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Operating Instructions
System Trac
Gigant 800
and
Gigant 800 S
Safety is our concern!
Part No. 175 1226
GB-5/05.03
LEMKEN GmbH & Co. KG
Weseler Straße 5, D-46519 Alpen / Postfach 11 60, D-46515 Alpen
Telefon (0 28 02) 81-0, Telefax (0 28 02) 81-220
E-Mail: lemken@lemken.com, Internet: http://www.lemken.com
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Summary of Contents for LEMKEN Gigant 800
- Page 1 Gigant 800 S Safety is our concern! Part No. 175 1226 GB-5/05.03 LEMKEN GmbH & Co. KG Weseler Straße 5, D-46519 Alpen / Postfach 11 60, D-46515 Alpen Telefon (0 28 02) 81-0, Telefax (0 28 02) 81-220 E-Mail: lemken@lemken.com, Internet: http://www.lemken.com...
- Page 3 We hope you will understand that LEMKEN can not take on the guarantee for operational disadvantages and damage being caused by using spurious parts!
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Page 4: Defined Use
Under „defined use“ the manufacturer’s prescribed operation-, maintenance- and repair conditions are to be adhered to! • The LEMKEN GIGANT may only be operated, maintained and repaired by such persons who have been made acquainted with it and who have been advised about the dangers! •... -
Page 5: Table Of Contents
CONTENT SAFETY INSTRUCTIONS ..................6 WARNING STICKERS..................... 9 General Instructions ................... 9 Meaning of the stickers ..................9 Positions of the warning stickers ..............11 PREPARATION OF TRACTOR ................13 Tyres........................13 Drawbar Coupling ..................... 13 Brake-System ....................13 Hydraulic Assembly ..................13 Axle loads ...................... - Page 6 TRANSPORT ON PUBLIC ROADS ..............24 10.1 General Instructions ..................24 10.2 Transport width ....................24 10.2.1 Gigant Kompaktor ..................24 10.2.2 Gigant Smaragd and Gigant Rubin ............24 10.3 Transport height..................... 25 10.3.1 Gigant Kompaktor ..................25 10.3.2 Gigant Smaragd ..................25 10.3.3 Gigant Rubin ....................
- Page 7 13.4 Adjustments of the Cutting Bar ..............37 13.4.1 Adjustments by means of an adjuster screw..........37 13.4.2 Hydraulic cutting bar adjustment..............37 13.5 Working Depth Adjustment of the Tines............38 ADJUSTMENTS – GIGANT RUBIN ..............39 14.1 Adjustment of the three-point hydraulics ............ 39 14.2 Working depth ....................
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Page 8: Safety Instructions
1. SAFETY INSTRUCTIONS • Read and adhere to these "General Health- and Safety precautions" before putting your implement into operation! • Before use, always check both the machine and the tractor for roadworthiness and operational safety. • Adhere to the general rules of health- and safety precautions as well as the advice in this instruction manual! •... - Page 9 • The release ropes for quick coupler should hang freely and in the lowered position must not release the quick coupling by themselves. • Never leave drivers seat whilst in motion! • Moving behaviour, steerability and braking are influenced by mounted implements, trailers and ballast weights.
- Page 10 • Regularly check the hydraulic pipes and replace them in the event of damage or signs of ageing. The replacement pipes must comply with the technical specification as laid down by Lemken. • Hydraulic oil escaping at high pressure can penetrate the skin and cause serious injury! •...
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Page 11: Warning Stickers
2. WARNING STICKERS 2.1 General Instructions The LEMKEN Gigant 800 is equipped with all features to ensure safe operation. Where potential danger areas of the implement can not be fully safeguarded, warning stickers are fitted which draw attention to these. Damaged, lost or unreadable warning stickers must be replaced immediately. - Page 12 WARNING: Pinch Point! 390 0506 WARNING: Keep well clear of the working and swinging area of the implement! 390 0510 WARNING: Keep distance to the folding area of the implement. 390 0540...
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Page 13: Positions Of The Warning Stickers
2.3 Positions of the warning stickers... -
Page 15: Preparation Of Tractor
3. PREPARATION OF TRACTOR 3.1 Tyres Ensure that all tyres- especially the rear ones - are at identical pressure. For heavy conditions it may be necessary to add wheel weights and/or water ballast. (See Manufacturer's Instructions). 3.2 Drawbar Coupling The system trac GIGANT must only be used with tractors equipped with a drawbar clevis. -
Page 16: Attaching And Detaching The Implement
4. ATTACHING AND DETACHING THE IMPLEMENT 4.1 Attaching to the tractor The system trac GIGANT must be parked, only, with folded wing sections. The tractor must be equipped with a which is designed for upwards and downwards loads of 20 KN (2,0 t). The draw eye (2) of the system trac GIGANT will be connected to the (1) of the tractor. -
Page 17: Detaching From The Tractor
4.2 Detaching from the tractor Park the implement always on firm and level ground; re-attachment will then be easier. It is recommended to park the GIGANT with folded-in wing sections, this saves space and reduces the effort of attaching and detaching the warning boards and the lighting equipment, if it is required to drive on public roads. -
Page 18: Folding Of The Wing Sections
5. FOLDING OF THE WING SECTIONS 5.1 Folding-in of the wing sections 5.1.1 Gigant Smaragd Before folding-in the Gigant Smaragd, the pins (18) und (20) of the depth adjustment (19) must be unlocked, removed and put into the tool box. If the Gigant Smaragd is equipped with double rollers, additionally the pins (SS) mut be unlocked, removed, fitted into the bores... - Page 19 For the folding-in operation the double acting spool valve will be used so that the lateral frames (11) with the wing sections will be folded upwards first and then in. Hold the spool valve in that position until wing sections folded-in completely and the securing pins, which serve as safety devices for transport, are...
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Page 20: Folding-Out Of The Wing Sections
5.2 Folding-out of the wing sections Before folding-out the lighting equipment with warning boards must be removed and put into the special holder in the front. Fold-out the wing sections, only, with the GIGANT fitted tractor prescribed detached lighting equipment and warning boards. Before folding-out the wing sections (40), detach lighting... -
Page 21: Gigant Rubin
5.2.2 Gigant Rubin After folding-out procedure, the carriers (S3) of the rollers must be set to working position. Therefore the pins (S2) and (S3) must be fitted and secured again. • Read and adhere to the General Safety Instructions as well as to the Instructions ‘Hydraulic equipment’! •... -
Page 22: Pendulum Balance
6. PENDULUM BALANCE The lower links (UL) of the three point hydraulics (13) are equipped with a pendulum balance (PA), which allows an individual adaption of the implement sections even in hilly conditions. On the left and right side of the lower links (UL) the lower link ends (UE) are positioned pivotably around the eccentric bolts (E). -
Page 23: Three-Point Hydraulic
With the double acting version with pressure control valve (DB1) the knob (DB3) must be turned out anti-clockwise to switch off the double acting function. 7.2 Gigant Rubin The Rubin working sections may only be fitted to the Gigant 800 S, not to the Gigant 800. In combination with the Rubin working... -
Page 24: Braking Assembly
With all system tracs Gigant 800 Smaragd (from production year 2001 on) and with all Gigant 800 S the parking brake (8) is fitted right outside at the V-pole. With older system tracs Gigant 800 (until productions year 2000) the parking... -
Page 25: Tyres
The chassis of the Gigant 800 is equipped with the tyres 500/50-17 with 10PR and the chassis of the Gigant 800 S with the tyres 550/45-22.5 with 12 PR. The depth wheels for the outer depth guiding of the Smaragd sections are equipped with the tyres 10.80-12 with 8PR. -
Page 26: Transport On Public Roads
They are not exceeded when the following points are ahered. 10.2 Transport width 10.2.1 Gigant Kompaktor With the Gigant 800 Kompaktor it must paid attention to that the locking device (21) is mounted as shown; otherwise the maximaum allowed transport width will be exceeded. -
Page 27: Transport Height
10.3 Transport height 10.3.1 Gigant Kompaktor In connection with the Gigant 800 Kompaktor the implement sections must be fitted in the front position to the supporting arms. Therewith the maximum allowed transport height in folded-in position will not be exceeded. -
Page 28: Gigant Rubin
10.3.3 Gigant Rubin With the Gigant Rubin the pins (S2) and (S3) must be unlocked and dismounted. Due to that the rollers in folded-in position swing downwards. In combination with double rollers additionally the pins (S4) must be unlocked and dismounted, before folding-in. -
Page 29: Adjustments - Smaragd Gigant
11. ADJUSTMENTS - SMARAGD GIGANT 11.1 Adjustment of the Three-Point hydraulics Set the three-point hydraulics into the floating position during work by setting the tractor valve concerned in the corresponding position. Raise the sections fully before folding-in. This ensures that the transport width will not be exceeded and that the securing pins (14) can be fitted. -
Page 30: Depth Adjustment Of The Tines
11.3 Depth Adjustment of the Tines The working depth of the tines will be adjusted by means of the lower pins (20), which are positioned in the adjuster plates (19) of the carriers (25). For this adjustment the implement must be lifted a little, in order to relieve the pin (20). The upper pins (18) must be positioned as low as possible above the carrier (25), in order to prevent the tube bar roller (26) sinking in too deep. -
Page 31: Share Position
With the Gigant 800 Smaragd with overload safety device, the share position can be altered by slackening and turning (180°) the eccentric bolt (30) having first slackened shearbolt (29). -
Page 32: Rollers
11.6 Rollers 11.6.1 General Instructions The Gigant Smaragd can be equipped with a number of rollers (W0): Tube bar roller RSW 400 or RSW 540, Double roller DRR 400 or DRF 400. The Trapeze ring roller TRW 500, Trapeze packer roller TPW 500, Trapeze disc roller TSW 500 or Packer roller ZPW 500 can be fitted also, but then the maximum allowed transport height will be exceeded. -
Page 33: Adjustment Of The Scrapers
11.6.2 Adjustment of the scrapers The adjustable scrapers (W1) of the 500 mm rollers will be adjusted by means of the adjuster nut (W2) and the eccentric nut (W5). The adjuster nuts (W2) of the packer rollers will be adjusted by means of a 19 mm spanner and the eccentric nuts (W6) with a 24 mm spanner. -
Page 34: Shearbolt Device
11.7 Shearbolt Device Each tine (24) and disc carrier (32) is fitted with a shearbolt device with shearbolt (29) which will protect the frame (33), the tines and disc carriers (32). Replace sheared bolt as follows: - Raise implement sections a few cm. - Remove all remains of the shearbolt (29). -
Page 35: Depth Wheels As Outer Depth Guiding
11.8.1 Depth wheels as outer depth guiding The depth wheels (SR) are fitted in front at the outer edge of each frame (RA) and can be adjusted in depth by means of the pin adjuster with pins (SB). After the adjustment the pin (SB) must be secured. -
Page 36: Changing Of The Sections
12. CHANGING OF THE SECTIONS 12.1 General Instruction The system trac GIGANT can be equipped with Smaragd sections as well as with Kompaktor sections and the GIGANT additionally with Rubin sections. For changing the sections (11) they will be detached in completely folded-out position and lowered lower links (UL). -
Page 37: Rubin Working Sections
12.3.2 Rubin working sections With the Rubin working sections the drawbar must always be fitted in the front fitting position. Sections with D55 L2 Z3 drawbars (36) may be attached, only. Part No. of the drawbar = 461 7923! The drawbars (36) will be secured by means of securing lugs (40) and bolts (41) and the top links (22) will be secured by means of securing pins. -
Page 38: Adjustments - Kompaktor Gigant
13. ADJUSTMENTS - KOMPAKTOR GIGANT 13.1 Pressure Load on the front Crumbling Rollers The pressure load on the front crumbling rollers (50) will be adjusted by lengthening or shortening the top link (22) Longer top links - less pressure load Shorter top links - more pressure load 13.2 Pressure Load on the rear Rollers... -
Page 39: Adjustments Of The Cutting Bar
13.4 Adjustments of the Cutting Bar 13.4.1 Adjustments by means of an adjuster screw Turn adjuster screw (56) clockwise = Cutting bars (55) move more soil back into crumbling roller better crumbling effect and levelling Turn adjuster screw anti-clockwise = Cutting bars move less soil back into the crumbling rollers = less power is required. -
Page 40: Working Depth Adjustment Of The Tines
13.5 Working Depth Adjustment of the Tines Fit pin (57) in a higher bore = increased working depth Fit pin (57) in a lower bore = reduced working depth Fit the adjuster pin (58) below the frame (59) if the tines (60) can’t keep their working depth. -
Page 41: Adjustments - Gigant Rubin
14. ADJUSTMENTS – GIGANT RUBIN 14.1 Adjustment of the three-point hydraulics During working the three-point hydraulics (13) must be set to “Neutral” position. Before folding-in the working sections, they must be lifted completely. Only this ensures that allowed transport measurements cannot be exceeded and the securing pin (14) for locking the three-point hydraulic (13) can be fitted. -
Page 42: Guide Boards
14.4 Guide boards guide borads (L1) which adjustable in an angle as well as height, are used for filling the groove made by the left hollow disc with soil. By means of the clamp screw (L2) the guide boards can be set individually. They should be positioned a little deeper than the harrow tines (P1). -
Page 43: Links
14.7 Links The links (L) may not opereate as depth control. Therefore – in combiantion with Rubin sections – the pins of the pin adjustment (SG) must be dismounted and put into the tool box. Via the sections (FD) the links will be kept in draw position. -
Page 44: Braking Device
15. BRAKING DEVICE The system trac GIGANT is equipped with a double-hose-air-pressure brakesystem. If required the implement is also available without braking axle. In this case no public roads may be used. Without own braking system the GIGANT may only be used in the field, if the combination is able to reach the prescribed braking deceleration. -
Page 45: Disconnection Of The Brake Hoses
15.4 Disconnection of the brake hoses After disconnecting the hose with the red coupling the brake will be activated = automatic braking. If required the brakes can be loosened by means of the valve (67) by pressing the knob (68). When pulling out the knob, the brake is activated again. -
Page 46: Maintenance
16. MAINTENANCE 16.1 System trac GIGANT • Replace hydraulic hoses and brake hoses immediately if they are damaged! At least after 6 six years after production date stated on the hoses. • Re-adjust the brake-rod linkage, if the rod (61) of the membrane ram will move out too much (more than 40 mm). -
Page 47: Smaragd Sections
16.2 Smaragd sections • The bearings of the hollow discs must be greased every 20 hours of use. • Grease the grease nipples of the NON- STOP devices of the tines every day of use. • Grease all other grease points regularly. •... -
Page 48: Lighting Equipment And Warning Boards
17. LIGHTING EQUIPMENT AND WARNING BOARDS Before folding out the wing sections, remove the lighting equipment and warning boards (70) and place them into their carriers (71) which are provided behind the air tank (64). When using public roads fit the lighting equipment and warning boards as required and make electric supply connections.
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