Table of Contents
Related Manuals for LEMKEN Gigant 12
Summary of Contents for LEMKEN Gigant 12
- Page 1 Operating Instructions System Trac Gigant 12, 12S - en - Item no. 175_4316 BA_04/02.20 LEMKEN GmbH & Co. KG Weseler Straße 5, 46519 Alpen / Germany Telephone +49 28 02 81 0, Fax +49 28 02 81 220 lemken@lemken.com, www.LEMKEN.com...
- Page 3 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.
- Page 4 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 ser- vice life and present risks and hazards that cannot be estimated by LEMKEN GmbH & Co. KG. They also increase the maintenance costs.
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Page 5: Table Of Contents
CONTENTS General information ....................10 Liability ......................... 10 Guarantee ........................10 Copyright ........................11 Optional accessories ....................11 Type plate ........................12 Symbols used in the Operating Instructions ............14 Hazard classes ......................14 Information........................14 Environmental protection ................... 14 Indication of passages .................... - Page 6 Applicable rules and regulations ................29 Operation on public highways ................... 30 3.9.1 Lighting system and identification ................30 3.9.2 Requirements on the tractor ..................30 3.9.3 Permitted transport speed ..................31 3.9.4 Check before departure ..................... 32 3.9.5 Correct behaviour in road traffic ................32 3.10 Obligation of the operator ..................
- Page 7 Required hydraulic equipment ................... 48 Brake system ....................... 48 6.6.1 Air brake system ......................49 6.6.2 Hydraulic brake system ..................... 49 6.6.3 Without brake system ....................49 Preparations on implement ..................50 Final assembly ......................50 Spring brake cylinders ....................50 Coupling and uncoupling implement ..............
- Page 8 11 Roller change-over ....................69 11.1 General information ....................69 11.2 Transport position ....................... 69 11.2.1 Smaragd 9 and 9 U ....................69 11.2.2 Rubin 9 U ....................... 71 11.2.3 Heliodor 9 ....................... 71 11.3 Working position ......................72 12 Attaching and detaching working sections ............73 12.1 General .........................
- Page 9 13.4 Rubin 9 U ........................101 13.4.1 Mechanical working depth adjustment ..............101 13.4.2 Adjust lowering depth of the rollers ..............103 13.4.3 Hydraulic working depth adjustment ..............104 13.4.4 Rebound harrow ....................105 13.4.5 Guide plates ......................106 13.4.6 Side limitation .......................
- Page 10 15 Maintenance/repairs ..................... 133 15.1 Special safety instructions ..................133 15.1.1 General ........................ 133 15.1.2 Personnel qualifications ..................133 15.1.3 Personal protective clothing ................. 134 15.1.4 Shutting down the device for maintenance/repairs ..........134 15.1.5 Work on the hydraulics ..................134 15.1.6 Work on the electrical system ................
- Page 11 16 Technical data ....................... 150 16.1 Dimensions ........................ 150 16.2 Weights ........................150 16.3 Permitted loads and weights ..................151 16.4 Tyres / tyre pressure ....................152 16.4.1 Chassis ........................ 152 16.4.2 Depth wheels ......................152 17 Noise, Airborne Sound ..................153 18 Notes ........................
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Page 12: General Information
Co. KG, in particular Section IX, shall apply. Liability. In line with the dimensions cited in these conditions the LEMKEN GmbH & Co. KG shall not be held liable for any personal or material damage, when such damage is caused by one or more of the following reasons: ... -
Page 13: Copyright
Infringements will result in a claim for damages. Optional accessories LEMKEN implements may be equipped with various accessories. The operating instructions below describe both series components and optional accessories. Please note: These accessories will vary depending on the type of equipment. -
Page 14: Type Plate
General information Type plate The implement is marked with a type plate. The type plate is located at the front right of the implement. The operating instructions can apply to va- rious implement types implement equipment. In the operating instructions, contents are marked that are only valid for a certain im- plement type... - Page 15 General information 1 Series 2 Type designation 3 Serial number 4 Year of manufacture 5 Vehicle class, subclass, speed index 6 EU type approval number 7 Vehicle identification number. The vehicle identification number is also engraved in the frame near the type plate. 8 Permitted gross weight [kg]* 9 Permissible drawbar load [kg] (axle 0) 10 Permissible axle load [kg] (axle 1)
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Page 16: Symbols Used In The Operating Instructions
Symbols used in the Operating Instructions SYMBOLS USED IN THE OPERATING INSTRUCTIONS Hazard classes The following symbols are used in the Operating Instructions for particularly im- portant information: DANGER Denotes an imminent hazard with high risk, which will result in death or severe physical injury, if not avoided. -
Page 17: Indication Of Passages
Symbols used in the Operating Instructions Indication of passages The following symbols are used for particular passages in the operating instruc- tions: Indicates work steps Indicates enumerations... -
Page 18: Safety Measures And Precautions
Safety measures and precautions SAFETY MEASURES AND PRECAUTIONS General safety instructions for the operator are specified in the chapter entitled «Safety measures and precautions». At the start of some main chapters the safety instructions, which refer to all work to be carried out in this chapter, are listed to- gether. -
Page 19: Safety Features Of The Device
Safety measures and precautions Safety features of the device To protect the operator and the device, the device is equipped with special safety features in accordance with country specific requirements. Always keep all safety devices in working order. Warning board for slow moving vehicles (depending on Stand national regulations) Side protective devices... -
Page 20: Safety And Warning Signs
Safety measures and precautions Wheel chocks Safety and warning signs 3.4.1 General information The implement features all equipment which ensures safe operation. If hazardous areas could not be completely secured with respect to operational safety, warning signs are affixed which indicate these resi- dual risks. -
Page 21: Position Of Safety And Warning Stickers
Safety measures and precautions 3.4.2 Position of safety and warning stickers Working sections – example of Heliodor 9... -
Page 22: Meaning Of Warning Signs
Safety measures and precautions 3.4.3 Meaning of warning signs Please familiarise yourself with the meaning of the warning signs. The following explanations provide detailed information. Please read and observe the operating in- structions and safety instructions before starting up the implement for the first time. Art. - Page 23 Safety measures and precautions Crushing hazard Keep out of the folding area of the imple- ment. Overhead lines Danger from electric current! This will re- sult in death or serious injuries. Keep distance from overhead lines. Always ensure that there is a sufficient rear axle load.
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Page 24: Meaning Of Other Symbols
Safety measures and precautions 3.4.4 Meaning of other symbols. Sling points Connection overview of hydraulic ho- P1 / T1 Folding Additional return line P3 / (T3) Three-point hydraulics working sections P5 Hydraulic cutting bar setting P11 / T11 Hydraulic working depth adjustment P16 / T16 Hydraulic top link P17 / T17 Hydraulic support leg... - Page 25 Safety measures and precautions Heliodor Depth adjustment - left (only for implements with mechanical depth adjustment) 12 – maximum working depth 1 – minimum working depth Heliodor Depth adjustment - right (only for implements with mechanical depth adjustment) ...
- Page 26 Safety measures and precautions Hydraulic depth adjustment scale (only on implements with hydraulic depth adjustment)
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Page 27: Special Safety Instructions
Safety measures and precautions Special safety instructions Risk of injury due to non-observance of the currently valid occupational safety guidelines If the currently valid occupational safety guidelines are bypassed WARNING or safety equipment is rendered unusable when handling the de- vice, there is a risk of injury. - Page 28 Safety measures and precautions Risk of injury when freeing casualties When rescuing people trapped or injured by the device, there is a risk of additional serious injury to the casualty if the hydraulic con- nections were not connected according to their colour coding as described in the section entitled "Required hydraulic equipment".
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Page 29: Danger Areas
Safety measures and precautions Danger areas 3.6.1 Danger areas during implement operation Moving danger area The danger area around the implement moves with the implement during operation. The danger area includes the area extending across the entire width (a) of the implement in the direction of WARNING travel. -
Page 30: Danger Areas When Folding And Unfolding
Safety measures and precautions 3.6.2 Danger areas when folding and unfolding Risk of impact and crushing from moving implement compo- nents There is a risk of impact or crush injuries from moving implement components. The danger area includes the area extending across the entire width of the implement (a). -
Page 31: Residual Risks
Safety measures and precautions Residual risks Residual risks are particular hazards which occur when handling the device and which cannot be eliminated despite a design in accordance with safety require- ments. Residual risks are not usually obvious and may be the source of a potential injury or health hazard. -
Page 32: Operation On Public Highways
Safety measures and precautions Operation on public highways 3.9.1 Lighting system and identification A proper lighting system, identification and equipment must be on the device if it is to be transported on public roads. Further information can be requested from the appropriate authorities. -
Page 33: Permitted Transport Speed
Safety measures and precautions Risk of accident through adjustable drawbar that is too weak or unsuitable If an adjustable drawbar is used that is too weak, the adjustable drawbar may break and the implement may be lost. As a result, DANGER other people or other road users may be injured or killed. -
Page 34: Check Before Departure
Safety measures and precautions 3.9.4 Check before departure Check function of implement brakes before driving off. Check the coupling pin is correctly locked. Check that the fold-out safety device for the side parts is correctly locked! Mount and check the transport equipment such as the lighting system, warning signs and protective devices. -
Page 35: Obligation Of The Operator
Safety measures and precautions 3.10 Obligation of the operator Before switching on the device, read the operating instructions. Follow the safety instructions! Wear appropriate protective clothing when carrying out any work on the device. Protective clothing must be tight-fitting! ... -
Page 36: Operating The Implement Safely
Safety measures and precautions 3.11 Operating the implement safely 3.11.1 General information Before starting work, familiarise yourself with all equipment and actuating ele- ments as well as their functions. Commission the implement only after ensuring that all protective devices have been fitted and enabled. -
Page 37: Handing Over The Implement
Handing over the Implement HANDING OVER THE IMPLEMENT As soon as the implement is delivered, ensure that it corresponds with the order package. Also check the type and completeness of any supplied accessories. When the device is handed over, your dealer will explain how it works. ... -
Page 38: Layout And Description
Layout and description LAYOUT AND DESCRIPTION Overview Hitch with drawbar eye Axle with wheels Stand in transport holder Folding frame (lateral part) Toolbox Folding frame (centre part) V - drawbar Depth control / Traction guide Three-point hydraulics Mounted implement... - Page 39 Layout and description Depth control – Rubin, Smaragd and Traction guide – Heliodor and System- System-Kompaktor (12 m) Kompaktor (16 m) Lower link Adjustable pressure relief valve Top link Self-levelling quick-release coupling...
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Page 40: Description
Layout and description Description 5.2.1 Drawbar with drawbar eye The drawbar with drawbar eye is used to attach the tractor by an appropriate dou- ble lashing drawbar. 5.2.2 Stand The stand ensures stability when the footing condition deteriorates. 5.2.3 Folding frame The working arrays are swivelled and swung forward into the transport position on the folding frame. -
Page 41: Adjustable Pressure Limiting Valve
The System Trac can be fitted with working sections comprising the following mounted implements: Smaragd 9 (Gigant 12 / 1200) System-Kompaktor (Gigant 12 / 1200, Gigant 12 S/1600) Rubin 9 U (Gigant 12 S/1000, Gigant 12 S/1200) Heliodor 9 (Gigant 12 S/1600) -
Page 42: Air Brake System
Layout and description 5.2.9 Air brake system Overview Compressed air tank Drain valve Park valve (parking brake) Release valve Trailer brake valve Filter Spring brake cylinder Brake lever Guiding screw Holder for guiding screw Functional description Parking brake The parking brake is ready for use when the guiding screw (9) has been removed, placed in the holder (10) and secured. - Page 43 Layout and description Trailer brake valve and release valve To release the service brake: Press the black button on the release valve (4). If the operating pressure falls below 3.0 bar, the black button on the release valve (4) is automatically pushed out. This applies the parking brake. Spring brake cylinder If the operating pressure in the braking system falls below 3.0 bar, the parking...
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Page 44: Hydraulic Braking System
Layout and description 5.2.10 Hydraulic braking system The hydraulic braking system consists of the following units: Service brake Parking brake Rapid emergency brake Service brake The service brake is operated hydraulically via the trailer brake valve on the tractor. Brake lever Tension spring Hydraulic cylinder... - Page 45 Layout and description Parking brake The parking brake prevents the implement from rolling away. Lever Stop device with locking lever Rope Breakaway cable (to the tractor) Locking lever Locking lever (5) in lock position To apply the parking brake: Move the locking lever (5) to the right (lock position).
- Page 46 Layout and description Rapid emergency brake Before driving on public roads: Release the parking brake. Move the locking lever (5) to the right (lock position). Connect the breakaway cable (4) to the tractor. If the implement breaks away from the tractor, the breakaway cable (4) fully acti- vates the brakes automatically.
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Page 47: Preparations On Tractor
Preparations on tractor PREPARATIONS ON TRACTOR Tyres The air pressure must be identical, particularly on the rear tractor tyres. Under dif- ficult conditions, additional wheel weights should be used or the tyres topped up evenly with water. Refer to the operating instructions from the tractor manufactu- rer. -
Page 48: Tractor Back Axle Load
Preparations on tractor 6.3.1 Tractor back axle load When turning at the headland, there is a negative drawbar load on the tractor drawbar. The load on the tractor’s back axle is reduced. This affects the tractor’s stability and traction. Danger if the back axle load is too low The tractor’s stability is compromised if the back axle load is too low. -
Page 49: Power Sources Required
Preparations on tractor Power sources required Damage to electrical components CAUTION The tolerance range for the power supply is between 10 V and 15 V. Overvoltages and undervoltages cause malfunctions and may destroy electrical and electronic components. Ensure that the power supply to the implement is within the specified tolerance range. -
Page 50: Required Hydraulic Equipment
P16 / T16 Hydraulic support leg Black P17 / T17 * Gigant 12: single acting, Gigant 12S: double acting. ** Interface between the system trac and the working sections, single acting once on each working section Brake system Danger through incompatibility of braking systems The braking system of the tractor and implement must be compat- ible and fully functional. -
Page 51: Air Brake System
Preparations on tractor 6.6.1 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. 6.6.2 Hydraulic brake system For the hydraulic brake system, the tractor must be fitted with a hydraulic coupling as per ISO 5676. -
Page 52: Preparations On Implement
Preparations on implement PREPARATIONS ON IMPLEMENT Final assembly For transportation-specific reasons, the implement is not always delivered in a ful- ly-assembled condition. Use the implement only when the implement has been fully assembled and a functional check has been performed. Spring brake cylinders Risk of accident due to deactivated brakes DANGER... - Page 53 Preparations on implement Loosen the nut (2) until the guiding screw (1) is no longer under spring force and is free. Turn the guiding screw (1) 90° and re- move it from the brake cylinder (3). Cover the aperture in the brake cylinder with the protective cap (4).
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Page 54: Coupling And Uncoupling Implement
Coupling and uncoupling implement COUPLING AND UNCOUPLING IMPLEMENT Danger of accidents due to weak or inappropriate double lashing drawbar When using a weak double lashing drawbar the drawbar may break and the device may be lost. This can result in serious or fa- DANGER tal injury to other persons or road users. - Page 55 Coupling and uncoupling implement Attach the stand to the side of the V- drawbar using the pins (3). Secure the pins (3) with linch pins (4). Connect the hydraulic hoses to the trac- tor.
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Page 56: Operation
Coupling and uncoupling implement 8.1.2 Operation Only use the hydraulic stand on a solid surface. Check that the hydraulic stand is fully installed. Open the shut-off valve (5). Extend the stand using the tractor spool valve. Set the traction loop to the required height. -
Page 57: Removal
Coupling and uncoupling implement 8.1.3 Removal Only remove the stand when the imple- ment is mounted on the tractor Retract the hydraulic stand using the tractor spool valve. Close the shut-off valve. Disconnect the hydraulic hoses from the tractor. - Page 58 Coupling and uncoupling implement Connect the hydraulic lines for the hyd- raulic stand (3) to the tractor. Using the stand, adjust the height of the traction loop to the height of the tractor drawbar. Leave room for a spacer disc (4) above the traction loop.
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Page 59: Detaching The Implement
Coupling and uncoupling implement Install the connections between the im- plement and tractor. Power supply Hydraulics Compressed air Attach the safety chain. Check the lighting and warning boards. Check the safety guards. Release the parking brake. Detaching the implement Park the implement in the folded position. - Page 60 Coupling and uncoupling implement Connect the hydraulic lines for the hyd- raulic stand to the tractor. Extend the hydraulic stand until there is no load on the traction loop. Release and remove the coupling pin. Drive the tractor forwards by 50 cm. ...
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Page 61: Safety Chain
Coupling and uncoupling implement Safety chain Depending on national regulations, attach the safety chain to the tractor. Always comply with any applicable national regulations. The safety chain must be attached such that: the implement cannot drop onto the ground when it is released from the trac- tor. - Page 62 Coupling and uncoupling implement Push the lock (2) away from the hook (3). The lock may also be placed cross- wise. Attach the safety chain (4) to a suffi- ciently robust attachment point on the tractor. Place the safety chain (4) in the hook (3).
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Page 63: Driving On Public Highways
Driving on public highways DRIVING ON PUBLIC HIGHWAYS General information A proper lighting system, identification and equipment must be on the implement, if it is to be transported on public roads. The country-specific valid laws and regu- lations pertaining to driving on public roads must be observed. Preparation for driving on public roads Before commencing a journey on public roads, the following components and sa- fety equipment must be checked to ensure they are working properly and can be... -
Page 64: Protective Devices For Rubin Working Sections
Driving on public highways Protective devices for Rubin working sections A bracket with hook and a load-securing strap with hook are available for each protective device. Connect the bracket hook in the centre of a working section with the stop sleeve on a rear (upper) blade. -
Page 65: Protective Devices For Heliodor Working Sections
Driving on public highways Protective devices for Heliodor working sections Two brackets (2) with hook (3) and two load-securing straps (4) with hook (5) are available for each protective device (1). Hook the hooks (3) of the brackets (2) in such a manner that they engage with the frame rail (6). -
Page 66: Transport Dimensions
Driving on public highways Transport dimensions Before transporting the device on public roads, it must be ensured that the count- ry-specific maximum allowable dimensions are not exceeded. In conjunction the double rollers must be brought in before folding into the transport position, see "roller conversion, page 69". Danger from a larger device height WARNING The height of the implement when it is folded in may be too high. -
Page 67: Folding And Unfolding
Folding and unfolding FOLDING AND UNFOLDING 10.1 Safety information for folding and unfolding Only fold and unfold implements when they are attached to a trac- Always fold the implement outdoors. Ensure that there is sufficient clearance from electricity cables WARNING and high-voltage power lines. - Page 68 Folding and unfolding Risk of accidents due to unsecured spool valves DANGER The working sections may accidentally unfold if the tractor spool valves are not secured during transport. This may result in death or serious injury to other road users. ...
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Page 69: Folding
Folding and unfolding 10.2 Folding Always fold the implement outdoors. Move the rollers into the transport positi- on. See “Converting the rollers”. Lift the working sections. Ensure that there is sufficient clearance from electricity cables and high-voltage power lines. -
Page 70: Unfolding
Folding and unfolding 10.3 Unfolding Mount the implement on the tractor. Always unfold the implement outdoors. Ensure that there is sufficient clearance from electricity cables and high-voltage power lines. Remove the safety guards. Move the tractor spool valve to “Lower” until the side sections are unfolded. ... -
Page 71: Roller Change-Over
Roller change-over ROLLER CHANGE-OVER 11.1 General information The implement is approx. 4.20 m high in transport position. In combination with certain roller variants, the transport height might be much higher. The rollers must therefore be moved to transport position before each road trans- port. - Page 72 Roller change-over...
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Page 73: Rubin 9 U
Roller change-over 11.2.2 Rubin 9 U Release and remove the upper guide pins (5) for the rebound harrow (6), then fit and secure again below the guide pins (7). Then release and remove the guide pins (8) and fit and secure below the guide pins (9). -
Page 74: Working Position
Roller change-over 11.3 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. -
Page 75: Attaching And Detaching Working Sections
Attaching and detaching working sections ATTACHING AND DETACHING WORKING SECTIONS 12.1 General Two working sections are mounted on the implement. The table below shows the available working sections for different implement models and working widths. System- Gigant Smaragd 9 Rubin 9 U Heliodor 9 Kompaktor 12S/1000... - Page 76 The implement must not be folded, unfolded or operated until the top link pin and cross shaft pivots have been properly secured. Only use LEMKEN-approved quick-release couplings and balls. CAUTION Before each use, check that all bolts and nuts on the three-point linkage hydraulics are tight.
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Page 77: Cross Shaft
Attaching and detaching working sections 12.2 Cross shaft Danger from unsecured cross shaft DANGER The cross shaft may slip out of the catch hooks if it is not secured. The working sections may then fall down or swing inwards or out- wards in an uncontrolled manner. -
Page 78: Top Links
Attaching and detaching working sections 12.3 Top links Top links with a lock nut: The top links (1) on the three-point linkage hydraulics are fitted with a lock nut (2) as a locking device. Release the lock nut on the top link. ... - Page 79 Attaching and detaching working sections Danger from unsecured top links and unsecured top link pins The top link may shift and fall apart if it is not secured. Unsecured top link pins can fall out. As a result: Working sections may swing outwards in an uncontrolled man- ner during transportation.
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Page 80: Before Attaching Working Sections For The First Time
Attaching and detaching working sections 12.4 Before attaching working sections for the first time Always attach working sections on a level surface.with a solid base. Use a crane to place the working sec- tions next to one another. When doing this, note the following: ... -
Page 81: Attaching
Attaching and detaching working sections Heliodor 9: Install the balls (5) between the weld pla- tes (6) with lower link pins (7). Secure the lower link pins with threaded connections (8). 12.5 Attaching Release all the catch hooks (1). ... -
Page 82: Detaching
Attaching and detaching working sections Lock all the catch hooks (1). Allow the locking lever (2) to engage in the closed position (b). The pawls fix the balls in the catch hooks. Attach the top links (4). ... - Page 83 Attaching and detaching working sections Release all the catch hooks (1). Pull the locking levers (2) out of the catch hooks and allow them to engage in the open position (a). Lower the lower links (3) until the catch hooks (1) are free.
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Page 84: Working Sections
Always follow the applicable health and safety and accident prevention regulations. 13.1 Three-point linkage hydraulics The Gigant 12 has single-acting three- point linkage hydraulics. The Gigant 12S has double-acting three- point linkage hydraulics and a pressure re- ducing valve. - Page 85 Working sections The Rubin 9 U and Heliodor 9 must only be used with the System Trac Gi- gant 12S. The double-acting three-point linkage hyd- raulics transfer weight from the chassis to the working sections. This ensures good soil penetration. To increase the pressure: ...
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Page 86: Depth Control / Traction Guide
Working sections 13.2 Depth control / Traction guide 13.2.1 Depth control with roller Use with the following implements: Rubin 9 U System-Kompaktor (12 m) Smaragd 9 The depth control (1) with pull rods (2) is mounted at the rear on the axle of the sys- tem trac. - Page 87 Working sections Only for Smaragd 9: In combination with Smaragd 9 U working sections, the depth control (1) together with support wheels guides the working sections (front) at the working depth. See also "Support wheels, page 100". The depth control (1) must then be adjusted with the aid of the pins (5) in such a way that the mounted implements (front centre) are guided at the working depth as desired.
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Page 88: Traction Guide
Working sections 13.2.2 Traction guide Use with the following implements: Heliodor 9 System-Kompaktor (16 m) The traction guide is used exclusively for transmission of traction forces. Adjustments are not necessary. -
Page 89: Smaragd 9
Working sections 13.3 Smaragd 9 Risk of accidents due to freely rotating rollers Particularly when adjusting the working depth, climbing onto freely DANGER rotating rollers brings a risk of crushing and pinching limbs be- tween the freely rotating rollers and fixed parts of the device. Adjustments may only be carried out by personnel who have been appropriately trained. -
Page 90: Working Depth
Working sections 13.3.1 Working depth The working depth of the Smaragd harrow can be adjusted between 5 cm and 25 cm. It is adjusted using guide pins. Slightly raise the attachments using the three-point hydraulics. Release the lower guide pins (1) by re- moving the split rings. - Page 91 Working sections 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.
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Page 92: Working Depth Of Hollow Discs
Working sections 13.3.2 Working depth of hollow discs The hollow discs (1) are automatically ad- justed 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. -
Page 93: Harrow
Working sections 13.3.3 Harrow CAUTION Loss of components If the guide pins are not secured, they can fall out due to vibra- tions in operation. The guide pins must always be secured. The harrow (1) is used to spread existing straw and also to crumble and level the soil. - Page 94 Working sections 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 clear- ance to the roller (2).
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Page 95: Share Position
Working sections 13.3.4 Share position WARNING Risk of injury due to dismantled shear bolt If the shear bolt is dismantled, the tines will swing freely. This can lead to crushing of the fingers in the region of the tines recess. ... - Page 96 Working sections Press out the shear bolt (2) with the ap- propriate tools. Rotate the tines into the desired position. Insert the shear bolt (2) into either hole A or B of the tine recess (3). Screw on the nut. ...
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Page 97: Shearbolt Device
Working sections 13.3.5 Shearbolt device WARNING Risk of injury due to sheared shear bolt If the shear bolt is sheared off, the teeth or the disk carrier will pivot freely. This can lead to crushing of the fingers in the region of the respective tines and blade recess. - Page 98 Working sections When the shear bolt is inserted into a different hole, the position of the tine and angle of attack of the coulters is changed. The shear bolt (4) of the disc carrier (2) is inserted into the blade recess (6) be- hind the carrier (2).
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Page 99: Automatic Overload Protection
Working sections 13.3.6 Automatic overload protection Tines Risk of accidents due to moving tines DANGER When an obstacle is encountered, the spring-loaded tine is moved very quickly to the rear and upwards. This can cause injury to per- sons in the area of the tines. Never climb onto the implement when working. - Page 100 Working sections 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 re- lease force of approx. 5,800 N (580 kp) at the share tip.
- Page 101 Working sections Hollow discs Risk of fatal injury due to high spring force When the tine / hollow disc is triggered and has not yet returned to DANGER the working position, it can suddenly spring back to the working position with huge force and at high speed. This can cause seri- ous injury or death to any persons in the tilting area of the tine.
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Page 102: Depth Wheels
Working sections 13.3.7 Depth wheels Risk of injury due to unsecured depth wheel If the pin and eccentric lever are both removed at the same time, WARNING the depth wheel is no longer held in place and will slide down- wards because it is not secured. -
Page 103: Rubin 9 U
Working sections 13.4 Rubin 9 U 13.4.1 Mechanical working depth adjustment Risk of accident due to freely rotating rollers When climbing onto freely rotating rollers, especially when adjus- DANGER ting the working depth, there is a risk of being crushed and trap- ped, i.e. - Page 104 Working sections The Rubin compact disc harrow can be adjusted to a working depth of 4 cm to 12 The depth is adjusted using pins. Lift the working sections slightly using the three-point hydraulics. Release the bottom pins (1) by removing the linch pins.
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Page 105: Adjust Lowering Depth Of The Rollers
Working sections 13.4.2 Adjust lowering depth of the rollers The lowering depth of the rollers when lif- ting is determined by the top pins (1). For each working depth (holes a to n) there is a corresponding hole for the lowering depth (holes 1 to 8). -
Page 106: Hydraulic Working Depth Adjustment
Working sections 13.4.3 Hydraulic working depth adjustment Read off current working depth on the scale of the hydraulic working depth set- ting. Set required working depth using the hydraulic system tractor (P11/T11). Scale of the hydraulic working depth set- ting: ... -
Page 107: Rebound Harrow
Working sections 13.4.4 Rebound harrow 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. -
Page 108: Guide Plates
Working sections 13.4.5 Guide plates The angle and height of the guide plates (1) can be adjusted. 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). - Page 109 Working sections screwed onto the bracket in the central lateral position - Fix the round stalk (4) of the side limita- tion (2) in place. - Release the nuts (5). - Move the round stalk (4) with side limita- tion to the desired position.
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Page 110: System-Kompaktor
Working sections 13.5 System-Kompaktor Risk of fatal injury if the top link is not secured DANGER The top link may shift and fall apart if it is not secured. The working sections may then swing outwards during transporta- tion and kill or injure other road users. ... -
Page 111: Pressure Load On The Front Crumbling Rollers
Working sections 13.5.1 Pressure load on the front crumbling rollers The pressure load on the front crumbling rollers is controlled by the length of the top link. A shorter top link (1) gives a higher pressure load on the front crumbling rol- lers (2) due to the weight of the support frame (3). - Page 112 Working sections a) Light soils (low pressure) Suspension bracket (4) of the combination section rests on the carrier tube (5). b) Medium soils (medium pressure) Approx. 1 cm clearance between the sus- pension bracket (4) and the carrier tube (5). Part of the support frame weight is trans- ferred to the combination section via the spring (6).
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Page 113: Pressure Distribution On Rear Rollers
Working sections 13.5.2 Pressure distribution on rear rollers Pin adjustment (1) with a guide pin (2) dis- tributes the pressure on the rear rollers as required. The guide pin (3) fixes the rear roller in place. Lower the attachments into working po- sition with the three-point hydraulics to relieve the load on the guide pins (3). -
Page 114: Wheelmark Eradicator
Working sections 13.5.3 Wheelmark eradicator The wheelmark eradicator (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 The working depth is adjusted as follows: ... - Page 115 Working sections Transport position In transport position, the wheelmark eradi- cators 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 wheelmark eradicator (1).
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Page 116: Shifting The Harrow Frames
Working sections 13.5.4 Shifting the harrow frames The harrow frames (1) are mounted on the rotary tiller frame (2) and can be shift- ed. 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. -
Page 117: Working Depth Of Tines
Working sections 13.5.5 Working depth of tines The working depth of the tines (1) can be set using the adjusting mechanism (2). Slightly raise the attachments by operating the three-point hydraulics. Release the guide pins (3). Remove the guide pins (3). ... -
Page 118: Cutting Bar
Working sections 13.5.6 Cutting bar The cutting bar (1) on the crumbling roller (2) accumulates soil. As a result, the ground is crumbled intensively and level- led. The cutting bar (1) is properly adjusted when the soil does not accumulate too much on the crumbling roller (2) as to cau- se the crumbling roller (2) to decelerate. - Page 119 Working sections Hydraulicadjustment of cutting bar In conjunction with the hydraulic cutting bar adjustment, the cutting bar (1) can be hy- draulically "opened" for a short period. For example this is required when there are changes in the ground and too much soil is accumulating on the crumbling roller (2) with the fear that the crumbling roller (2) may become clogged or stop.
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Page 120: Height Adjustable Side Plates
Working sections Opening the cutting bar via the correspon- ding single acting tractor controller Cutting bar open Turn the spool valve to "T" = Tank Cutting bar returned Turn the spool valve to "P" = Pressure When the cutting bars (1) must be opened relatively frequently, this is a sign that they are not optimised. -
Page 121: Stone Guards
Working sections 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). 13.5.8 Stone guards The stone guards (5) are located on the inside of the side plates (1) immediately... -
Page 122: Heliodor 9
Working sections 13.6 Heliodor 9 13.6.1 Mechanical working depth adjustment Raise the implement using the tractor’s three-point linkage. Release the lower pins (1) by pulling the linch pins out of the pins. Select the working depth required (see label on the implement). -
Page 123: Hydraulic Working Depth Adjustment
Working sections 13.6.2 Hydraulic working depth adjustment Read off current working depth on the scale of the hydraulic working depth set- ting. Set required working depth using the hydraulic system tractor (P11/T11). Scale of the hydraulic working depth set- ting: ... -
Page 124: Setting The Roller Lowering Depth
Working sections 13.6.3 Setting the roller lowering depth The roller lowering depth on lifting is set using the upper pins (1). Each working depth (holes 1 to 12) has a corresponding hole for the lowering depth (holes a to l). The correct combination of holes, e.g. -
Page 125: Hollow Disc Adjustment In The Tractor Track
Working sections 13.6.4 Hollow disc adjustment in the tractor track The implement can be fitted with adjustab- le hollow discs in the tractor track area. The adjustable hollow discs are used for wheelmark eradication and to optimise le- velling. The spring tines on the hollow discs have holes for three different mounting positi- ons. -
Page 126: Lateral Limiters
Working sections 13.6.5 Lateral limiters Danger from unsecured parts CAUTION If the lateral limiters are not secured during adjustment, they may slip downwards in an uncontrolled manner. This may cause crush injuries to the hands or foot injuries. Secure the lateral limiters. The lateral limiters (1) prevent the rear right hollow disc and the front left hollow disc from leaving furrows or throwing up... - Page 127 Working sections Swivelling the lateral limiter outwards: Release the locking pin (1). Pull the locking pin out of the hole (2). Select the hole for the swivel position (3) by swivelling the carrier with the lateral limiter outwards. ...
- Page 128 Working sections Changing the height and angle of the lateral limiter: Loosen the clamping screws in the clamping fixture (1). Turn the round stalk (2) in the clamping fixture until it is at the required angle. Set the height of the round stalk (2) in the clamping fixture.
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Page 129: Rollers
Working sections 13.7 Rollers 13.7.1 General The implement can be fitted with different types of roller. See the roller table be- low. The rollers control the working depth of the implement. The degree of recon- solidation or crumbling is determined by the type of roller used. This table does not include the rollers and crumblers on the System-Kompaktor because these rollers and crumblers do not require any specific adjustment after factory-fitting. -
Page 130: Knife Rollers
Working sections 13.7.2 Knife rollers Adjusting the knife roller Blade working depth On both sides of the roller: Take any loads off the upper bolt (4). o Turn the screw (3) clockwise to do so. Release the upper bolt (4). ... - Page 131 Working sections the support plate (1). o The knives operate more ag- gressively if the deflection trav- el is short. Large deflection travel (for very light or rocky soils): Insert the lower bolt (5) into the lower holes in the adjustment plate (2). ...
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Page 132: Flex Ring Roller
Working sections Blade position There are two mounting positions for the blades (11) on the knife bar (8): Front position (9) (standard) Rear position (10) (after wear) After wear: Reposition the blades (11) towards the rear (10). 13.7.3 Flex ring roller The flex ring roller is fitted with scrapers. -
Page 133: Flex Ring Roller Scrapers
Working sections 13.7.4 Flex ring roller scrapers The scrapers (1) on the flex ring roller (2) must be replaced when worn down to a thickness of 5 mm so as to prevent the remaining piece from being lost and sub- sequent damage from being incurred. -
Page 134: Turning At The Headland
Turning at the headland TURNING AT THE HEADLAND The headland 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. -
Page 135: Maintenance/Repairs
Maintenance/repairs MAINTENANCE/REPAIRS 15.1 Special safety instructions 15.1.1 General Risk of injury during maintenance and repair work During maintenance and repair work, there is always a risk of inju- WARNING Only use suitable tools, climbing equipment, platforms and sup- ports. ... - Page 136 Maintenance/repairs 15.1.3 Personal protective clothing CAUTION Risk of accident when working without protective clothing There is always an increased risk of accidents during mainte- nance, repair and care work. Always wear appropriate protective clothing. 15.1.4 Shutting down the device for maintenance/repairs Risk of accidents when tractor starts up If the tractor starts to move during maintenance/repair work, this WARNING...
- Page 137 Maintenance/repairs 15.1.6 Work on the electrical system Damage to device when working under voltage CAUTION 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 pri- or to all work on the electrical system.
- Page 138 Maintenance/repairs 15.1.8 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.
- Page 139 Maintenance/repairs 15.2 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. 15.3 Lubrication Eye injuries due to grease...
- Page 140 Maintenance/repairs 15.3.1 Lubrication chart Only use environmentally friendly quality grease for all lubrication work. Item Number of Every Every Every Every Before a After a win- (see lubricating winter ter break Fig. XX) points break Operating hours * Number of lubricating nipples per unit...
- Page 141 Maintenance/repairs 15.3.2 Overview of lubricating points a) Folding frame joints b) Base frame joints c) Bottom link joints d) Hydraulic cylinder pins e) Pendulum balance joints f) Braking axle...
- Page 142 Maintenance/repairs g) Braking axle h) Top link thread k) Top link (Rubin / Smaragd) Hollow disc joints (Rubin) Frame joints (Rubin) l) Depth wheel bearing (Smaragd) m) Depth guide...
- Page 143 Maintenance/repairs n) Overload protection joints (Smaragd) o) Hollow disc bearing (Smaragd)
- Page 144 The hydraulic hoses must be replaced at the latest 6 years after the date of manufacture. Use hydraulic ho- ses authorised by LEMKEN only. Safety equipment Check that the safety equipment functions properly.
- Page 145 Maintenance/repairs 15.4.3 Weekly checks Check What to do? Wheel nuts Check that all wheel nuts are tight. If required, retighten the wheel nuts to the approp- riate tightening torque. Compressed air tank Drain the compressed air tank with the drain valve. See "Draining the compressed air tank"...
- Page 146 Maintenance/repairs 15.5 Tightening torques 15.5.1 General Secure self-locking nuts that have been loosened against working themselves loose again by: Replacing them against new self-locking nuts Using lock washers Using locking compounds such as Loctite The tightening torques set out below refer to screw connections that are not specifically mentioned in these operating instructions.
- Page 147 Maintenance/repairs 15.5.3 Wheel bolts and wheel nuts Diameter / thread [Nm] M18 x 1,5 M20 x 1,5 M22 x 1,5 15.6 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.
- Page 148 Maintenance/repairs 15.8 Cleaning the filter Set down the device and disconnect the brake hoses. Remove the retaining washer (1) and remove the filter insert from the filter hous- ing (2). (The filter insert is held in position by a spring.) ...
- Page 149 Maintenance/repairs 15.9 Checking and adjusting length of tension struts Checking length of tension struts Fold out lateral parts with working sec- tions. Lift working sections. o The chain (1) is tensioned. o In an ideal case the chain is a- ligned with the tension struts (2).
- Page 150 Maintenance/repairs Adjusting length of tension struts Fold in lateral parts until the springs ha- ve been relieved. Remove bolted connection (M20x75— 10.9) from the tension strut (2). Position tension strut (2) shorter or lon- ger. Mount tension strut (2) between both ad- justment bars (4) using the bolted connection (M20x75-10.9).
- Page 151 Maintenance/repairs 15.10 Checking connections to the tractor 15.10.1 Couplings Risk of accident due to spraying hydraulic fluid Fluid (hydraulic oil) escaping under high pressure can penetrate WARNING the skin and cause severe injuries. In case of injury, seek medical attention immediately. ...
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Page 152: Technical Data
Width Height System trac [cm] [cm] [cm] Gigant 12S/1000 Rubin 9 U 415 - 480 Gigant 12(S)/1200 Smaragd 9 U 350* 415 - 480 Gigant 12(S)/1200 System-Kompaktor 350* 415 - 480 Gigant 12S/1200 Rubin 9 U 415 - 480 Gigant 12S/1600 Heliodor 9... - Page 153 Technical data 16.3 Permitted loads and weights Gigant 12S/1000 Rubin 6500 3500 2600 12000 15000 12/1200 System-Kompaktor 6000 3500 2100 12000 15000 12/1200 Smaragd 9 6000 3500 2400 12000 15000 12S/1200 Rubin 9 7000 3500 3200 12000 15000 12S/1600 Heliodor 5000 3500 3200...
- Page 154 Technical data 16.4 Tyres / tyre pressure Danger due to wrong tyre pressure WARNING Excessive tyre pressure can cause the tyres to burst, while insuf- ficient tyre pressure can result in overloading of the tyres. This has a negative impact on the implement’s ability to follow the correct track, which obstructs and endangers road users.
- Page 155 Noise, Airborne Sound NOISE, AIRBORNE SOUND The noise level of the implement does not exceed 70 dB (A) during work. NOTES As the version of equipment is depending from the order, the equipment of your implement and its description concerned may deviate in some cases. To ensure a continuously updating of the technical features, we reserve the right to modify the design, equipment and technique.
- Page 156 Index INDEX Chassis ......................152 Depth wheels ....................100 Dimensions ....................... 150 Flex ring roller ....................130 Folding ........................ 67 FOLDING ......................65 Guide plates ...................... 106 Harrow frames ....................114 Hollow discs ......................90 Knife rollers ....................... 128 Lateral limiters ....................124 MAINTENANCE ....................
- Page 157 Index Stone guards ..................... 119 System-Kompaktor .................... 108 Technical Data ....................150 Tightening torques .................... 144 Transport speed ....................31 TURNING ......................132 Type plate ......................12 Tyre pressure ....................152 Tyres ......................... 152 Unfolding ......................68 UNFOLDING ....................... 65 Warning signs .....................
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