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Original Operating and Assembly Instructions
Fixed cornheader
CORN CHAMPION S
ZIEGLER GmbH
Schrobenhausener Straße 74
D-86554 Pöttmes, Germany
Tel: +49 (0) 82 53 / 99 97-0
Fax: +49 (0) 82 53 / 99 97-47
Web: www.ziegler-harvesting.com
EDV Nr.12-080507A-EN Vers. 02
Last update: 07/2018
- The information contained herein is subject to change without notice -
Keep the operating instructions
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- Page 1 Original Operating and Assembly Instructions Fixed cornheader CORN CHAMPION S ZIEGLER GmbH Schrobenhausener Straße 74 D-86554 Pöttmes, Germany Tel: +49 (0) 82 53 / 99 97-0 Fax: +49 (0) 82 53 / 99 97-47 Web: www.ziegler-harvesting.com EDV Nr.12-080507A-EN Vers. 02...
- Page 4 This certificate furnishes proof of the conformity of individual attachment parts with the fundamental safety specifications (in accordance with EU Directive 2006/42/EC) and may be assigned a CE mark when fitted to combine harvesters and other devices. Pöttmes, 01.09.2014______ Ort und Datum; Place and date Dipl. BW (FH) M. Ziegler (Managing Director)
- Page 6 I will also include these documents with the machine / set in the event of its resale and inform the buyer of the obligation to pass on the instructions with the machine. I am aware that a guarantee claim can be made against ZIEGLER GmbH only after ZIEGLER GmbH have received a completed and signed version of this declaration.
- Page 7 The Ziegler CORN CHAMPION S cornheader is a harvest front attachment for mounting to a forage har- vester / combine harvester and serves the harvesting of corn and other bulky forage crops.
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Page 8: Table Of Contents
INHALTSVERZEICHNIS CONTENTS CONTENTS Page FOREWORD ..............................10 INTRODUCTION ............................ 11 Intended use ............................11 Validity ..............................11 Contact partner ............................11 SAFETY ..............................12 MARKING OF INFORMATION IN THE OPERATING INSTRUCTIONS ..........12 MARKING OF THE DANGER WARNINGS ................... 12 Personnel qualification and training ....................... - Page 9 CONTENTS 4.10 Snapping roller ............................30 4.11 Chopper ..............................31 4.12 Chopper body ............................32 4.13 Changing the rotation speed ........................33 4.14 Connection coupling between the picking rows ..................33 OPERATION ............................34 Test run ..............................34 Commissioning; important information ....................36 Cross auger / feed ..........................
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Page 10: Foreword
FOREWORD Dear customer, In purchasing our cornheader, you have decided for a high-quality ZIEGLER product As such, we should like to thank you for your expression of trust. Please read these operating instructions carefully and before use so as to ensure the best possible use of the cornheader. -
Page 11: Introduction
1.1 Intended use The Ziegler CORN CHAMPION S cornheader is a harvest front attachment for mounting to a forage harvester / combine harvester and serves the harvesting of corn and other bulky forage crops. Modifications to the corn stalk chopper / combine harvester are required to harvest other plants such as sunflowers. -
Page 12: Safety
SAFETY SAFETY 2.1 MARKING OF INFORMATION IN THE OPERATING INSTRUCTIONS The safety information provided in these operating instructions (failure to follow them can result in the endangerment of persons) is marked with general danger symbols: 2.2 MARKING OF THE DANGER WARNINGS Danger! DANGER! –... -
Page 13: Safety-Conscious Working
SAFETY 2.5 Safety-conscious working Follow the safety information provided in these operating instructions; any valid accident-prevention regulations; and any internal working, operating and safety regulations. The health and safety and accident-prevention regulations of the appropriate professional associations are binding. Follow the safety information of the vehicle manufacturer. Comply with the relevant highway code when driving on public highways (in Germany StVZO and StVO) Be prepared for any emergencies. -
Page 14: Attached Devices
SAFETY 2.7 Attached devices Exercise especial caution when coupling and uncoupling the cornheader to or from the forage harvester / combine harvester. The cornheader may only be attached to the type of forage harvester / combine harvester intend- ed for the purpose. - Page 15 SAFETY When connecting the hydraulic hoses to the hydraulic connections of the forage harvester / com- bine harvester, ensure that the hydraulics are depressurized on both sides. Given hydraulic function connections between the forage harvester / combine harvester and the front attachment, ensure that the coupling sleeves and plugs are marked so as to prevent incor- rect operation.
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Page 16: Maintenance
2.13 Safety information on the machine The ZIEGLER front attachment device is fitted with all the necessary safety equipment. Not all danger points on this machine can be secured entirely against function-loss. The corresponding safety warn- ings are located on the machine which point to the remaining residual dangers. -
Page 17: The Meaning Of The Safety Labels
SAFETY 2.14 The meaning of the safety labels Fig. 1 Read and comply Do not remain in the Never stand in the Persons are only per- with the operating area of the drive shaft. danger area between mitted to be in the instructions and the Danger of injury! the front attachment... -
Page 18: Technical Data And Designation
Please note ZIEGLER original spare parts and manufacturer-authorized accessories serve the security of the ma- chine. The use of spare parts, accessories and other devices not produced, tested or authorized by ZIEGLER will result in the loss of liability for the resulting damage. -
Page 19: Technical Data
TECHNICAL DATA AND DESIGNATION 3.4 Technical data All the information, diagrams and technical specifications made in these operating instructions corre- spond to the latest state of technology at the point of publication. We reserve the right to make alterations to the design at any time and without the need to specify rea- sons. -
Page 20: Installation
Comply with the correct sequence before fitting any form of seal 4.1 General transport Transport on a HGV When transporting the cornheader on a HGV, al- ways use the ZIEGLER transport frame. Secure the cornheader against falling down using tensioning belts in accordance with the locally-valid regulations. -
Page 21: Unpacking The Cornheader
The transport frame is designed in such as way that the cornheader can be secured to the frame so as to prevent it falling out. You can use the ZIEGLER transport frame to transport the cornheader with a forklift truck. We recommend driving at a walking pace. - Page 22 The machine may only be transported by a forklift truck using the Ziegler transport frame. Fig. 12 Placing down the cornheader Hook a vertical cornheader as depicted in Fig. 13 and position the forks of the forklift truck on point A.
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Page 23: Attaching The Cornheader
INSTALLATION 4.3 Attaching the cornheader Adaption to the harvester Place the cornheader on the parking supports. Check the correctness of the adaption parts. Move the harvester to the picker. Lift up the picker with the feeder channel. Check the correct position of the adaption (A). The presence of persons between the harvester and the cornheader is imper- missible during the connection. -
Page 24: Cornheader Drive
INSTALLATION Additional weights Depending on the weight of the installed cornhead- er, additional weights may be required on the steer- ing shaft of the harvester. The dimensions of these additional weights are specified in the motor vehicle certification of the combine harvester handbook. -
Page 25: Hydraulic Connections
INSTALLATION Hillside combine drive All cornheaders are driven via drive shafts directly mounted by hand. Specific combinations of combine harvester - picker require a wide angle or special drive shafts. Comply with all the regulations and the drive shaft designs. Check the pivot area and length of the drive shaft before commissioning. -
Page 26: Fitting The Divider Tips
INSTALLATION Connection via a screw / plug connection If only simple screw / plug connections are present, mark double and single-acting lines. Establish a secure connection so that oil can flow. Mark the lines and always make identical connec- tions so that the working sense remains unchanged. Fig. -
Page 27: Adjusting The Snapping Plates
INSTALLATION Setting the divider tips Remove the anti-lowering clamp. Place the picker on a level surface and lower to a clearance of 15 cm from the ground. Set the divider tips with screws so that they have a 2 cm clearance to the floor (normal setting). If the harvester falls strongly into the field, adjust the settings. - Page 28 INSTALLATION Adjusting the snapping plate of the fixed corn- header The clearance of the snapping plates can be set (infinitely-variable) from the driver’s cab via the dou- ble-acting cylinders. If the snapping plates are to be readjusted, first bring the hydraulic adjustment into the most tight-fitting position possible.
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Page 29: Feeder Chains
INSTALLATION 4.8 Feeder chains Feeder chains Chain tensioning device The feeder chains are tensioned automatically and maintenance-free through even spring pressure. When is it necessary to replace the feeder chains? Renew the chain if the maximum of the tensioner has been reached. The feeder chain is to be replaced if it is damaged by foreign bodies. -
Page 30: Snapping Roller
INSTALLATION Reference dimensions of the picking row frames The correct clearance of the frame support (X) in the fore section (A) is of especial importance for the function of the cornheader. A collision can alter this clearance. The support arm can bend at the far right and left-hand sides, as this is no longer supported by a connection series. -
Page 31: Chopper
INSTALLATION 4.11 Chopper Drive (E) Ventilator (K) Inspection glass (W) Anti-wrap guard Check the oil level regularly The chopper bearing is fitted with a lifetime lubrica- tion system and is maintenance-free. Fig. 36 Arrangement of the chopper blades The chopper blade (M) is to be fitted above the blade carrier using the original bushing. -
Page 32: Chopper Body
INSTALLATION 4.12 Chopper body Blade carrier Safe operation of the chopper requires that worn, bent or damaged parts are replaced immediately. Caution: Blade over-travel for two minutes. Switch off the motor and activate the lowering lock before commencing any work on the machine. Wear the corresponding protective clothing. -
Page 33: Changing The Rotation Speed
INSTALLATION 4.13 Changing the rotation speed The nominal speed is not reached If the nominal speed of the picker (c. n = 600 U/min) is not reached, it is possible to correct the rotation speed by changing the sprocket within the drive (K). Check whether the starting rotation speed on the harvester on the drive shaft guard connection in question (B) corresponds with the works specifica-... -
Page 34: Operation
OPERATION OPERATION DANGER! – The cornheader could start up unexpectedly during setting work Impact: Danger to life or of serious injuries. Lower the cornheader completely Switch off the combine harvester completely, remove the ignition key and secure the machine against reactivation (operating Instructions of the com- bine harvester) ... - Page 35 OPERATION Test run only when lowered Considerations of safety require that the picker and chopper are only started up when lowered or subject to a test run. Take steps to prevent objects from entering the picker or the chopper during the test run. Switch off the motor and activate the lowering lock before commencing any work on the machine.
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Page 36: Commissioning; Important Information
OPERATION 5.2 Commissioning; important information Working angle (basic setting) If larger or smaller tyres are fitted on the harvester than in series, we recommend checking the working angle. The same applies to the use of caterpillar tracks. This check is best performed under real operating conditions on the field with the usual clearance to the ground. - Page 37 OPERATION Securing the corn field Ensure that no-one may is the proximity of the corn- header before commissioning the commissioning. Danger of death for all persons in the corn field! Persons could be drawn in by the cornheader and suffer severe inju- ries.
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Page 38: Cross Auger / Feed
OPERATION Drip-feed lubricator The drip-feed lubricator must be set so that a drop falls through the inspection glass every three sec- onds. Fig. 55 Cross auger / feed Cross auger The cross augers are fitted with fitting irons (B) in the area of the channel opening. -
Page 39: Cross Auger
OPERATION Baffle plate of the cross auger The height of the baffle plate is adjusted via the screw connection (V). The clearance between the auger and the hood should be as large as possible to allow sufficient passage for corn leaf, leaf and even stalks. Switch off the diesel motor when perform- ing all work on the cornheader. -
Page 40: Maintenance And Care
MAINTENANCE AND CARE MAINTENANCE AND CARE 6.1 Accident protection / operating safety DANGER! – The cornheader could start up unexpectedly during maintenance work Impact: Danger to life or of serious injuries. Lower the cornheader completely Switch off the combine harvester completely, remove the ignition key and secure the machine against reactivation (operating Instructions of the com- bine harvester) ... -
Page 41: Lubricants / General Information / Disposal
MAINTENANCE AND CARE Lateral straw chopper – safety equipment With certain models of picker and series clearances, it is possible that the chopper blade runs to the right or left (even to the right and left) of the outside en- closure of the picker. -
Page 42: Maintenance / Care / Inspection
MAINTENANCE AND CARE General instructions All moving parts should be lubricated and cared for to a degree usual for a machine construction con- text. Regular cleaning and the removal of deposits serves the value-retention and operating safety. Components subject to regular or irregular move- ment also require periodic oiling or greasing. - Page 43 MAINTENANCE AND CARE Inspection after the harvest season When performing repeated inspections (after the harvest season) the following components must be checked and replaced if necessary: Rubber strip Cutting tool Safety equipment of the power take-off shaft Fig.
- Page 44 MAINTENANCE AND CARE Roller chains The roller chains fitted for the cross auger are to be kept rust-free during storage. The pertinent recommendations regarding caring for the roller chains apply. Fig. 71 Storage The cornheader is best stored in a well-ventilated hall, either standing in its transport frame or placed down on dry ground.
- Page 45 MAINTENANCE AND CARE Lubrication plan Perform the first check before commissioning the cornheader. Fig. 74...
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Page 46: Decommissioning And Dismantling
MAINTENANCE AND CARE Decommissioning and dismantling DANGER! – The machine can tip! Impact: Danger to life or of serious injuries. Apply the transport lock Secure the machine correctly with tension belts Ensure that the machine has a steady position. ... -
Page 47: Faults And Troubleshooting
FAULTS AND TROUBLESHOOTING FAULTS AND TROUBLESHOOTING HYDRAULICS Fault Cause Remedy Page Cornheader front at- Insufficient quantities of Refill oil tachment hydraulic oil Insufficient lift force Additional lift cylinder required Hydraulic function of Hydraulic connections have Check the connections / couplings / the picker does not no throughflow screw connections... - Page 48 FAULTS AND TROUBLESHOOTING PICKING UNIT Fault Cause Remedy Page The picker remains Drive belts not tightened Perform a service stationary during har- handbook vesting Working speed too high Adapt Straw content too high Snapping plates Open the snapping plate as far apart as possible Working speed Adapt the working speed to the condi-...
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Page 49: Options
OPTIONS OPTIONS 9.1 Sunflower kit Caution - Danger of injury from sharp blade. Impact: Injuries When replacing the cutting tools, use tools appropriate to cutting tools and wear suitable gloves. Loosen the chain and the chain tensioner Fig. 77 Remove the chain Remove the chain tensioner Fig. - Page 50 OPTIONS Slide in in the fixed blade from the front to the back. Fig. 80 Bring the sunflower kit into position and fix with screws. Fig. 81 Tighten the fixed blade. Fig. 82 Check the distance between the fixed and rotating blade.
- Page 51 OPTIONS (Only necessary if the distance is not 1mm). The distance between the blades can be adjusted with shims. If you need more space, you have to re- move the shims or if you want to reduce the space you have to add shims. For this work, you have to remove the sprocket.
- Page 52 OPTIONS Remove the stalk-roller to the top. Remove the stalk-roller to the top. Fig. 88 Put on the stalk-roller-cover and fix it. Fig. 89 To return everything, proceed in the reverse fashion.
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Page 53: Down Maize Auger
OPTIONS 9.2 Down maize auger Fitting the down maize auger Maintain the sequence with fitting and dismantling Remove the cover of the drive gearbox Fig. 90 Loosen the chain tensioner Fig. 91 Open the chain lock, remove the chain, disman- tle the document roll and fit outside Fig. - Page 54 OPTIONS Removing the drive shaft completely Remove the sprocket Remove the protective ring Lock collar Loosen the grub screw (e.g. hook wrench) Remove the circlip using pliers Remove the drive collar with the puller if necessary, then remove the feather key ...
- Page 55 OPTIONS Remove the circlip using pliers Fig. 97 Remove the drive collar with the puller if neces- sary, then remove the feather key Fig. 98 Remove the screws on the flange bearing on both sides of the drive gearbox Fig.
- Page 56 OPTIONS Insert the feather key on the shaft Fig. 101 Tighten the sprocket and secure with the circlip Install the shaft in the drive gearbox, place the bearing on the outside of the shaft Fig. 102 Please note: place on the inner bearing with the lock collar side facing towards the inside of the picker ...
- Page 57 OPTIONS Insert the feather keys, set the hub onto the shaft; bringing into position with light blows, se- curing with the circlip Fig. 105 Maintain the clearance of the drive collar to the drive gearbox (30-065144) Fig. 106 ...
- Page 58 OPTIONS Check the alignment of the sprocket Fig. 109 Fit the chain and the chain lock, set the chain tensioner. The chain must not hang through. Fig. 110 Dismantle the lid Fig. 111...
- Page 59 OPTIONS Unscrew the bracket Fig. 112 Screw on the down maize auger Fig. 113 Screw on the down maize auger Fig. 114 Screw on the erasing blade Fig. 115...
- Page 60 OPTIONS Cut out the pre-lasered area Fig. 116 Install the pump with console Tighten the screws lightly Fig. 117 Place on the chain, tension slightly and the tight- Fig. 118 Place the fully-fitted tank and fix with 4 screws Fig.
- Page 61 OPTIONS Connect the hoses (A and B) Fig. 120 With the drive below, the pump (A) must be in- stalled. Fig. 121 Connect the hydraulic hoses (A,B,C) on the right-hand side After installing, remove the centre of the three flat-headed screws in the side hood (E) and fit the hose clamps (see Fig.
- Page 62 OPTIONS Connect the hydraulic hoses (C and D) on the left-hand side After installing, remove the centre of the three flat-headed screws in the side hood (E) and fit the hose clamps (see Fig. 122 and Fig. 120) Fig.
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Page 63: Extraction Torque For Screws
OPTIONS Extraction torque for screws Minimum torques for the screw classes II correspond to 1c Apply to solid screws Use suitable tools with which to achieve the tightening torque. Dimensions M nominal value in Nm M nominal value in Nm M nominal value in Nm Strength class 8.8 Strength class 10.9... - Page 64 HRB 17559 Geschäftsführer: M. Ziegler, Dipl. BW (FH) Geschäftsführer: M. Ziegler, Dipl. BW (FH) Place of performance: Pöttmes, Place of jurisdic- Managing director: M. Ziegler, Dipl. BW (FH) tion: Aichach Tax no. 102/168/10401 Managing director: M. Ziegler, Dipl. BW (FH)