LELY LOTUS 460 Stabilo User manual

OPERATOR'S MANUAL
LOTUS 460 / 520
Bhe013-b.chp
AWS®, LOTUS®and STABILO are registered trademarks. The right of exclusive use belongs to the companies
of the LELY Group.
©2000. All rights reserved. Nothing of this publication may be reproduced and/or published by printing,
photocopying, microfilm or any other way without the prior written permission of LELY INDUSTRIES N.V..

TABLE OF CONTENTS .................................................................................................page
PREFACE ..........................................................................................................................23
WARRANTY CONDITIONS.............................................................................................23
TYPE AND SERIAL NUMBER OF YOUR MACHINE...................................................23
SAFETY INSTRUCTIONS ...............................................................................................24
EXPLANATION OF SAFETY DECALS ON THE MACHINE........................................25
1 INTRODUCTION .........................................................................................................26
2 MOUNTING BEHIND THE TRACTOR ......................................................................27
3 TRANSPORT ...............................................................................................................28
4 MACHINE ADJUSTMENTS........................................................................................29
5 OPERATING THE LOTUS..........................................................................................30
5.1 General instructions .........................................................................................30
5.2 Forward speed and PTO speed ......................................................................31
5.3 STABILO Self Steering Device........................................................................31
5.4 Recommended operation procedure ..............................................................31
6 DISMOUNTING FROM THE TRACTOR...................................................................32
7 MAINTENANCE...........................................................................................................33
7.1 Maintenance after operations..........................................................................33
7.2 Lubrication .........................................................................................................33
7.3 Intermittent maintenance .................................................................................34
Supplement
A TECHNICAL DETAILS ................................................................................................36
21

PREFACE
This Operator's Manual is meant for personnel that are
operating the machine and are responsible for its daily
maintenance.
Kindly read this manual fully prior to starting work.
Such instructions as are related to your safety and/or that
of others are marked in the margin by a warning triangle
with exclamation mark. These instructions should be
observed with particular care and attention.
Instructions which may lead to serious material damage
in case of non-compliance or incorrect use are marked in
the margin by an exclamation mark.
The machine described in this manual may contain compo-
nents which do not form part of the standard equipment but
are available as optional extras. This is not made clear in all
cases, because standard specifications may differ from
country to country.
Furthermore, machines and optional extras may be adjusted
to specific regional conditions whilst they are also subject to
permanent research and innovation. For this reason, the
specifications of your machine may not be consistent with the
pictures in this manual.
WARRANTY CONDITIONS
For those parts which fail in 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.
Warranty shall not apply if the instructions mentioned in this
manual have not been met, or if they have not been met
completely or correctly. Neither shall warranty apply in case
of modification of the machine by you or third parties
without our foreknowledge and/or authorisation.
TYPE AND SERIAL NUMBER OF
YOUR MACHINE
The type/serial number plate is fitted to the drive, beside the
central gearbox.
In case of correspondence and ordering of spare parts, kindly
state the type- and serial number of your machine. Complete
the box below with these numbers.
23
type number
serial number
!

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 occurring on the machine.
- Operate this machine in a safe way.
- The machine should be operated by authorised persons
only.
- Be alert and observe all safety precautions.
- Make sure that all safety guards and protection devices
are in place.
- Keep out of reach of moving parts.
- Stop engine, PTO and moving parts before adjusting,
cleaning or lubricating the machine.
- Take care that nobody will be within the dangerous zone
while the machine is in operation and be sure 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.
- Use always a tractor with a cab.
- Clear the field of objects that could be thrown up by the
machine.
- Observe the prevailing legislation for public road tran-
sport.
- Use flashing lights or other safety signs, when required.
- Don't stand on the machine.
- Use genuine parts only.
- Remove the pressure from hydraulic systems before
starting work on them and/or before coupling/un-
coupling 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.
24

EXPLANATION OF SAFETY DECALS ON THE
MACHINE
• Carefully read operator's manual before handling the
machine. Observe instructions and safety rules when
operating.
• Attention! Moving parts.
Stay clear of rotating machine parts.
• Danger of flying objects.
Maintain a sufficient, safe distance from the machine as
long as the tractor engine is running.
• Danger of rotors dropping down.
Keep away from the machine movement area.
• Tractor PTO speed is never allowed to exceed 540 r.p.m.
• Danger of moving parts!
Read the operating instruction of the PTO shaft.
Never use a PTO shaft without protection.
25

1 INTRODUCTION
The LOTUS 460 and 520 are rotary tedders which are used
for tedding mown grass and for spreading out windrows.
The LOTUS tedder is equipped with 4 rotors. Each rotor is
fitted with six tine arms with double spring steel tines (fig.
1). The special tine shape ensures that the crop is picked up
and spread out with minimum loss of material.
The rotors can pivot in respect of one another allowing the
LOTUS tedder to smoothly follow field undulations.
Ground contours are followed without any problem because
the wheels are positioned closely behind the tines (fig. 2).
A hydraulic control ensures quick and simple folding of the
machine.
Depending on machine model, a trail type headstock or a
STABILO self steering device is fitted.
The construction of the STABILO self steering device is such
(four pivot points - see fig. 3) that any side sway is corrected
rapidly.
26
1
2
3

2 MOUNTING BEHIND THE TRACTOR
LOTUS tedder with self steering headstock / STABILO self
steering device:
- Adjust the tractor 3 point hitch lower arms at equal height.
- Fit the lower arms to the linkage pins of the machine's
headstock.
- Fit the tractor top link to the machine by means of a
category II top link pin.
- Place the 3 parking jacks in the raised position (fig. 4).
- Secure the tractor lever arms by means of stabilisation
chains or rods keeping the machine from making sideward
movements.
- Check if the PTO shaft telescopes smoothly.
- Fit the PTO shaft to the tractor PTO shaft.
LOTUS tedder with drawbar:
- Fit the drawbar to the tractor’s swivel hook.
- Push the lateral supporting jack up.
- Turn in the frontmost parking jack and fit it to the chassis
in a horizontal position (fig. 5). Hook up the handle in the
rubber ring fitted to the locking pin.
- Check for easy telescoping of the PTO shaft.
- Fit the PTO shaft to the tractor PTO.
- Fold down the holder of the PTO shaft.
The following applies to all models of the LOTUS tedder:
At first assembly or use of another tractor: check the
minimum and maximum overlap of the PTO shaft halves.
(Consult the instruction supplied with the PTO shaft.)
Also check if the PTO shaft remains clear of the headstock
when the smallest possible bend is made with the tractor. If
not, make allowance for this when manoeuvering and always
take generous bends.
Fit the safety chain of the protection tube to a rigid part of
the tractor.
- Connect the hydraulic hose to a single acting hydraulic
tractor valve.
Max. allowed oil pressure: 17,5 MPa (175 bar).
- Place the end of the control cord for locking the ram in the
tractor cab.
27
4
!
5

3 TRANSPORT
The LOTUS tedder can be transported on the tractor's 3 point
hitch.
Use all such lighting and warning signals as are manda-
tory by law.
For transport on public roads: make sure that the front
axle weight is sufficient (fit front weights, if necessary)
and that the rear axle weight allowed as a maximum is not
exceeded.
- Secure the trail type headstock / STABILO self steering
device by means of the locking pin (fig. 6).
- Fold up the side rotors by means of the tractor hydraulics.
- Make sure that the cylinder has been secured by the locking
hook (fig. 7).
- Adjust the tines of the two innermost rotors inwards
(fig. 8).
- Adjust the wheel supports of the lateral rotors to the
position in which the wheels stick out least (fig. 8).
- Lift the machine from the ground.
The machine is now ready for transport.
Never allow the PTO shaft to rotate when the machine is in
the transport position.
28
6
7
8

4 MACHINE ADJUSTMENTS
Adjust the machine to the working position (spreading and
tedding) as follows.
- Set the wheel supports of the lateral rotors and those of the
central rotors in the same position.
- Remove the blocking pin from the headstock / self steering
device and place it in the appropriate hole on top of the
headstock (STABILO) or in a vacant hole of the top link
plate (fig. 9).
- Lower the machine onto the ground.
- Tighten the control rope for the locking hook. Lower the
rotors carefully by means of the hydraulic valve.
Land wheel adjustment should be such that the machine has
its highest position from the ground (fig. 10).
In light crop conditions, or if there is a strong wind blowing,
a more level machine adjustment may be necessary.
- Lift the machine from the ground to adjust the position of
the wheel supports.
Switch off the tractor engine and take precautions to
eliminate sudden lowering of the machine before you
proceed to wheel support adjustment.
- Set the tines in the most outward position (A, fig. 11).
- Adjust the working angle of the rotors in respect of the
ground by means of the top link in such a way that the tines
gently sweep the ground ensuring adequate crop pick-up.
-Deep adjustment causes undue strain which increases
wear and tear as well as the risk of tine breakage. In
addition to this, the crop is bound to get contaminated
more easily.
It may be desirable to "rake" the crop from headlands for
which the following adjustments are necessary.
- Set the tines of the rotor on the headland side inwards (B,
fig. 11).
- Lower this rotor by adjusting the wheel support 1 or 2
positions.
29
!
9
10
11
A
B

5 OPERATING THE LOTUS®
Make sure that nobody is near the machine at the moment
the PTO is engaged.
Do not allow anyone to come within a 25 m radius from
the machine during work.
Stop the tractor engine before leaving the tractor cab.
- If the machine is newly commissioned: first carry out the
check and maintenance duties which are specified in "7.3
Intermittent Maintenance" before starting the operation.
5.1General instructions
- Engage the PTO at the lowest possible r.p.m. rate; then
drive away.
Never drive through a crop when the rotors are not rotating,
since this may cause damage to the tines and tine arms.
Especially in the early stage of the process, fast and airy
tedding twice a day at a low r.p.m. rate is better than intensive
spreading at a high rotor speed.
The LOTUS tedder behaves as if it were a trailed machine.
Continued tedding in bends is no problem.
During lifting of the machine, the STABILO self steering
device is blocked in the angle of the machine in respect of the
tractor (see "5.3 STABILO Self Steering Device").
If the machine is fitted with a trail type headstock, it assumes
a position straight behind the tractor.
- For a machine with a trail type headstock it is advisable to
lift the machine only if the tractor is straight in front of the
machine.
If crosswise tedding on slopes causes the LOTUS tedder to
sway akwardly, it is possible to work with a locked trail type
headstock/self steering device.
- Block the trail type headstock/self steering device by
means of the locking pin (fig. 12).
- Lift the machine when having to make a turn.
30
12

5.2Forward speed and PTO speed
Both pick-up and spreading of the crop are dependent on the
forward speed and rotor r.p.m. speed.
- Select the highest possible forward speed (up to 15 km/h as
a maximum).
- Operate at the lowest possible PTO output (400 - 450
r.p.m.) always ensuring that the crop is picked up effec-
tively.
- Reduce your PTO output when "windrows" are formed
during the tedding operation.
5.3STABILO Self Steering Device
When the machine is lifted, the STABILO self steering
device is blocked automatically. A conical pin is forced into
the locking strip B through the tumbler A (fig. 13) to which
the top link is fitted.
The locking strip has an array of holes so that the machine
(roughly) assumes its angle at the moment of lifting.
If there is a difference between the angles during lowering
and lifting of the machine, the conical pin may not be
released from the hole because of the forces exerted on the
locking strip.
- If so: steer the tractor in line with the lifting angle or drive
back to discharge the locking strip.
5.4Recommended operating procedure
- Work the central part of the plot by driving up and down.
Stay clear of one full strip all around the field (, fig. 14).
In windy conditions, drive up and down in line with the
direction of the wind.
- Adjust the rotor which is facing the headland 1 or 2
positions lower and set its tines inwards.
- Finish the plot by making a circular bout ().
31
13
A
B
14
direction of the
wind

6 DISMOUNTING FROM THE TRACTOR
- Block the trail type headstock / STABILO self steering
device (fig. 15).
The machine can be stored in either of two positions: folded
out or folded up. Storage in the folded-out position is
recommended.
• Storage in folded-out position.
- Adjust all wheel supports in the same position.
- Lower the machine onto the ground.
- Gently lower the lateral rotors by means of the hydraulic
valve.
- Lower the machine onto the ground by means of the
tractor hydraulics.
• Storage in folded-up position
- Adjust the wheel supports of the innermost rotors in the
closest position to the dish (fig. 16) thus ensuring the
most stable machine position.
- Place the machine on a hard and solid surface.
All other instructions for dismounting the machine from the
tractor are identical for both kinds of storage.
- Switch off the tractor engine. Disengage the PTO shaft
from the tractor PTO.
- Place the PTO shaft in the hook (fig. 17).
- Remove the pressure from the hydraulic system and
uncouple the hydraulic hose. Slide the dust cap onto the
plug.
- Remove the control cord for the locking hook from the
tractor cab.
- Set the two parking jacks of the headstock in the lowest
position.
- Screw in the top link until the parking jacks are on ground
level.
- Adjust the rear parking jack in the lowest possible position
(fig. 17).
- Disengage the top link from the machine.
- Uncouple the lower arms from the machine.
32
15
16
17

7 MAINTENANCE
Correct machine servicing is necessary with a view to
reliable and safe working.
7.1Maintenance after operations
- Clean the machine thoroughly.
- Check the tines and tine arms for tightness and damage, if
any.
- Grease the machine with a rust preventive.
Pay special attention to the tines. Smooth tines without any
rust stimulate an unhampered crop flow.
- Grease the piston rod with an anti-corrosion agent if a
longer period of inactivity is anticipated. Remove the agent
when putting the machine back into operation. If not,
sealing of the ram may be affected after hardening of the
anti-corrosion agent.
7.2Lubrication
- PTO shaft to be greased every 8 working hours at the grease
nipples on the cross assemblies, protection tubes and free
wheel clutch (fig. 18).
- Profiled tubes of the PTO shaft to be greased every 8
working hours.
- Cross assemblies of double universal joints to be greased
every 8 working hours (fig. 19).
- Gears in gearboxes to be greased every 8 working hours
(fig. 20). When greasing, keep turning the rotors bit by bit
ensuring effective distribution of grease all over the gears.
- Pivot pins of lateral rotors to be greased every 40 working
hours (fig. 20).
- Pivots of the STABILO self steering device to be greased
every 40 working hours (fig. 21).
- Pivot point of trail type headstock to be greased every 40
hours (fig. 21).
- Grease or lubricate all remaining pivot points every 40
working hours.
33
!
18
8h
19
8h
40 h
20
8h
8h

7.3Intermittent maintenance
Intermittent maintenance has to be carried out:
• at the start of the 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 shaft telescopes smoothly. A damaged
PTO shaft may cause excessive wear and tear to the
machine and tractor.
- Check the tyre pressure (fig. 22).
inner rotors : 275 kPa (2,75 bar).
outer rotors : 150 kPa (1,5 bar).
- Check all bolts and nuts for tightness.
When tightening loose bolts/nuts the torques listed below
should be applied.
- Check the rotors for sagging (fig. 23).
• Place the machine on a level surface.
• Place the 2 central wheels on an elevation of 60 mm.
• Ensure horizontal machine position.
• The stop bolts should only just foul the abutment
surfaces.
- Check the machine for damage and flaws.
34
21
22
275 kPa
(2,75 bar)
150 kPa
(1,5 bar)
23
40 h
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
60 mm
40 h

- Convince yourself of the presence and undamaged condi-
tion of all safety decals on the machine (fig. 24).
A(P/N 9.1170.0408.0)
B(P/N 9.1170.0407.6) -4x-
C(P/N 9.1170.0410.2)
D(P/N 9.1170.0420.5)
E(P/N 9.1170.0125.4)
F(P/N 16.61.175)
- Check the gearbox for grease leakage
Grease to be renewed every 500 working hours for which
the cover at the rear side of the gearbox (fig. 25) has to be
removed. Contents: 0,25 kg/specification Shell Alvania
WR-0. When fitting the cover: apply fluid sealing material
(Loctite 574) to the gearbox rim and bolt holes.
35
24
B
CD
B
F
E
A
C
B
D
A
EB
F
25
SHELL ALVANIA WR-0
0,25 kg
A
EB

A TECHNICAL DETAILS
All details are without engagement and may
be altered without prior notice.
36 Supplement A
LOTUS®460 520
Working width 4,60 m 5,20 m
Transport width 2,75 m 2,75 m
Parking height 2,50 m 2,60 m
Machine length 2,20 m 2,20 m
Weight 600 kg 640 kg
Power required 15 kW (20 HP)25kW(34 HP)
PTO output 400 - 450 r.p.m. (540 r.p.m. as a maximum)
Forward speed 15 km/h as a maximum
Linkage Category II
Number of tines 4 x 6 double tines
Overload safety K33 slip clutch
Hydraulic connection 1 single acting valve
maximum working pressure 17,5 MPa (175 bar)
Tyres 16x6,5-8 6 ply
Tyre pressure 275 kPa (2,75 bar) inner rotors
150 kPa (1,50 bar) outer rotors