Related Manuals for Ziegler CORN CHAMPION GEN III
Summary of Contents for Ziegler CORN CHAMPION GEN III
- Page 1 CORN CHAMPION GEN. III Corn header foldable Data: 17.07.2023 Ziegler-Nr.: 12-106392A_EN_Vers.00_BTA...
- Page 5 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, 01.01.2021______ Ort und Datum; Place and date Dipl. BW (FH) M. Ziegler (Managing Director)
- Page 7 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 9 The Ziegler CORN CHAMPION GEN. III 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. Any other form of use is acknowledged as non-intended use.
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Page 10: Table Of Contents
CONTENTS CONTENTS Page FOREWORD ..............................12 INTRODUCTION ............................ 13 Intended use ............................13 Validity ..............................13 Contact partner ............................13 SAFETY ..............................14 Marking of information in the operating instructions ................14 Marking of the danger warnings ......................14 Personnel qualification and training ....................... 14 Dangers for failure to follow the safety information ................ - Page 11 CONTENTS 4.12 Chopper body ............................33 4.13 Connection coupling between the picking rows ..................34 4.14 Bevel gear .............................. 34 DEMONTAGE ............................35 Connection process ..........................35 Foldable version ............................. 36 OPERATION ............................37 Test run ..............................37 Commissioning ............................39 Cross auger / feed ..........................
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Page 12: 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 13: Introduction
1.1 Intended use The Ziegler CORN CHAMPION 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. Modifications to the corn stalk chopper / combine harvester are required to harvest other plants such as sunflowers. -
Page 14: 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 15: 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 16: Attached Devices
SAFETY 2.7 Attached devices ➢ Exercise especial caution when coupling and uncoupling the cornheader to or from the forage har- vester / combine harvester. ➢ The cornheader may only be attached to the type of forage harvester / combine harvester intended for the purpose. -
Page 17: Hydraulic System
SAFETY Please note Follow the information of the manufacturer of the drive shaft. (Separate operating instructions). 2.9 Hydraulic system ➢ The hydraulic system is pressurized. ➢ When connecting hydraulic cylinders and motors, ensure that you connect the hydraulic hydraulic hoses in the correct fashion. ➢... -
Page 18: 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 warnings are located on the machine which point to the remaining residual dangers. -
Page 19: 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 in- area of the drive shaft. danger area between mitted to be in the structions and the Danger of injury! the front attachment... -
Page 20: 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 21: Overview Of The Machine
TECHNICAL DATA AND DESIGNATION Model rows row distance Length (mm) Weight (kg) GEN. III 70 cm 4400 x 2750 mm 2.500 kg GEN. III 75 cm 4400 x 2750 mm 2.600 kg CLASSIC LINE 70 cm 4400 x 2750 mm 2.550 kg CLASSIC LINE 75 cm... -
Page 22: 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 23: 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 24 The machine may only be transported by a forklift truck using the Ziegler transport frame. Fig. 10 Placing down the cornheader Hook a vertical cornheader as depicted in Fig. 11 and position the forks of the forklift truck on point A.
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Page 25: Attaching The Cornheader
INSTALLATION 4.3 Attaching the cornheader Adaption to the harvester Fig. 13 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 26: Cornheader Drive
INSTALLATION Additional weights Depending on the weight of the installed corn- header, additional weights may be required on the steering shaft of the harvester. The dimensions of these additional weights are specified in the motor vehicle certification of the combine harvester handbook. Comply with the certification conditions Fig. -
Page 27: Hydraulic Connections
INSTALLATION 4.5 Hydraulic connections Multicoupling If the combine harvester is fitter with a multicoupling, the picker should also be fitted with a multicoupling. The correct coupling is included in the scope of de- livery. Fig. 20 Operation is performed in accordance with the reg- ulations and instructions of the manufacturer of the combine harvester. -
Page 28: Fitting The Divider Tips
INSTALLATION 4.6 Fitting the divider tips Putting up the hood flap Centre covers and side covers are deflected at the rear. To lift it, you must knock over the tip, remove the locking pin A and release the lever B. Then raise the hood and make sure you place the hood support C correctly in its seat to prevent accidental closing of the hood while inspecting the machine. -
Page 29: Feeder Chains
INSTALLATION Snapping plates It is not possible to rule out soiling resulting from the operation. Open and close the snapping plates (L) a minimum of once a day to ensure that they are free and to remove all soiling. Oil the joints every 100 h. After concluding the harvest, clean the support plate (C) and the adjustable snapping plate (L) an protect against corrosion. -
Page 30: Settings And Reference Dimensions
INSTALLATION Removing the draw-in chains Loosen screw (A) and slide the idler sprocket (B) backwards. Now dismantle the chain. Clearance 1m Worn +3.5cm. Unscrew A Unscrew C Slide B t the rear Fig. 28 4.9 Settings and reference dimensions Scraper on the picker cylinders Highly effective scrapers are located at specific po- sitions on the picker cylinders (A) to provide pro- tection against winding plants, grass or similar. -
Page 31: 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 32: 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. 33 Arrangement of the chopper blades The chopper blade (M) is to be fitted above the blade carrier using the original bushing. -
Page 33: 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 34: Connection Coupling Between The Picking Rows
INSTALLATION 4.13 Connection coupling between the picking rows Duplex chains Subject the Duplex chain (C) to regular checks for the state of the elastic elements (E) and the state of the drive claw. Replace worn parts promptly. Fig. 39 4.14 Bevel gear Bevel gear Check the oil level regularly. -
Page 35: Demontage
DISASSEMBLY DISASSEMBLY 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 combine harvester) ➢... -
Page 36: Foldable Version
DISASSEMBLY 5.2 Foldable version Fig. 42 On machines with internal drive, align the length and height of the corn head drive with that of the combine harvester using the side plates. If necessary, shorten the corn head drive shaft to be able to mount the joint. - In some cases, it will be likely to use an adapted cardan shaft. -
Page 37: 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 combine harvester) ➢... - Page 38 OPERATION Test run only when lowered Considerations of safety require that the picker Fig. 45 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 39: Commissioning
OPERATION 6.2 Commissioning Working angle (basic setting) If larger or smaller tires than the standard equip- ment are mounted on the harvester, it is advisable to check the working angle. The same also applies when using caterpillar tracks. The check should preferably be carried out under real operating conditions in the field with the usual ground clearance. - Page 40 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 41: Cross Auger / Feed
OPERATION 6.3 Cross auger / feed Cross auger The cross augers are fitted with fitting irons (B) in the area of the channel opening. Optionally availa- ble transport claws (K) for the transport of the har- vest can be fitted here. The number of the claws (K) or their width can differ according to the model of picker and depend on the feeder channel width of the respective harvester. -
Page 42: Cross Auger
OPERATION 6.4 Cross auger Picker fittings A series of overload protections and friction cou- plings have been fitted to the machine to ensure its secure operation. Should these systems activate, deactivate the picking front attachment immediately. Switch off the diesel motor and secure the picker against unintended lowering. -
Page 43: Maintenance And Care
MAINTENANCE AND CARE MAINTENANCE AND CARE 7.1 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 combine harvester) ➢... -
Page 44: Lubricants / General Information / Disposal
MAINTENANCE AND CARE Lateral straw chopper – safety equipment With certain models of picker and series clear- ances, it is possible that the chopper blade runs to the right or left (even to the right and left) of the out- side enclosure of the picker. -
Page 45: 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 46 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 Fig. 65 shaft •...
- Page 47 MAINTENANCE AND CARE Storage The cornheader is best stored in a well-ventilated hall, either standing in its transport frame or placed down on dry ground. Protect all bare metal parts from rust. Load handling attachments may only be used for their intended purpose.
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Page 48: Residual Risks
MAINTENANCE AND CARE 7.4 Residual risks The residual risks are dangers that cannot be eliminated by design and/or the use of special safety measures. These risks can also be traced back to non-obvious risk potentials. Examples of residual risks are: ➢... -
Page 49: Lubrication Plan
MAINTENANCE AND CARE 7.5 Lubrication plan Perform the first check before commissioning the cornheader. Maintenance Hours Lubricate the couplings of the picker row. Check the tension of the drive chains. Lubricate the drive shafts or the knuckle joints. Lubricate the coupling units for the cornheader with internal drive. Make sure there are no oil leaks that could cause damage on roads or pollute the ground. -
Page 50: Decommissioning And Dismantling
DESCOMMISSIONING AND DISMANTLING 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 51: Faults And Troubleshooting
FAULTS AND TROUBLESHOOTING FAULTS AND TROUBLESHOOTING HYDRAULICS Fault Cause Remedy Page Cornheader front at- Insufficient quantities of hy- Refill oil tachment draulic 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 52 FAULTS AND TROUBLESHOOTING PICKING UNIT Fault Cause Remedy Page The picker remains Drive belts not tightened Perform a service stationary during har- hand- vesting book 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 53: Options
OPTIONS OPTIONS 10.1 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. Note: Set the picking plate to the greatest distance! Fig. 73 Push in the counter blade from the front as far as it will go. Fig. - Page 54 OPTIONS Fig. 75 Push in the counter blade from the front as far as it will go. Fig. 76 Install the sunflower kit, tighten the screws. Tighten the counter blade screws! Fig. 77 Install the tensioner and the chain in reverse order and tension the chain. Note: To ensure a gentle picking of the sunflowers stalk roller must be removed!
- Page 55 OPTIONS Fig. 78 Dismantle the knife guard, remove the screws of the stalk roller holder. Fig. 79 Pull out the stalk roller and holder towards the front. Fig. 80 Put on the stalk roller cover and tighten it. Note: The picking plates can no longer be adjusted! When retrofitting, carry out the points in reverse order.
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Page 56: Corn Auger
OPTIONS 10.2 Corn auger Fig. 81 Flat corn auger assembly By using the lateral augers, the corn harvest is eas- ier. The hydraulic power transmission of these au- gers is equipped with a safety valve calibrated by the manufacturer at 80 bar. It is NOT recommended to vary this calibration, which allows the immediate stop in case of significant load on the auger and in case of accidental touch with a hand. -
Page 57: Extraction Torque For Screws
EXTRACTION TORQUE FOR SCREWS EXTRACTION TORQUE FOR SCREWS 11.1 Tightening torque for galvanized screws Tightening NOMINAL DIAMETER - NORMAL THREAD Strength torque class 0.56 1.28 2.50 10.5 1030 1340 ft/lb 0.41 0.94 1.84 1.28 2.90 5.75 16.5 1350 1830 2360 3050 ft/lb 0.94... - Page 58 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)