LEMKEN Albatros 20 User manual

Operating Manual
Trailed sprayers
Albatros 20, 30, 40, 50
and 60
- EN -
Safety is our Concern!
Part No.175 4014
1/02.06
LEMKEN GmbH & Co. KG
Soil tilling and Drill technics
Works Alpen
Weseler Straße 5, D-46519 Alpen /
Postfach 11 60, D-46515 Alpen
Tel. [phone], Fax [phone]
E-Mail: [email protected],
Internet: http://www.lemken.com
Plant protection
Works Meppen
Kopenhagener Str. 1, D-49716 Meppen
Tel. [phone], Fax . [phone]
E-Mail: [e-mail];
[email protected]
Internet: http://www.lemken.com

Dear customer!
We would like to thank you for the confidence in buying this implement.
The advantages of this implement will be shown, only, when operated and used
with due care and attention.
When handing over this implement your dealer has already instructed you with
regard to operation, adjustment and maintenance. But this short introduction
requires an additional detailed study of the instruction book.
Therefore read this instruction book carefully before the first use. Please pay
attention to the safety instructions mentioned in this instruction book.
Any changes and modifications carried out not being mentioned expressly in this
instruction book, may only be carried out with a written agreement of the
manufacturer.
Ordering spare-parts
When ordering spare-parts please state type and serial No. of the implement. This
information will be found on the identification plate.
Put down this data on the following table so that it is always available.
Type of implement:
Serial No.:
Only use genuine LEMKEN spare-parts. Spurious parts negatively influence the
function of the implement, show a shorter lifetime and increase in nearly all cases
the maintenance effort.
We trust that you will understand that LEMKEN is unable to guarantee poor
operation and damage caused by using spurious parts!
1

DEFINDED USE
•Please familiarise yourself with your LEMKEN - sprayer and its
operations before putting the implement to work. Therefore use
this instruction book with the ’General Health- and Safety
precautions’!
•Your LEMKEN - sprayer is intended to be used for transport and output of
pesticides as insecticides, fungicides, herbicides in form of suspensions,
emulsions and mixtures as well as liquid manure.
•The LEMKEN - sprayer corresponds to the state of developpements. It has
been designed purely for the agricultural use, special crops, vegetable growing,
non-arable land and grassland! (defined use). Any use beyond the one
stipulated above is no longer considered as defined use!
•Under „defined use“ the manufacturer’s prescribed operation-, maintenance-
and repair conditions are to be adhered to!
•The LEMKEN - sprayer 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!
•The applicable accident prevention advices as well as the generally accepted
safety technical, working, medical and road traffic rules should be adhered to!
•Own modifications at the implement exclude the manufacturers’ liability for
damages caused by the modifications.
•According to the general operating licence, the maximum speed necessitated
by the design is 25 km/h (exception the 40 km/h version). The manufacturer
shall neither accept a warranty nor a liability for damages resulting from speeds
in excess of this maximum speed.
2

TABLE OF CONTENTS
Definded Use............................................................................................................. 2
Table of contents...................................................................................................... 3
1Safety information.............................................................................................. 6
1.1 General regulations................................................................................................6
2Warning pictograms ........................................................................................ 13
3Initial installation.............................................................................................. 14
3.1 Power supply ........................................................................................................14
3.2 Installing the operator panel ...............................................................................14
3.3 Hitching up............................................................................................................15
3.4 Mounting the drive shaft......................................................................................15
3.5 Mounting the hydraulic lines...............................................................................16
3.6 Establishing the electric connection ..................................................................16
3.7 Function of the compressed air brake system ..................................................16
3.8 Track widths .........................................................................................................17
3.9 Drawbar versions .................................................................................................18
3.10 Control of the yoke drawbar steering system....................................................18
4Initial start-up.................................................................................................... 19
5Filling the tanks................................................................................................ 20
5.1 Filling the spray mixture tank..............................................................................20
5.1.1 Filling via the dome cover .................................................................................20
5.1.2 Filling with suction hose via the suction fitting...................................................20
5.1.3 Filling via hydrant connection ............................................................................21
5.2 Filling the clean water tank..................................................................................21
5.3 Level indicator ......................................................................................................22
5.4 Checking the dosage ...........................................................................................22
6Adding the pesticide........................................................................................ 23
6.1 Adding the pesticide via the dome cover...........................................................23
6.2 Adding the pesticide via the induction hopper..................................................23
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7Folding the boom ............................................................................................. 25
7.1 Unfolding the boom: ............................................................................................25
7.2 Folding the boom: ................................................................................................25
8Spraying ............................................................................................................ 26
9Albatros-control box........................................................................................ 27
10 Further functions.............................................................................................. 28
10.1 Residual quantities ..............................................................................................28
10.2 Diluting the spray mixture ...................................................................................28
10.3 Internal tank cleaning ..........................................................................................29
10.4 Washing the fittings, filters, spray lines and nozzles .......................................29
11 Maintenance information................................................................................. 30
11.1 Reciprocating diaphragm pump .........................................................................30
11.2 Suction filter – 50 meshes per cm² .....................................................................30
11.3 Pressure filter – 80 meshes per cm² ...................................................................30
11.4 Filling sieve – 18 meshes per cm².......................................................................30
11.5 Two-circuit compressed air brake system.........................................................30
11.6 Tyre pressure........................................................................................................31
11.7 Wheel nuts and hubs ...........................................................................................31
11.8 Over winter storage..............................................................................................31
11.9 Inspections and inspection intervals .................................................................32
12 Trouble shooting.............................................................................................. 33
13 Lubrication diagram......................................................................................... 37
Lubrication diagram boom............................................................................................37
Lubrication diagram pumps..........................................................................................37
Lubrication diagram.......................................................................................................38
Lubrication diagram drawbar steering system............................................................38
Lubrication diagram induction hopper ........................................................................39
14 Diagram............................................................................................................. 40
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14.1 Diagram spray technologies LEMKEN Albatros................................................40
14.2 Diagram LEMKEN Albatros 20 – 30 ....................................................................41
14.3 Diagram LEMKEN Albatros 40 – 60 ....................................................................42
15 Equipment......................................................................................................... 43
16 Sprayer tables................................................................................................... 48
5

1 SAFETY INFORMATION
1.1 General regulations
•Prior to every start-up, check the device’s roadworthiness and operating safety!
•Apart from the information contained in these operating instructions, also follow
generally valid safety and accident prevention regulations!
•Attached warning and information signs provide important information for a safe
operation. Observing these signs is for your own safety!
•When using public roads, comply with the respective road traffic regulations!
•Acquaint yourself with all devices and control elements and their function before
starting with the work! It is too late to do so when you are already busy with the
work!
•The user’s clothes should fit tightly! Avoid loosely worn clothing!
•It is imperative that the tractor’s and device’s mounting categories match or are
matched to each other!
ATTENTION! Device without tractor only in fold state parking!
•Hitch / unhitch the device as instructed!
•Before driving off and before start-up, check the immediate vicinity and provide
for sufficient visibility! It is prohibited to stay in the immediate vicinity of the
device!
•Check and mount transport equipment, for instance warning signs, lighting and
possible machine guards!
•Only start the device if all machine guards are in place and have been
activated!
•Observe permissible dimensions, axle loads and overall weights!
•The axle loads change when hitching up a device. In case the load on the front
axle is reduced too much, attach front weights to guarantee the tractor’s
steerability!
•When using trailed sprayers, check the brake function!
•Take into account the device’s wide overhang and/or gyrating mass when
cornering!
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•Passengers are not permitted on the device during work and transport rides!
•Never leave the driver’s cab while driving!
•Before leaving the tractor, remove the ignition key, apply the handbrake and
wait until all mobile parts have come to a standstill!
•Nobody may stay between tractor and device without the device being secured
against rolling away by means of the parking brake and/or wheel chocks!
•When folding and unfolding the boom, nobody may stay in its swivelling range!
•There are places on all of the hydraulically operated folding parts where you
might cut or bruise yourself!
Hydraulic system
•The hydraulic system is highly pressurised. When connecting the hydraulic lines
to the tractor’s hydraulic system, attention needs to be paid that the hydraulic
system both on the tractor and on the device side has been depressurised!
•Connect the hydraulic lines according to the specifications in these operating
instructions! Colour-code plug and socket to prevent them being mixed up!
•If terminals are mixed up, functions will be reversed (e.g. lifting instead of
lowering)!
•Regularly check hydraulic lines and replace if damaged and/or showing signs of
ageing! The replacement lines must correspond to the device manufacturer’s
technical requirements!
•Before working on the hydraulic system, you must first depressurise the system,
lower boom onto the rack, switch off the tractor engine and wait until all mobile
parts have come to a complete standstill!
•Liquids escaping under high pressure (e.g. hydraulic oil) can penetrate the skin
and cause serious injuries! Immediately consult a doctor in case of injuries!
Danger of infection!
•It is forbidden to carry out repairs on hydraulic lines!
•All lines and screw connections must be checked for leaks and externally visible
damage by an expert at least once a year!
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•Immediately dispose of any damaged parts!
•Oil squirting from the device can not only cause injuries, but also start a fire!
•Even if stored properly and subjected to permissible stresses only, hydraulic
lines are subject to natural ageing. Their useful life is therefore limited.
•Improper storage, mechanical damage and impermissible stresses are the most
common reasons for accidents.
•Hydraulic lines should not be used for longer than six years, including a
maximum storage time of two years (pay attention to the date of manufacture
on the hose assembly).
•Use on the limits of permissible stress ranges may shorten the period of use!
•Hoses and hose assemblies need to be replaced, if any of the following criteria
are detected during the inspection:
Damage to the outer layer down to the intermediate layer (e.g. chafe marks,
cuts and tears);
Embrittlement of the outer layer (e.g. cracking of the outer material)
Deformations, which do not correspond to the natural shape of the line, both
in a depressurised and in a pressurised state or if there are any deflections,
e.g. delamination, blistering;
Leaks;
Non-compliance with installation requirements;
Damage or deformation of the hose fitting, which might reduce the strength
of the fitting or of the connection line/fitting;
Line movement out of the fitting;
Fitting corrosion, which reduces function and strength;
Period of storage and use has been exceeded.
•Only use original spare parts as replacement!
•Lines and hoses must be expertly laid!
•Do not mix up connections!
8

Power take off shaft
•Only use a drive shaft approved for the device and equipped with prescribed
safety devices!
•The drive shaft’s protective pipe and protective funnel as well as power take-off
shaft protection on the tractor and device side must be in place!
•Only hitch or unhitch the device if the power take-off shaft and the engine have
been switched off and the ignition key has been removed!
•Ensure correct installation and safeguarding of closure!
•Ensure the prescribed pipe covering is in place in working and transport
position!
•Secure drive shaft guard against revolving by attaching the chain!
•Before switching on the power take-off shaft, make sure that the selected tractor
shaft speed matches the permissible maximum pump speed!
•Before switching on the power take-off shaft, ensure that nobody is staying in
the hazardous area around the device!
•After dismantling the drive shaft, push the protective cover back onto the shaft
stub!
•Clean and lubricate the drive shaft only if the power take-off shaft and the
engine have been switched off and the ignition key has been removed!
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•Never switch on the power take-off shaft while the engine is switched off! Switch
off power take-off shaft if excessive bends are generated and if it is not
required. Place disconnected drive shaft onto the transport mount provided for
that purpose.
•Possible damages need to be rectified immediately before working with the
device.
Brake system
•Check the brakes’ function before every ride!
•The braking system must be regularly subjected to a thorough inspection!
•Adjustment and repair work on the brake system may only be carried out by
expert workshops or acknowledged brake after-sales service centres!
Pesticide handling
•At the time the device is introduced to the market, the manufacturer only knows
of a few pesticides registered by the BBA that could cause damage to the
device.
•For instance, the pesticides Elancolan, Tramat, Betanal, Lasso, Teridox, Stomp,
Iloxan and Mudecan may cause damage to the pump diaphragms, non-return
diaphragm and hoses in case of lengthier exposure periods. This list of
pesticides does not claim to be complete.
•Refrain from inadmissible mixtures of different pesticides as these mixtures
could cause hitherto unknown reactions.
•Comply with the pesticide manufacturer’s recommendations:
Protective clothing
Safety information
Dosage, application and cleaning regulations
•Take into consideration any information regarding the compatibility of pesticides
and device materials!
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•Substances that tend to bond or congeal may not be sprayed!
Filling the tank
•For the protection of man, animal and the environment, pesticide sprayers may
not be filled from open waters!
•State laws and municipal regulations regarding the use of water need to be
observed.
•Pesticide sprayers may only be filled in free fall from the public water supply. If
they are not filled in free fall, adequate safety devices (according to DIN 1988)
are required, which need to be in proper working order at all times.
•The nominal volume may not be exceeded!
Maintenance/repair
ATTENTION! By overpressure can hose burst! It can be that hose chafe.
Spray thread out uncontrolled!
•Do not open pressurised lines!
•Repair work inside the spray mixture tank may only be carried out after the tank
has been thoroughly cleaned and only wearing a respirator!
ATTENTION! For safety reasons, a second person must monitor the
progress of work from outside the tank.
•Repair of sprayers used for liquid fertilizer application with urea-ammonium-
nitrate (UAN) solutions:
UAN residues may form salts inside or on the device when the water
evaporates.
This results in pure ammonium nitrate and urea. In combination with organic
substances, e.g. urea, pure ammonium nitrate is explosive, if critical
temperatures are reached during repair work (welding, grinding, filing).
The UAN salt is water-soluble, i.e. by thoroughly washing down the device
or the parts to be repaired with water, this danger can be removed.
11

•The device therefore needs to be thoroughly cleaned with water before any
repair or maintenance work is carried out!
•Always carry out any service, maintenance and repair work or the elimination of
malfunctions while the drive is switched off and the engine is standing still.
Regularly check nuts and bolts for tight seat and retighten if necessary!
•When carrying out maintenance work on the lifted device, always secure by
means of suitable support elements!
•Used oil must be duly disposed of!
•When carrying out electric welding work on the tractor and on the mounted
device, disconnect cables on the generator and the battery cable!
•Spare parts must at least comply with the technical requirements specified by
the device manufacturer. This can for instance be ensured if you only use
original spare parts.
12

2 WARNING PICTOGRAMS
Before using the device for the first time, read and
follow the operating instructions and safety
information!
Before leaving the tractor and before carrying out
any maintenance and repair work, remove the
ignition key and wait until all mobile parts have
come to a complete standstill!
Never climb into the tank!
Danger of intoxication!
It is forbidden to stay underneath unsecured loads!
Maintain safe distance!
It is forbidden to stay in the swivelling range of
mobile parts!
Maintain sufficient distance to high-voltage lines!
13

3 INITIAL INSTALLATION
3.1 Power supply
On new tractors that are equipped with a power supply socket according to DIN
9680, it is possible to plug the operator panel’s power supply cable directly into
the DIN-socket.
On older tractors that are not equipped with a DIN-socket, the battery cable
included in the supply is required and needs to be directly connected with the
battery. It is imperative that you pay attention to the correct polarity when making
the terminal connections! The two cable terminals are marked with + and -. The
terminal with the integrated 20 Ampere fuse must be connected to the + terminal.
Make sure that contacts are clean!
(It is not possible to establish the power supply via the so-called cigar lighter, as it
is not able to provide the required amperage).
3.2 Installing the operator panel
The operator panel (Müller Spray-Control S, Müller Uni-Control S, Müller Uni-
Control S with chip card, Müller LBS-Control, ACT, Basic-Terminal, TeeJet 844E,
TeeJet 834 or others) is installed by means of the assembly kit enclosed in the
supply.
With this kit, it is possible to mount the operator panel without any problems in the
driver’s visual and operating range. If necessary, appropriate fastening holes need
to be drilled. When drilling these holes, you need to pay attention that no electric
or liquid-carrying lines are damaged.
The operator panel is supplied with power via the battery cable enclosed in the
supply. This cable is run from the tractor cabin to the battery. The operator panel’s
cable can then be connected with the mounted battery cable by means of a plug-
and-socket connection.
The device is connected with the operator panel via the loom of cables on the
device. This loom is passed through the eye on the drawbar, run to the cabin and
connected.
It is imperative that you follow the operating and installation instructions for the
operator panel included in the supply that also contain further installation
information!
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3.3 Hitching up
−by setting the parking hydraulic support, bring the device into a horizontal
position
−Adjust the tractor’s yoke to the height of the drawbar eye
−If it is not possible to optimally hitch up the device using the tractor’s adjustment
possibilities, you can adjust the height of the end piece incl. drawbar eye at the
fastening flange (see illustration 3.3.1)
−Hitch up the device and ensure that the bolt on the yoke is properly locked.
−hydraulic support by adjusting the pump move up and bring the device into a
transport position (see illustration 3.3.2)
−Release parking brake by unscrewing the crank (see illustration 3.3.3)
−Attach brake blocks to the machine.
−Unhitch in reverse order.
illustration 3.3.1 illustration 3.3.2
illustration 3.3.3
•Remove the device only with one completely emptied tank!
•Before parking the machine on the support foot, secure it against
rolling away!
3.4 Mounting the drive shaft
−Always first mount the drive shaft on the device side.
−Push the drive shaft onto the journal bearing until the locking pin engages.
−Test whether the locking pin has engaged by pushing and pulling.
−Mount the drive shaft on the tractor side following the same procedure and
ensure it has locked correctly.
15

−Secure drive shaft guard against revolving by means of chains both on the
tractor and on the device side.
−The max. power take-off shaft speed of 540 rpm may not be exceeded.
3.5 Mounting the hydraulic lines
Proceed as follows when connecting a device without electrohydraulic control:
−The two hydraulic lines that are marked with the same cap (to extend and
retract the boom BLUE) are connected to a double-acting control unit (da)
−The hydraulic line that is marked differently (to lift and lower the boom RED) is
connected to a single-action control unit (sa)
Proceed as follows when connecting a device with electrohydraulic control:
−The RED hydraulic line (delivery line/feed line) is connected to the tractor’s
single- or double-acting control unit.
−The differently coloured hydraulic line is, if possible, connected to the free return
line to prevent the hydraulic oil from heating.
When disconnecting the hydraulic lines, the plug-and-socket connections must be
closed with the protective caps. Make sure that the plug-and-socket connections
remain clean!
3.6 Establishing the electric connection
„HYDRAULICS“ (only for electrohydraulic control).
Also connect the cables for the boom section circuit and the computer control with
the operator panel in the tractor.
Establish the power supply for the operator panel as described under the heading
„Power supply“.
3.7 Function of the compressed air brake system
According to Motor Vehicle Safety Standards, trailed farming devices with a
maximum permissible weight above 3.5 t may not be operated without service
brake.
The Albatros-pesticide sprayers for the German market (except Albatros 20/..) are
as a standard equipped with a
two-circuit compressed air brake system.
16

When hitching up the device, make sure
that the two airlines are connected.
First connect the yellow line (control line)
with the corresponding connection on the
tractor.
Then connect the red line (tank line).
Before driving away, ensure that the
brake-pressure regulator (middle of the
device) is set according to the device’s
degree of filling. (see illustration 3.7.1)
Illustration 3.7.1
Spray mixture tank filled = full load 1/1
Spray mixture tank partially filled = half load 1/2
Spray mixture tank empty = empty 0 release X
When the brake line is uncoupled, the pressure in the tank causes the device to
be braked automatically.
However, while it is parked, the device must always be secured against rolling
away by means of the parking brake, as the braking effect may gradually fade due
to possible leaks.
If the device is to be manoeuvred in an unhitched state or with uncoupled brake
lines, it is possible to release the brake via the brake-pressure regulator.
If the device is parked on sloping ground, wheel chocks must be used to
additionally secure it against rolling away.
3.8 Track widths
If nothing to the contrary has been specified on conclusion of contract, the track
width of the trailed pesticide sprayers LEMKEN-Albatros 20/.., 30/.. and 40/.. is set
to 1.50 m at the factory. However, it is possible to subsequently change the track
width to 1.80 m by exchanging the wheels, i.e. left wheel to the right, right wheel
to the left, and turning the rims.
If nothing to the contrary has been specified on conclusion of contract, the track
width of the trailed pesticide sprayers LEMKEN-Albatros 50/.. and 60/.. is set to
1.80 m at the factory.
17

3.9 Drawbar versions
It is possible to equip the trailed sprayer with two different drawbars: as a standard
the height-adjustable yoke drawbar is installed. A yoke drawbar steering system
(tracking system) is available as special equipment.
It is possible to equip both drawbar versions with a spring borne drawbar end
piece.
3.10 Control of the yoke drawbar steering system
The yoke drawbar steering system has three functions:
•track-true tracking
•manual tilt control
•automatic centre locking
These are controlled electrohydraulically by means of the control unit in the
tractor. Control can either be automatical or manual.
(Caution by manual actuation the drawbar steering, it is forbidden to stay in the
swivelling range of mobile parts!)
When driving with load on public roads, the yoke drawbar steering system must
be locked!
18

4 INITIAL START-UP
As the manufacturer renders the device ready for operation and checks its
functions prior to delivery, the purchaser need not take any action with regard to
device set-up. The operator panel has also been matched to the respective
device.
However, the purchaser should acquaint himself with the device by means of the
operating instructions and test all functions as described before using the device
for the first time.
ATTENTION! After the device has been in use for 10 hours, check the
tight seat of all screws and screw fastenings and
retighten if necessary! The device should for the first
time always be used with water. Do not use any pesticide!
19