LELY LOTUS 1020 Profi User manual

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www.lely.com
Lely Industries N.V.
900 / 1020 Profi
LELY LOTUS
Operator’s manual
T-H002.0802VT
LOTUS 1020 Profi

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EN-1
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OPERATOR’S MANUAL
LELY LOTUS
900 / 1020 Profi
Th0020802en-tp.fm
English
LOTUS®is a registered trademark. The right of exclusive use belongs to the companies of the LELY Group.
©2008. All rights reserved. Nothing from this publication may be reproduced and/or published by printing, photo-
copying, microfilm or any other way without the prior written permission of LELY INDUSTRIES N.V.

EN-2
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EN-3
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TABLE OF CONTENTS .......................................................................................................page
PREFACE .........................................................................................................................5
WARRANTY CONDITIONS .............................................................................................5
TYPE AND SERIAL NUMBER OF YOUR MACHINE ........................................................5
SAFETY INSTRUCTIONS..................................................................................................6
EXPLANATION OF SAFETY DECALS ON THE MACHINE ...............................................7
1 INTRODUCTION..............................................................................................................8
2 LINKAGE TO THE TRACTOR...........................................................................................9
3 TRANSPORT...................................................................................................................10
4 MACHINE ADJUSTMENTS.............................................................................................11
4.1 Tine adjustment..................................................................................................11
4.2 Rotor angle and working height.......................................................................11
5 OPERATING THE LOTUS®.............................................................................................12
5.1 General instructions ...........................................................................................12
5.2 Forward speed and PTO speed ..........................................................................12
5.3 Recommended procedure..................................................................................13
6 DISMOUNTING FROM THE TRACTOR ..........................................................................13
7 MAINTENANCE .............................................................................................................14
7.1 Maintenance after operation ............................................................................14
7.2 Lubrication..........................................................................................................14
7.3 Periodic maintenance.........................................................................................15
7.4 Changing of grease in gearbox .........................................................................16
Supplements:
A OPTIONAL EXTRAS .......................................................................................................17
B NARROW OR WIDE TYRES ...........................................................................................17
C HYDRAULIC DIAGRAM .................................................................................................18
D TECHNICAL DETAILS .....................................................................................................19

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EN-5
PREFACE
This Operator’s Manual is meant for personnel who operate the ma-
chine and are responsible for its daily maintenance.
Kindly read this entire manual prior to starting work.
Instructions relating to your safety and/or that of others are
marked in the margin by a warning triangle containing an ex-
clamation mark. Always observe these instructions with par-
ticular care and attention.
Instructions which may lead to serious material damage in
case of non-compliance or incorrect use are indicated in the
margin with an exclamation mark.
The machine described in this manual may contain components
which do not form part of the standard equipment but are available
as optional extras.
This is not indicated in all cases since standard specifications may dif-
fer from country to country.
Furthermore, machines and optional extras may be adapted to spe-
cific regional conditions and are also subject to permanent research
and innovation.
For this reason, the specifications of your machine may not be con-
sistent with the pictures in this manual.
WARRANTY CONDITIONS
For those parts which fail under normal operating conditions, the
factory will make replacement parts available, free of charge, for a
period of 12 (twelve) months from the date of purchase.
The warranty shall not apply if the instructions mentioned in this
manual have not been followed, or if they have not been followed
completely or correctly.
Nor will the warranty apply if you or third parties modify the ma-
chine without our foreknowledge and/or authorisation.
TYPE AND SERIAL NUMBER OF YOUR MA-
CHINE
The type/serial number plate is fitted to the front of the machine on
the fixation plate for the safety panel support.
Please specify the type and serial number of your machine in any cor-
respondence and when ordering spare parts.
Complete the box below with these numbers.
!
Type number
Serial number

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SAFETY INSTRUCTIONS
- Use the machine only for the purpose for which it was designed.
- Follow all prevailing safety regulations, including those laid down
in this manual and indicated on the machine.
- Operate this machine in a safe manner.
- The machine should be operated by authorised persons only.
- Be alert and observe all safety precautions.
- Ensure that all safety guards and protection devices are in place.
- Keep out of reach of moving parts.
- Stop the engine, PTO and moving parts before adjusting, cleaning
or lubricating the machine.
- Take care that nobody is within the dangerous zone while the ma-
chine is in operation and ensure that people are kept well away
from the machine. This is especially important when working
along roads and near or on fields that are accessible to the public.
- Always use a tractor with a cab.
- Clear the field of any objects that could be thrown up by the ma-
chine.
- Observe prevailing legislation for public road transport.
- Use flashing lights or other safety signs, when required.
- Do not stand on the machine.
- Use genuine LELY parts only.
- Remove the pressure from hydraulic systems before starting work
on them and/or before coupling/uncoupling hydraulic hoses.
- Use protective clothing, gloves and/or safety glasses if required.
- Clean the safety decals regularly so that they can be read at all
times.

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EXPLANATION OF SAFETY DECALS ON THE
MACHINE
-Read the operator’s manual carefully before operating the ma-
chine. Observe instructions and safety rules during operation.
-Danger! Moving parts.
Stay clear of rotating machine parts.
-Danger: flying objects!
Maintain a sufficient, safe distance from the machine while the
tractor engine is running.
-Danger: risk of being trapped by moving parts!
Keep outside the movement range of parts for as long as they
have not been secured or prevented from moving in another man-
ner.
-Danger: folding parts.
Keep away from the folding areas of parts.
- Never allow the machine to operate at a PTO speed greater
than 540 r.p.m.
- If you need to hoist the machine, only use hoisting points as in-
dicated by means of the decals.
-Danger: moving parts!
Read the operating instructions of the PTO shaft.
Never use a PTO shaft without any protection.

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1 INTRODUCTION
The LELY LOTUS 900 and Profi 1020 are pull-type tedders that are
used for tedding mown grass and for spreading out windrows.
A tremendous capacity can be realised thanks to the large working
widths of 9.0 or 10.2 m and the high forward speed (up to 15 km/h).
De LOTUS schudder heeft 8 rotoren. Each rotor is fitted with tine
arms featuring double spring steel tines (fig. 1).
The special tine shape ensures that the crop is picked up and spread
out with a minimum loss of material.
Since the top-link ram is fitted to a slotted hole connection and the
rotors can pivot in relation to one another, the LOTUS tedder can
follow field undulations with ease.
Ground contours are followed without any problem because the
wheels are positioned closely behind the tines (fig. 2). 2).
Hydraulic controls ensure that the machine can be adjusted to the
transport position quickly and simply. The machine can be transport-
ed behind the tractor with ease since its transport width is only 3.0
m.
The LOTUS Profi tedder is coupled to the tractor's hydraulic lift. The
pivoting point of the special headstock is positioned further back
than that of the traditional LOTUS 900 and 1020 models (fig.3). The
machine therefore has a wider turning circle, allowing easy manoeu-
vring in tight bends.
The LOTUS Profi offers the possibility of adjusting the tedding angle
infinitely by means of the wheel assembly (fig. 3).
1
2
3

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2 LINKAGE TO THE TRACTOR
Link the machine to the tractor as follows:
- Adjust the tractor’s three-point-hitch arms at equal height.
- Fit the lower arms to the linkage pins (cat II) of the headstock
(fig.4).
Better access to the linkage points of the headstock can be obtained
by turning away the warning signs at the front of the machine.
- Remove the locking pins (fig. 4) from the pivot points before turn-
ing away the warning signs.
- Lift the drawbar slightly so that the parking jacks are just clear of
the ground. Maintain this height adjustment of the tractor lift
during operation and transport.
- Place the parking jacks in the raised position.
- Secure the tractor’s lower arms by means of stabilisation chains or
rods to eliminate any sideways movements.
- Place the wheel wedges in the supports fitted on the rear of the
safety signs.
- Check if the PTO shaft telescopes smoothly.
- Fit the PTO shaft to the tractor PTO.
During first assembly or when using another tractor, check
the minimum and maximum overlap of the PTO shaft halves*.
- Fit the safety chain of the protection tube to a rigid part of
the tractor.
- Connect the hydraulic hose with the blue mark to a single-acting
hydraulic tractor valve.
Permitted maximum oil pressure: 21.0 MPa (210 bar).
- Connect the hydraulic hoses with the white mark to a double-act-
ing hydraulic tractor valve with floating position.
Permitted maximum oil pressure: 21.0 MPa (210 bar).
- Insert the plug of the lighting cable into the tractor socket
and check if the lighting is operating correctly.
- Turn the warning signs back to the front position and se-
cure them with the locking pins.
*. Consult the instructions supplied with the PTO shaft
4
A
!

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3 TRANSPORT
The LOTUS tedder can be transported by the tractor after it has been
adjusted to the transport position. The transport width is approxi-
mately 3.0 m.
Put the machine into the transport position as follows:
- Position the tractor straight before the machine. If this is not
done, the moving lateral rotors may hit the tractor and/or head-
stock.
- Extend the small ram completely using the single-acting tractor
spool valve and then set the valve in the closed position.
- Pull the rotors forward by means of the double-acting spool valve
(A, fig. 5) and fold the lateral rotors forwards (B).
- Lower the lateral rotors onto the supports by means of the single-
acting spool valve (C, fig. 5, fig. 6).
- Tip the protection brackets at the rear of the machine backwards
so that they indicate the corners of the machine (A, fig. 7).
- Use all lighting and warning signals required by law (or
other regulations prescribed by the authorities).
- For transport on public roads, ensure that the front axle
weight is sufficient (fit front weights, if necessary) and
that the permitted maximum rear axle weight is not ex-
ceeded.
The machine is now ready for transport.
Never allow the PTO shaft to rotate when the machine is in
the transport position.
5
A
B
C
6
7
Transport
Work
A
B
!

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4 MACHINE ADJUSTMENTS
Ensure that no-one is near the machine when it is changed
from the transport position into the working position.
Put the machine into the working position as follows:
- Position the tractor straight before the machine. If this is not
done, the moving lateral rotors may hit the tractor and/or head-
stock.
- Fold the protection brackets at the rear of the machine forwards
(B, fig. 7).
Brackets that are not folded in can cause damage when the
machine is unfolded!
- Push the lateral rotors over the supports by means of the single-
acting spool valve (A, fig. 8).
- Fold out the lateral rotors (B, fig. 8) and lower the rotors onto the
ground by means of the double-acting spool valve (C).
- Place the double-acting spool valve in the floating position.
4.1 Tine adjustment
- Adjust the tines to the outer position (A, fig. 9).
For headland tedding:
Adjust the tines of the rotor on the plot side to the inner position
(B).
4.2 Rotor angle and working height
The wheels have the following preferred setting:
- LOTUS 900 (S): highest/second-to-highest position;
- LOTUS 1020 (S): second-to-highest/ middle position.
A more level machine adjustment may be required when handling
light crops or in windy conditions.
- Lift the rotors clear from the ground using the tractor's double-
acting hydraulic valve.
- Switch off the tractor engine and take the necessary precautions
to ensure the machine does not suddenly lower before you start
adjusting the wheel supports.
Adjust the wheels to the desired position (A, fig. 10).
For headland tedding:
Adjust the rotor on the plot side 1 position lower than the remain-
ing rotors.
- Lower the rotors.
- Adjust the working angle of the rotors in relation to the ground
via the spindle (B) in such a way that the tines gently sweep the
ground ensuring adequate crop pick-up. Rule of thumb: the tines
should touch the ground over a width of approximately 25 cm.
Deep adjustment causes an excessive load, which increases
wear and tear as well as the risk of tine breakage. The crop
will also become contaminated more easily.
Since the Lotus 900 and 1020 tedders can be equipped with narrow
or wide transport wheels, there are also two different basic settings
for the wheel assemblies. The correct setting is explained in appen-
dix B.
!
8
A
B
C
9
AB
10
A
B
25 cm
!

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5 OPERATING THE LOTUS®
• Ensure no-one is near the machine at the moment the
PTO is engaged.
• Do not allow anyone to come within a 25 m-radius of the
machine while it is operational.
• Stop the tractor engine before leaving the tractor cab.
• The safety guards are essential protective components of
the machine. For this reason, only operate the tedder if it
these components are duly fitted.
5.1 General instructions
- Lift the rotors from the ground by means of the double-acting
valve.
- Engage the PTO at the lowest possible engine r.p.m.
- Increase the motor speed.
- Drive forward.
Never drive the machine through the crop while the rotors are on
the ground and are not rotating. This may damage the tines and
tine arms.
- Lower the rotors into the crop.
Place the double-acting hydraulic valve in the floating position;
the rams must telescope smoothly during operation.
During the early stage of the process in particular, fast and airy ted-
ding twice a day at a low r.p.m. rate is better than intensive tedding
at a high rotor speed.
The machine can continue operating when taking bends in the field.
- When turning on headlands, lift the rotors using the double-act-
ing hydraulic valve.
Keep the machine running at a reduced r.p.m. until the rotors are
lowered again.
5.2 Forward speed and PTO speed
Both crop pick-up and spreading depend on the forward speed and
rotor speed.
- Select the highest possible forward speed (up to a maximum of
15 km/h).
- Operate at the lowest possible PTO output (400-450 r.p.m.) so that
the crop is picked up effectively.
- Reduce your PTO output when windrows develop during the ted-
ding operation.
- Adjust the forward speed and PTO speed to field and crop condi-
tions.

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5.3 Recommended procedure
- Work the central part of the field by driving up and down. Leave
a strip equal to 1 working width free on all sides of the field (c,
fig. 11).
In windy conditions, drive up and down into the direction of the
wind.
- Adjust the rotor that hugs the plot side 1 or 2 positions lower and
adjust the tines of this rotor inwards.
- Finish the plot by driving round and round (d).
6 DISMOUNTING FROM THE TRACTOR
The machine can be dismounted from the tractor both in the work-
ing and in the transport position.
Always place the machine on hard, even ground.
- Place the wedges against the transport wheels in order to prevent
the machine from rolling away accidentally.
- Place the parking jacks in the bottom position.
- Lower the tractor hydraulics until the parking jacks rest on the
ground.
- Switch off the tractor engine.
Better access to the linkage points of the headstock can be obtained
by turning away the warning signs at the front of the machine.
- Remove the locking pins (fig. 12) from the pivot points before
turning away the warning signs.
- Disengage the PTO shaft from the tractor PTO.
- Place the PTO shaft in the hook (fig. 12).
- Depressurize the hydraulic system and disconnect the hydraulic
hoses.
- Place the dust caps on the plugs and hang the plugs on the sup-
port on the headstock (fig. 12).
- Remove the plug for the lighting from the tractor socket.
- Disconnect the lower arms from the machine.
- Turn the warning signs back to the front position and secure them
with the locking pins.
11
Wind direction
12
A

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7 MAINTENANCE
• Correct machine servicing is vital for ensuring reliable
and safe operation.
7.1 Maintenance after operation
- Clean the machine thoroughly.
- Check the tines and tine arms for tightness or any damage.
- Grease the machine with an anti-corrosion agent.
Pay special attention to the tines. Smooth tines without any rust
stimulate an unhampered crop flow.
- Grease the piston rods with an anti-corrosion agent if the machine
will not be used for a long period.
Remove the agent before using the machine again. If this is not
done, the seals of the rams may be damaged when the anti-corro-
sion agent hardens.
7.2 Lubrication
All lubrication points of the machine can be greased with a biode-
gradable grease (Total Biomultis SEP2), unless stated otherwise.
- PTO shafts must be greased every 8 working hours via the grease
nipples on the cross assemblies, protection tubes and slip clutch
(fig. 13).
- Grease the profiled tubes of the PTO shaft every 8 working hours
(fig. 13).
!
13
8 h
8 h
14
8 h
40 h
8 h
8 h
40 h
40 h
8 h
100 h

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- Apply grease to all nipples on the machine (fig. 14).
When greasing the gearboxes, keep turning the rotors bit by bit
to ensure the grease is distributed effectively all over the gears.
7.3 Periodic maintenance
Periodic maintenance must be carried out:
• at the start of the haymaking season;
• before prolonged storage of the machine;
• when the machine is used extensively during the season.
- Grease all points of the machine listed in § 7.2 “Lubrication”.
- Grease the spring-loaded locking pins of the yoke lock of the PTO
shaft.
- Check if the PTO shafts telescope smoothly.
A damaged PTO shaft may cause excessive wear and tear to the
machine and tractor.
- Check the machine for any damage and flaws.
- Check the gearbox for any oil leaks.
(Changing of grease: see § 7.4.)
- Check the tyre pressure (fig. 15).
- Check all bolts and nuts for tightness.
Tighten loose bolts/nuts to the torques specified below.
- Check the rotors for sagging (fig. 16).
• Place the machine on a level floor.
• To adjust the outermost rotors, place the 6 central wheels on an
elevation of 30 mm; to adjust the second-to-most exterior rotor,
only the 4 central wheels need to be placed on an elevation.
• Ensure the machine is horizontal.
• The stop bolts (fig. 16) should then only just touch the stops.
M6 M8 M10 M12 M14 M16 M20 M24
Nm 10 25 50 85 135 215 410 710
kgm 1.0 2.5 5.0 8.5 13.5 21.5 41.0 71.0
15
275 kPa
150 kPa
100 kPa
(2.75 bar)
(1.5 bar)
(1.0 bar)
300 kPa (3.0 bar)
16
30 mm

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EN-16
- Check whether all safety decals are on the machine and not dam-
aged (fig. 17).
A P/N 9.1170.0408.0
B P/N 9.1170.0407.6 -2x-
C P/N 9.1170.0410.2 -2x-
D P/N 9.1170.0420.5
E P/N 9.1170.0125.4
F P/N 9.1170.0173.3 -2x-
G P/N 9.1170.0437.1 -2x-
H P/N 16.61.175 -2x-
7.4 Changing of grease in gearbox
Change the grease in the gearbox every 500 working hours. Remove
the cover on the front of the gearbox for this purpose (fig 18). En-
sure the shims are not damaged.
Contents 0.25 kg; Shell Alvania WR-0.
An incorrect quantity of grease may lead to overheating and
cause irreparable damage to the gearbox.
Change the grease more often when operating the machine
in extreme working conditions.
17
A
E
H
B
CF B
C
D
G
18
60 Nm (6 kgm) (4x)
!
A
B
C
D
E
G
H
F

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A OPTIONAL EXTRAS
Tyres
Two tyre sizes are available for the LOTUS Profi tedder: 10.0/75-15.3
or 15.0/55-17. This choice allows you to adjust your machine's tyre
size to prevailing ground conditions.
Spare wheel with support
To enable a flat tyre to be mended quickly in the field, the LOTUS
tedder can be fitted with a support for a spare wheel.
B NARROW OR WIDE TYRES
Since narrow tyres are slightly lower than wide tyres, this has an ef-
fect on the height of the machine's carrier. This also influences the
height adjustment of the tines.
- When using narrow (10”) transport wheels, the pivot points of the
wheel assembly must be used in the low position (A, fig. B-1).
- When using wide (15”) transport wheels, the pivot points of the
wheel assembly must be used in the high position B, fig. B-1).
When the correct pivot points for the wheel assembly are used with
the corresponding tyre size, the wheel height adjustment will have
the proper range.
Adjust the machine to the correct tyre size as follows:
- Put the machine into the working position.
- Support the carrier near the transport wheels.
- Remove the pivot pins C (fig. B-1).
- Position the pivot points of the wheel assembly in front of the cor-
rect holes on the carrier.
- Fit the pivot pins C. Secure the pivot pins using the bolt M12x35
and the roll pin Ø8x50.
B-1
A
B
C
Supplements A & B

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C HYDRAULIC DIAGRAM
Legend:
1. Single-acting ram
2. Double-acting ram
3. Throttle
4. Breather
11
1
22
1
33
44
4
Supplement C