175_4316-gigant 12 Und 12s-05_10-en

Transcript

Operating Instructions System-Trac Gigant 12 and 12S - EN Item no. 175_4316 2/05.10 LEMKEN GmbH & Co. KG Weseler Straße 5, D-46519 Alpen / PO Box 11 60, D-46515 Alpen Telephone (0 28 02) 81-0, Fax (0 28 02) 81-220 E-mail: [email protected], Internet: http://www.lemken.com Dear customer, Thank you for the trust you have placed in us by purchasing this device. The device can only be used to its full advantage when operated and used properly. When the device was delivered, you will already have been instructed in operation, adjustment and maintenance by your dealer. However, this brief instruction is not a substitute for thorough study of the operating instructions. These operating instructions will help to familiarise you with the LEMKEN GmbH & Co. KG device and the options available for using it. The operating instructions contain important information about how to operate the device safely, properly and efficiently. Following the instructions will help to prevent hazards, faults and down times and will increase reliability and service life. Read the operating instructions carefully and attentively before commissioning. Make sure that the operating instructions are always available at the location where the device is used. The operating instructions must be read and followed by anyone who is involved in carrying out the following work: • Coupling and uncoupling • Adjustments • Operation • Maintenance and repairs • Troubleshooting, and • Final shutdown and disposal. These operating instructions are deemed to be the original operating instructions. 1 Spare parts ordering This device is supplied with a specification listing all assemblies that are relevant for the product. The spare parts list valid for your device includes both those assemblies relevant to you and those that are not intended for your device. Make sure that you only order spare parts that belong to the assemblies that can be found on your specification or the enclosed print out. When ordering spare parts, state the type designation and serial number of the device. This information can be found on the rating plate. Enter this data in the fields below so that it is always to hand. Type designation: Serial number: Remember that you should only use genuine LEMKEN spare parts. Reproduction parts have a negative influence on the function of the device, have a shorter service life and present risks and hazards that cannot be estimated by LEMKEN GmbH & Co. KG. They also increase the maintenance costs. Service and spare parts Information on service and spare parts is available from your local dealer or our website at www.lemken.com. 2 Contents CONTENTS Contents ........................................................................................................................... 3 1 Turning at the field perimeter .................................................................................. 8 2 Safety Instructions .................................................................................................. 10 3 Safety equipment .................................................................................................... 15 4 5 6 3.1 General information .................................................................................................... 15 3.2 Protective equipment.................................................................................................. 15 Special hazards ....................................................................................................... 16 4.1 General information .................................................................................................... 16 4.2 Hazards during operation ........................................................................................... 16 4.3 Hazards during transportation ................................................................................... 17 Symbols used in the Operating Instructions........................................................ 18 5.1 Hazard classes ............................................................................................................ 18 5.2 Information................................................................................................................... 18 5.3 Environmental protection ........................................................................................... 18 5.4 Indication of passages................................................................................................ 19 Warning Stickers ..................................................................................................... 20 6.1 General Instructions ................................................................................................... 20 6.2 Meaning of the Stickers .............................................................................................. 20 6.3 Position of warning symbols...................................................................................... 22 7 Other symbols ......................................................................................................... 25 8 Design and description .......................................................................................... 26 8.1 Overview ...................................................................................................................... 26 8.2 Towing gear with drawbar eye ................................................................................... 28 8.3 Folding frame with three-point hydraulics ................................................................ 29 8.4 Axle with wheels.......................................................................................................... 29 8.5 Three-point hydraulics................................................................................................ 29 8.6 Depth guide with roller ............................................................................................... 29 3 Contents 8.7 Quick coupler with pendulum balance...................................................................... 29 8.8 Adjustable pressure limiter valve .............................................................................. 29 8.9 Servo wheel (servo depth wheel, servo uni wheel) .................................................. 29 8.10 Servo uni wheel ........................................................................................................... 29 8.11 Sensors ........................................................................................................................ 30 8.12 Tail brake ..................................................................................................................... 30 8.13 Wheel arm joint (servo wheel).................................................................................... 30 9 Braking system ....................................................................................................... 31 9.1 Compressed air braking system ................................................................................ 31 9.1.1 Overview .................................................................................................................. 31 9.1.2 Function description ................................................................................................. 31 9.2 Hydraulic braking system........................................................................................... 33 10 Servo wheel ............................................................................................................. 34 10.1 General information .................................................................................................... 34 10.2 Servo depth wheel....................................................................................................... 34 10.3 Servo uni wheel ........................................................................................................... 35 10.4 Hydraulic system for servo wheel ............................................................................. 36 10.5 Adjusting the servo wheel .......................................................................................... 37 10.5.1 From working position to transport position .......................................................... 37 10.5.2 Locking the joint.................................................................................................... 38 11 Preparations on tractor .......................................................................................... 39 11.1 Tyres............................................................................................................................. 39 11.2 Hitch coupling ............................................................................................................. 39 11.2.1 Supporting load table............................................................................................ 40 11.3 Axle load ...................................................................................................................... 41 11.4 Required power sockets ............................................................................................. 41 11.5 Required hydraulic control units ............................................................................... 42 11.6 Brake system ............................................................................................................... 42 11.6.1 4 Air brake system................................................................................................... 42 Contents 11.6.2 Hydraulic brake system ........................................................................................ 42 12 Coupling and uncoupling ....................................................................................... 43 12.1 Coupling the device .................................................................................................... 43 12.2 Uncoupling the device ................................................................................................ 44 13 Extending/retracting ............................................................................................... 46 13.1 General information .................................................................................................... 46 13.2 Retracting (without servo wheel) ............................................................................... 46 13.3 Extending (without servo wheel) ............................................................................... 47 13.4 Retracting (with servo wheel)..................................................................................... 48 13.5 Extending (with servo wheel) ..................................................................................... 50 14 Roller adjustment .................................................................................................... 52 14.1 General information .................................................................................................... 52 14.2 Transport position....................................................................................................... 53 14.2.1 Smaragd 9 and 9 U .............................................................................................. 53 14.2.2 Rubin 9 U.............................................................................................................. 54 14.3 Working position ......................................................................................................... 54 15 Attaching and detaching wing sections ............................................................... 55 15.1 General information .................................................................................................... 55 15.2 Coupling....................................................................................................................... 56 15.3 Uncoupling................................................................................................................... 61 16 Three-point hydraulics ........................................................................................... 63 16.1 Gigant Smaragd and Gigant system compactor ..................................................... 63 16.2 Gigant Rubin................................................................................................................ 63 16.3 Top link ........................................................................................................................ 64 17 Adjustments............................................................................................................. 67 17.1 Spring operated brake cylinder.................................................................................. 68 17.2 Smaragd 9 U ................................................................................................................ 70 17.2.1 Working depth ...................................................................................................... 70 17.2.2 Working depth of hollow discs .............................................................................. 72 5 Contents 17.2.3 Harrow .................................................................................................................. 73 17.2.4 Share position....................................................................................................... 75 17.2.5 Shear device......................................................................................................... 76 17.2.6 Automatic overload protection .............................................................................. 78 17.3 Rubin 9 U ..................................................................................................................... 80 17.3.1 Working depth ...................................................................................................... 80 17.3.2 Rebound harrow ................................................................................................... 81 17.3.3 Guide plates ......................................................................................................... 82 17.3.4 Side limitation ....................................................................................................... 83 17.4 System compactor ...................................................................................................... 84 17.4.1 Pressure load on front crumbling rollers ............................................................... 84 17.4.2 Pressure distribution on rear rollers...................................................................... 87 17.4.3 Wheel track eliminator (accessory)....................................................................... 88 17.4.4 Shifting the harrow frames.................................................................................... 90 17.4.5 Working depth of tines.......................................................................................... 91 17.4.6 Cutting bars .......................................................................................................... 92 17.4.7 Height adjustable side plates................................................................................ 94 17.4.8 Stone guards ........................................................................................................ 95 17.5 Rollers .......................................................................................................................... 95 17.5.1 General information .............................................................................................. 95 17.5.2 Scrapers ............................................................................................................... 96 17.5.3 Scraper GRW ....................................................................................................... 97 17.5.4 Blade rollers.......................................................................................................... 98 17.6 Depth guide................................................................................................................ 100 17.7 Depth wheels (Smaragd 9U attachments only)....................................................... 102 18 Maintenance/repairs ............................................................................................. 104 18.1 Special safety instructions ....................................................................................... 104 6 18.1.1 General............................................................................................................... 104 18.1.2 Personnel qualifications...................................................................................... 104 18.1.3 Personal protective clothing................................................................................ 105 18.1.4 Shutting down the device for maintenance/repairs ............................................. 105 18.1.5 Work on the hydraulics ....................................................................................... 105 18.1.6 Work on the electrical system............................................................................. 106 Contents 18.1.7 Working under raised device .............................................................................. 106 18.1.8 Tools used .......................................................................................................... 107 18.2 Environmental protection ......................................................................................... 107 18.3 Lubrication................................................................................................................. 108 18.4 Maintenance intervals............................................................................................... 108 18.4.1 After commissioning (within 2 hours).................................................................. 108 18.4.2 Daily check ......................................................................................................... 109 18.4.3 Weekly check ..................................................................................................... 110 18.4.4 Monthly check..................................................................................................... 110 18.4.5 Lubrication chart ................................................................................................. 111 18.4.6 Overview of lubricating points............................................................................. 112 18.5 Tightening torques.................................................................................................... 115 18.5.1 Wheel nuts.......................................................................................................... 115 18.5.2 Other screw connections .................................................................................... 115 18.6 Draining the compressed air tank............................................................................ 116 18.7 Adjusting the brake................................................................................................... 116 18.8 Changing the brake pads.......................................................................................... 116 18.9 Cleaning the filter ...................................................................................................... 117 19 Technical data ....................................................................................................... 118 19.1 Dimensions approx. cm............................................................................................ 118 19.2 Weights approx. kg ................................................................................................... 118 19.3 Supporting and axle loads approx. kg .................................................................... 119 19.4 Tyres / Air pressure................................................................................................... 120 19.4.1 Chassis............................................................................................................... 120 19.4.2 Depth wheels and servo wheels ......................................................................... 120 Index ............................................................................................................................. 121 EU Declaration of Conformity .................................................................................... 123 7 Turning at the field perimeter 1 TURNING AT THE FIELD PERIMETER 3 1 The field perimeter should have sufficient width to allow rapid turning and connection manoeuvres. Depending on the tractor used, a width of 20 m to 24 m is sufficient. Only raise and lower attachments when driving straight forwards. The attachments should always be positioned straight behind the tractor. Raising and lowering the attachments while cornering increases the loads on the components unnecessarily and has a negative influence on the service life of the attachments. − When the field perimeter is reached, fully raise the attachments (1) using the three-point hydraulics. This relieves a greater or lesser proportion of the load on the rear axle of the tractor, depending on the attachment used. See "Supporting load table" section. − Execute the turn in a curve in such a way that the tractor and device are pointing straight at the field exactly one working width further across. − Completely lower the attachments again using the three-point hydraulics. 8 Turning at the field perimeter 2 − With three-point hydraulics with pressure limiter valve (2), hold the operating lever or button on the tractor control unit in the lowering position for several seconds to allow the set operating pressure to build up. − Then turn the tractor control unit to "Neutral". With a servo wheel (3), part of the weight of the attachments is borne by the corresponding servo wheel during the turn. This relieves less of the load on the rear axle of the tractor and places less load on the chassis axle. See "Supporting load table" and "Servo wheels" sections. 9 Safety Instructions 2 SAFETY INSTRUCTIONS General Safety Instructions • Before using the machine, always check both it and the tractor for roadworthiness and operational safety! • As well as the notes in these instructions the operator is advised to comply with the generally applicable safety at work regulations and those relating to use of the public highway! • When driving on public roads with a raised machine the lifting control lever should be locked against unintentional lowering! • The fitted warning and advisory plates give important information for safe operation; adhering to these increases your own safety! • When using public roads adhere to applicable traffic rules! • The operator should familiarise him-/herself with all controls and their functions before starting work. During work could be too late! • The clothing of the operator should fit tight. Avoid wearing any loose clothing! • To avoid danger of fire keep the implement clean! • Before beginning to drive check surroundings area (children)! • Sitting or standing on the implement during operation or during transport is not permissible. • Attach implements as advised and only to the stipulated positions! • Special care should be taken when the implement is coupled to or uncoupled from the tractor. • When coupling or uncoupling the implement bring the supporting stands into the corresponding position (standing safety)! • Fit weights only to the fixing points provided for those purposes! • Adhere to the maximum permissible axle loads, total weights and transport width! 10 Safety Instructions • Fit and check transport gear, road lights and warning guards! • The release ropes for quick coupler latches should hang freely and in the lowered position must not release the quick coupling by themselves. • Never leave the driver's seat whilst in motion! • Handling behaviour, steerability and braking are influenced by mounted implements, trailers and ballast weights. Check for sufficient steerability and braking! • When driving round bends note the width of the machine and/or changing centre of gravity of the implement. • Put implement into operation only when all guards are fixed in position! • Never stay or allow anyone to stay within the operating area! • Never stay in the turning and slew area of the implement! • Do not operate any hydraulic controls while anybody is in the operating area! • On all pivoting parts actuated by power assistance (e.g. hydraulics) exists danger of injury by bruising and crushing! • Before leaving the tractor lower the machine to the ground. Apply the parking brake, stop the engine and remove the ignition key! • Do not allow anybody between the tractor and implement if the parking brakes are not applied! • Swing attachment arm to transport position and secure! Trailed implements • Secure implement and tractor against unintended rolling! • Never exceed the maximum permissible load of the drawbar or hitch! • When fitting the implement to a drawbar or hitch, ensure sufficient movement at the hitch-point. 11 Safety Instructions Attached devices (system trac) • For three-point coupling, the coupling categories of the system trac's three-point hydraulics and the attachments must always be identical or be co-ordinated. • There is a risk of crushing or shearing injury around the three-point linkage. • When driving on the road with the attachments retracted, the operating lever must be locked to prevent extension. Hydraulic Equipment • The hydraulic pipes are under pressure! • When connecting hydraulic rams, the pipes must be connected as directed! • Always release hydraulic pressure from both tractor and implement before coupling! • When connecting hydraulic pipes to the tractor ensure that incorrect use is avoided. If the connections are reversed, the opposite function is carried out (e.g. raising/lowering) and there is a risk of accidents! • Regularly check the hydraulic pipes and replace them in the event of damage or signs of ageing. The replacement pipes must comply with the technical specification as laid down by Lemken! • When searching for leaks appropriate aids should be used because of the danger of injury! • Hydraulic oil escaping at high pressure can penetrate the skin and cause serious injury! When injured see a doctor immediately! Danger of infection! • Before working on any hydraulic equipment - lower all implements/attachments, release hydraulic pressure where possible and switch off the tractor engine! 12 Safety Instructions Tyres • When working on the tyres make sure that the implement has been placed on the ground safely and that it is secured by chocks against unintentional rolling! • Fitting tyres requires knowledge and special tools! • Repair work on tyres may only be conducted by trained staff and with suitable tools! • Check air pressure regularly and adhere to the advised air pressure! Maintenance • Repair-, maintenance- and cleaning operations as well as adjustments and remedy of function faults should principally be conducted with engine stopped and brakes applied. Remove ignition key! • Check and tighten nuts and bolts regularly! • When conducting maintenance work on a lifted implement always place suitable supports underneath! • For replacing any tools with cutting edges always use suitable tools and gloves! • Dispose of old oils, grease and filters as prescribed by law. • Before working on the electric gear disconnect battery cables! • When conducting electrical welding operations on the tractor or on the mounted implement remove cable from the generator and the battery! • Any spare parts fitted must meet with the implement manufacturer's fixed technical standards! This is for example ensured by using genuine spare parts! • To avoid danger of explosion only use nitrogen for filling up gas tanks! 13 Safety Instructions Brakes • Check function of brakes before each drive! • The braking systems must be checked regularly! • Repair work on brakes may only be conducted by trained staff and with suitable tools! 14 Safety equipment 3 SAFETY EQUIPMENT 3.1 General information Before each use, the function of all safety equipment must be checked and it must be used or operated as specified in this manual. 3.2 Protective equipment Where the system trac can be transported on public roads, the protective equipment (1) must be fitted before commencing transportation. The protective equipment is fastened to the relevant attachment using hooks (2) and straps (3). 3 1 3 3 1 3 2 15 Special hazards 4 SPECIAL HAZARDS 4.1 General information To use the device safely, it is essential to observe the following points. 4.2 Hazards during operation • Always maintain sufficient clearance from masts, buildings, trees and other obstructions during operation. • The device is simulatenously extended upwards and outwards / retracted downwards and backwards. Only extend and retract the device when no persons are in the vicinity; minimum clearance to side and rear = 10 m! • The device is more than 4 m in height when retracted. Never extend and retract the device in the vicinity of electrical and high-voltage cables or inside or in underpasses or under bridges. • When extending, the device reaches a height of 5 to 6m. Only extend and retract the device where there are no height restrictions. • The device requires a large space for extending. Only extend the device where there is clearance of at least 10 m to the rear and at least 8 m to the left and right to masts, buildings, trees and other obstructions. In case of doubt, extend the device in another location. • When working, the view can be impaired by dust. Stop work immediately if persons are present in the field or dust impairs the view excessively. • When turning at the field perimeter, the load on the rear axle of the tractor is reduced. Make sure that the device is only used with a tractor that has a rear axle load of at least 7000 kg. • During work, the hitch coupling is subject to both downward and upward (negative supporting load) loads. Make sure that the hitch coupling is suitable for these loads (see supporting load table). 16 Special hazards 4.3 Hazards during transportation • The device is 3.50 or 4 m wide in transport position. Only transport on roads and paths that allow safe transportation. • The device is more than 4 m in height. Only transport on roads and paths that allow safe transportation. • Depending on the operating width and equipment fitted, the axle load may be greater than 10 t; refer to the "Technical Data" section in this manual. Only use roads and paths that are suitable for these axle loads. • The tractor and device have a large combined weight. Make sure that there is always adequate braking for the tractor and device and that the specified braking power is achieved. 17 Symbols used in the Operating Instructions 5 SYMBOLS USED IN THE OPERATING INSTRUCTIONS 5.1 Hazard classes The following symbols are used in the Operating Instructions for particularly important information: DANGER Denotes an imminent hazard with high risk, which will result in death or severe physical injury, if not avoided. WARNING Denotes a possible hazard with medium risk, which could result in death or severe physical injury, if not avoided. CAUTION Denotes a low-risk hazard, which could cause light or medium physical injury or property damage, if not avoided. 5.2 Information Denotes special user tips and other particularly useful or important information for operation and efficient utilisation. 5.3 Environmental protection Indication of special recycling and environmental protection measures. 18 Symbols used in the Operating Instructions 5.4 Indication of passages The following symbols are used for particular passages in the operating instructions: − Indicates enumerations and work steps • Indicates instructions for action and information in safety instructions 19 Warning Stickers 6 WARNING STICKERS 6.1 General Instructions The LEMKEN implement is equipped with all features to ensure safe operation. Where potential danger areas of the implement can not be fully safeguarded, warning stickers are fitted which draw attention to these. Damaged, lost or unreadable warning stickers must be replaced immediately. The stated part numbers are used as order numbers. 6.2 Meaning of the Stickers Familiarise with the meaning of the stickers. The following descriptions inform about them in detail. WARNING: Read and adhere to this instruction book and these „General Health- and Safety precautions„ before putting the implement to work! WARNING: Shut off engine and remove key before performing maintenance or repair work! WARNING: Keep well clear of the working and swinging area of the implement! 20 Warning Stickers WARNING: Pinch point! WARNING! Keep well clear of the folding area of the implement! 390 0540 WARNING: Hydraulic accumulator contains gas and oil under pressure. For removal and repair instructions in technical manual must be followed! ATTENTION: Keep a sufficient distance away from electric high-voltage lines 21 Warning Stickers CAUTION: Always ensure that there is a sufficient rear axle load! 390 0617 6.3 22 Position of warning symbols Warning Stickers 23 Warning Stickers 24 Other symbols 7 OTHER SYMBOLS Lubricate and service implement in accordance with maintenance chart! 25 Design and description 8 DESIGN AND DESCRIPTION 8.1 Overview 11 12 1 3 4 2 1 2 3 4 5 6 7 8 9 26 6 10 9 Towing gear with drawbar eye V pole Stand in transport bracket Toolbox Base frame Folding frame (central section) Folding frame (side section) Axle with wheels Three-point hydraulics 10 11 12 13 14 15 16 Depth guide with roller Attachment Bottom link Top link Quick coupler with pendulum balance Adjustable pressure limiter valve Axle Design and description 11 3 1 2 3 4 5 6 7 8 9 4 2 Towing gear with drawbar eye V pole Stand in transport bracket Toolbox Base frame Folding frame (central section) Folding frame (side section) Axle with wheels Three-point hydraulics 5 8 9 10 11 12 13 14 15 16 Depth guide with roller Attachment Bottom link Top link Quick coupler with pendulum balance Adjustable pressure limiter valve Axle 13 9 15 5 16 12 14 27 Design and description 17 Servo (uni) wheel 26 18 Hydraulic cylinder for wheel arm 24 25 19 Hydraulic cylinder for tail wheel axle 19 20 Sensor for excavation limiter 18 21 Sensor for detecting transport position 22 Sensor for detecting working position 17 23 Tail brake for tail wheel axle 24 Locking screw for wheel arm Servo uni wheel in transport position 25 Pressure gauge indicating pressure of servo uni wheel in transport position 26 Locking bolt 17 Servo wheel when turning 22 18 23 20 21 8.2 Towing gear with drawbar eye The towing gear with drawbar eye is used for attaching a suitable dual-axle hitch coupling on a tractor. 28 Design and description 8.3 Folding frame with three-point hydraulics The folding frame is used to extend and retract the attachments fitted to the threepoint hydraulics. The slanted pivoting axles are used to pivot the side sections in a curve over the wheels. 8.4 Axle with wheels The axle with wheels is designed for axle loads of well above 10t. The servo wheel can be used to significantly reduce the load on each axle. 8.5 Three-point hydraulics The three-point hydraulics allow various attachments to be fitted. In conjunction with the servo wheel, when turning at the field perimeter the three-point hydraulics bear more or less of the weight of the attachments depending on the oil pressure. 8.6 Depth guide with roller The depth guide with roller controls the depth of the Smaragd 9 U attachments and depth wheels. With Rubin attachments, this improves the lateral guidance of the attachments. 8.7 Quick coupler with pendulum balance The quick coupler makes it easier to couple and uncouple attachments. The pendulum balance ensures that the attachments are individually adjusted to the soil conditions. 8.8 Adjustable pressure limiter valve When used with Rubin attachments, this valve allows the weight of the system trac to be transferred to the attachments. This is necessary if the hollow discs penetrate poorly into the soil. 8.9 Servo wheel (servo depth wheel, servo uni wheel) The servo wheel relieves the axle load on the system trac when turning at the field perimeter and reduces the negative supporting load on the hitch coupling by more than 2000 kg. 8.10 Servo uni wheel The servo uni wheel carries part of the weight of the system trac during transportation and thus allows the axle load of the chassis to be kept below 10t on the Gigant 12S/1000 and Gigant 12/1200. 29 Design and description 8.11 Sensors Sensors are used to detect the individual positions of the servo wheel and the control uni automatically processes the signals to ensure fault-free operation when changing from the working position to the transport position and vice versa. 8.12 Tail brake The tail brake slightly brakes the tail axle of the servo uni wheel to ensure stable trailing of the servo uni wheel. 8.13 Wheel arm joint (servo wheel) A locking pin can be used to lock the wheel arm joint. This is required when changing the attachments and the servo wheel has to be pivoted upwards. This is the only way to move the system trac away from uncoupled attachments or towards attachments that are to be coupled to it. 30 Braking system 9 BRAKING SYSTEM 9.1 Compressed air braking system 9.1.1 Overview 1 Compressed air tank 2 Drain valve 3 Parking valve (parking brake) 4 Discharge valve 5 Trailer brake valve 6 Filter 7 Spring operated brake cylinder 8 Brake lever 9 Guiding screw 10 Holder for guiding screw 11 Brake rod 3 1 5 6 2 4 7 10 8 9 11 9.1.2 Function description Parking brake The parking brake is not ready to use until the guiding screw (9) has been removed, inserted in the holder (10) and secured. The parking valve (3) operates the parking brake. To apply the parking brake, pull out the red button on the parking valve (3) slightly. Pressing the red button in again releases the parking brake. Disconnecting the brake pipes After disconnecting the brake hose with the red coupling button, braking is initiated = automatic braking. Manoeuvring is then no longer possible. 31 Braking system Trailer brake valve with discharge valve The discharge valve (4) can release the locked brake. To do this, press the black button on the discharge valve (4). Pull up the black button on the discharge valve (4) to lock the released brake again. 4 If the operating pressure falls below 3.0 bar, the black button on the discharge valve (4) is automatically pressed out, locking the brake. Spring operated brake cylinder 8 11 32 If the operating pressure in the braking system falls below 3.0 bar, the springs on the spring operated brake cylinder lock the brake. The brake rod (11) moves out slightly and locks the brake using the brake lever (8). If the brake lever (8) moves by more than 40 mm, the brake must be adjusted. See "Maintenance" section. Braking system 9.2 Hydraulic braking system The hydraulic braking system is still in the development process. It is not yet available. Hazard due to poorly maintained braking system WARNING A poorly maintained braking system has little or no braking effect. This leads to long braking distances, rear end collisions or even overturning of the tractor. • Maintain the brakes regularly. • Check the functioning of the braking system before each use. 33 Servo wheel 10 SERVO WHEEL 10.1 General information A servo depth wheel or a servo uni wheel can be supplied as the servo wheel. With Rubin attachments, a servo wheel must always be used so that the load on the rear axle of the tractor is not reduced excessively when turning at the field perimeter. See supporting load table. 10.2 Servo depth wheel 1 2 3 34 When the attachments (1) are extended and retracted or raised to working position using the three-point hydraulics, a large negative supporting load is exerted on the tractor hitch coupling. This negative supporting load is reduced by approx. 2000 kg if a servo wheel (2) such as a servo depth wheel or servo uni wheel is used. Servo wheel 10.3 Servo uni wheel 1 2 If the axle load of the chassis (3) is too high in transport position, the servo uni wheel (2) can be used to reduce the axle load by approx. 3000 kg. The servo uni wheel (2) then bears a load of approx. 3000 kg including its own weight. In addition, the supporting load on the hitch coupling is increased by almost 1000 kg. See supporting load table. 2 35 Servo wheel 10.4 Hydraulic system for servo wheel If the system trac is equipped with a servo depth wheel or servo uni wheel, the system trac hydraulic system must be switched over using a 6/2 way valve (4). 5 4 4 5 Lever (5) up = Attachments can be retracted and extended. In the retracted transport position, the servo depth wheel or servo uni wheel can be tilted into transport position using a separate tractor control unit and the servo uni wheel can then be lowered to bear a load of up to 3000 kg using a further control unit (system pressure = 170 bar), see pressure gauge on rear servo uni wheel. Lever (5) down = In extended working position, the attachments can be raised and lowered and the servo wheel can be lowered and raised in parallel. 36 Servo wheel 10.5 Adjusting the servo wheel 10.5.1 From working position to transport position After retracting the attachments, the servo wheel is tilted forward into transport position by operating the associated control units. The servo uni wheel must then be lowered into support position using a further tractor control unit to reduce the axle load on the system trac. 37 Servo wheel 10.5.2 Locking the joint 6 8 7 Joint locked 6 7 Joint released 38 If attachments are to be attached to or detached from the system trac, the servo wheel must be raised until it can be moved over the attachments. To do this, with the servo wheel tilted backwards to working position, the joint (6) must be locked using the pin (7) and the servo wheel then raised by approx. 2m. After attaching and detaching attachments, lower the servo wheel and release the joint (6) again. To do this, insert the pin (7) in the hole (8). Preparations on tractor 11 PREPARATIONS ON TRACTOR 11.1 Tyres The air pressure must be identical, particularly on the rear tractor tyres. Under difficult conditions, additional wheel weights should be used or the tyres topped up evenly with water. Refer to the operating instructions from the tractor manufacturer. 11.2 Hitch coupling 3 1 The GIGANT system trac can only be attached to tractors with a dual axis hitch coupling (1) approved to support at least the upward and downward loads listed in the supporting load table below, depending on the equipment and operating width used. 2 The permissible supporting load on the hitch coupling is at its highest when the hitch coupling is retracted to its shortest position. The hitch coupling must be secured in the retracted position. A wear resistant washer (3) must be fitted above the drawbar eye (2) to protect against wear. Refer to the operating instructions from the tractor manufacturer. 39 Preparations on tractor 11.2.1 Supporting load table Gigant system trac Supporting load on hitch coupling in transport position 12/1000 Rubin 12/1000 Rubin with servo depth wheel Rubin with servo uni wheel 12/1000 12/1200 System compactor 12/1200 System compactor with servo depth wheel System compactor with servo uni wheel Smaragd Smaragd with servo depth wheel Smaragd with servo uni wheel Rubin Rubin with servo depth wheel Rubin with servo uni wheel 12/1200 12/1200 12S/1200 12S/1200 12S/1200 Supporting load on hitch coupling in working position Negative supporting load on hitch coupling when turning 2,000 kg ‹ 1,000 kg -3500 kg to -3800 kg 1,900 kg ‹ 1,000 kg -1,500 kg to -1,800 kg 2,900 kg ‹ 1,000 kg -1,500 kg to -1,800 kg 1,700 kg ‹ 1,000 kg -2,600 kg to 2,900 kg 1600 ‹ 1,000 kg -700 kg to -1,000 kg 2600 ‹ 1,000 kg -700 kg to -1,000 kg 1,800 kg ‹ 1,000 kg -2,700 kg to -3,000 kg 1,700 kg ‹ 1,000 kg -800 kg to -1,100 kg 2,700 kg ‹ 1,000 kg -800 kg to -1,100 kg 2,400 kg ‹ 1,000 kg -4,200 kg to -4,500 kg 2,300 kg ‹ 1,000 kg -2,200 kg to -2,500 kg 3,300 kg ‹ 1,000 kg -2,200 kg to -2,500 kg The data for the servo wheel assumes that the servo wheel is pivoted to its working position and the system pressure in the hydraulic cylinder for the boom is set to approx. 115 bar. Any earth adhering to the tools and rollers and changes to the absorption of supporting loads by the servo depth wheel or servo uni wheel can slightly alter the above values. Influencing factor In transport position Turning Adhering earth Increase in supporting load Increase in negative supporting load Greater absorption of supporting load Lower absorption of supporting load With servo uni wheel Reduction in negative supporting load Increase in supporting load With servo uni wheel Increase in negative supporting load Reduction in supporting load 40 Preparations on tractor 11.3 Axle load When turning at the field perimeter, the load on the rear axle of the tractor is reduced. The amount by which the load on the rear axle is reduced corresponds to the negative supporting load that occurs when turning at the field perimeter. For example, 2700 to 3000 kg on the Gigant 12/1200 Smaragd. See supporting load table. WARNING Hazard when using unsuitable tractors • Only use tractors that have a minimum load of 7 t on the rear axle without the device attached. 11.4 Required power sockets The following power sources are required on the tractor for the electrical consumers. Consumer Volts Direct connection to tractor battery Power socket Lighting system 12 - In line with DIN-ISO Controller for servo wheel 12 - In line with DIN 9680 When parking the tractor, disconnect the plug for the power supply to the servo wheel controller from the power socket. The electrical valves for the servo wheel still consume power even when the tractor engine is turned off. 41 Preparations on tractor 11.5 Required hydraulic control units For operation of the specific hydraulic equipment listed below, the tractor must be equipped with the following control units. Double acting control unit Colour Extending/retracting X Red Three-point hydraulics Giant 12S X Green Hydraulic equipment Three-point hydraulics Giant 12 Single acting control unit X Servo depth wheel Pivoting boom Servo uni wheel Pivoting boom Servo uni wheel Pivoting tail wheel Hydraulic cutting bar adjustment 11.6 X Green X Blue X Blue X Yellow Black Brake system 11.6.1 Air brake system For the air brake system of the implement the tractor must be equipped with a two-hose air brake system with coupling heads according to ISO 1728. 11.6.2 Hydraulic brake system In combination with a hydraulic brake system the tractor must be equipped a hydraulic coupling of the size BG 3. 42 Coupling and uncoupling 12 COUPLING AND UNCOUPLING CAUTION • Only couple the device to a dual axle hitch coupling (1). • The hitch coupling (1) must be suitable for bearing the positive and negative supporting loads shown in the supporting load table. 12.1 Coupling the device If the tractor is equipped with a suitable and appropriate hitch coupling (1), couple the device as follows: − Adjust the height of the drawbar eye (2) using the crank (3) on the stand (4) so that it can be coupled correctly. The drawbar eye (2) is adjusted correctly when a plastic washer (5) can be fitted above the drawbar eye (2). 6 1 7 5 6 2 1 − If required, position spacer washers (6) below the drawbar eye (2) to slightly reduce the clearance between the lugs on the hitch coupling (1) and the drawbar eye (2). Make sure that there is sufficient freedom of movement between the drawbar eye and the hitch coupling. − Connect the drawbar eye (2) to the hitch coupling (1) using coupling pins (7). − Secure the coupling pins (7). 3 4 43 Coupling and uncoupling − Place the stand (4) in the transport bracket (8) and secure. 4 8 − Connect the electrical cables, brake hoses and hydraulic hoses. If the transport route will include public roads, a legally acceptable lighting system with warning signs must be attached and the protective equipment fitted. − Remove the wheel chocks (9) and place in the bracket on the V pole. − Release the parking brake. 9 12.2 Uncoupling the device We recommend parking the device in retracted position; this saves space and reduces the work involved in attaching and detaching the protective equipment. − Apply the parking brake. − Disconnect the electrical cables, brake hoses and hydraulic hoses and place on the V pole. 44 Coupling and uncoupling 4 − Remove the wheel chocks (9) from the bracket and secure the device against rolling away using the wheel chocks. 8 − Remove the stand (4) from the transport bracket (8) and fit in the parking position. − Adjust the stand (4) using the crank (3) so that the load on the drawbar eye (2) is relieved. − Release and remove the coupling pins (7). Place the plastic washer (5) and spacer washers (6) in the toolbox (10) to ensure that they are not lost. 5 3 4 7 5 6 10 9 2 45 Extending/retracting 13 EXTENDING/RETRACTING 13.1 General information WARNING • The device may only be extended and retracted when coupled to the tractor. • There must be sufficient space for extending and retracting: - 8 m to the left and right of the retracted device 10 m to the rear behind the axle - at least 8 m above the device. • The minimum requirements for the tractor must be observed, for example refer to the "Hitch coupling" and "Axle load" sections in the "Preparations on the tractor" chapter. • The device may only be extended and retracted on a solid, flat surface. 13.2 46 Retracting (without servo wheel) Extending/retracting − Only retract the device outside. − Before retracting, the roller brackets must be moved to transport position. See "Roller transport position" section. − Fully raise the attachment. − Make sure that no electrical or high voltage cables are in the vicinity. − Turn the tractor control unit for the hydraulics to Lift until the side sections are fully retracted. − Turn the tractor control unit to "Neutral". − Fit the protective equipment. If the system trac is retracted without attachments, the top links must first be removed. 13.3 Extending (without servo wheel) − Only extend the device outside and when coupled to the tractor. − Make sure that no electrical or high voltage cables are in the vicinity. − Remove the protective equipment. − Turn the tractor control unit for the hydraulics to Lower until the side sections are fully extended. − Turn the tractor control unit to "Neutral". The roller brackets must then be moved to working position. See "Roller working position" section. 47 Extending/retracting 13.4 Retracting (with servo wheel) Before retracting, the roller brackets must be moved to transport position. See "Roller transport position" section. 1 3 − Connect the power supply for the servo wheel (2) control unit (1) to a 3-pin socket complying with DIN 9680. − Turn the lever (3) on the 6/2 way valve up into transport or retracting position. − Switch the control unit for retracting and extending the attachments (4) to the retracting position until the attachments (4) are completely retracted. 4 4 − Then adjust the control unit for moving the tail axle (7) such that the hydraulic cylinder (8) retracts and the factory set pressure is reached, e.g. 180 bar for the Gigant 12S/1000 Rubin, Gigant 12/1200 and Gigant 12S/1200 (only possible with servo uni wheel). 2 5 7 8 6 9 2 48 − Switch the control unit for adjusting the boom (5) to the retracting position. The boom (5) then retracts to the stop (6). Extending/retracting The servo wheel (2) is in the correct position when the guide axle (10) engages in the curved track (11). 11 7 10 When parking the tractor, disconnect the plug for the power supply to the servo wheel controller from the power socket. The electrical valves for the servo wheel still consume power even when the tractor engine is turned off. 49 Extending/retracting 13.5 Extending (with servo wheel) − Drive to a suitable location in the field, where safe extending is ensured. 8 11 − Make sure that the servo wheel (2) is tilted backwards. − Turn the lever (3) on the 6/2 way valve up into transport or extending position. 7 − Connect the power supply for the servo wheel (2) control unit (1) to a 3-pin socket complying with DIN 9680. 2 1 3 5 11 2 50 − Switch the control unit for adjusting the tail axle (7) so that the hydraulic cylinder (8) fully extends and the tail axle no longer runs through the track (11). − Then completely extend the boom (5) until the servo wheel (2) touches the ground. Hold the control unit at this pressure setting for a few more seconds to allow the required system pressure to build up in the servo wheel hydraulic system (2). − Switch the control unit for retracting and extending the attachments to the extending position and completely extend the attachments. Extending/retracting 5 − Turn the lever (3) on the 6/2 way valve down into working position. 4 The hydraulic system is now set to working position. The attachments can be raised if required using the three-point hydraulics, e.g. for turning at the field perimeter. The servo wheel then bears part of the weight of the attachments and prevents too much of the load being removed from the tractor's rear axle. 2 The roller carriers must then be moved to working position. See "Roller working position" section. 2 4 3 51 Roller adjustment 14 ROLLER ADJUSTMENT 14.1 General information The device is approx. 4.20 m high in transport position if the rollers are also moved to transport position. However, the transport height can be significantly higher with some types of rollers. Therefore, the rollers must always be moved to transport position before transportation. To do this, the position of the guide pins has to be changed. During retraction, the rollers then tilt inwards and slightly downwards. No adjustment work is required for system compactor attachments. Keep in mind and note the setting for work position and the position of the guide pins. 52 Roller adjustment 14.2 Transport position Adjustment from the working to the transport position is carried out if the device is still in the working position and the affected guide pins are relieved of load. 14.2.1 Smaragd 9 and 9 U Release and remove the depth setting guide pins (1), then fit and secure below the guide pins (2). 1 For double rollers, release and remove guide pins (3), insert in the holes (4) and secure. 2 4 2 3 1 53 Roller adjustment 14.2.2 Rubin 9 U 8 7 Then release and remove the guide pins (8) and fit and secure below the guide pins (9). With a double roller, the guide pins (10) also need to be released and removed and inserted and secured in free holes in the carrier (11). 9 6 11 14.3 5 Release and remove the upper guide pins (5) for the rebound harrow (6), then fit and secure again below the guide pins (7). 10 Working position The rollers are adjusted from the transport position to the working position after extending the device. Feed the device into the soil until the rollers limit the working depth. The removed guide pins can now be fitted as before. CAUTION Crushing and shearing can occur in the area of the depth setting guide pins and the guide pins for adjusting the harrow weeder. 54 Attaching and detaching wing sections 15 ATTACHING AND DETACHING WING SECTIONS 15.1 General information Only two Rubin 9 U attachments can be attached to the Gigant 12 S/1000 system trac. 2 4 1 3 5 4 Either two Smaragd 9U attachments, two system compactor attachments or two Rubin 9U attachments can be attached to the Gigant 12 S/1200 system trac. Only two two Smaragd 9U attachments or two system compactor attachments can be attached to the Gigant 12/1200 system trac. These attachments are coupled to the three-point hydraulics (1) with top link (2) and bottom link (3), each of which is equipped with quick release couplings (4) with pendulum balance (5). 5 The pendulum balance (5) allows the attachments to be individually adjusted to the soil, even on hilly land. • Only retract/extend or operate the device if you have ensured that the coupling pins for the top link and the coupling lugs for the bottom link connection are secured correctly. CAUTION • Only use quick release couplings and balls with guide cones that are approved by LEMKEN. • Before each use, check that all screws and nuts for the threepoint hydraulics are securely fitted. Tighten if required. • Before each use, check the functioning of all securing fixtures for the top and bottom links. Replace any damaged or worn components immediately. • Always fit the top link pins from the centre of the device. 55 Attaching and detaching wing sections 15.2 Coupling 8 9 7 6 4 Before coupling for the first time, the attachments must be positioned next to one another on a perfectly flat surface using a crane. The coupling points must be in a straight line. The distance between the two headstocks must correspond exactly to the distance between the three-point hydraulics on the system trac. The procedure described above is not necessary for repeated coupling and uncoupling. In this case, the attachments will automatically be in an optimum position for coupling after being uncoupled. Make sure that the ball guide cones (6) are fitted and secured on the lugs (7) of the drawing rails (8) and that the spacer sleeves (9) are fitted as shown. CAUTION • Only carry out coupling and uncoupling with an experienced instructor. • The instructor may never be in the coupling area between the attachment and the system trac. • Observe the safety instructions for "Coupled devices". 56 Attaching and detaching wing sections Coupling is carried out as follows: − Release all arresting hooks (10). 6 7 10 − If the system trac is equipped with a servo wheel, the servo wheel must be raised so that it can be moved over the attachments with no risk of collision. − With the system trac coupled to the tractor, drive towards the attachments so that they can both be coupled at the same time. Make sure that the arresting hooks (10) are positioned exactly below the lugs (7). − Carefully set the tractor control unit for the three-point hydraulics (1) to "Lift". 1 57 Attaching and detaching wing sections 14 − Pivot the servo wheel (11) to working position. − Release the locking pin (12) and remove it. − Insert the locking pin (12) into the hole (13) to secure the joint (14) for the servo wheel. 11 − Raise the servo wheel (11) by approx. 2m. 13 12 12 14 11 58 Attaching and detaching wing sections 6 16 9 8 − Then check that all arresting hooks (10) are properly locked. An arresting hook is locked when the locking lever (15) is positioned as shown and the catch (16) secures the ball guide cone (6) as shown. 15 10 2 − Lock the arresting hooks (10) as soon as the drawing rails (8) with the ball guide cones (6) are positioned in the arresting hooks (10). 17 − Finally, attach the top link link (2) and secure the top link pins (17). Always fit the top link pins from the centre of the device. The ends of the pins with the split ring then point outwards in working position. 59 Attaching and detaching wing sections 14 − Lower the servo wheel (11) to working position. − Release the locking pin (12) and insert it into the hole (18). − Secure the locking pin (12). The joint (14) is then released again. 11 See also "Servo wheel" section. 12 18 12 14 14 CAUTION • Only operate the device if the attachments are coupled and secured as specified. • Never retract Risk of tipping. 60 the device with an attachment fitted. Attaching and detaching wing sections 15.3 Uncoupling Only park attachments on a solid and absolutely flat surface. 2 − Release the top link pins (17). − Remove the top link pins (17). − Pivot the top links (2) forwards. − Pull the locking lever (15) upwards to release the arresting hooks (10). 17 15 − Set the tractor control unit for the threepoint hydraulics to "Lower". 10 61 Attaching and detaching wing sections 14 If the system trac is equipped with a servo wheel, the servo wheel must be raised so that it can be moved over the attachments with no risk of collision. − To do this, release the locking pin (12) and remove it. − Insert the locking pin (12) into the hole (13) to secure the joint (14) for the servo wheel (11). 11 − Raise the servo wheel (11) by approx. 2m. 13 12 − Check whether the arresting hooks (10) are lowered and, if so, carefully move the system trac away from the attachments. 14 14 12 11 62 Three-point hydraulics 16 THREE-POINT HYDRAULICS 16.1 Gigant Smaragd and Gigant system compactor The Gigant 12 is equipped with single acting three-point hydraulics (1) and the Gigant 12 S with double acting three-point hydraulics (1) with pressure limiter valve (2). In conjunction with Smaragd 9U and system compactor attachments, the tractor control unit for the three-point hydraulics (1) must generally be set to float position when extended in the working position. On the Gigant 12S with the double acting version of the three-point hydraulics (1) with pressure limiter valve (2), the adjusting dial (3) must be completely unscrewed anticlockwise. This deactivates the double acting function. 16.2 Gigant Rubin The Rubin 9U attachments may only be coupled to the Gigant 12 S, not to the Gigant 12. In conjunction with Rubin 9 U attachments, the weight must be transferred from the chassis to the attachments to ensure effective penetration. To do this, the adjusting dial (3) must be turned clockwise to a greater or lesser extent. 1 3 2 After turning at the field perimeter, the tractor control unit for the three-point hydraulics (1) must be switched to the lowering position for approx. 5 seconds. This lowers the Rubin sections into working position and restores the system pressure of the three-point hydraulics (1) to the pressure set with the adjusting dial (3). The tractor control unit must then be reset to neutral position. 63 Three-point hydraulics 16.3 Top link 3 1 The top link (1) of the three-point hydraulics includes a lever (3) with cam (4) and spring clamp (5) as a locking mechanism. The top link must always be installed with the lever (3) at the top. The threaded section of the top link (1) contains a groove (6) into which the cam (4) on the lever (3) positively engages as a locking mechanism. The top link (1) must be installed in such a way that both the groove (6) and the lever (3) are at the top. 4 6 CAUTION If the top link (1) is turned by 180° when installe d (the lever (3) then points downwards), the top link will be damaged or destroyed during use. 64 Three-point hydraulics 1 7 8 After installation, the top link bolts (7) and the top link (1) itself must be secured. The top link bolts (7) are secured by split rings (8) with chain. The top link (1) is secured by a lever (3) with cam (4) and spring clamp (5). The top link is adjusted as follows: − Operate the three-point hydraulics to relieve the load on the top link (1). − Turn the lever (3) 90° upwards. 5 3 − Adjust the top link by 360° at a time using the lever (3). − Return the lever (3) back to its initial position; the cam (4) must engage in the groove (6) and the handle of the lever (3) in the spring clamp (5). 65 Three-point hydraulics − Risk of fatal injury due to unsecured top link and top link bolts If the top link is not secured, the top link can twist and fall apart. If the top link bolts are not secured, they can slip out and be lost. DANGER This can cause the attachments to swing outwards during transportation, causing injury or death to other road users. The attachments can suddenly extend in an uncontrolled fashion during the extending procedure. This damages the system trac and the attachments when retracting. This can cause the attachments to change their working position in an uncontrolled fashion during work. • The top link must always be properly secured. • The top link pins must always be secured. 66 Adjustments 17 ADJUSTMENTS Risk of accidents while making adjustments DANGER When making all adjustments to the attachments and the system trac there is a risk of crushing, cutting, pinching and impacts to the hands, feet and body from heavy and, in some cases, spring loaded and/or sharp-edged parts. • Adjustments may only be carried out by personnel who have been appropriately trained. • Always wear appropriate protective clothing. • Always follow the applicable health and safety and accident prevention regulations. 67 Adjustments 17.1 Spring operated brake cylinder Risk of accident due to deactivated brakes DANGER To allow unloading and shunting without a compressed air supply, the spring operated brake cylinders and thus the entire braking system have been deactivated in the factory using guiding screws. The guiding screws must be removed before commissioning. 6 − Turn the guiding screw (1) by 90° and remove it from the spring operated brake cylinder (3). 1 2 − Cover the aperture in the spring operated brake cylinder with the protective cap (4). 3 4 5 68 − Loosen the nut (2) until the guiding screw (1) is no longer under spring force and is free. − Insert the guiding screw in the holder (5) on the spring operated brake cylinder and secure it with a split pin and nut. Adjustments 7 WARNING 6 Risk of injury due to spring force The screws (6) may not be loosened. If the tightening straps (7) are loosened, the spring operated brake cylinder can fly apart explosively. This can cause death or serious injury. 69 Adjustments 17.2 Smaragd 9 U 17.2.1 Working depth The working depth of the Smaragd harrow can be adjusted between 5 cm and 25 cm. It is adjusted using guide pins. Risk of accidents due to freely rotating rollers Particularly when adjusting the working depth, climbing onto freely rotating rollers brings a risk of crushing and pinching limbs between the freely rotating rollers and fixed parts of the device. DANGER • Adjustments may only be carried out by personnel who have been appropriately trained. • Never climb onto freely rotating rollers. 4 3 1 2 − Slightly raise the attachments using the three-point hydraulics. − Release the lower guide pins (1) by removing the split rings. − Insert the lower guide pin (1) in a hole in the adjusting plates (2) corresponding to the desired working depth: Lower hole => Greater working depth Higher hole => Less working depth − Insert the device. When the working depth is reached, the load on the upper guide pins (3) is relieved. − Insert the upper guide pins (3) directly above the carrier (4) so that the weight of the rollers provides additional support for the device's penetration. Raising the attachments increases the clearance between the rollers and the ground. − Secure the guide pins by inserting the split rings. 70 Adjustments Pivoting rollers DANGER If the guide pins are not secured by the split rings, the guide pins can be lost. This results in hazards. During transportation, the rollers can pivot outwards and exceed the maximum transport width. This can cause injury to other road users. The attachment penetrates too deeply during operation. • Secure all guide pins with split rings after adjusting the working depth. If the system trac is equipped with depth guide (5) with draw links (6) and rollers (7) and with depth wheels (8), the settings for the depth guide (5) and the depth wheels (8) must be adjusted after adjusting the working depth. See "Depth guide" and "Depth wheels" sections. 7 5 8 6 The photo shows the Gigant 10 version 71 Adjustments 17.2.2 Working depth of hollow discs 2 3 1 The hollow discs (1) are automatically adjusted to the new working depth when the depth of the tines is adjusted. However, a basic adjustment of the hollow discs (1) must be made before using for the first time. This adjustment is made using the guide pin (2): − Release the guide pin (2). − Slide the disc carrier (3) slightly upwards to relieve the load on the guide pin (2). − Remove the guide pin (2). − Slide the disc carrier (3) to the desired position. − Re-insert the guide pin (2). − Secure the guide pin (2). Loss of components DANGER If the guide pins are not secured, they can fall out due to vibrations in operation. This can result in components being lost during operation and transportation and can cause accidents or damage to the device and the tractor. The guide pins must always be secured. 72 Adjustments 17.2.3 Harrow 5 3 6 4 1 7 2 The harrow (1) is used to spread existing straw and also to crumble and level the soil. The clearance to the rollers and its angle can be adjusted. Flat angle = Less risk of clogging, less crumbling effect Steep angle = Greater risk of clogging, improved crumbling effect The harrow (1) is adjusted using guide pins (3, 4 and 5). − Release the guide pin (3). − Remove the guide pin (3). − Slide the harrow (1) forwards or backwards to the desired position and fix in place with the guide pin (3). − Secure the guide pin (3). − Release the guide pin (4). − Insert the guide pin (4) below the carrier (6) so that the desired angle is achieved. Make sure that the harrow tines (7) are not touching the roller (2). In case of doubt, position the harrow (1) with greater clearance to the roller (2). 73 Adjustments 3 5 4 6 7 − Secure the guide pin (4). − Release the guide pin (5). − Insert the guide pin (5) above the carrier (6) so that the harrow does not swing too far forwards when raising the device. − Secure the guide pin (5). CAUTION Loss of components If the guide pins are not secured, they can fall out due to vibrations in operation. • The guide pins must always be secured. 74 Adjustments 17.2.4 Share position The share position or the contact angle of the tines (1) can be altered. A "flat" share position ensures an even seedbed (share point and wings work at almost the same depth) and reduce the traction required, even in difficult and sticky soils. 3 A 2 B 1 A "steep" share position ensures that the tines (1) achieve good penetration even in hard and dry soils. The tine position and thus the share position is altered by adjusting the shear bolt (2). To do this, the shear bolt (2) is either inserted in hole A or B in the tine carrier (3). 3 Hole A = Flat share position Hole B = Steep share position 2 1 − Raise the attachment by a few centimetres. − Loosen and remove the nut for the shear bolt (2). − Press out the shear bolt with a suitable tool. − Tilt the tines into the desired position. − Insert the shear bolt into hole A or B in the tine carrier (3) as required. − Replace the nut. − Tighten the nut. 75 Adjustments WARNING Risk of injury from removed shear bolt If the shear bolt is removed, the tines can pivot freely. This can lead to crushing of the fingers around the tine carrier. − Replace a removed shear bolt immediately. 17.2.5 Shear device − Each tine (1) and disc carrier (2) is fitted with a shear device with shear bolt (3), which protects the frame, the tines (1) and the disc carrier (2) against overloading. If a shear bolt breaks, replace as follows: 4 − Raise the attachment by a few centimetres. 3 1 − Secure the attachment against unwanted lowering. − Tilt the tine (1) or disc carrier (2) into working position. − Remove the remains of the shear bolt. − Insert the new shear bolt (3) into the hole previously used in the tine carrier (4). 4 3 76 2 − Screw on the nut for the shear bolt and tighten. Only use shear bolts specified in the table as only these shear bolts protect against overloading and prevent premature shearing. Adjustments Device Smaragd 9 U Tine Disc carrier with shear device Disc carrier with overload protection 301 3391 M12x60 B=15/10.9 301 3240 M 10x45 B=10/8.8 --------- 77 Adjustments WARNING Risk of injury due to sheared shear bolt If the shear bolt has sheared off, the tine or disc carrier can pivot freely. This can lead to crushing of the fingers around the tine carrier. 17.2.6 Automatic overload protection Tine 2 1 The tines (1) on the Smaragd 9 U are fitted with automatic overload protection with compression springs (2), which are under high pretension. The overload protection is preset to a release force of approx. 5800 N (580 kp) at the share point. This setting may not be altered. When an obstruction is encountered in the soil, the tine tilts backwards and upwards and is then returned to the working position automatically when the obstruction has been passed. DANGER Risk of accidents due to moving tines When an obstruction is encountered, the tine tilts very quickly upwards by spring force. This can cause injury to persons in the area of the tines. • Never climb onto the device when working. 78 Adjustments Hollow discs 4 3 The hollow discs (3) with overload protection are fitted with a compression spring (4) that is under high pretension. When an obstruction is encountered in the soil, the hollow disc tilts backwards and upwards and is then returned to the working position automatically after passing over the obstruction. Risk of fatal injury due to high spring force DANGER When the tine / hollow disc is triggered and has not yet returned to working position, it can suddenly spring back to working position with huge force and at high speed. This can cause serious injury or death to any persons in the tilting area of the tine. • Only approach the tine / hollow disc when it has completely returned to working position. 79 Adjustments 17.3 Rubin 9 U 17.3.1 Working depth The working depth of the Rubin disc harrow can be adjusted between 4 cm and 12 cm. It is adjusted using guide pins. Risk of accidents due to freely rotating rollers DANGER Particularly when adjusting the working depth, climbing onto freely rotating rollers brings a risk of crushing and pinching limbs between the freely rotating rollers and fixed parts of the device. • Adjustments may only be carried out by personnel who have been appropriately trained. • Never climb onto freely rotating rollers. 4 2 − Slightly raise the attachments using the three-point hydraulics. 3 1 − Release the lower guide pins (1) by removing the split rings. − Insert the lower guide pin (1) in a hole in the adjusting plates (2) corresponding to the desired working depth: Lower hole => Greater working depth Higher hole => Less working depth − Insert the device. When the working depth is reached, the load on the upper guide pins (3) is relieved. − Insert the upper guide pins (3) directly above the carrier (4) so that the weight of the rollers provides additional support for the device's penetration. Raising the attachments increases the clearance between the rollers and the ground. − Secure the guide pins by inserting the split rings. 80 Adjustments Pivoting rollers If the guide pins are not secured by the split rings, the guide pins can be lost. This results in hazards. DANGER During transportation, the rollers can pivot outwards and exceed the maximum transport width. This can cause injury to other road users. The attachment penetrates too deeply during operation. • Secure all guide pins with split rings after adjusting the working depth. 17.3.2 Rebound harrow Both the distance of the rebound harrow (1) from the hollow discs and its height can be adjusted. The lower and the closer it is to the hollow discs, the greater its levelling effect. 1 Adjusting the height − Release the guide pins (2 and 3) by removing the split rings (5). − Adjust the rebound harrow (1) to the appropriate height using the guide pin (2). 3 5 2 4 3 Adjusting the distance − Fix the rebound harrow (1) in the desired working position with the guide pins (3) after adjusting the height. − Secure the guide pins by inserting the split rings (5). 81 Adjustments The row of holes (4) should always be approximately perpendicular to the ground. Loss of components, component collision CAUTION If the guide pins are not secured on the rebound harrow, they can fall out due to vibrations in operation. This can cause the rebound harrow to strike the rollers. • The guide pins must always be secured by split rings. 17.3.3 Guide plates The angle and height of the guide plates (1) can be adjusted. 3 The guide plates (1) refill the groove left by the rear left hollow disc with earth. − Adjust the guide plates (1) accordingly using the clamping screws (2). 2 1 − Make sure that the guide plates (1) are slightly lower than the harrow tines (3) on the rebound harrow. 82 Adjustments 17.3.4 Side limitation Side limitation (2) prevents the rear right hollow disc and the front left hollow disc on the outside from leaving grooves or raising ridges. They are screwed directly onto the frame with their brackets (1) using clamping screws and can be adjusted laterally. 1 − The clamping fixture (3) can be used to move them forwards and backwards and adjust the angle. 2 In the default setting, they are - offset by 5°, and - screwed onto the bracket in the central lateral position 5 3 4 − Fix the round stalk (4) of the side limitation (2) in place. − Release the nuts (5). − Move the round stalk (4) with side limitation to the desired position. − Tighten the nuts (5). Make sure that during work the left side limitation is approx. 23 cm above the ground and the right side limitation approx. 14 cm. 83 Adjustments Risk of unsecured parts CAUTION If the side limitation is not secured during adjustment, it slides downwards. This can lead to crushing of the hands or to foot injuries. • The side limitation should always be fixed in place so that it cannot slip downwards. 17.4 System compactor 17.4.1 Pressure load on front crumbling rollers Shortening or lengthening the top link (1) loads more or less of the weight of the support frame (3) onto the front crumbling rollers (2). 1 The photo shows the system trac with Rubin attachments 3 2 Light soils (low pressure) 6 84 Suspension bracket (4) of combination section rests on supporting arm (5). Adjustments Medium soils (medium pressure) 4 5 Approx. 1 cm clearance between suspension bracket (4) and supporting arm (5). The spring (6) enables the combination section to bear a large portion of the supporting frame weight. 6 Heavy soils (high pressure) 8 1 Approx. 3 cm clearance between suspension bracket (4) and supporting arm (5). The spring (6) enables the combination section to bear a large portion of supporting frame weight. − Lower the device using the three-point hydraulics (7) to relieve the load on the top link (1). 7 − Turn the lever (8) upwards. 5 − Adjust the length of the top link (1) as required. 4 − Secure the top link (1) against twisting. To do this, turn the lever (8) downwards and secure it using the spring clamp. See "Top link" section. 6 85 Adjustments Risk of fatal injury due to unsecured top link DANGER If the top link is not secured, the top link can twist and fall apart. This can cause the attachments to swing outwards during transportation, causing injury or death to other road users. • The top link must always be properly secured. • The top link pins must always be secured. 86 Adjustments 17.4.2 Pressure distribution on rear rollers Pin adjustment (1) with a guide pin (2) distributes the pressure on the rear rollers as required. The guide pin (3) fixes the rear roller in place. 1 2 4 3 − Lower the attachments into working position with the three-point hydraulics to relieve the load on the guide pins (3). − Release the guide pins (3). − Remove the guide pins (3). − Slightly raise the attachments with the three-point hydraulics to relieve the load on the guide pins (2). − Release the guide pins (2). − Remove the guide pins (2). − Insert the guide pins (2) in the desired hole above the carrier (4). − Secure the guide pins (2). − Lower the attachments into working position with the three-point hydraulics. − Insert the guide pins (3) in the next hole directly below the carrier (4). − Secure the guide pins (3). 87 Adjustments Pivoting rollers WARNING If the guide pins are not secured, they can be lost. This results in hazards. During transportation, the rollers can pivot outwards and exceed the maximum transport width. This can cause injury to other road users. The attachment penetrates too deeply during operation. • Secure all guide pins after adjusting the working depth. 17.4.3 Wheel track eliminator (accessory) The wheel track eliminator (1) should be positioned approx. 2 - 5 cm lower than the soil tracks. Setting it too low brings wet soil to the surface. Working depth 4 3 5 6 2 1 The working depth is adjusted as follows: − Slightly raise the attachment to relieve the load on the wheel track eliminator (1). − Release the guide pin (2). − Fix the wheel track eliminator (1) in place by hand. − Remove the guide pin (2). − Slide the wheel track eliminator (1) to the desired position. − Insert the guide pin (2) in hole (5) or (6). − Secure the guide pin (2). 88 Adjustments Transport position In transport position, the wheel track eliminators protrude at the side and endanger other road users. They must be moved to transport position before transportation. − Slightly raise the attachment to relieve the load on the wheel track eliminator (1). − Release the guide pin (2). − Fix the wheel track eliminator (1) in place by hand. − Remove the guide pin (2). − Slide the wheel track eliminator (1) upwards as far as possible. − Insert the guide pin (2) in hole (5) or (6). − Secure the guide pin. Loss of components DANGER If the guide pins are not secured, they can fall out due to vibrations in operation. This can result in components being lost during operation and transportation and can cause accidents or damage to the device and the tractor. The guide pins must always be secured. 89 Adjustments 17.4.4 Shifting the harrow frames The harrow frames (1) are mounted on the rotary tiller frame (2) and can be shifted. The harrow frames are front mounted as standard. Only when the tines (3) are clogged, e.g. by vegetation, should the harrow frames (1) be shifted to the rear. The additional holes (4) in the rotary tiller frame can be used for this purpose. 6 5 1 3 4 − Lower the attachments onto a solid and even surface using the three-point hydraulics. 7 4 7 − Release the guide pins (5) and (6). − Remove the guide pins (5) and (6). − Loosen and remove the screws (7). − Move the harrow frames (1) as required. − Fit the screws (7) and tighten the nuts. Replace the guide pins (5) and (6). See "Working depth of tines" section. − Secure all guide pins. 90 Adjustments 17.4.5 Working depth of tines The working depth of the tines (1) can be set using the adjusting mechanism (2). 2 6 5 4 3 1 − Slightly raise the attachments by operating the three-point hydraulics. − Release the guide pins (3). − Remove the guide pins (3). − Completely lower the attachments by operating the three-point hydraulics. − Release the guide pins (4). − Remove the guide pins (4). − Insert the guide pins (4) in the desired holes in the adjusting plate (5) above the frame carrier (6). − Secure the guide pins (4). − Slightly raise the attachments by operating the three-point hydraulics. − Insert the guide pins (3) directly below the frame carrier (6). − Secure the guide pins (3). 91 Adjustments 17.4.6 Cutting bars The cutting bars (1) pile up earth in the crumbling rollers (2). This intensively crumbles and levels the soil. 3 1 4 The cutting bars (1) are adjusted correctly when they pile up earth in the crumbling rollers (2) and no longer slow down the crumbling rollers (2) too much. 2 Adjustment using spindle Before using for the first time, the following basic adjustments of the cutting bars (1) must be made. Turn the spindle (3) clockwise to the end stop. Then turn the spindle (3) back by five or six revolutions. If the cutting bars are still not at an optimum setting, Turn the spindle (3) clockwise => Greater accumulation effect Turn the spindle (3) to the left => Lower accumulation effect The spring (4) prevents the cutting bar (1) from piling up too much earth when the spindle (3) is turned all the way back. 3 92 3 Adjustments Hydraulic cutting bar adjustment Hydraulic cutting bar adjustment enables the cutting bar (1) to be "opened" hydraulically for a short time. For example, this is required if too much earth is piled up on variable soils and the crumbling rollers (2) stop or there is a danger of the crumbling rollers (2) becoming clogged. The opening angle can be adjusted with the adjusting mechanism (3). 3 − Release the guide pin (4). 6 − Remove the guide pin (4). 4 5 − Insert the guide pin (4) in the desired hole. 1 2 − Secure the guide pin (4). Increase the opening angle - insert the guide pin (4) in a rear hole (5). Reduce the opening angle - insert the guide pin (4) in a front hole (5). 4 3 5 6 2 2 1 1 The cutting bar is opened using the corresponding single acting tractor control unit. Open cutting bar - Set control unit to "T" = Tank. Return cutting bar - Set control unit to "P" = Pressure. If the cutting bars (1) need to be opened relatively frequently, this indicates that they are not in an optimum position. The spindle (6) should then be adjusted by half a turn or more to the left. 93 Adjustments 17.4.7 Height adjustable side plates The height adjustable side plates (1) are intended to prevent any ridge formation. If required, they can be adjusted upwards or downwards as follows. − Lower the attachments using the threepoint hydraulics. 1 − Support the side plates (1) at the front and rear along with the intermediate plate (2). 4 2 − Loosen and remove the screws (3) and (4). 3 The screws (4) fix the stone guards (5) in place, and these may also need to be adjusted. 5 2 1 − Place the side plates (1) and intermediate plate (2) in the desired position. − Fit a screw (3) at the front and rear and slightly tighten them. − Then fit the remaining screws (3). − Securely tighten all screws (3). − Fit the stone guards (5) as before using the screw (4). The screw (4) must be in line with the screws (3). − Securely tighten the screws (4). 94 Adjustments 17.4.8 Stone guards The stone guards (5) are located on the inside of the side plates (1) immediately behind the bearings for the crumbling rollers. They prevent stones from getting jammed. If the side plates (1) are adjusted upwards or downwards, the stone guards (5) must also be moved. The fixing screws for the side plates and the stone guards must always be aligned. 5 1 17.5 Rollers 17.5.1 General information The attachments can be fitted with various roller types, see the roller table below for details. This table does not include the rollers and tillers for the system compactor as these rollers and tillers do not require any specific settings after factory installation. Attachments Smaragd 9 U Attachments Rubin 9 U RSW 400 x x RSW 540 x x Roller type Tube bar roller RSW 600 Double roller Trapezoidal cker roller Toothed roller x DRF 400 x x DRR 400 x x pa- TPW 500 packer ZPW 500 x x x Rubber ring roller GRW 590 x x Blade roller MSW 600 x x 95 Adjustments The tube bar rollers and double rollers do not require any further adjustments. The trapezoidal packer rollers, toothed packer rollers and rubber ring rollers are equipped with adjustable scrapers that need to be adjusted from time to time, see "Scrapers" section for details. The blade rollers are equipped with a blade bar with blades as scrapers, offering a variety of adjustment options, see "Blade rollers" for details. 17.5.2 Scrapers The distance between the scraper and the roller casing (1) is adjustable with 500 rollers. 3 It is adjusted using adjusting nuts (4) for toothed packer rollers and using eccentric nuts (2) for trapezoidal packer rollers. 2 Before adjusting an eccentric nut, the associated screw (3) must be loosened and re-tightened after adjustment. 1 Clearance between scraper and roller casing 4 1 The clearance between the scraper (1) and the roller casing (5) must be set in line with the following schedule. The adjusting instructions apply to all toothed packer rollers and trapezoid packer rollers. Adjust the relevant scraper on the rubber ring roller so that it has a clearance of between 8 and 12 mm to the rubber rings. 96 Adjustments 5 Coated scrapers 1 Plastic scrapers 5 1 (must rest against the roller casing (5) with slight pretension) Plated scrapers 5 or carbide scrapers 1 17.5.3 Scraper GRW 7 The scrapers (6) on the rubber ring rollers (7) have slots to allow adjustment. − Release the self-locking nut (8). 8 − Adjust the relevant scraper on the rubber ring roller so that it has a clearance of between 8 and 12 mm to the rubber rings. 6 8 – 12 mm − Re-tighten the self-locking nut. 97 Adjustments 17.5.4 Blade rollers Working depth of blades 1 4 The working depth of the blades (6) is adjusted using the guide pins (3) as follows: 2 3 − Turn the spindles clockwise to the stop until the guide pins (3) have been relieved of load. − Release and remove the guide pins (3) above the support plate (1). − Move the supporting arms (4) to the desired position using the spindles (2). − Insert the guide pins (3) in one of the free holes on the supporting arms (4). − Secure the guide pins (3) with split rings. − Turn the spindles (2) back slightly anticlockwise to relieve them of load. 6 98 Adjustments Movement of blades 4 Upward movement of the blades (6) is limited using the guide pins (5). If necessary, slight movement upwards can be permitted. 3 5 Position of blades The blades are generally screwed onto the blade frame (7) in the front position. In case of wear, the blades (6) can be moved backwards. 8 7 6 Adjusting the blade frame If the adjusting range using the guide pins (3) is insufficient, the blade frame (7) can be moved higher in relation to the supporting arms (4). To do this, remove the screws from the holes (8) and move the blade frame (7). With extremely sticky or light ground conditions, adjusting the blades upwards is recommended. If a greater working intensity is required, the blades (6) must be lowered. This is done by moving the blade frame (7) downwards. CAUTION Loss of components If the guide pins are not secured, they can fall out due to vibrations in operation. • The guide pins must always be secured by split rings. 99 Adjustments 17.6 Depth guide 4 2 3 1 6 5 The depth guide (1) with draw links (2) is fitted on the rear of the axle (3) on the system trac. The draw links (2) and catch brackets for the attachments stabilise the attachments at the side. This improves the lateral guidance of the attachments. The rollers (4) for the draw links engage in the catch brackets during operation and are permanently held in position by the springs (5). Depending on the use, the draw links (2) can freely pivot against the force of the springs (5) or be limited to downwards pivoting by guide pins (6). On the Rubin 9 U, the pivoting may not be restricted. When used with Rubin 9 U attachments, the connecting rods may only absorb tensile forces. The guide pins (6) must then be released, removed and stored in the toolbox. When used with Smaragd 9 U attachments, the working depth of the front attachments and depth wheels is controlled by the depth guide (1). See also "Depth wheels" section. 100 Adjustments The depth guide (1) must then be adjusted using the guide pins (6) in such a way that the front attachments in the centre can be guided to any working depth required. Front hole = Greater working depth Rear hole = Less working depth The working depth of the attachments at the outer front is controlled by depth wheels, which also need to be adjusted accordingly. See "Depth wheels" section. The working depth of the attachments is generally controlled by the rollers. The depth guide is only intended to: - improve the lateral guiding with Rubin attachments, and - prevent the tines from penetrating too far in the centre on Smaragd attachments. The draw links may therefore only be loaded with a small proportion of the device weight. 101 Adjustments 17.7 Depth wheels (Smaragd 9U attachments only) The depth wheels are fitted on the front of the frame and, in conjunction with the depth guide, improve the guidance of the attachments. Too much weight may not be applied to the depth wheels as this can have a negative influence on the penetration of the attachments. − Slightly raise the attachments using the three-point hydraulics. − The height is adjusted using the guide pin (2) and the cam lever (1). 3 1 2 − Insert the cam lever (1) directly above the console (3) and secure the lever (1) with the split ring. − Relieve the load on the guide pin (2) by turning the cam lever (1). − Release the locking pin (2) and remove it. − Move the depth wheel to the desired position by turning the cam lever (1). − Re-insert the guide pin. − Secure the guide pin (2) with the split ring. The photos show depth wheels from a different device that are adjusted in a similar way. 102 Adjustments Risk of injury from unsecured depth wheel WARNING If the guide pin and cam lever are simultaneously removed, the depth wheel is no longer held in place and can slide downwards when unsecured. This can result in crushing and foot injuries. • Never remove the guide pin and cam lever simultaneously. • Secure the cam lever (2) with the split ring. 103 Maintenance/repairs 18 MAINTENANCE/REPAIRS 18.1 Special safety instructions 18.1.1 General Risk of injury during maintenance and repair work WARNING During maintenance and repair work, there is always a risk of injury. • Only use suitable tools, climbing equipment, platforms and supports. • Always wear protective clothing. • Maintenance and repair work should only be carried out on a device that is extended and set down or secured against extending or falling by appropriate supports. 18.1.2 Personnel qualifications Risk of accidents due to inadequate maintenance and repair personnel qualifications Maintenance and repair work require appropriate training. CAUTION • All maintenance and repair work described in the "MAINTENANCE/REPAIRS" section may only be carried out by trained and instructed personnel. • In particular, adjustment and repair work on the braking system may only be carried out by specialist workshops or authorised brake service centres. • All maintenance and repair work not described in the "MAINTENANCE/REPAIRS" section may only be performed by specialist workshops. 104 Maintenance/repairs 18.1.3 Personal protective clothing CAUTION Risk of accident when working without protective clothing There is always an increased risk of accidents during maintenance, repair and care work. • Always wear appropriate protective clothing. 18.1.4 Shutting down the device for maintenance/repairs Risk of accidents when tractor starts up WARNING If the tractor starts to move during maintenance/repair work, this can lead to injury. • Turn off the tractor prior to all work on the device. Secure the tractor against unintentional starting. Remove the ignition key. • Place a warning sign in front of the device and the tractor to notify people that maintenance work is in progress. • Secure the tractor against rolling away using wheel chocks. 18.1.5 Work on the hydraulics Risk of accident due to spraying hydraulic fluid WARNING Fluid (hydraulic oil) escaping under high pressure can penetrate the skin and cause severe injuries. In case of injury, seek medical attention immediately. • Prior to any work on the hydraulic system, it must always be depressurised. • When carrying out any work on the hydraulic system, you must always wear appropriate protective clothing. 105 Maintenance/repairs 18.1.6 Work on the electrical system CAUTION Damage to device when working under voltage If the device is still connected to the tractor power supply, there is a risk of damage when working on the electrical system. • Always disconnect the device from the tractor power supply prior to all work on the electrical system. 18.1.7 Working under raised device Risk of accident due to falling and extending of components and devices WARNING Performing work under the raised device or adjacent to retracted components or devices is potentially fatal. • Always secure the tractor against rolling away. Remove the ignition key and secure the tractor against unauthorised use. • Support and secure the raised or retracted components and devices with appropriate supports. 106 Maintenance/repairs 18.1.8 Tools used Risk of accidents if using inappropriate tools WARNING Working with inappropriate or defective tools can cause accidents and injury. • Always carry out all work on the device using appropriate and fully functional tools. This is particularly important when using lifting gear. Risk of back injuries WARNING Working with an inappropriate posture when assembling or fixing heavy/bulky components can cause back injuries and long periods of convalescence. • Assembly and maintenance work may only be carried out by trained and instructed personnel. • Always carry out all work on the device using appropriate and fully functional tools. This is particularly important when using lifting gear. Risk of accident due to slipping tools WARNING When applying significant force, e.g. when loosening screws, the tool can slip. This can cause hand injuries on sharp-edged parts. • Avoid exerting large forces by using appropriate equipment (e.g. extensions). • Check nuts and screw heads etc. for wear and, if required, consult a specialist. 18.2 Environmental protection Ensure that all materials and operating supplies used to maintain and care for the device are disposed of in line with environmental regulations. All recyclable components should be recycled. Observe the national regulations applicable in your country. 107 Maintenance/repairs 18.3 Lubrication Eye injuries due to grease WARNING When lubricating the lubrication points, grease can escape between components at high pressure and cause injury to the eyes. In case of injury, seek medical attention immediately. • Wear protective clothing during lubrication, particularly goggles. − Lubricate all lubrication points as specified on the lubrication chart. In addition, before every winter break and long periods without use: − Grease all guide pins. − Grease all piston rods on the hydraulic cylinders with an acid-free grease. − Grease all surfaces that could rust, e.g. shares, hollow discs, outer discs, guide plates etc. − Close the protective caps on the compressed air and hydraulic pipes. 18.4 Maintenance intervals 18.4.1 After commissioning (within 2 hours) Check What do do? Wheel nuts − Tighten all wheel nuts to the appropriate tightening torque, see "Tightening torques" section. Screw connections 108 − Tighten all other screws and nuts on the device to the appropriate tightening torque. See "Tightening torques" section. Maintenance/repairs 18.4.2 Daily check Check What do do? Tyres − Check the tyres for damage and wear. − Check the air pressure and correct if necessary. See "Tyres / Air pressure" section. Hydraulic hoses − Check hydraulic hoses for damage and leaks. Replace damaged or defective hydraulic hoses immediately. The hydraulic hoses must be replaced 6 years after the date of manufacture at the latest. Only used hydraulic hoses approved by Lemken. Safety equipment − Check that all safety equipment is functioning properly. See "Safety equipment" section. 109 Maintenance/repairs 18.4.3 Weekly check Check What do do? Wheel nuts − Check all wheel nuts for a secure fit and if necessary tighten them to the appropriate tightening torque. Screw connections − Tighten all screws and nuts on the device to the appropriate tightening torque. − If necessary, secure the screw connections with screw locking devices. See "Tightening torques" section. Compressed air tank − Drain the compressed air tank with the drain valve. See "Draining the compressed air tank" section. Compressed air filter − Clean the filter for the braking system. See "Cleaning the filter" section. 18.4.4 Monthly check Check What do do? Tilling device − Check all tilling tools (hollow discs, discs, shares, harrow tines, guide plates etc.) for wear. Replace any damaged components. 110 Maintenance/repairs 18.4.5 Lubrication chart Only use environmentally friendly quality grease for all lubrication work. Item (see Fig. XX) Number of Every Every Every Every lubricating 10 20 50 100 points Operating hours Before a winter break After a winter break a) 2 X X X b) 2 X X X c) 2 X X X d) 4 X X X e) 4 X X X f) 4 X X X g) 2 X X X h) 4 X X X i) 1* X X X j) 8 X X k) 8 X X l) 2 X X X m) 2 X X X n) 2* X X o) 1* p) 1 X X X q) 1 X X X r) 1 X X s) 2 X X X t) 3 X X X X X X X * Number of lubricating nipples per unit 111 Maintenance/repairs 18.4.6 Overview of lubricating points a b a) Folding frame joints b) Base frame joints d c c) Bottom link joints d) Hydraulic cylinder pins f e e) Pendulum balance joints 112 f) Braking axle Maintenance/repairs h g g) Braking axle h) Top link thread j k i i) j) Hollow disc joints (Rubin) Frame joints (Rubin) k) Top link (Rubin / Smaragd) l m l) Depth wheel bearing (Smaragd) m) Depth guide 113 Maintenance/repairs o n n) Overload protection joints (Smaragd) o) Hollow disc bearing (Smaragd) p r p) Stand q) Wheel bearing t) Boom joints s t t t s) Hydraulic cylinder pins t) Boom joints 114 q t Maintenance/repairs 18.5 Tightening torques 18.5.1 Wheel nuts Diameter / Thread Tightening torque [Nm] M12x1.5 80 M14x1.5 125 M18x1.5 290 M20x1.5 380 M22x1.5 510 18.5.2 Other screw connections Diameter / Thread Strength category 8.8 [Nm] Strength category 10.9 [Nm] Strength category 12.9 [Nm] M6 9,7 13,6 16,3 M8 / M8x1 23,4 32,9 39,6 M10 / M10x1.25 46,2 64,8 77,8 M12 / M12x1.25 80,0 113 135 M14 127 178 213 M16 / M16x1.5 197 276 333 M20 382 538 648 M24 / M24x2 659 926 1112 M30 / M30x2 1314 1850 2217 115 Maintenance/repairs 18.6 Draining the compressed air tank Allow the condensation to drain out of the compressed air tank (2) regularly. − Pull or push the pin (1) on the drain valve to the side. The compressed air forces the condensation out of the compressed air tank. 1 2 18.7 Adjusting the brake 1 Adjust the brake if the brake lever (1) moves by more than 40 mm when braking. The brake must be adjusted using the adjusting screw (2) so that the brake lever only moves by 25 - 35 mm. 2 This adjustment must be carried out by a specialist engineer. 18.8 Changing the brake pads Check the condition of the brake pads regularly. Worn brake pads should be replaced with appropriate new brake pads in a specialist workshop. 116 Maintenance/repairs 18.9 Cleaning the filter 1 − Set down the device and disconnect the brake hoses. − Remove the retaining washer (1) and remove the filter insert from the filter housing (2). (The filter insert is held in position by a spring.) 2 − Blow the filter insert through with compressed air. Replace the filter insert if required, depending on the level of contamination. − Replace the filter insert. − Insert the retaining washer. 117 Technical data 19 TECHNICAL DATA 19.1 Dimensions approx. cm Gigant 12/1000 system trac Rubin 9 U Length without servo wheel Length with servo wheel 865 865 865 865 1080 1080 1080 1080 350 350 * 350 * 400 420 - 480 420 - 480 420 - 480 420 - 480 Width Height approx. Gigant 12/1200 system trac Gigant 12S/1200 system trac System compacSmaragd 9 U Rubin 9 U tor * 400 cm with tyres 800/40-26.5 19.2 Weights approx. kg Gigant 12/1000 system trac Rubin 9 U Without servo wheel With servo depth wheel With servo uni wheel Servo depth wheel Gigant 12/1200 system trac Gigant 12S/1200 system trac System compacSmaragd 9 U Rubin 9 U tor 13572* 12046* 11544** 14936* 14572* 13046* 12544** 15936* 14672* 13146* 12644** 16036* 1000 1000 1000 1000 Servo uni wheel 1100 1100 1100 1100 Added weight with rubber ring roller GRW 590 675 900 - 900 * With double roller DRF 400 ** With crosskill roller 118 Technical data 19.3 Supporting and axle loads approx. kg Gigant 12/1000 system trac Max. permitted axle load Chassis Max. permitted axle load Servo uni wheel Max. permitted supporting load Max. permitted axle load with tyres 800/45-26.5 Max. permitted axle load with tyres 580/65-R 22.5 Axle load (without servo uni wheel Axle load (with servo depth wheel) Axle load (with servo uni wheel in transport position) Supporting load Gigant 12/1200 system trac System compacRubin 9 U tor Rubin 9 U Smaragd 9 U 16000 16000 16000 16000 3000 3000 3000 3000 3500 3500 3500 3500 14800 14800 14800 14800 13200 13200 13200 13200 11800 10000 9700 12400 13000 11200 10900 13600 9600 7700 7400 10700 1800 2000 1900 2600 * With double roller DRF 400 ** With crosskill roller The specified values may slightly increase or reduce depending on the rollers used. 119 Technical data 19.4 Tyres / Air pressure 19.4.1 Chassis The chassis can be fitted with the tyres listed in the table. The following minimum and maximum permitted air pressures are approved, depending on the tyre size, the profile and the PR figure or the load index. The PR figure or load index and the profile designation are stamped into the tyres. Designation Profile Load index Min. permitted air pressure [bar] Max. permitted air pressure [bar] 580/65R22.5 Twin Radial 159 D 3,0 3,2 800/45-26.5 T404 172 A 8 2,6 2,8 Min. permitted air pressure [bar] Max. permitted air pressure [bar] 12 2,5 3,2 8 2,6 2,8 19.4.2 Depth wheels and servo wheels Designation Profile Ply rating [PR] 550/45-22.5 10.0/80-12 WARNING AW Hazard due to incorrect air pressure Excessive air pressure in the tyres can cause the tyres to burst, while insufficient air pressure can cause overloading of the tyres. This has a negative influence on accurate towing of the device. This causes an obstruction and a hazard to other road users. 120 Index INDEX Air pressure....................................................................................................... 120 Axle load ............................................................................................................. 41 Blade rollers ........................................................................................................ 98 Brake system ...................................................................................................... 42 Chassis ............................................................................................................. 120 Coupling.............................................................................................................. 56 Cutting bars......................................................................................................... 92 Depth wheels .................................................................................................... 102 Dimensions ....................................................................................................... 118 Extending ............................................................................................................ 47 Guide plates ........................................................................................................ 82 Harrow frames..................................................................................................... 90 HAZARDS ........................................................................................................... 16 Hollow discs ........................................................................................................ 72 MAINTENANCE ................................................................................................ 104 Overload protection ............................................................................................. 78 PREPARATIONS ON TRACTOR........................................................................ 39 Pressure load ...................................................................................................... 84 Rebound harrow.................................................................................................. 81 REPAIRS .......................................................................................................... 104 Required hydraulic control units .......................................................................... 42 Retracting............................................................................................................ 46 Rollers................................................................................................................. 95 Rubin................................................................................................................... 63 Scrapers.............................................................................................................. 96 Servo wheel ........................................................................................................ 34 Share position ..................................................................................................... 75 121 Index Shear device ....................................................................................................... 76 Side limitation...................................................................................................... 83 Side plates .......................................................................................................... 94 Smaragd ............................................................................................................. 70 Smaragd ............................................................................................................. 63 Spring operated brake cylinder............................................................................ 68 Stone guards....................................................................................................... 95 System compactor ........................................................................................ 63, 84 TECHNICAL DATA ........................................................................................... 118 Three-point hydraulics......................................................................................... 63 Top link ............................................................................................................... 64 TURNING.............................................................................................................. 8 Tyres ................................................................................................................. 120 Uncoupling .......................................................................................................... 61 WARNING STICKERS ........................................................................................ 20 Weights ............................................................................................................. 118 Wheel track eliminator......................................................................................... 88 Working depth ..................................................................................................... 70 122 EU Declaration of Conformity EU DECLARATION OF CONFORMITY In accordance with EG Directive for Machines 2006/42/EG We, Lemken GmbH & Co. KG Weseler Strasse 5 D-46519 Alpen, Germany hereby declare that the implement described below System-Trac Gigant 12 and 12S ___ ___ ___ ___ ___ ___ Model Serial number in the plant shipped equipment scope, complies with the pertinent regulations of EU Directive for Machines 2006/42/EG. Alpen, Place and date of issue Signature of authorised person G.Giesen J. Roelse (Head of Development) (Technical Documentation) Authorised person for compilation of technical documentation: J. Roelse Weseler Straße 5 46519 Alpen, Germany 123