Pottinger BOSS ALPIN 211 Operating instructions

1631_80_enV.0

Original Operating Instructions

Self-loading trailers

BOSS ALPIN 211

1631

Machine No.: +..00001

Dear Customer

The Operating instructions will allow you to become acquainted with your machine and pro-

vide clear information about safe and correct handling, maintenance and care. Take the time

to read the instructions all the way through.

The operating instructions are a part of the machine. They must be stored in an accessible

location at the workplace for the entire service life of the machine. The user must independ-

ently supplement the instructions regarding national regulations on accident prevention, traf-

fic safety and environment protection.

All persons that are entrusted with the operation, maintenance or transport of the machine

must read and understand these instructions, in particular the safety instructions, before be-

ginning work. Any warranty claims lapse on non-observance of these Instructions.

If you have any questions regarding the contents of these Operating instructions or further

questions regarding the machine, please contact your PÖTTINGER service partner.

Correct maintenance and care according to the defined maintenance intervals will ensure the

operational and traffic safety, as well as the reliability of your machine.

Use only original spare parts or spare parts and accessories that are approved by PÖTTING-

ER Landtechnik GmbH. Only original spare parts that are approved by us have been tested

and accordingly are appropriate for use in your machine. The use of any unapproved parts

forfeits any guarantee or guarantee claim. Even after the end of the warranty period we rec-

ommend using original spare parts to ensure the performance of your machine.

The Product Liability Law obligates manufacturers/dealers to transfer operating instructions

when selling machines, as well as to instruct clients regarding the safety, operation and

maintenance regulations concerning the machine. Confirmation in the form of a declaration

of transfer is required to verify that the implement and Instructions have been transferred cor-

rectly. The declaration of transfer is delivered together with the machine.

Every self-employed person and farmer is an entrepreneur within the meaning of the product

liability legislation. Therefore corporate property damage according to the Product Liability

Law is excluded from the liability of PÖTTINGER. Corporate property damage according to

the Product Liability Law refers to damage caused by the machine. Damage to the machine

is not property damage according to the Product Liability Law.

The operating instructions are a part of the machine, therefore you must transfer them when

selling/transferring the machine to a new user. Train and instruct the new owner in the regu-

lations stated.

The PÖTTINGER service team wishes you the best of luck.

2 | Original Operating Instructions BOSS ALPIN 211 1631_80_enV.0

PÖTTINGER - Trust creates Affinity since 1871

"Quality pays for itself." We therefore apply the highest quality standards to our products,

which are permanently monitored by our in-house quality management team and our man-

agement board Because the safety, perfect function, highest quality and absolute reliability of

our machines in operation are the core competencies for which we stand.

Technical alterations

There may be deviations between these document and the product as we are constantly de-

veloping our products. Therefore no claims may be derived from the data, illustrations and

descriptions. Please contact your Specialist Service Centre for any binding information about

specific features of your machine.

Legal notes

Please note that only the German operating manual constitutes the original operating manual

in regards to the guidelines 2006/42/EC. Operating manuals on languages different than

German, are translations of the German original manual of operation.

We would ask you to please understand that changes to the scope of supply with regard to

form, equipment and technical specifications are possible at any time.

Any form of reprint, translation or reproduction, including excerpts, requires the written appro-

val of PÖTTINGER Landtechnik GmbH.

All rights according to copyright law are expressly reserved by PÖTTINGER Landtechnik

GmbH.

Guarantee and warranty

Please note that the statutory guarantees and warranties granted voluntarily by PÖTTINGER

Landtechnik GmbH can only be invoked for damage stemming from construction, production

or material faults.

PÖTTINGER Landtechnik GmbH cannot be held liable for damage stemming from the use of

consumables such as belts, chains, shafts, gears, tyres, knives teeth or tarpaulins or covers

made from fabric materials or for damage stemming directly or indirectly from contact with

foreign bodies (stones, metal fragments, etc.).

You can find additional information about your machine in MyPöttinger.

Are you looking for suitable accessories for your machine? No problem! All the information

you require is here at your disposal. And if we don't have what you're looking for, then your

Specialist Service Centre is there for you with help and advice.

Scan the QR code on the type plate of the machine or visit http://www.mypoettinger.com

1631_80_enV.0 Original Operating Instructions BOSS ALPIN 211 | 3

You will find the following representations in this operating manual

DANGER

If you do not follow the instructions in a text section with this marking, there is a risk

of fatal or life-threatening injury.

► All instructions in such text sections must be followed!

WARNING

If you do not follow the instructions in a text section with this marking, there is a risk

of severe injury.

► All instructions in such text sections must be followed!

CAUTION

If you do not follow the instructions in a text section with this marking, there is a risk

of injury.

► All instructions in such text sections must be followed!

NOTICE

If you do not follow the instructions in a text section with this marking, there is a risk

of damage to property.

► All instructions in such text sections must be followed!

TIP

Marked text sections contain recommendations and advice on handling the machine.

ENVIRONMENT

Marked text sections contain advice on the subject of environmental protection.

Equipment marked as optional is available only for certain machine models or in certain

countries.

Images may differ in detail to your machine and should only be considered as indicative.

4 | Original Operating Instructions BOSS ALPIN 211 1631_80_enV.0

Instructions for product handover

Please verify the listed items in accordance with the product liability obligation

Please, tick off where appropriate.

Machine checked according to delivery note. All packing materials removed, all

safety devices, cardan shafts and control elements present.

Machine operation, commissioning and maintenance discussed with and explained

to the clients using the operational instructions.

Tyre air pressure verified.

Tightness of wheel nuts verified.

Reference to correct p.t.o. speed and direction of rotation.

Adaptation to tractor complete; three point adjustment, drawbar height, attachment

of handbrake lever in tractor cab, forced steering set, compatibility of all necessary

electrical, hydraulic and pneumatic connectors to tractor checked and established.

Cardan shaft correctly cut to length.

Test run of all machine functions in addition to parking brake and operating brake

completed and no defects noted.

Function explanation during test run.

Tilting to transport and working position explained.

Information regarding optional equipment provided.

References made to compulsory reading of the operational instructions.

Confirmation is required to prove that the machine and the operating instructions have been

properly handed over. For this purpose you have received a confirmation e-mail from PÖT-

TINGER. If you have not received this mail, please contact your local dealer. Your dealer can

fill in the handover declaration online.

Austria

PÖTTINGER Landtechnik GmbH

Industriegelände 1

4710 Grieskirchen

Phone+43 7248 600-0

Fax+43 7248 600-2513

[email protected]

1631_80_enV.0 Original Operating Instructions BOSS ALPIN 211 | 5

Amendment index

Date Index Amendment reason Amended chapter

6 | Original Operating Instructions BOSS ALPIN 211 1631_80_enV.0

Truck transport

Unload the machine by crane........................................................................................... 13

Factory standard tightening torque

Tightening torque.............................................................................................................. 14

Layout and function

Functional elements.......................................................................................................... 15

Accessories included in the scope of delivery................................................................... 17

Upgrade program.............................................................................................................. 17

At a glance

Identification...................................................................................................................... 18

Type plate with CE marking......................................................................................... 18

Description

EU - declaration of conformity........................................................................................... 20

Intended use..................................................................................................................... 21

Non-approved useage....................................................................................................... 21

Technical data

Dimensions....................................................................................................................... 22

Attachment........................................................................................................................ 22

Weights............................................................................................................................. 22

Tyres — chassis................................................................................................................ 23

Blade................................................................................................................................. 23

Power requirements.......................................................................................................... 23

Hydraulic pressure and flow rate....................................................................................... 24

Electrics............................................................................................................................. 24

Noise emission.................................................................................................................. 24

Safety and the environment

Safety advice..................................................................................................................... 25

Qualification of personnel............................................................................................ 25

Performing maintenance work..................................................................................... 25

Contents

1631_80_enV.0 Original Operating Instructions BOSS ALPIN 211 | 7

Organisational measures............................................................................................. 25

Fuel efficiency and soil protection............................................................................... 25

Maintaining operational safety..................................................................................... 25

Special hazards........................................................................................................... 26

Safety devices................................................................................................................... 27

Warning signs.............................................................................................................. 27

Traffic safety equipment.............................................................................................. 33

Environmental protection.................................................................................................. 37

Handling hazardous substances................................................................................. 37

Disposal of the machine.............................................................................................. 37

Control terminal operation

DIRECT CONTROL Terminal operation........................................................................... 39

DIRECT CONTROL Terminal overview...................................................................... 39

DIRECT CONTROL keys/soft keys............................................................................. 41

Basic functions............................................................................................................ 42

Turn terminal on/off and open "START" menu.................................................................. 42

"WORK" menu............................................................................................................. 43

"SET" menu................................................................................................................. 49

Calibrating pick-up angle sensors..................................................................................... 50

“CONFIG” menu.......................................................................................................... 51

"TEST" menu............................................................................................................... 53

"DATA" menu.............................................................................................................. 57

“DIAG” menu (diagnosis menu)................................................................................... 58

SELECT CONTROL.......................................................................................................... 59

SELECT CONTROL Terminal overview...................................................................... 59

Keys / Softkeys............................................................................................................ 61

Basic functions............................................................................................................ 62

SELECT CONTROL Operating diagram........................................................................... 62

Turn terminal on/off and activate START menu................................................................ 62

"WORK" menu............................................................................................................. 63

"SET" menu................................................................................................................. 66

“CONFIG” menu.......................................................................................................... 67

"TEST" menu............................................................................................................... 68

"DATA" menu.............................................................................................................. 69

“DIAG” menu (diagnosis menu)................................................................................... 71

Contents

8 | Original Operating Instructions BOSS ALPIN 211 1631_80_enV.0

Valves / cover / auxiliary equipment

Opening / closing cover and valves.................................................................................. 72

Side protection / front protection operation.................................................................. 72

Auxiliary and special functions.......................................................................................... 72

Support stand with support wheel handling................................................................. 72

Operation

Initial operation.................................................................................................................. 75

Determine tractor ballast............................................................................................. 75

Determine the required tractor ballast weights using the weighing method...................... 76

Determine the required tractor ballast weights using calculation...................................... 77

Adapting the tractor hydraulics.................................................................................... 78

Adjustment of the cardan shaft.................................................................................... 79

Check PTO drive............................................................................................................... 81

Emergency-brake adjustment bolt position (hydraulic single pipe brake H1L)............ 81

Adjusting and retrofitting................................................................................................... 82

Roof ropes................................................................................................................... 83

Adjust pivoting drawbar............................................................................................... 83

Adjusting the insertable handbrake............................................................................. 88

Breakaway cable attachment (emergency brake valve hydraulic single pipe brake

H1L)............................................................................................................................. 90

Rear operation adjustment.......................................................................................... 91

Adjusting the dry fodder unit relief............................................................................... 92

Adjusting the telescopic tailgate struts (option)........................................................... 93

Coupling............................................................................................................................ 95

Attach drawbar............................................................................................................ 96

Connect cardan shaft.................................................................................................. 97

Connecting the overrun brake breakaway cable......................................................... 99

Attaching the safety cable........................................................................................... 99

Connect hydraulic hoses............................................................................................. 100

Reset machine and braking force / manual regulator (H2L + H1L)............................. 103

Load sensing valve adjustment................................................................................... 103

Connect cables............................................................................................................ 104

Mounting/installing the hydraulic control unit............................................................... 104

DIRECT CONTROL Terminal installation.................................................................... 105

Mounting the SELECT CONTROL terminal................................................................ 106

Work assignment.............................................................................................................. 107

Contents

1631_80_enV.0 Original Operating Instructions BOSS ALPIN 211 | 9

Emergency brake valve Hydraulic brake .................................................................... 108

Manual load matching valve setting (hydraulic brake)................................................. 108

Permissible cardan shaft angle................................................................................... 109

Dry fodder unit manual operation................................................................................ 109

Hydraulic operation of the tailgate............................................................................... 111

Tailgate manual operation........................................................................................... 113

Loading procedure....................................................................................................... 116

Loading procedure general tips......................................................................................... 116

Adjusting the pick-up......................................................................................................... 116

Loading procedure............................................................................................................ 117

Unloading procedure................................................................................................... 120

Unloading and dry fodder unit........................................................................................... 120

Decommissioning ............................................................................................................. 121

Switching off the machine............................................................................................ 121

Unhitching......................................................................................................................... 122

Uncoupling the cardan shaft........................................................................................ 123

Uncouple the machine from the tractor....................................................................... 123

Care and maintenance

Ensure operational readiness........................................................................................... 125

General tips....................................................................................................................... 125

Lifting jack lifting points..................................................................................................... 126

Trailer brake valve quick release position (air brake)........................................................ 126

Oil filling, oil drainage and oil level control plugs............................................................... 127

Cardan shaft maintenance................................................................................................ 128

Checking the friction clutch.......................................................................................... 129

Check the cardan shaft cam clutch............................................................................. 130

Daily maintenance............................................................................................................. 130

Check/correct tyre pressures....................................................................................... 130

Check hydraulic system............................................................................................... 131

Checking/correcting overrun brake.............................................................................. 132

Check / replace warning signs, warning triangles, warning sheets............................. 135

Check the brake hoses and hose couplings................................................................ 136

Draining the compressed air tank................................................................................ 137

Before every season......................................................................................................... 138

Topping up the gear oil................................................................................................ 138

Change gear oil........................................................................................................... 138

Before every season and then after every 40 operating hours......................................... 139

Contents

10 | Original Operating Instructions BOSS ALPIN 211 1631_80_enV.0

Lubricate the pick-up drive chains............................................................................... 139

After every season............................................................................................................ 140

Clean outside of machine............................................................................................ 140

As required........................................................................................................................ 141

Fold out or swivel out sideways the cutter bar............................................................. 141

Cutter unit removal (rigid cutter bar)............................................................................ 145

Cutter removal/installation (hydraulic cutter bar)......................................................... 147

Knife sharpening.......................................................................................................... 148

Clean the cutter safety device..................................................................................... 149

Hydraulic oil filter change............................................................................................ 150

Clean terminal............................................................................................................. 150

Checking/retensioning the scraper floor chains........................................................... 151

Readjusting the insertable handbrake......................................................................... 152

Setting the tailgate adjustment.................................................................................... 153

After service life................................................................................................................. 155

Initially after 10 hours, then first loaded journey after tyre changes, then every

500 hours..................................................................................................................... 155

Retighten washers............................................................................................................ 155

Every 200 operating hours.......................................................................................... 156

Check the brake linings..................................................................................................... 156

Every 40 loads............................................................................................................. 156

Lubricate press conveyor combs...................................................................................... 156

Every 80 loads............................................................................................................. 157

Lubricate press main bearing............................................................................................ 157

Adjust the press drive chain.............................................................................................. 157

x per year..................................................................................................................... 158

Check the gear oil fill level................................................................................................ 158

Lubricating the support wheel locking bolts...................................................................... 159

2x per year................................................................................................................... 159

Lubricate the overrun device of the overrun brake............................................................ 159

Every 4 years............................................................................................................... 160

Check and adjust hydraulic pressure accumulator........................................................... 160

Every 6 years............................................................................................................... 161

Hydraulic hoses................................................................................................................. 161

Lubrication plans............................................................................................................... 161

Hydraulics diagrams.......................................................................................................... 163

Electrical diagram.............................................................................................................. 166

Contents

1631_80_enV.0 Original Operating Instructions BOSS ALPIN 211 | 11

Operating materials

Equipment specification.................................................................................................... 176

Working materials and fill quantities.................................................................................. 176

Help and advice

What to do if...................................................................................................................... 177

Inertia brake troubleshooting....................................................................................... 177

Pressure line cannot be disconnected (3-way valve).................................................. 178

Pressure line cannot be disconnected (cabin operation, variant 2)............................. 179

Malfunctions/causes/remedies.................................................................................... 180

Plans

Hydraulic diagram, cabin operation................................................................................... 183

Electrical circuit diagram................................................................................................... 184

Contents

12 | Original Operating Instructions BOSS ALPIN 211 1631_80_enV.0

Unload the machine by crane

Prerequisite

• Take note of technical information (weight)!

• Only use a lifting device with adequate dimensions.

• Use lifting gear with lifting beams, to avoid pushing side walls.

Attachment points for lifting gear

Implementation

► Carefully attach and secure hoists to the attachment points.

CAUTION

Danger of injury through machine falling!

► To remain under the suspended load is prohibited!

► Remove the fastenings from the loading surface.

► Lift the machine horizontally from the loading surface and place on level, load-bearing

ground.

► Remove hoist.

Truck transport

1631_80_enV.0 Original Operating Instructions BOSS ALPIN 211 | 13

Tightening torque

This factory standard applies to all metric bolts for which no special tightening torque is

specified in the drawing/manual. The relevant grade is visible on the bolt head.

• The values given are nominal and are valid for a head friction rate of IJ=0.14 and a

thread friction of IJ=0.125 Slight tensioning force differences can exist through differing

friction rates. The values given are to be kept to a tolerance of ± 10%.

• By using the given tightening torque and the existing friction rate used, then up to 90%

of the minimum yield strength of the bolt material is used in accordance with DIN ISO

898 .

• If a specific tightening torque is given for a bolt connection, then all these bolt connec-

tions are to be tightened to the specified tightening torque using a torque wrench.

Thread Grade 8.8 Grade 10.9

Tightening tor-

que in Nm

Tensioning force

in N

Tightening tor-

que in Nm

Tensioning force

in N

M 4 3.1 4000 4.4 5700

M 5 6.2 6600 8.7 9300

M 6 10.5 9300 15 13000

M 8 25 17000 36 24000

M 10 50 27000 70 38000

M 12 86 39500 121 56000

M 14 135 54000 195 76000

M 16 215 75000 300 105000

M 20 410 117000 580 164000

M24 710 168000 1000 237000

M 30 1400 270000 2000 380000

M 8 x 1 27 18700 38 26500

M 10 x 1.25 53 29000 74 41000

M 12 x 1.25 95 44500 130 63000

M 14 x 1.5 150 60000 210 85000

M 16 x 1.5 230 81000 320 115000

M 20 x 1.5 460 134000 650 189000

M 24 x 2 780 188000 1090 265000

Factory standard tightening torque

14 | Original Operating Instructions BOSS ALPIN 211 1631_80_enV.0

Functional elements

Names and functions

Pos. Element Function

1 Articulated drawbar Hydraulically or manually actuated. Attaching to tractor

and setting the machine height.

2 Handbrake Manually actuated

3 Dry crop extension Hydraulically or manually swivelled. Special for low den-

sity crops such as straw or hay.

4 Tailgate Hydraulically actuated

5 Scraper floor Hydraulically actuated. Conveys the loaded material

during loading and unloading with selectable speed.

6 Cutting unit Shredding of the crop. Cutter replacement via quick-

change cutter holder.

7 Pick up The pick-up adapts to the uneven ground due to the

flexible suspension and enables quick and clean picking

up of the crop from the field and transfer to the rotor and

cutting unit

8Support wheel Manually actuated. Placing the machine on a level and

load-bearing surface.

Layout and function

1631_80_enV.0 Original Operating Instructions BOSS ALPIN 211 | 15

Layout and function

16 | Original Operating Instructions BOSS ALPIN 211 1631_80_enV.0

Accessories included in the scope of delivery

B = Splash-proof box for the accompanying documentation

D = Drawbar immobilizer (differs depending on drawbar design)

No illustration = chocks

Accompanying documentation

• Operating manual

• Parts list

• Delivery declaration; See "Instructions for product handover" on page 5.

Upgrade program

The PÖTTINGER Landtechnik GmbH upgrade program offers many upgrade possibilities.

You can receive additional information from your service dealer.

Layout and function

1631_80_enV.0 Original Operating Instructions BOSS ALPIN 211 | 17

Identification

Type plate with CE marking

T = Vehicle identification plate position

(1) Type plate

Before making any enquiries about the machine or technical details, note down the model

and type from the nameplate and keep them handy. Chassis no. and/or serial no. are re-

quired for ordering spare parts.

(2) CE label

The CE label confirms that the machine conforms with the provisions of the Machinery Direc-

tives.

Included data

The following data is displayed on the identification plate for each machine type and design.

Data

Chassis number

Model

Vehicle identification number

Type

Type number

Serial number

Basic weight

Permissible total weight

At a glance

18 | Original Operating Instructions BOSS ALPIN 211 1631_80_enV.0

Data

Model year

Bearing load

Axle load per axle

Model year

Year of mfr

At a glance

1631_80_enV.0 Original Operating Instructions BOSS ALPIN 211 | 19

EU - declaration of conformity

Description

20 | Original Operating Instructions BOSS ALPIN 211 1631_80_enV.0

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Pottinger BOSS ALPIN 211 Operating instructions

Pottinger BOSS ALPIN 211 Operating instructions

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