mobilube 1
SHC
75W-90
Spirax A
80w-90
Geartex
EP-C
80w-90
Section 4: 29
THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK
RICHARD WESTERN
Brake system
This section contains information that must be
followed to ensure the correct functioning of the
ABS wheel brakes.
If in doubt contact the manufacturer or the
manufacturers agent for further information or
advice.
Failure to adhere to these instructions may
affect the performance of the brakes and
axles and could therefore lead to injury
For additional Information refer to the
manufacturers documentation
Section 5: 1
5
Section 5 : 2
RICHARD WESTERN
Brake system
Two Line Air / Hydraulic with Mechanical Load
Sensing Valve
Component Description
1
Load Sensing Emergency Relay Valve (Mech Suspension)
2
Load Sensing Valve Linkage
3
Load Sensing Valve Fixing Bracket
4
Telescopic Rod
5
Rubber Isolation Mount
6
Hose
7
Shunt Valve
8
Red Connection Coiled Hose
9
Yellow Connection Coiled Hose
10
Reservoir
11
Drain Valve
12
Inline Filters
13
Bulkhead Connectors
14
Test Point (Brake Chamber)
15
Test Point Tee (Load Sensing Valve)
16
Tube
17
Tube
18
Connector
19
Coupling
20
Coupling
21
Coupling
22
Coupling
23
Air Brake Actuators
24
Air Hydraulic Brake Actuators
Notes
Section 5: 3
5
Section 5 : 4
RICHARD WESTERN
Brake system
Two Line Air or Air / Hydraulic with Mechanical
Load Sensing Valve & ABS
Component Description
1
Load Sensing Emergency Relay Valve (Mech Suspension)
2
Load Sensing Valve Linkage
3
Load Sensing Valve Fixing Bracket
4
Telescopic Rod
5
Rubber Isolation Mount
6
Hose
7
Shunt Valve
8
Red Connection Coiled Hose
9
Yellow Connection Coiled Hose
10
Reservoir
11
Drain Valve
12
Inline Filters
13
Bulkhead Connectors
14
Test Point (Brake Chamber)
15
Test Point Tee (Load Sensing Valve)
16
Tube
17
Tube
18
Connector
19
Coupling
20
Coupling
21
Coupling
22
Coupling
23
Air Brake Actuators
24
Air Hydraulic Brake Actuators
25
ABS Modulating Valve 12V 2 Sensor
26
Diagnostic cable & Socket
27
ABS Socket DIN 7638
28
ABS Flexible Connection
29
Sensor Cable
30
Wheel Sensor
Section 5: 5
5
Brake system
For Tractors not fitted with an ABS Connection the
following diagram shows what is required.
A
E
1
+
B
2
C
5
G
D
F
3
5
Component Description
Notes
1
Red Cable to Battery Positive
2
Red / White to Ignition Switch
3
Brown / Blue return to Battery Negative (Ground)
1.5mm2 Cable
4
Brown return to Battery Negative (Ground)
6mm2 Cable
5
Blue / Yellow ABS Warning Lamp
A
Fuse 25 Amp
6mm2 Cable
B
Fuse 5 Amp
1.5mm2 Cable
C
Fuse 5 Amp
1.5mm2 Cable
D
Warning Lamp
2W rating
E
Ignition Switch
F
Optional Connection to 24S Socket Pin 2
G
ISO 7638 Connector
Section 5 : 6
1.5mm2 Cable
RICHARD WESTERN
ISO 7638
The following Diagram shows the correct cable
connections for the ISO 7638 ABS Socket
28
27
Pin
Component Description
Notes
1
Battery Positive
2
Switched Ignition Live
3
Battery Negative (Ground)
1.5mm2 Cable
4
Battery Negative (Ground)
6mm2 Cable
5
Warning Lamp
6
Not Used
7
Not Used
6mm2 Cable
Section 5: 7
5
Two-line trailer air braking systems
General description
The two-line trailer braking system is based on the
commercial trailer braking systems which are
designed to meet the criteria set by European
Council Directive 71/320/EEC.
These systems use one Red air line (known as a
supply or emergency line) which, when coupled to
the tractor is permanently pressurised, and one
Yellow line (known as the service or control line)
which has a variable pressure.
This variable pressure is controlled by the driver, and
is determined by the how quickly the driver wishes to
slow down, or whether the tractor’s parking brake is
applied.
It is commonplace for this line to be fully pressurised
when the tractors ignition is switched OFF.
Non ABS refer to page 5:2
The schematic diagram on page 5:2 is a typical
layout of a tandem-axle trailer, with a Relay
Emergency Load Sensing Valve (RELSV) (1), whilst
the circuit shown on 5:4 shows the combined RELSV
(1) and Advanced Brake System (ABS)
controller (25)
The RELSV (1) is mounted between the axles, and
connects to either a telescopic pole or an angle iron
(4) which fits between them, the angle iron system is
sometimes supported by rubber isolation mounts (5).
For a two sensor ABS system the front axle is ABS
sensed (30), the layout also shows extra (optional)
ABS sensors connected to the rear axle. These
extra ABS sensors should ensure that the rear axle
does not lock.
Where no ABS system is fitted, then the RELSV (1)
delivers the air directly to the brake chambers (23)
from each of its delivery ports.
(The brake chambers are also fitted with hydraulic
cylinders (24), which are fed directly from the
tractor’s hydraulic brakes, when the tractor does not
provide trailer air braking.)
For tri-axle trailers with ABS, then the centre axle is
normally ABS sensed, when using a two ABS sensor
system. With a four ABS sensor system, the extra
two sensors are fitted on the front or rear axle,
dependent upon trailer design and weight
distribution.
With a tri-axle trailer the RELSV (1) is generally
fitted above the centre axle and connected directly to
it.
Section 5 : 8
ABS refer to page 5:4
RICHARD WESTERN
Two-line Pneumatic trailer braking
systems
Operation
Refer to diagrams on 5:2 & 5:4
The air enters the trailer via the Red flexible
connection line (8), and passes through a filter (12).
The filter is designed to trap particles of dirt, and to
stop them entering the sytem, it is not designed to
stop water entering the trailers system.
12
Water separation is a function of the tractors
pneumatic braking system as they should be fitted
with an air dryer. Filters should be dismantled and
cleaned from time to time to remove any debris.
The air then passes through a shunt valve (7), which
is mounted on the side of the trailer, the air pressure
pushes out its button. This button can be pushed in
to release the trailers brakes, when a tractor with air
braking is not available. The button can be pulled
out again, to re-apply the brakes, or it will
automatically be reset after the Red flexible
connection line (8), is re-connected to a tractor with
air braking.
The air travels into the combined RELSV (1) at
port 1, before exiting at port 1-2 to feed the air
reservoir (10).
7
The reservoir is linked back to the shunt valve (7), air
in this line signals the RELSV (1) simulating that the
Red flexible connection line (8), has been
re-connected, after the shunt button is pushed in.
The reservoir (10) is then charged with air until it
reaches the system pressure set by the tractor.
This is normally between 6.5 bar and 8.5 bar, and
this pressure is also present at port 1 of the ABS
modulator valve (25).
Note: Pipes shown as Red on pages 5:2 & 5:4 (and
the Black pipe between the tank and ABS module
(25) in 5:4) will be pressurised when ever the tractor
is connected, and charged up.
None of these pipes should be removed, for
diagnostic or repair purposes, until the tractor has
been disconnected from the trailer and all of the air
drained from the trailers reservoirs.
1
Section 5: 9
5
Operation contd.
Reservoir Draining
Draining should be undertaken periodically to
remove any water that has condensed in the air
reservoirs.
A drain valve which is fitted at the bottom of each air
reservoir.
Failure to drain the reservoirs will lead to a reduction
in the available air capacity, affecting the brake
performance.
11
10
This water may also freeze in the winter, causing
other problems.
Brake Application
During braking, a control pressure is sent to the
trailer through the Yellow flexible connection (9).
This pressure in this line is determined by how hard
the driver presses the brake pedal, and the pressure
may be anything up to the maximum pressure in the
tractor’s system.
However, under normal braking (known as check
braking) this control pressure is often around 2 bar.
The control pressure enters the trailer and passes
through the yellow line filter (12), before reaching the
RELSV (1) at port 4.
2
The RELSV (1) has several functions, one of which
is load sensing.
The RELSV (1) is connected to the suspension via a
vertical linkage rod (2) and its operating arm.
With tandem axled trailers it is common to be
connected between the two axles by either
telescopic pole or an angle iron (4), in order to give
the RELSV (1) an average spring deflection.
The service pressure may be modified by the RELSV
(1) based upon the physical load sensed by the
valve, as weight is removed from the trailer its
chassis rises, causing the RELSV (1) operating arm
to lower (rotate clockwise).
This has the effect of increasing the ratio between
input and output pressures, thus reducing the
braking pressures.
This new, modified pressure exits the RELSV (1) at
port 2, and signals the ABS modulator valve (25) at
port 4 (just below where the ABS sensors plug in).
The ABS modulator then delivers this same pressure
to all of the brake chambers, unless “wheel locking ”
is detected.
Section 5 : 10
1
RICHARD WESTERN
5
Operation contd.
Air / Hydraulic Actuators
The brakes are applied in a controlled manner, as
the pressure builds up behind a rubber diaphragm
housed inside the brake chambers (23), and the
output forces act on the slack adjusters (or levers)
increasing the torque entering the foundation brakes
via the camshafts.
As the driver releases the brakes, the control
pressure drops. This results in the air within the
brake chambers returning back up to the ABS
modulator (25), where it exhausts to atmosphere.
23
No pressure should be evident at the brake
chambers whilst the service brakes are not being
applied.
This can be checked using the test points (14), one
of which is fitted to a spare port in each of the brake
chambers.
14
The RELSV (1) of a two-line air braking system also
fulfils an “emergency” function, which is designed to
apply full tank pressure into the brake chambers
(irrespective of load condition) should the Red
flexible connection be removed, or become ruptured.
A comparison of the pressure in the Red line and
that in the reservoir (10) is made in the RELSV (1)
Should the Red line pressure fall below 2.5 bar the
remaining pressure in the reservoir is supplied
directly to the Air / Hydraulic actuators (23).
This happens automatically when the trailer’s Red
flexible connection is removed during uncoupling.
This emergency function is not be used as a
substitute for the trailer’s mechanical parking brake,
as any air leak will cause the brakes to release, and
the trailer would be left without any effective parking
brake.
Section 5: 11
Basic checks
Test 2 (Red Line/Leak Test)
Before Operation
Fully charge the trailer and disconnect the Red
Flexible Connection.
Some basic but functional air checkscan be
undertaken by the operator as and when required.
Two calibrated air pressure gauges are required,
along with suitably long connecting hoses, it is useful
to have long test hoses so that two gauges can be
positioned close together and viewed
simultaneously.
Test 1 (Charging Test)
Disconnect the Red flexible connection from the
tractor, and drain all of the air from the trailers
reservoirs.
Attach one gauge to a test point on one tank (fit test
point if necessary – normally M22x1.5 threaded).
Fit a second gauge in the Red line, push in the shunt
valve button (7) and reconnect the Red flexible
connection.
The button should pop out as the Red flexible
connection is connected.
Read the two gauges side-by-side and monitor each
gauge as the system charges up. The reservoir
pressure should rise in line with the pressure in the
Red line (it may be slightly behind), until the tank is
fully charged and the tractor compressor unloads
If the tank pressure is much lower than the red line
pressure when the tractor unloads, then this
indicates an internal problem with the RELSV (1), or
the pipe work leading to port 1.
This pipe can be tested by disconnecting the Red
flexible connection, and temporarily removing the
pipe from port 1 of the RELSV (1), and replacing it
with a new one.
This new pipe can then be connected to the tractor’s
red coupling, and the test repeated.
If the pressures now rises correctly, then examine
any filters for blockages, and the original pipe work
for kinks.
If the pressures still fail to equalize, then the RELSV
has an internal fault. Repair or replace as
necessary.
A “chuff” of air should be heard as the air exits the
open Red line.
Observe the gauge connected to the trailer’s air
reservoir, the pressure should drop momentarily, then
stabilize.
If the reservoir pressure continues to drop, then check
the open Red line for the presence of air pressure
(A new thin rubber glove is ideal for this, as it can be
attached to the open Red flexible connection, and
sealed with tape/cable tie and left. If it inflates quickly,
this indicates a leaking RELSV).
If no air is seen leaking from the open Red flexible
connection, this indicates that the leak is downstream
of the RELSV, and this is best identified using a soapwater mixture.
Pay particular attention to pipe fittings, and note that
these do not require to be tightened too much, as their
seals will often become damaged by over-tightening.
Finally, if the tank pressures drop very slowly over an
extended period, then this is acceptable as long as the
leaking is not audible. This is known as “permissible
leakage”.
Test 3 (Smooth Operation/No Residual Pressure)
Swap the test coupling to the Yellow line, or attach the
gauge and test hose to any test point in the Yellow line
leading up to port 4 of the RELSV (1).
Attach the other gauge to a test point on any brake
chamber.
Fully charge the trailer, and keep the Red flexible
connection.
Place the two gauges close together, and monitor
them both as the service brakes are slowly and
repeatedly applied on and off.
Both pressures should be seen to rise and fall
smoothly, with both showing zero bar when the
tractor’s brakes are released. (Do not worry if the
pressure at the brake chamber is lower than that of the
Yellow line, as the settings of the RELSV are not yet
being tested.)
If the pressure in the Yellow line is unstable then the
brake chamber pressure will be aswell.
This would indicate a problem with the tractor’s brakes,
in particular with its trailer control valve.
Section 5 : 12
RICHARD WESTERN
5
If the Yellow line pressure is smooth, but unstable at
the brake chamber, then the problem is trailer related,
and this is found by moving the gauge from the brake
chamber to the output of the RELSV (port 2).
The test can be repeated, and if the pressure still is not
smooth then this indicates a faulty RELSV. If it was
smooth, then the problem is inside the ABS modulator
(25), as it must be creating an unstable pressure, even
though it is signalled with a stable one.
The same tests can be repeated for residual pressure
problems, should both gauges not show zero pressure
when the service brakes are released.
Test 3 (Output of the RELSV)
The RELSV (1) is connected between the chassis and
axles, and senses the way the springs deflect, as
increasing weight causes them to flatten. This
movement is transferred to the RELSV operating arm
via a vertical linkage (2) . This linkage, along with any
other components (angle iron, flexible mounts etc)
should be periodically checked for signs of damage, or
becoming loose.
In order to check that the RELSV is functioning
correctly, the linkage can be removed from the
operating arm, and the service brakes applied.
The Red Flexible connection needs to be connected
for this test. An air gauge in the brake chamber will
show the output pressure, and this gauge can be
observed whilst the operating arm is rotated. As the
operating arm is raised the brake chamber pressure
should increase until it matches the service line
pressure, and decrease as the arm is lowered. This
demonstrates that the load sensing function of the
RELSV is working.
When the vertical linkage is reattached to the
operating arm, it is important that the arm is at the
correct angle to give the proper braking pressure for
the weight being carried.
A decal is fitted to the arm, which rotates with the arm
passing a pointer on the RELSV’s casting. This decal
shows the approximate setting for the RELSV, but the
valve is best set when the trailer is empty, and the
linkage adjusted until the correct unladen pressure is
given, when a known “test pressure” is used.
A typical unladen decal position is shown to the left,
but this is only shown for a guide.
The trailer builder should be able to provide this
information, if it does not appear on a LSV data plate
attached to the chassis.
Section 5: 13
RELSV Setting procedure
Before Operation
The RELSV is probably the most important part of
the trailer’s braking system, whether ABS is fitted or
not.
A poorly set up RELSV can be both dangerous and
expensive.
Too little output pressure leads to under braking, and
this could result in a jack-knife.
Too much pressure can cause the trailer to lock, and
“swing” past the tractor.
Additionally, too much pressure causes premature
and expensive trailer tyre wear.
Periodically, and when connecting to a different
tractor it is worthwhile checking the RELSV output
pressures, and making sure they match the
suspension correctly.
To do this properly you will require two gauges, a
tape measure, calculator and a little patience!
1
With the trailer standing on firm level and
connected to the tractor, load it to the
maximum weight allowed.
If the RELSV is connected to one axle, then
measure the distance between the top of this
axle and the underside of the chassis (If the
trailer is fitted with a bar between the axles,
then you can measure the distance above
each axle and halve the total).
Record this measurement in mm
2
Remove the load and repeat the same
measurements as taken above.
The difference between these two
measurements is the “unladen to laden spring
deflection”.
For this example we shall assume it is 25mm.
3
Typically these could be 6.0 bar (Test) 2.5 bar
(Unladen) and 6.0 bar (Laden). If you cannot
get access to the actual test pressures for
your trailer, then the above figures may be
close enough.
Find out the recommended unladen LSV
setting pressure for your trailer. This may be
on a data plate, or available from the trailer
manufacturer.
This is not the pressure present in the trailer’s
brakes during normal unladen braking, but is a
pressure used for setting up the RELSV!.
Along with this unladen pressure you should
also get its associated “test pressure”, as well
as the laden brake pressure.
Section 5 : 14
4
Calculate the “regulating ratio”.
An acceptable way of doing this is by dividing
the test pressure by the unladen pressure.
Using the example above, this would be 6.0
divided by 2.5 = 2.4
5
Look at the graph (Figure 2 below), and find the
point on the left hand column which relates to
the regulating------- ratio (2.4) which you have
just calculated. Mark that point.
In the central column find the point which
relates to your unladen to laden spring
deflection, which you measured in Step 2
(25mm). Mark that point.
Draw a straight line from the point you marked
in the left column, through the point in the
second column, and extend this line until it
crosses the right hand column.
Where it crosses this column read off the
measurement, as this is the correct RELSV arm
length for this trailer. This length is measured
from where the arm connects to the RELSV
(centre of the securing bolt head) and the point
where the rubber linkage fits on the other end.
Adjust the arm length on the valve accordingly,
and tighten the securing bolt.
RICHARD WESTERN
5
Section 5: 15
RELSV Setting procedure contd
6
Check the unladen setting by applying the test
pressure to the Yellow line (6.0 bar used in
this example), and measure the RELSV output
pressure.
This can be measured directly at any unused
port 2, or on a brake chamber.
If the pressure is correct (2.5 bar in this
example), then the valve is now set up.
If the pressure is too low (2.0 bar for example),
then the vertical linkage between the RELSV
arm and the axle (or bar) is too short.
If the output pressure is too high, then the
vertical linkage is too long.
Amend the length until the unladen output
pressure is correct (tolerance ± 0.2 bar).
Having set the RELSV at its correct unladen setting,
and adjusted the arm length to match the true
unladen/laden spring deflections, the valve should
now automatically adjust to the correct brake
pressure settings.
Section 5 : 16
RICHARD WESTERN
5
Brake system
ABS
General Description
The ABS system is designed to stop the wheels from
locking, when the trailer is braked and the road
surface is slippery.
Under normal braking operation the ABS does not
affect the braking performance, but merely monitors
the changing wheel speeds. By doing this it
compares the differing wheel speeds and determines
if there is a tendency for one or more wheels to lock.
The ABS system consists of an Electronic Control
Unit (ECU) and a modulator valve (25) which is hard
wired directly onto the ECU.
The ECU and modulator are internally split into two
halves, so that one half of the ECU controls one half
of the modulator, which in turn controls the braking
system for one side of the trailer.
25
Note ! A trailer may have four wheels but just Two
ABS sensors, the unsensed wheels still receive ABS
modulated braking. However, unsensed wheels may
still lock, as the ECU cannot detect this locking
tendency, unless sensors are fitted to all wheels.
Note ! Failure of the ABS lamp to illuminate will not
cause a failure of the brakes to apply. However, the
ABS functions may be impaired to a greater or lesser
extent, so wheel locking may be evident which could
lead to a loss of stability, and an accident.
The braking system for the other side of the trailer is
controlled by the other half of the ECU and
modulator.
Two ABS sensors (30) are mounted in the brake
assemblies on at least one axle, and these are in
close proximity to toothed “polewheels”, which pass
by the ABS sensors, as the wheels rotate.
These ABS sensors are connected to the ECU by
extension cables, and they are connected so that the
nearside sensor controls the braking for the nearside
wheels.
Operation
If the ABS warning lamp illuminates
whilst driving, proceed with caution until it
is safe to stop. Check the sytem for faults
before proceeding.
Braking systems and brake related
equipment must only be serviced by
competent persons using the correct
maintenance equipment
The ABS system when correctly operated is
automatic and requires no inputs from the operator.
ABS systems are available in either 12 Vdc or 24Vdc
variants. A 24Vdc version cannot be towed by a
12Vdc tractor and vice versa.
The main connection to the tractor is via the
dedicated supply socket (ISO 7638 see page 5:7)
When connected to tractor as the tractor is started
the ECU “exercises” the Modulator valve (25), this
will be heard as a series of clicks, and if the service
brake is applied some rapid exhaust sounds.
During initial power up, a cab mounted trailer ABS
warning lamp should illuminate briefly, before going
out. This warning lamp will indicate any ABS related
failure to the driver.
Section 5: 17
Operation contd
The ABS ECU (25) monitors, processes and
compares the wheel speeds detected at the wheel
sensors (30) , and only acts on this information if it
determines that one, or more of the sensed wheels
are about to lock.
At that point the ECU transmits a signal to the half of
the modulator valve which is connected to that
wheel, and this closes the inlet port, stopping further
pressure building up in the brake cylinders.
If the locking tendency persists, a further signal is
also transmitted to the exhaust port, resulting in air
being relieved from the respective brake chambers.
The wheels speeds are controlled in this way until
the ECU is determines that the lock-up condition has
been averted, and then normal braking is resumed.
25
Basic Checks
The cab-mounted warning lamp should illuminate
and extinguish once the tractor’s ignition has been
switched on. If this happens, then no checks are
necessary.
Power and warning lamp checks are best performed
using two wires attached to a 21watt bulb, with the
voltage to match the ABS system, rather than an LED
tester or multimeter.
Should the warning lamp stay on until the vehicle is
moving, then this is also OK, and no further checks
are required.
These checks can be performed in stages, initially at
the tractor’s ISO 7638 socket, then into an attached
ABS flexible connection cable, and finally in the ISO
7638 power cable after removing it from the ABS ECU.
In this way the various segments of the cabling are
checked in turn, which will pinpoint any cable
problems.
However, should the warning lamp fail to illuminate
upon ignition, or fail to extinguish when pulling away,
or come on again during driving, then a few basic
checks may help find the cause.
General faults may be caused by poor electrical
connections or damage to the cables .
These are best done with the ignition ON, following
the warning lamp going out.
Trace the cable gently moving them and their
connectors, check to see if the cab warning lamp
illuminates, or flickers, or whether the ABS is heard
to exercise again. If the ABS exercises, then you
know that it switched OFF momentarily whilst the
cable was moved, this could indicate a break in the
power feed.
Testing the ABS sensor extension cables, where
they connect to the ECU in this way, is also
worthwhile, ensure any loose connections or pins are
tightened and ensure correct operation.
Always make sure that they are correctly
reconnected following any removal.
Section 5 : 18
All of the power and ABS warning lamp tests on the
following pages are conducted within the ISO 7638
power supply (28).
RICHARD WESTERN
5
Brake system
ABS
Testing
Test 1 (Exercise check)
When the tractor ignition is switched ON, the trailer
will exercise the Modulator valve (25) (This is often
four sharp clicks, or click chuff click chuff, if the
service brakes are applied.)
If these four noises are heard, then the ABS is being
powered correctly.
If OK ignore Test 3 (ABS Power Test).
Test 2 (ABS warning lamp check)
28
With the ABS flexible connection between the tractor
and trailer disconnected (ignition ON) the ABS
warning lamp should be OFF.
(If the ABS warning lamp is ON, the tractor has a
wiring problem.)
At the tractor socket (28) using a multimeter or test
lamp, connect one terminal to pin 5, and the other to
pin 4 (see 5:7 for pin functions). The ABS warning
lamp should illuminate, but not the test bulb (If the
test bulb illuminates brightly, the tractor has a wiring
fault).
If the warning lamp fails to switch ON and OFF as
the test lamp is connected and disconnected, then
the ABS warning lamp fault is within the tractor
wiring.
If the warning lamp operates correctly, repeat the
tests into the plug on the ABS flexible connection
between the tractor and trailer (27), having firstly
reconnected it to the tractor, and disconnected it
from the trailer’s ABS socket .
If the lamp is still working correctly, repeat the test
into the ISO Power cable where the cable connects
to the ABS ECU (25), this time using pins 4 and 7.
ISO POWER CABLE TO ECU
If the warning lamp is functioning correctly, then all of
the ABS warning lamp wiring is correct.
Should the ABS warning lamp fails to illuminate after
reconnecting all of the cables, and switching the
ignition ON, then the fault must be inside the ABS
ECU. (25)
However, if the ABS warning lamp stays on, then
further tests are required.
By cycling the ignition ON (2 seconds) OFF (2
seconds) and ON again, a request is sent to the
trailer’s ABS ECU to give out a “blink code”. If the
ABS warning lamp starts flashing, this indicates that
the ECU is functioning correctly, make a note of the
number of flashes, as these can be used to identify
the source of the problem.
Section 5: 19
Testing contd
Test 3 (ABS Power Test)
Using a multimeter or a 21 Watt test lamp, and with
the ignition switched ON, check that it illuminates
brightly when connected across pins 2 and 3 of the
tractor’s socket (28).
If it fails to illuminate then check the tractor fuse
(often 5 Amp). Refer to the tractors operation &
maintenance manual for details of the electrical
system.
Check that that it switches ON/OFF with the ignition
ON/OFF.
Repeat the test with the test lamp across pins 1 and
4.
If the lamp fails to illuminate then check the fuse
(often 25 Amp). With the test lamp across pins 1 and
4, the lamp may stay illuminated, even after the
ignition is switched OFF, and if it does then this is
OK.
Connect the test lamp across pins 4 and 5. The
lamp must not illuminate, but the cab warning lamp
should come on.
28
All of the above tests can be repeated the ABS
ISO7638 flexible connection between the tractor and
trailer (27) having firstly disconnected it from the
trailer’s socket, in order to check the connection for
damage.
Finally the remainder of the ISO 7638 cable can be
checked by repeating the tests at the ABS ECU (25),
remembering that the pin numbers are different, so
refer to ISO Power cable to ECU wiring diagram
shown on the previous page.
TYPICAL TRACTOR ABS
ELECTRICAL CIRCUIT
Section 5 : 20
RICHARD WESTERN
5
Brake system
ABS
Testing contd
Basic blink code errors
By starting the blink code routine (see page 5:19),
any current ABS wiring fault error codes are shown
by the ABS warning lamp, located in the tractor.
The error codes are repeated three times.
FAULT CODE
COMPONENT
COMMENTS
3
ABS Sensor BU1 c
Broken wire – normally nearside of trailer
4
ABS Sensor YE1 d
Broken wire – normally offside of trailer
5
ABS Sensor BU2 e
Broken wire – normally nearside with 4 sensor system
6
ABS Sensor YE2 f
Broken wire – normally offside with 4 sensor system
7
Extra Modulator
Broken wire/solenoid – only on 4S/3M systems
9
Internal Modulator
Broken wire – new ABS assembly required
10
Internal Modulator
Broken wire – new ABS assembly required
11
Internal Modulator
Broken wire – new ABS assembly required
14
Power Supply
Check for over/under voltage
15
Internal ECU fault
Replace ABS assembly
Note! Fault codes 3,4,5,6,7,14 & 15, correspond to
numbers cast into the ABS ECU valve body (25),
allowing the faults to be traced to a specific
connection.
Component Testing
The ABS system consists of three basic components
(ECU (25), Cables (29) and ABS Sensors (30)) the
most effective method of fault diagnosis may be by
substitution.
This is ideal for checking cabling/ABS Sensor wiring
problems, when no specialist diagnostic tools are
available.
When removing any cable it is vital that the cable is
marked, so it can be returned to its original position.
It is also imperative to ensure that no unused
electrical connections are left open, as water will
enter the electronics and cause premature failure.
Water can also enter the electronics via “repaired
cables”, where water migrates up the inside of the
repaired cable, and corrodes the inside of the ECU.
The cable connections to the ECU (25) are shown
opposite, only the two central ABS cables are used
for a two ABS Sensor system.
If in doubt contact your dealer or a specialist ABS
repairer!
25
Section 5: 21
Troubleshooting Guide
Problem
TRACTOR (TRAILER CIRCUIT) LOW
PRESSURE WARNING BUZZER ON ALL
OF THE TIME
TRAILER BRAKES DO NOT RELEASE
WHEN SYSTEM FULLY CHARGED, AND
THE TRACTOR'S HAND BRAKE IS
RELEASED
Cause
Solution
AIR LEAK IN SYSTEM
DISCONNECT TRAILER TO ASCERTAIN
WHETHER LEAK IS IN THE TRACTOR, OR
TRAILER
COMPRESSOR OR UNLOADER/AIR
DRYER PROBLEM
CHECK IF COMPRESSOR IS BLOWINGOFF AT UNLOADER, OR AIR DRYER.
LOW PRESSURE SWITCH PROBLEM
CHECK CONNECTIONS - REPAIR AS
NECESSARY CHECK LP SWITCH
PRESSURES AGAINST THOSE IN THE
AIR TANK (TRAILER CIRCUIT)
INSUFFICIENT RED LINE "FLOW"
CHECK SELF-SEAL VALVE TO ENSURE IT
IS LIFTING SUFFICIENTLY TO ALLOW A
HIGH FLOW OF AIR TO THE TRAILER
INSUFFICIENT RED LINE PRESSURE
CHECK PRESSURE AT THE TRACTOR'S
RED COUPLING USING CALIBRATED AIR
GAUGE. PRESSURE SHOULD BE
BETWEEN 6.5 BAR AND 8.5 BAR
CHECK TRACTOR'S IGNITION IS
SWITCHED ON
PRESSURE STILL IN YELLOW LINE
CHECK CABLE LINKAGE (IF FITTED) TO
TRACTOR'S TRAILER CONTROL VALVE,
AND ADJUST/REPAIR AS NECESSARY
RELSV EXHAUST PORT BLOCKED
ENSURE RELSV EXHAUST IS OPEN
CHECK LIFTER VALVE PRESENT IN
TRAILER'S YELLOW SUSIE
INSUFFICIENT YELLOW LINE "FLOW"
TRAILER BRAKES DO NOT APPLY
DURING TRACTOR BRAKING
CHECK SELF-SEAL VALVE IN TRACTOR'S
YELLOW COUPLING
CHECK TRAILER'S YELLOW AIR LINES
FOR KINKS OR BLOCKAGES
INSUFFICIENT PRESSURE IN TRAILER'S
AIR RESERVOIR
CHECK THAT AIR FLOWS
UNRESTRICTED FROM PORT 1-2 OF
RELSV, WHEN THE RED SUSIE IS
CONNECTED AND PRESSURISED
CHECK FOR KINKED OR BLOCKED PIPES
INSUFFICIENT PRESSURE IN TRAILER'S
AIR RESERVOIR
POOR AIR FLOW TO TRAILER'S AIR
RESERVOIR
CHECK THAT AIR FLOWS
UNRESTRICTED FROM PORT 1-2 OF
RELSV, WHEN THE RED SUSIE IS
CONNECTED AND PRESSURISED
TRAILER'S BRAKES "SNATCHING"
RELSV NOT WORKING SMOOTHLY INPUT AND OUTPUT PRESSURES JERKY
WHEN COMPARED USING AIR GAUGES
REPAIR/REPLACE RELSV AND ENSURE
THAT ANY REPLACEMENT IS SET UP
CORRECTLY
INCORRECT LSV SETTING
CHECK SETTINGS AGAINST
RECOMMENDATION
INCORRECT SLACK-ADJUSTER LENGTH
CHECK LENGTH AGAINST
RECOMMENDATION
INCORRECT BRAKE CHAMBER SIZE
CHECK SIZE AGAINST
RECOMMENDATION
LSV LINKAGE DAMAGED
CHECK LINKAGE AND ANGLE IRON
HAND BRAKE PARTIALLY APPLIED
CHECK HANDBRAKE CABLES/
ADJUSTMENT
RESIDUAL PRESSURE IN BRAKES
ENSURE NO AIR TRAPPED IN YELLOW
LINE
HYDRAULIC LINE ALSO CONNECTED
DISCONNECT HYDRAULIC BRAKE LINE
TRAILER BRAKING TOO HARD, OR TOO
WEAK
TRAILER BRAKES GETTING TOO HOT
Section 5 : 22
RICHARD WESTERN
Brake system
Problem
TRAILER BRAKES NOT GOING INTO
"EMERGENCY", AFTER RED LINE
REMOVED
ABS WARNING LAMP IN TRACTOR CAB
ILLUMINATED WHEN NO ABS TRAILER
CONNECTED
ABS WARNING LAMP IN TRACTOR CAB
DOES NOT ILLUMINATE WHEN TRACTOR
CONNECTED TO TRAILER WITH ABS
FITTED
Cause
Solution
KINKED PIPE IN LINE TO RELSV
CHECK ALL PIPES TO PORT 1 OF RELSV
INCORRECT RED SUSIE COUPLING
CHECK COUPLING HAS NO SELF-SEAL
VALVE
RELSV EXHAUST PORT BLOCKED
ENSURE RELSV EXHAUST IS OPEN
EARTH PROBLEM WITHIN TRACTOR'S
ISO 7638 WIRING
CHECK ABS SOCKET FOR TOUCHING,
LOOSE WIRES
CHECK WIRING FROM ABS SOCKET TO
CAB ABS WARNING LAMP.
ABS WARNING LAMP BULB BLOWN
REPLACE BULB
ABS WARNING LAMP FUSE BLOWN
REPLACE FUSE (OFTEN 5 AMP)
NO ABS SUSIE CONNECTED
CONNECT ABS SUSIE TO TRACTOR'S
SOCKET
FAULTY ABS SOCKET
IS PIN 5 PUSHED BACK INTO ABS
SOCKET?
FAULTY ABS SUSIE
REPLACE ABS SUSIE
FAULTY ABS POWER CABLE
CHECK/REPLACE (SEE TEST
INFORMATION)
FAULTY ABS ECU
REPLACE ABS UNIT
CHECK FOR 12 VOLTS ACROSS PINS 1 &
4 OF ABS SOCKET
CHECK FOR 12 VOLTS ACROSS PINS 2 &
3 OF ABS SOCKET
POWER FAULT
ABS WARNING LAMP IN TRACTOR CAB
DOES NOT EXTINGUISH AFTER CIRCA 2
SECONDS, WHEN CONNECTED TO
TRAILER WITH ABS FITTED
ABS WARNING LAMP IN CAB GOES OUT
AFTER CIRCA 2 SECONDS, BUT
ILLUMINATES AGAIN WHILST DRIVING
CHECK FOR 12 VOLTS ACROSS PINS 1 &
8 OF ABS POWER CABLE, AT ABS ECU
END
CHECK FOR 12 VOLTS ACROSS PINS 3 &
4 OF ABS POWER CABLE, AT ABS ECU
END
ABS SENSOR SHORT/OPEN CIRCUIT
CHECK BLINKCODE FOR SENSOR FAULT
LOCATION (SEE LIST)
ECU PROBLEM
CHECK BLINKCODE FOR 12 FLASHES REPLACE IF NECESSARY
ABS POWERED FOR EXTENDED TIME
TOW TRAILER AND CHECK THAT LAMP
GOES OUT AFTER CIRCA 7 KM/H
ABS SENSOR AIR GAP
CHECK ABS SENSOR INSTALLATION,
AND PUSH SENSOR UPTO ABS
POLEWHEEL
POLEWHEEL WOBBLE
CHECK ABS SENSOR AND POLEWHEEL
INSTALLATION, AS WELL AS WHEEL
BEARING
CHECK FOR 12 VOLTS ACROSS PINS 1 &
4 OF ABS SOCKET
CHECK FOR 12 VOLTS ACROSS PINS 2 &
3 OF ABS SOCKET
SYSTEM DOES NOT "EXERCISE" AFTER
POWERING UP (NO CLICKING/CHUFFING
AUDIBLE)
POWER FAULT
CHECK FOR 12 VOLTS ACROSS PINS 1 &
8 OF ABS POWER CABLE, AT ABS ECU
END
CHECK FOR 12 VOLTS ACROSS PINS 3 &
4 OF ABS POWER CABLE, AT ABS ECU
END
FAULTY ABS ECU
REPLACE ABS UNIT
Section 5: 23
5
Troubleshooting Guide
Problem
WHEELS LOCK DURING BRAKING - NO
ABS WARNING LAMP ILLUMINATED
Cause
Solution
TOO MUCH BRAKE PRESSURE
CHECK RELSV SETTINGS
NO ABS SENSORS FITTED TO LOCKING
WHEELS
ADD EXTRA ABS SENSORS TO LOCKING
AXLE TO CONVERT TO A 4S/2M SYSTEM
CHECK FOR 12 VOLTS ACROSS PINS 1 &
4 OF ABS SOCKET
CHECK FOR 12 VOLTS ACROSS PINS 2 &
3 OF ABS SOCKET
POWER FAULT
WHEELS LOCK DURING BRAKING - ABS
WARNING LAMP ILLUMINATED
Section 5 : 24
CHECK FOR 12 VOLTS ACROSS PINS 1 &
8 OF ABS POWER CABLE, AT ABS ECU
END
CHECK FOR 12 VOLTS ACROSS PINS 3 &
4 OF ABS POWER CABLE, AT ABS ECU
END
ABS SENSOR AIR GAP
CHECK ABS SENSOR INSTALLATION,
AND PUSH SENSOR UPTO ABS
POLEWHEEL
POLEWHEEL WOBBLE
CHECK ABS SENSOR AND POLEWHEEL
INSTALLATION, AS WELL AS WHEEL
BEARING
RICHARD WESTERN
Brake system
Euro-Safe (TM) Hydraulic System
General Description
The 'Euro-Safe' Automatic Fail-Safe/Emergency
braking system is a dual line system, the service line
is Hydraulic and the emergency line electric.
It has been designed to fully comply with the revised
EU Braking Regulations for towed trailers and
implements travelling faster than 25 KPH.
The system provides automatic application of the
trailer brakes in the event of the trailer becoming
detached from the towing vehicle as well as a
temporary parking brake.
The Euro-Safe brake valve is controlled by an
Electro Controller located inside the cab of the
towing vehicle. The use of the Electro Controller
allows the operator, to fully control the trailers
brakes, applying-releasing and overriding them
without leaving his seat.
When applied the Euro-Safe brake valve delivers a
brake pressure of 90-100Bar, which is essential
when parking heavy trailers as the tractors parking
brake is only designed to hold the weight of the
tractor. A built in Safety Feature ensures that
the trailer brakes do not release until the system has
been fully recharged. An integrated high-pressure
filter ensures no debris enters the system, which may
cause malfunction or brake failure.
Typical Installation of Hydraulic Brake components
Typical Installation of Electro Controller components
Section 5: 25
5
Initial Setup
Operating the Euro Safe valve for the First time or
after a major Service
Connect the trailer to the tractor.
Connect the hydraulic brake coupling and ABS
brake plug to the tractor.
Unscrew all the brake pipes from the brake
cylinders.
Place containers beneath each cylinder to
recover any waste oil and debris exhausted
from the cylinders.
With the Electro Controller switched ‘OFF’, start
up the tractor, depress the tractors brake pedal
for 10 seconds, this will flush the brake lines
free of any debris that has entered the system.
Retighten the connectors and then bleed each
brake cylinder individually making sure the
system is air free.
Check tightness of all connectorsand check for
signs of any leakage.
Switch ‘ON’ the Electro Controller – the Red
power light will illuminate and low-pressure
warning buzzer will sound.
Allow the accumulator to charge by depressing
the tractors brake pedal for 25-35 seconds
(depending on oil temperature), until the trailer
brakes release, the low-pressure warning
buzzer stops and green light illuminates.
Keep brake pedal depressed for a further 10
seconds, the system is now ready for use.
Re-setting the Pressure switch
IF LOW PRESSURE WARNING BUZZER
CONTINUES TO SOUND!
Check the tractors trailer-braking valve maximum
pressure, if the maximum braking pressure is
lower than120 Bar, the valve needs repairing or
replacing.
Reset the pressure switch to suit the tractors
maximum trailer braking pressure.
Section 5 : 26
Note! The pressure switch is factory set and
sealed. If seal is broken warranty for the unit
becomes void.
Pull back the protective sleeve from the pressure
switch.
Switch ‘ON’ the Electro Controller in the cab.
Recharge the accumulator by depressing the tractor
brake pedal for 30-40 seconds depending on oil
temperature.
If low-pressure buzzer continues to sound slowly turn
the adjusting screw anti-clockwise, until the
trailer brake’s release, buzzer stops and green light
illuminates.
Turn the adjusting screw a further eighth of a turn
anticlockwise (450).
Switch ‘OFF’ the Electro Controller then repeat the
above steps ensure the correct adjustment has been
made.
Push the protective sleeve back over the pressure
switch.
Test the trailer brakes: - Switch ‘OFF’ the Electro
Controller – this applies the trailer brakes, slowly
drive the towing vehicle forward, if trailer brakes are
locked ’ON’ – the system is working,
If not: Check that the trailer brakes are fully adjusted
replace worn parts if necessary.
If in doubt contact the manufacturer or your dealer.
RICHARD WESTERN
Brake system
Euro-Safe (TM) Hydraulic System
Operation
When operating the tractor/trailer brakes under
normal driving conditions oil from the tractors trailer
brake circuit passes through the EURO-SAFE brake
valve, applying the trailer brakes, in the usual way.
Oil stored in the accumulator is used for temporary
parking and emergency braking only.
Operating the EURO-SAFE fail-safe/emergency
brake valve: Connect trailer, hydraulic brake coupling and
electrical brake ABS plug to the tractor.
Switch 'ON' the Electro Controller the red power light
will illuminate.
If low-pressure buzzer sounds, recharge the
accumulator by depressing the tractor brake pedal
for 20 -30 seconds, until trailer brakes release, the
buzzer stops, and the Green light illuminates.
Note! Keep brake pedal depressed for a further 10
seconds after green light illuminates this ensures that
the accumulators are charged to maximum tractor
pressure.
THE TRAILER BRAKES WILL APPLY WHEN: a) The Electro Controller is switched 'OFF'
b) The ABS plug is disconnected or the
electrical power is lost or interrupted.
THE ACCUMULATOR PRESSURE AND THE
BRAKES CAN BE RELEASED AT ANY TIME BY: a) Switching the Electro Controller 'OFF' - this
will apply the trailer brakes.
b) Push and hold the override button the
Electro Controller, Red power light will
illuminate
Alternatively twist and hold the Manual Override
button mounted on the brake valve for 10 seconds.
This will discharge the accumulator and release the
trailer brakes.
IMPORTANT! Whilst driving if the green light goes
out and the buzzer sounds . Push and hold
the red override button until you can safely stop.
If all electric supply to the tractor is lost the trailer
brakes can be released by twisting the Manual
Override button.
Section 5: 27
5
Parking the Trailer
To park trailer with brakes applied.
The Trailer brakes will apply when the Electro
Controller is switched 'OFF' or the electrical supply is
interupted or ABS plug removed.
It is still legal requirement to have a
mechanical parking brake fitted and
working on agricultural trailers and
implements, and should be used when
parking the trailer up for long periods.
To park trailer with brakes released
Switch the Electro Controller to 'OFF' - this will apply
the trailer brakes.
Push and hold the override button the Electro
Controller, the Red power light will illuminate.
Alternatively twist and hold the Manual Override
button mounted on the brake valve for 10 seconds,
this will discharge the accumulator and release the
trailer brakes.
ABS Socket Connections
ATTENTION! it is still legal requirement to have a
mechanical parking brake fitted to agricultural trailers
and implements, and should be used when parking
the trailer up for very long periods.
Or chock up the wheels securely, then release the
mechanical parking brake or Euro-Safe brake valve.
(This prevents the brake shoes sticking to the drum)
IMPORTANT! WHEN THE EURO-SAFE BRAKE
VALVE IS FITTED TO A TRAILER THE BRAKES
CAN ONLY BE OPERATED IF
THE TRACTOR IS FITTED WITH THE ELECTRO
CONTROLLER.
It is IMPORTANT that the Male-Female breakaway
couplings provided are fitted into the trailers brake
line, which connects from the Euro-Safe brake valve
to the Female brake coupling. (See diagram above)
This ensures that if the trailer breaks away from the
tractor accidentally the couplings automatically
disconnect making sure no hoses are damaged and
also preventing any oil spillage on to the highway.
If trailer brakes are operated via the tractor spool
valve: - Activate the spool valve until the system is
fully charged,
buzzer stops, green light illuminates and trailer
brakes release.
Ensure that the spool valve pressure does not
exceed 150 Bar or damage may occur to the trailer
brakes.
Section 5 : 28
Trailer Wiring connections
RICHARD WESTERN
Brake system
Euro-Safe (TM) Hydraulic System
Adjusting the Minimum braking pressure
Unscrew Locknut B
Turn the Valve head A clockwise to increase the
brake pressure or Counter clockwise to decrease.
Check the minimum pressure setting.
If satisfactory, retighten lock nut B
The same principles apply to the hydraulic system as
earlier described for the Pneumatic system..
The load sensing valve should be set with the trailer
sitting level. It should be checked when the trailer is
first attached and re-checked whenever the trailer is
connected to a different towing vehicle.
This is because any variation of the drawbar height
will change the setting of the valve.
Note! For trailers fitted with the Heavy Duty (50mm
thickness) spring the Distance L should be 70mm
and for those fitted with the Light Duty (40mm
thickness) the distance L should be 120mm.
Section 5: 29
5
Troubleshooting Guide
Problem
LOW PRESSURE WARNING BUZZER ON
ALL THE TIME: –
TRAILER BRAKES WILL NOT RELEASE
Cause
PRESSURE SWITCH SET TOO HIGH
RESET PRESSURE SWITCH
TRACTOR -TRAILER BRAKE VALVE NOT
DELIVERING THE CORRECT PRESSURE
CHECK THE PRESSURE- IF THE MAX
PRESSURE IS BELOW 120BAR REPAIR
OR REPLACE TRACTOR-TRAILER BRAKE
VALVE
LOOSE CONNECTION, WIRING LOOM
DAMAGED
CHECK CONNECTIONS - REPLACE
WIRING LOOM
JOHN DEERE TRACTORS
TRAILER BRAKING PRESSURE TOO LOW
NEW HOLLAND, CASE , MF CLAAS
TRACTORS
AIR IN THE TRACTOR BRAKE LINE
CAUSING TRAILER BRAKE VALVE TO
MALFUNCTION
LOW PRESSURE WARNING BUZZER
SOUNDS WHILST DRIVING.
PRESSURE SWITCH SET TOO HIGH
PRESS OVERRIDE BUTTON UNTIL YOU
CAN SAFELY STOP THEN ADJUST
PRESSURE SWITCH 1/4 TO 1/2 TURN
ANTICLOCKWISE
Section 5 : 30
REPLACE HIGH PRESSURE FILTER
ELEMENT
TAKE OUT VALVE C1 CLEAN
THOROUGHLY AND FLUSH SYSTEM
RETURN FILTER BLOCKED WITHIN THE
TRACTOR-TRAILER BRAKING VALVE
JOHN DEERE TRACTORS
CLEAN OUT RETURN FILTER WITHIN
TRACTOR TRAILER BRAKING VALVE
TRAILER BRAKE COUPLINGS WORN
RESTRICTING FLOW
REPLACE WITH NEW
HIGH PRESSURE FILTER BLOCKED
REPLACE ELEMENT
DEBRIS WITHIN SYSTEM CAUSING C2
VALVE TO JAM
REMOVE VALVE C2 CLEAN
THOROUGHLY AND FLUSH SYSTEM
TRACTOR - TRAILER WIRING LOOM OR
PLUG & SOCKET DAMAGED
REPAIR OR REPLACE
LOOSE CONNECTION OR WIRING LOOM
DAMAGED
CHECK CONNECTIONS, REPAIR OR
REPLACE LOOM
BLOWN FUSE
REPLACE FUSE
WATER HAS ENTERED CONTROLLER
REPLACE CONTROLLER
PRESSURE SWITCH SET TOO LOW
RESET PRESSURE SWITCH
TRACTOR - TRAILER VALVE NOT
DELIVERING THE CORRECT PRESSURE
TEST TRAILER BRAKING PRESSURE. IF
LOWER THAN 120BAR REPAIR OR
REPLACE TRACTOR - TRAILER BRAKE
VALVE . CONSULT DEALER
TRAILER BRAKES NEED ADJUSTING
ADJUST,CHECK AND REPLACE WORN
PARTS AS REQUIRED
ACCUMULATOR PRE-CHARGE
PRESSURE DEPLETED
REPLACE ACCUMULATOR
NO POWER TO ELECTRO CONTROLLER
TRAILER BRAKES DO NOT APPLY WHEN
ELECTRO CONTROLLER IS SWITCHED
OFF
BLEED THE TRACTOR BRAKES, FIRST
RIGHT SIDE THEN LEFT. TEST TRAILER
BRAKING PRESSURE. IF LOWER THAN
120BAR CONSULT DEALER
CLEAN TERMINALS AND SPRAY WITH
ANTI CORROSION COMPOUND
DEBRIS WITHIN SYSTEM CAUSING
VALVES TO MALFUNCTION
ELECTRO CONTROLLER NOT
FUNCTIONING CORRECTLY
ADJUST TRACTOR-TRAILER BRAKE
VALVE PRESSURE TO 150 BAR MAX
(REFER TO DEALER)
PLUG & SOCKET TERMINALS
CORRODED
PRESS & HOLD OVERRIDE BUTTON
UNTIL YOU CAN SAFELY STOP
TRAILER BRAKES WILL NOT RELEASE
WITH SYSTEM CHARGED
Solution
RICHARD WESTERN
Brake system
Problem
TRAILER BRAKES NOT GOING INTO
"EMERGENCY", AFTER RED LINE
REMOVED
ABS WARNING LAMP IN TRACTOR CAB
ILLUMINATED WHEN NO ABS TRAILER
CONNECTED
ABS WARNING LAMP IN TRACTOR CAB
DOES NOT ILLUMINATE WHEN TRACTOR
CONNECTED TO TRAILER WITH ABS
FITTED
Cause
Solution
KINKED PIPE IN LINE TO RELSV
CHECK ALL PIPES TO PORT 1 OF RELSV
INCORRECT RED SUSIE COUPLING
CHECK COUPLING HAS NO SELF-SEAL
VALVE
RELSV EXHAUST PORT BLOCKED
ENSURE RELSV EXHAUST IS OPEN
EARTH PROBLEM WITHIN TRACTOR'S
ISO 7638 WIRING
CHECK ABS SOCKET FOR TOUCHING,
LOOSE WIRES
CHECK WIRING FROM ABS SOCKET TO
CAB ABS WARNING LAMP.
ABS WARNING LAMP BULB BLOWN
REPLACE BULB
ABS WARNING LAMP FUSE BLOWN
REPLACE FUSE (OFTEN 5 AMP)
NO ABS SUSIE CONNECTED
CONNECT ABS SUSIE TO TRACTOR'S
SOCKET
FAULTY ABS SOCKET
IS PIN 5 PUSHED BACK INTO ABS
SOCKET?
FAULTY ABS SUSIE
REPLACE ABS SUSIE
FAULTY ABS POWER CABLE
CHECK/REPLACE (SEE TEST
INFORMATION)
FAULTY ABS ECU
REPLACE ABS UNIT
CHECK FOR 12 VOLTS ACROSS PINS 1 &
4 OF ABS SOCKET
CHECK FOR 12 VOLTS ACROSS PINS 2 &
3 OF ABS SOCKET
POWER FAULT
ABS WARNING LAMP IN TRACTOR CAB
DOES NOT EXTINGUISH AFTER CIRCA 2
SECONDS, WHEN CONNECTED TO
TRAILER WITH ABS FITTED
ABS WARNING LAMP IN CAB GOES OUT
AFTER CIRCA 2 SECONDS, BUT
ILLUMINATES AGAIN WHILST DRIVING
CHECK FOR 12 VOLTS ACROSS PINS 1 &
8 OF ABS POWER CABLE, AT ABS ECU
END
CHECK FOR 12 VOLTS ACROSS PINS 3 &
4 OF ABS POWER CABLE, AT ABS ECU
END
ABS SENSOR SHORT/OPEN CIRCUIT
CHECK BLINKCODE FOR SENSOR FAULT
LOCATION (SEE LIST)
ECU PROBLEM
CHECK BLINKCODE FOR 12 FLASHES REPLACE IF NECESSARY
ABS POWERED FOR EXTENDED TIME
TOW TRAILER AND CHECK THAT LAMP
GOES OUT AFTER CIRCA 7 KM/H
ABS SENSOR AIR GAP
CHECK ABS SENSOR INSTALLATION,
AND PUSH SENSOR UPTO ABS
POLEWHEEL
POLEWHEEL WOBBLE
CHECK ABS SENSOR AND POLEWHEEL
INSTALLATION, AS WELL AS WHEEL
BEARING
CHECK FOR 12 VOLTS ACROSS PINS 1 &
4 OF ABS SOCKET
CHECK FOR 12 VOLTS ACROSS PINS 2 &
3 OF ABS SOCKET
SYSTEM DOES NOT "EXERCISE" AFTER
POWERING UP (NO CLICKING/CHUFFING
AUDIBLE)
POWER FAULT
CHECK FOR 12 VOLTS ACROSS PINS 1 &
8 OF ABS POWER CABLE, AT ABS ECU
END
CHECK FOR 12 VOLTS ACROSS PINS 3 &
4 OF ABS POWER CABLE, AT ABS ECU
END
FAULTY ABS ECU
REPLACE ABS UNIT
Section 5: 31
5
Problem
FEMALE BRAKE COUPLING WILL NOT
CONNECT TO TRACTOR. EXCESS
RESIDUAL PRESSURE IN BRAKE LINE
Section 5 : 32
Cause
Solution
DISCONNECTED THE HYDRAULIC LINE
BEFORE THE ELECTRICAL LINE
DISCONNECT THE ELECTRICAL LINE
BEFORE THE HYDRAULIC LINE
BACK PRESSURE IN TRAILER BRAKE
LINE
RELEASE PRESSURE, DISCONNECT
BREAKAWAY COUPLING AND
RECONNECT.
DEBRIS CAUSING VALVE MALFUNCTION
REMOVE VALVE C2 CLEAN
THOROUGHLY AND FLUSH SYSTEM
Published and Printed in the
United Kingdom for
Richard Western Trailers Ltd
REF RW 11/2013
Original Documents
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