Bauer LINESTAR 9000 User manual

OPERATING MANUAL
for
BAUER - LINESTAR 9000
with hose feed
Version: XII / 2013
850 9898

II
Operating Manual for BAUER LINESTAR 9000 with hose feed
INTRODUCTION
Thank you for buying BAUER LINESTAR 9000!
The present manual is a very important document that describes how to operate and service BAUER LINESTAR
9000.
This manual describes the system as detailed as possible. If you need still more information, please contact your
dealer or turn directly to BAUER in Voitsberg.
Please note that the content of this manual neither constitutes part of nor alters in any way any previous or existing
agreement, promise or legal relationship. BAUER’s commitment is based solely on the respective purchase
contract which also contains the complete and only valid warranty agreement. Said contractual warranty is neither
extended nor limited by the content of this manual.
All information contained in the present manual is based on the latest product details available at the time of
printing.
BAUER reserves the right to change without notice without assuming any liability!
BAUER LINESTAR 9000 is designed for highest performance safety and reliability provided it is operated in
accordance with the present operating instructions.
Therefore you should study this manual thoroughly before starting your BAUER LINESTAR 9000!
Strictly observe all instructions pertaining to system handling, operation and service!
On this condition, BAUER LINESTAR 9000 will operate to your satisfaction for many years!
Non-observance of this manual may cause personal injury or damage the equipment!
Please make this manual available to your staff. State the pump type and serial number of your
BAUER LINESTAR 9000 in all inquiries, correspondence, warranty problems, or parts orders.
We wish you a lot of success with your BAUER LINESTAR 9000!
This manual is to be considered an integral part of BAUER LINESTAR 9000. Suppliers of both new and used
systems are advised to put down in writing that they delivered the manual together with the system.

Operating Manual for BAUER LINESTAR 9000 with hose feed III
Owner of the machine
This machine with the serial number
Belongs to
Name
Address
residence
Telephone number
Tutor:
Bauer dealer
Service – technician
Telephone number

IV
Operating Manual for BAUER LINESTAR 9000 with hose feed
Handing over record
A duly test run has been done in the presence of the customer or a nominated agent of the
customer. The customer confirms by signing that the machine has been test run before taken
over. A copy of the handing over record needs to be sent back to the company BAUER
Ges.m.b.H.
Comments:
For the customer For the company BAUER GMBH
______________________________ ______________________________

Operating Manual for BAUER LINESTAR 9000 with hose feed V
Product details
Date of delivery .......................................................................................
Date of initial operation .......................................................................................
Type BAUER LINESTAR 9000
Serial number ..................................................................................................
Central unit 2 wheels …………………… 4 wheels ........................................
Configuration of span .................................................................................................
Spans fixed ................................... towable ..........................................
Booster pump yes ………………………………. no .................................................
End gun yes ………………………..... no .................................................
Equipment ..................................................................................................
Linear control cable ………………… furrow ………………… induction ..................
Water supply ditch ................................... hose ............................................
Feeding hose diam .………....................... length ...........................................
Generator unit ................................................................................................
Comments .................................................................................................
.................................................................................................
Producer of the machine: Röhren- und Pumpenwerk BAUER Ges.m.b.H.
Kowaldstrasse 2
A – 8570 Voitsberg
Tel.: [phone] – 0
Fax: [phone] / -340
e-mail: [email protected]
www.bauer-at.com
Dealer: Name: ………………………………………………………………….
Address: ………………………………………………………………….
………………………………………………………………….
Tel. / Fax: ………………………………………………………………….

VI
Operating Manual for BAUER LINESTAR 9000 with hose feed
INDEX
1GENERAL INSTRUCTIONS..............................................................................................................................1
2WARNING SYMBOLS.......................................................................................................................................2
3GENERAL..........................................................................................................................................................3
4GENERAL INSTRUCTIONS FOR SAFETY AND ACCIDENT PREVENTION................................................3
5SAFETY PRECAUTIONS FOR LINESTAR 9000.............................................................................................4
5.1ELECTRICAL SYSTEM..............................................................................................................................4
5.2MECHANICAL SYSTEM............................................................................................................................4
6TECHNICAL DESCRIPTION.............................................................................................................................5
6.1COMPONENTS OF THE LINESTAR 9000................................................................................................5
6.1.1COMPONENTS OF THE BELOW GROUND GUIDANCE.................................................................... 6
6.2CENTRE FEED - END FEED.....................................................................................................................8
6.2.1CENTRE FEED.......................................................................................................................................... 8
6.2.2END FEED ................................................................................................................................................. 8
7USE OF LINESTAR...........................................................................................................................................9
7.1GENERAL LIMITS......................................................................................................................................9
7.1.1INCLINATION........................................................................................................................................... 9
7.1.2PERMISSIBLE BENDING ANGLES........................................................................................................ 9
7.2LIMITS WITH BELOW GROUND GUIDANCE.........................................................................................10
7.2.1LIMITS WHEN USING AN OPEN CONDUCTOR LOOP.................................................................... 10
7.2.2LIMITS WHEN USING AN OPEN CONDUCTOR LOOP WITH ASYMMETRICAL LAYOUT...... 11
7.3TRACK DETERMINATION AND MAINTENANCE...................................................................................12
7.3.1TRAVEL DIRECTION ............................................................................................................................ 12
8LINESTAR CENTRAL UNIT............................................................................................................................13
8.1FOUR-WHEEL MAIN CART.....................................................................................................................13
8.2TWO-WHEEL CENTRAL UNIT................................................................................................................14
9CONTROL CENTRE........................................................................................................................................15
9.1CONTROL CENTRE LINESTAR PRO.....................................................................................................15
9.1.1STANDARD BUILT-IN COMPONENTS............................................................................................... 16
9.2CONTROL CENTRE LINESTAR PRO-G.................................................................................................18
9.2.1STANDARD BUILT-IN COMPONENTS............................................................................................... 19
10LINEAR CONTROL SYSTEM.........................................................................................................................20
10.1GENERAL ................................................................................................................................................20
10.2SPECIFIED MINIMUM CURVE RADIUS.................................................................................................21
10.3FURROW GUIDANCE .............................................................................................................................22
10.4CABLE GUIDANCE INSTALLATION AND ADJUSTMENT.....................................................................22
10.5BELOW GROUND GUIDANCE ...............................................................................................................24
10.5.1OSCILLATOR BOX, STEERING ANTENNAS, TRACK UNIT........................................................... 24
10.5.2BELOW GROUND CABLE .................................................................................................................... 27
10.6SETTING LINEAR CONTROL .................................................................................................................28
10.6.1FURROW AND CABLE GUIDANCE.................................................................................................... 28
10.6.2BELOW GROUND GUIDANCE............................................................................................................. 29
10.7SETTING STOP SWITCH........................................................................................................................29
11DIESEL GENERATOR UNIT...........................................................................................................................31
12ALIGNMENT OF THE LINESTAR...................................................................................................................31
12.1ALIGNING THE CENTRAL UNIT PARALLEL TO THE LINEAR GUIDANCE (FURROW, CABLE) .......31
12.2ALIGN SPANS 90° AT RIGHT ANGLE TO THE CENTRAL UNIT ..........................................................32
12.3ALIGNING THE CENTRAL UNIT TO THE LINEAR GUIDANCE (BELOW GROUND GUIDANCE).......32
13ALIGNMENT CONTROL.................................................................................................................................34
13.1MICROSWITCH ADJUSTMENT..............................................................................................................34
14ELECTRICAL SYSTEM...................................................................................................................................35
14.1CABLES AND MARKINGS.......................................................................................................................35
14.2INSTALLATION, CONNECTION OF CONTROL CENTRE.....................................................................36
14.3ALIGNMENT CONTROL CONNECTION.................................................................................................36

Operating Manual for BAUER LINESTAR 9000 with hose feed VII
15FIRST START-UP ...........................................................................................................................................36
15.1CHECKING OF CENTRAL UNIT.............................................................................................................36
15.2CHECKING OF TRUSS, END TOWER AND OVERHANG.....................................................................37
15.3GEARBOXES AND DRIVE MOTORS.....................................................................................................37
15.3.1GEARBOXES ...........................................................................................................................................37
15.3.2DRIVE MOTOR........................................................................................................................................38
15.4OSCILLATOR BOX (ONLY WITH BELOW GROUND GUIDANCE).......................................................38
15.5CONTROL CENTRE................................................................................................................................39
15.5.1CHECKING VOLTAGE AND WIRING..................................................................................................39
15.5.2CHECKING TOWER TRAVEL DIRECTION.........................................................................................39
15.6ALIGNMENT OF THE TOWERS.............................................................................................................40
15.7ALIGNMENT CONTROL ADJUSTMENT ................................................................................................40
15.8CHECKING ALIGNMENT ........................................................................................................................41
15.9MACHINE OFFSET FROM LINEAR GUIDANCE....................................................................................43
15.9.1ALIGNMENT OF THE MACHINE WITH FURROW / CABLE GUIDANCE ......................................43
15.9.2AUSRICHTEN DER MASCHINE MIT UNTERGRUNDSTEUERUNG ...............................................44
16TERMINOLOGY ..............................................................................................................................................46
17START-UP.......................................................................................................................................................47
17.1START LINESTAR IN OPERATING MODE “LINEAR”............................................................................47
17.1.1START LINESTAR WITH HOSE FEED.................................................................................................47
17.2STARTING AFTER INTERMEDIATE STOP............................................................................................47
17.3SHUT-DOWN PROCEDURE...................................................................................................................48
17.3.1SYSTEM SHUT OFF DURING IRRIGATION .......................................................................................48
17.3.2AUTOMATIC SYSTEMM SHUT OFF AT FIELD END........................................................................48
17.4STARTING LINESTAR TO RUN IN OPPOSITE DIRECTION AFTER AN AUTOMATIC SHUT-DOWN 48
17.5STARTING THE LINESTAR IN OPERATING MODE “WHEEL SWIVELLING”......................................49
17.6STARTING THE LINESTAR IN OPERATING MODE “PIVOTING”.........................................................49
17.7SHUT DOWN PROCEDURE...................................................................................................................50
17.7.1LINESTAR SHUT DOWN DURING IRRIGATION...............................................................................50
17.7.2AUTOMATIC SHUT-OFF OF LINESTAR .............................................................................................50
17.7.3STARTING INTO OPPOSITE DIRECTION AFTER AUTOMATIC SHUT-DOWN OF LINESTAR..51
18MAINTENANCE INSTRUCTIONS ..................................................................................................................51
18.1SERVICE INTERVALS.............................................................................................................................51
18.2SERVICE PLAN.......................................................................................................................................52
18.3POST-SEASON MAINTENANCE............................................................................................................54
18.4PRE-SEASON MAINTENANCE ..............................................................................................................54
18.4.1PRELOAD FORCES AND TIGHTENING TORQUES OF BOLTS.......................................................55
19TROUBLESHOOTING ....................................................................................................................................56
19.1RESTART AFTER DOGLEGGING..........................................................................................................57
20TECHNICAL DATA .........................................................................................................................................58
20.1DIMENSIONS OF BAUER LINESTAR 9000 – 2 WHEEL .......................................................................58
20.2DIMENSIONS OF BAUER LINESTAR 9000 - 4 WHEEL ONE SIDED..................................................58
20.3DIMENSIONS OF BAUER LINESTAR 9000 - 4 WHEEL DOUBLE SIDED............................................58
21OPTIONS.........................................................................................................................................................59
21.1LOW PRESSURE SHUT-OFF.................................................................................................................59
21.2ELECTRIC SHUT-OFF VALVE (CENTRAL UNIT)..................................................................................59
21.3END GUN.................................................................................................................................................59
21.4BOOSTER PUMP FOR END GUN..........................................................................................................59
21.5AUTOMATIC INTERVAL CONTROL.......................................................................................................60
21.6AUTOMATIC „ON/OFF” AND INTERVAL CONTROL.............................................................................60
21.7TOWER ALIGNMENT SWITCH...............................................................................................................60
21.8RUNNING LIGHT.....................................................................................................................................60
21.9END STOP...............................................................................................................................................60
21.10STOP RAMP............................................................................................................................................61
22TOWING OF LINESTAR 2-WHEEL................................................................................................................61
22.1TOWING THE LINESTAR FROM CENTRAL UNIT.................................................................................61
22.1.1SWIVELLING CENTRAL UNIT WHEELS............................................................................................62
22.1.2SWIVELLING TOWER WHEELS...........................................................................................................62
22.1.3MOUNTING THE TOW CABLES ON “-WHEEL CENTRAL UNIT ....................................................62

VIII
Operating Manual for BAUER LINESTAR 9000 with hose feed
22.2TOWING THE LINESTAR AT THE END TOWER..................................................................................63
22.2.1SWIVELLING CENTRAL UNIT WHEELS (PROCEED ACCORDING TO ITEM 17.5)...................... 63
22.2.2SWIVELLING TOWER WHEELS.......................................................................................................... 63
22.2.3BRACING THE END TOWER................................................................................................................ 64
22.3TOWING THE LINESTAR AT A FREESTANDING SPAN.....................................................................64
22.3.1SWIVELLING CENTRAL TOWER WHEELS (ACCORDING TO ITEM 17.5) .................................. 64
22.3.2SWIVELLING TOWER WHEELS.......................................................................................................... 64
22.3.3BRACING THE END TOWER AND THE CENTRAL UNIT................................................................ 65
23ELECTRICAL WIRING DIAGRAMS ...............................................................................................................66
23.1CONTROL CENTER LINESTAR PRO.....................................................................................................67
23.1.1CONTROL CENTER LINESTAR PRO - WIRING DIAGRAM 1 .........................................................67
23.1.2CONTROL CENTRE LINESTAR PRO - INFEED................................................................................. 70
23.2CONTROL CENTRE LINESTAR PRO WITH BELOW GROUND GUIDANCE.......................................72
23.2.1CONTROL CENTRE LINESTAR PRO W. BELOW GROUND GUIDANCE - WIRING DIAGRAM 173
23.2.2CONTROL CENTRE LINESTAR PRO W. BELOW GROUND GUIDANCE - INFEED.....................76
23.3CONTROL CENTRE LINESTAR PRO-G.................................................................................................81
23.3.1CONTROL CENTRE LINESTAR PRO-G - WIRING DIAGRAM 1..................................................... 81
23.3.2CONTROL CENTRE LINESTAR PRO-G - INFEED............................................................................. 84
23.4LINESTAR LINEAR CONTROL ...............................................................................................................86
23.4.1FURROW GUIDANCE - WIRING DIGRAM......................................................................................... 87
23.4.2CABLE GUIDANCE - WIRING DIGRAM............................................................................................. 88
23.4.3BELOW GROUND GUIDANCE OSCILLATOR BOX - WIRING DIGRAM....................................... 89
23.4.4BELOW GROUND GUIDANCE TRACK UNIT - WIRING DIGRAM 1.............................................. 90
23.4.5BELOW GROUND GUIDANCE TRACK UNIT - WIRING DIGRAM 2.............................................. 91
23.5LINESTAR TOWER BOX.........................................................................................................................92
23.5.1TOWER BOX - STANDARD.................................................................................................................. 92
23.5.2TOWER BOX - WITH TOWER ALIGNMENT SWITCH ..................................................................... 92
23.5.3TOWER BOX - WITH END TOWER MONITORING........................................................................... 94
23.5.4TOWER BOX - WITH TOWER ALIGNMENT SWITCH & END TOWER MONITORING............... 95
23.5.5END TOWER BOX - STANDARD......................................................................................................... 96
23.5.6END TOWER BOX - WITH TOWER ALIGNMENT SWITCH ............................................................ 97
23.5.7END TOWER BOX - WITH END STOP ................................................................................................ 98
23.5.8END TOWER BOX - WITH END STOP & TOWER ALIGNMENT SWITCH ....................................99
23.5.9END TOWER BOX - WITH END STOP & AUTOREVERSE............................................................. 100
23.5.10END TOWER BOX - WITH END STOP & AUTOREVERSE............................................................. 101
23.6BOOSTER PUMP FOR END GUN........................................................................................................102
24SERVICE – EVIDENCE.................................................................................................................................103
25CONFORMITY CERTIFICATE......................................................................................................................107

Operating Manual for BAUER LINESTAR 9000 with hose feed 1
1 GENERAL INSTRUCTIONS
CE SYMBOL
The CE symbol that has to be affixed on the machine by the manufacturer outwardly demonstrates
compliance of the machine with the directives for machines and other relevant EU directives.
EU conformity certificate (see Annex)
This “Warning” symbol refers to important safety instructions in this manual. Whenever
you see this symbol be aware of possible injury hazards. Read the note following the
symbol very carefully and inform the other operators accordingly.
Non-observance of this instruction may damage or destroy the machine or individual
components.
It is very important to observe this note or instruction carefully!
Qualified operators
These are persons who on behalf of their training, experience and instruction as well as their knowledge of relevant
standards, rules, precautions to be taken for accident prevention, and prevailing operating conditions, have been
authorised by the person in charge of plant safety to perform the respective tasks required, and in doing so are
able to recognise and avoid potential hazards. Among other things, knowledge of first-aid procedures is also
required.
Product liability
According to the product liability law every farmer is an entrepreneur!
According to §9 PHG (Product Liability Law), liability for damage to corporeal things caused by defective products
is expressly excluded. This exclusion of liability also applies to parts not manufactured by BAUER itself but
purchased from external suppliers.
Duty to furnish information
Even if he passes on the machine to a new owner later-on, the customer is obliged to hand on the operating
manual to the new owner, too. The receiver of the machine must be instructed with reference to the mentioned
regulations.
Intended use
BAUER LINESTAR 9000 has been constructed exclusively for use in normal irrigation (intended use).
Any employment beyond this normal use is considered non-conforming. The manufacturer is not liable for
damage resulting from such non-conforming use, the sole liability for damage from non-conforming use is with
the user.
Intended use also includes compliance with manufacturer’s operating, maintenance and service instructions.
BAUER LINESTAR 9000 may be used and operated only by persons who are familiar with the system and
aware of the hazards involved.
Al l relevant rules for accident prevention as well as any other generally accepted specifications and regulations
relating to safety, work medicine and traffic law must be strictly observed.
Unauthorised modifications on the machine release the manufacturer from liability for damage resulting
therefrom.
WARNING !
CAUTION !
NOTE!

2
Operating Manual for BAUER LINESTAR 9000 with hose feed
2 WARNING SYMBOLS
Danger points on the pivot system are specifically marked by safety stickers. These stickers must be affixed at the
mentioned points clearly visible and serve for protection of persons working on or near the system.
1.
WARNING !
Study and observe the manual and all safety instruction carefully before you put the system
into operation.
2.
WARNING !
Before maintenance and repair work, always stop the system, disconnect all power, and read
the operating manual.
3.
WARNING !
1. This system is powered by 400 Volts!
Danger of electrical shock / injury hazard !
2. Do not attempt to check any components while the system is live!
3. Open the inner pivot panel door only when main switch is OFF.
4.
WARNING !
1. The working range of the pivot must always be at a safe distance from electrical power
lines.
2. Pull towable systems only at a safe distance from electrical power lines.
Make sure that the water jet from spray nozzles and end gun does not hit electrical lines.
The water jet of the nozzles and of the end gun must not touch electrical wires!
5.
WARNING !
The system can start automatically. Always keep a safe distance from the towers.