LEMKEN EuroLux 800 TL User manual

Operating Manual
Mounted fieldsprayer
EuroLux
TL und TLE
- EN -
Safety is our Concern!
Part No.175 4036
1/04.06
LEMKEN GmbH & Co. KG
Soil cultivation and sowing
Work Alpen
Weseler Straße 5, D-46519 Alpen /
Postfach 11 60, D-46515 Alpen
Tel. [phone], Fax [phone]
E-Mail: [e-mail],
Internet: http://www.lemken.com
Plant protection
Work Hetzerath
Bahnhofstraße 65, D-54523 Hetzerath
Postfach 11 17, D-54523 Hetzerath
Tel. [phone], Fax [phone]
E-Mail: [e-mail]
Internet: http://www.lemken.com

1
Dear customer!
We would like to thank you for your 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 will have 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 at-
tention 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 manufac-
turer.
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 fol-
lowing 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 op-
eration and damage caused by using spurious parts!

Definded Use
2
DEFINDED USE
Please familiarise yourself with the LEMKEN-implement and its
operations before putting the implement to work. Therefore use
this instruction book with the ’General Health- and Safety precau-
tions’!
Your LEMKEN-field sprayer has been designed purely for the spraying of insec-
ticides, fungicides, herbicides in the form of suspensions, elmusions and mix-
tures as well as of liquid fertilizers for the agricultural use.
The relevant accident prevention advices as well as the plant protection rules as
well as the generally accepted safety technical, working, medical and road traf-
fic rules must be adverted too!
The LEMKEN-implements have been designed purely for the agricultural 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-implement may only be operated, maintained and repaired by
such persons who have been made acquainted with it and who have been ad-
vised 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.
CONTENTS
Definded Use....................................................................................................................2
Contents...........................................................................................................................2
1 Effects of certain pesticides on the field sprayer..................................................7
2 Safety Instructions....................................................................................................8
3 Warning Stickers.....................................................................................................14
3.1 General Instructions....................................................................................................14

Contents
3
3.2 Meaning of the Stickers...............................................................................................14
4 Tractor preparations...............................................................................................17
4.1 Power supply ...............................................................................................................17
4.2 Power sockets..............................................................................................................17
4.3 Speed sensor...............................................................................................................18
4.4 Installation of the operating terminal or the on-board computer............................18
4.5 PTO-shaft......................................................................................................................19
4.6 Hydraulic equipment ...................................................................................................19
4.7 Three-point linkage......................................................................................................19
4.8 Axle Loads....................................................................................................................20
5 Mounting and dismounting the implement...........................................................21
5.1 Mountin to the tractor..................................................................................................21
5.2 Dismounting from the tractor.....................................................................................22
6 Device description ..................................................................................................23
6.1 General .........................................................................................................................23
6.2 Symbols and their meaning........................................................................................24
6.2.1 Distribution valve......................................................................................................24
6.2.2 Agitator.....................................................................................................................24
6.2.3 Chemical inductor.....................................................................................................24
6.2.4 General.....................................................................................................................25
6.3 Device frame ................................................................................................................25
6.3.1 General.....................................................................................................................25
6.3.2 Supports...................................................................................................................25
6.3.3 Transport rollers .......................................................................................................26
6.4 Tank ..............................................................................................................................26
6.4.1 Main tank..................................................................................................................26
6.4.2 Hand washing tank...................................................................................................27
6.4.3 Water tank................................................................................................................27
6.5 PARASOL - suspension and spray boom..................................................................28
6.5.1 PARASOL suspension .............................................................................................28

Contents
4
6.5.2 Spray boom..............................................................................................................30
6.5.3 SP & SPH boom.......................................................................................................30
6.5.4 SH boom...................................................................................................................31
6.5.5 Electric motor slope compensation with centre display ............................................32
6.6 Setting the cradle frame..............................................................................................32
6.7 Flow diagram series (without chemical inductor).....................................................34
6.8 Flow diagram with chemical inductor........................................................................35
6.9 Induction side ..............................................................................................................36
6.10 Pressure side...............................................................................................................37
6.11 Chemical inductor .......................................................................................................38
6.11.1 ProFlow nozzle for chemical inductor ...................................................................40
6.12 Electric remote control Elcomat-PLUS......................................................................40
6.13 Operating unit for EuroLux TL....................................................................................42
6.14 Operation with constant-pressure fittings (EuroLux TL) .........................................43
6.15 Pumps...........................................................................................................................44
6.15.1 Pumps with air chamber........................................................................................45
6.16 Agitators.......................................................................................................................46
6.17 Filter..............................................................................................................................47
7 Operation .................................................................................................................48
7.1 General .........................................................................................................................48
7.2 Valve switch positions ................................................................................................48
7.2.1 General.....................................................................................................................48
7.2.2 Selection valve .........................................................................................................49
7.2.3 Stop valve clean water .............................................................................................50
7.2.4 Stop valve injector....................................................................................................51
7.2.5 Distribution valve......................................................................................................52
7.2.6 Changeover valve.....................................................................................................54
7.3 Filling the main tank with water..................................................................................55
7.3.1 General.....................................................................................................................55
7.3.2 Filling via the dome cover.........................................................................................55

Contents
5
7.3.3 With filling hose ........................................................................................................56
7.3.4 Via filling connection.................................................................................................56
7.4 Filling the main tank with pesticides .........................................................................57
7.4.1 Filling via the dome cover.........................................................................................57
7.4.2 Via the chemical inductor .........................................................................................58
7.5 Spraying .......................................................................................................................59
7.5.1 General.....................................................................................................................59
7.5.2 Spraying...................................................................................................................59
7.6 Filter cleaning ..............................................................................................................60
7.6.1 General.....................................................................................................................60
7.6.2 Suction filter..............................................................................................................60
7.6.3 Central pressure filter...............................................................................................60
7.6.4 Line- and nozzle filters..............................................................................................60
7.7 Machine cleaning.........................................................................................................61
7.7.1 General.....................................................................................................................61
7.7.2 System cleaning with empty spray tank....................................................................63
7.7.3 System cleaning with full/partly filled tank ................................................................63
7.8 Machine emptying .......................................................................................................64
7.9 Volumetric measurement and calibration..................................................................65
7.9.1 General.....................................................................................................................65
7.9.2 Checking the nozzle output......................................................................................65
7.9.3 Vehicle speed determination....................................................................................66
7.9.4 Calibration with controlling computer........................................................................66
8 Maintenance.............................................................................................................67
8.1 Maintenance intervals and work to be performed ....................................................67
8.1.1 Daily .........................................................................................................................67
8.1.2 After operating hours................................................................................................68
8.1.3 As required...............................................................................................................68
8.1.4 Monthly.....................................................................................................................68
8.1.5 Annually....................................................................................................................68
8.2 Pump maintenance and repairs..................................................................................69
8.2.1 Protection against frost.............................................................................................69
8.2.2 Diaphragm replacement ...........................................................................................69

Contents
6
8.3 Winter care...................................................................................................................72
9 Troubleshooting......................................................................................................73
9.1 General .........................................................................................................................73
9.2 Pump.............................................................................................................................73
10 Technical data .........................................................................................................76
10.1 Dimensions and weights.............................................................................................76
10.1.1 Basic device and boom.........................................................................................76
10.1.2 Container ..............................................................................................................77
10.2 Liquid system...............................................................................................................77
10.3 Pumps...........................................................................................................................78
10.4 Pressure gauge............................................................................................................78
10.5 Electronic pressure indicator (SPRAYDOS)..............................................................78
10.6 Filter system.................................................................................................................79
10.7 Technical residual quantities......................................................................................79
10.8 Matrices........................................................................................................................80
11 Noise, Airborne Sound ...........................................................................................82
12 Disposal ...................................................................................................................82
13 Notes ........................................................................................................................82
14 ACCESSORIES........................................................................................................82
Index ...............................................................................................................................83
EC Certificate of Conformity ........................................................................................85

Effects of certain pesticides on the field sprayer
7
1 EFFECTS OF CERTAIN PESTICIDES ON THE FIELD SPRAYER
At the time of manufacture of the machine, the manufacturer is aware of some of
the authorised pesticides and mixtures which can have damaging effects on the
field sprayer materials. These are usually solvent-based pesticides and mixtures
such as BETANAL with TRAMAT, (BETANAL-TANDEM), ELANCOLAN, ILOXAN,
LASSO, MUDECAN, RACER, RIPCORD 40, TERIDOX, STOMP, liquid manure
(AHL) but also
Mixtures with AHL: ALANDAN, or liquid NEXID 100.
Damaging effects can also occur with the subsequent products of the above mate-
rials and mixtures.
IMPORTANT! For mixtures not “covered” by any equipment application, it is rec-
ommended to test the materials mentioned above with several
hours of submersion tests before starting work. Pesticides or other
substances which tend to harden or stick must not be used with
the device.
ATTENTION! The usage instructions of the respective pesticide manufacturer
must be strictly followed before starting work.
The equipment parts which can be affected by the pesticides mentioned above
are usually hoses, spray lines, seals, tanks and pump diaphragms.
If hoses become particularly soft or seals or diaphragms swell, these are signs of
damaging effects. The affected parts must then be replaced immediately. These
damaging effects can often be avoided if the equipment is intensively flushed im-
mediately after dispensing the materials and mixtures shown above (e.g. rinsing
and disposal of the technical residues on the field).

Safety Instructions
8
2 SAFETY INSTRUCTIONS
General Safety Instructions
Before using the machine, always check both it and the tractor for roadworthi-
ness and operational safety!
As well as the notes in these instructions the operator is advised to comply with
the generally applicable safety at work regulations and those relating to use of
the public highway!
When driving on public roads with a raised machine the lifting control lever
should be locked against unintentional lowering!
The fitted warning and advisory plates give important information for safe op-
eration; adhering to these increases your own safety!
When using public roads adhere to applicable traffic rules!
The operator should familiarise him-/herself with all controls and their functions
before starting work. During work could be too late!
The clothing of the operator should fit tight. Avoid wearing any loose clothing!
To avoid danger of fire keep the implement clean!
Before beginning to drive check surroundings area (children)!
Sitting or standing on the implement during operation or during transport is not
permissible.
Attach implements as advised and only to the stipulated positions!
Special care should be taken when the implement is coupled to or uncoupled
from the tractor.
When coupling or uncoupling the implement bring the supporting stands into
the corresponding position (standing safety)!
Fit weights only to the fixing points provided for those purposes!
Adhere to the maximum permissible axle loads, total weights and transport
width!

Safety Instructions
9
Fit and check transport gear, road lights and warning guards!
The release ropes for quick coupler latches should hang freely and in the low-
ered position must not release the quick coupling by themselves.
Never leave the driver's seat whilst in motion!
Handling behaviour, steerability and braking are influenced by mounted imple-
ments, trailers and ballast weights. Check for sufficient steerability and braking!
When driving round bends note the width of the machine and/or changing cen-
tre of gravity of the implement.
Put implement into operation only when all guards are fixed in position!
Never stay or allow anyone to stay within the operating area!
Never stay in the turning and slew area of the implement!
Do not operate any hydraulic controls while anybody is in the operating area!
On all pivoting parts actuated by power assistance (e.g. hydraulics) exists dan-
ger of injury by bruising and crushing!
Before leaving the tractor lower the machine to the ground. Apply the parking
brake, stop the engine and remove the ignition key!
Do not allow anybody between the tractor and implement if the parking brakes
are not applied!
Swing attachment arm to transport position and secure!
Attached Implements
Before mounting or dismounting implements on/from the three-point linkage,
move the raise / lower control to the position at which accidental raising or low-
ering cannot take place!
In the case of three-point linkage mounting, ensure that the tractor balls and
the mounting pins of the implement are of the same category!

Safety Instructions
10
There is the risk of injury from pinch and shear points in the three-point linkage
area!
When operating the external lift controls for the three-point linkage, do not
stand between the tractor and implement!
Always ensure sufficient lateral limitation for the three-point linkage of the trac-
tor in the transport position of the implement!
When driving on roads with the implement raised, the raise/lower control must
be locked to prevent lowering!
Hydraulic Equipment
The hydraulic pipes are under pressure!
When connecting hydraulic rams, the pipes must be connected as directed!
Always release hydraulic pressure from both tractor and implement before
coupling!
When connecting hydraulic pipes to the tractor ensure that incorrect use is
avoided. If the connections are reversed, the opposite function is carried out
(e.g. raising/lowering) and there is a risk of accidents!
Regularly check the hydraulic pipes and replace them in the event of damage
or signs of ageing. The replacement pipes must comply with the technical
specification as laid down by Lemken!
When searching for leaks appropriate aids should be used because of the dan-
ger of injury!
Hydraulic oil escaping at high pressure can penetrate the skin and cause seri-
ous injury! When injured see a doctor immediately! Danger of infection!
Before working on any hydraulic equipment - lower all implements/attachments,
release hydraulic pressure where possible and switch off the tractor engine!

Safety Instructions
11
Maintenance
Repair-, maintenance- and cleaning operations as well as adjustments and
remedy of function faults should principally be conducted with engine stopped
and brakes applied. Remove ignition key!
Check and tighten nuts and bolts regularly!
When conducting maintenance work on a lifted implement always place suit-
able supports underneath!
For replacing any tools with cutting edges always use suitable tools and gloves!
Dispose of old oils, grease and filters as prescribed by law.
Before working on the electric gear disconnect battery cables!
When conducting electrical welding operations on the tractor or on the mounted
implement remove cable from the generator and the battery!
Any spare parts fitted must meet with the implement manufacturer's fixed tech-
nical standards! This is for example ensured by using genuine spare parts!
To avoid danger of explosion only use nitrogen for filling up gas tanks!
Power Take-Off Shaft Operation
Only drive shafts stipulated by the manufacturer may be used!
Both halves of the protective tube of the PTO shaft must be anchored to pre-
vent rotation - and be in working order!
At PTO shafts always see to the advised tube overlapping in transport- and
working position!
Fit and remove the PTO shaft only when the power take-off drive is discon-
nected, the engine is switched off and the ignition key has been removed!
Always ensure the correct assembly and safety of the PTO shaft!

Safety Instructions
12
Prevent PTO guard from spinning by fixing the provided chain to a nearby
static part!
Before engaging the power take-off drive, ensure that the selected speed of the
tractor's power take-off shaft matches the permissible speed of the power har-
row!
When using the speed-related PTO shaft take into account that the PTO speed
depends on the driving speed and that the turning direction is reversed when
driving backwards!
Before engaging the power take-off drive, ensure that nobody is standing in the
hazard area of the power harrow!
Never connect the power take-off shaft when the engine is switched on!
When working with the power take-off shaft, nobody must stand in the area of
the rotating power take-off shaft.
Always disengage the power take-off drive if excessive angular displacements
occur.
Caution: After disengaging the power take-off drive, the rotors take a few sec-
onds to come to rest. Do not approach the power harrow too closely during this
time. Work must not be carried out upon it until it comes to a complete stand-
still!
Clean, lubricate or adjust the appliance driven by the power take-off shaft only
when the power take-off shaft is disconnected, the engine is switched off and
the ignition key has been removed!
Retain the uncoupled PTO shaft on the mount provided!
After removing the PTO shaft replace the screw-on guard over the tractor PT0.
In the event of damage, rectify it prior to continuation of work.

Safety Instructions
13
Plant protection
As well as the general safety and accident prevention regulations for tractors, ma-
chine and work process which always apply, the recommendations and instruc-
tions of the pesticide manufacturers must be observed.
- Wear protective clothing
- Pay attention to warnings
- Observe metering, application and cleaning regulations
Do not open pressurised lines
Only suitable hoses for the maximum permitted operating pressure which also re-
sist the chemical, mechanical and thermal load are permitted as replacement
hoses. As a matter of principle, only suitable hose clamps must be used during
installation. The regulations for marking and connecting hoses must be observed.
Repair work in the spray tank must only be done after thorough cleaning and while
wearing a respirator. For safety reasons, a second person outside the tank must
supervise the work.
The following must be observed for the repair of spray equipment which is used
for liquid fertilisation with urea ammonium nitrate solutions:
Residues of urea ammonium nitrate solutions can form salt on or in the equipment
due to evaporation: This produces pure ammonium nitrate and urea. In pure form,
ammonium nitrate in combination with organic substances e.g. urea is explosive if
the critical temperatures are reached during repair work (e.g. welding, grinding,
filing). The salt of the urea ammonium nitrate solution can be dissolved in water;
this means that this danger is resolved by thorough washing of the machine or
parts for repair with water. Therefore, always clean the machine thoroughly with
water before a repair.

Warning Stickers
14
3 WARNING STICKERS
3.1 General Instructions
The LEMKEN implement is equipped with all features to ensure safe operation.
Where potential danger areas of the implement can not be fully safeguarded,
warning stickers are fitted which draw attention to these. Damaged, lost or un-
readable warning stickers must be replaced immediately. The stated part numbers
are used as order numbers.
3.2 Meaning of the Stickers
Familiarise with the meaning of the stickers. The following descriptions inform
about them in detail.
WARNING: Read and adhere to this instruction book and these
„General Health- and Safety precautions„ before
putting the implement to work!
390 0555
WARNING: Shut off engine and remove key before performing
maintenance or repair work!
390 0509

Warning Stickers
15
WARNING: Keep well clear of the working and
swinging area of the implement!
390 0510
WARNING: Pinch point!
390 0506
ATTENTION: Danger of poisoning –Never climb into the tank
ATTENTION: Do not open or remove safety covers when the mo-
tor is running

Warning Stickers
16
ATTENTION: Keep a sufficient distance away from electric
high-voltage lines

Tractor preparations
17
4 TRACTOR PREPARATIONS
4.1 Power supply
For new tractors which are fitted with a
socket according to DIN 9680, the power
supply cable of the operating terminal or
the on-board computer can be directly
connected to the DIN socket. For older
tractors without a DIN socket, the supplied
battery connection cable is required which
must be directly connected to the tractor
battery.
Pay strict attention to the correct polarity when making the connection. The two
wires of the cable are marked with + (brown) and –(blue). The + or brown wire
with the integrated 25 Ampere fuse must be connected to the + (positive) terminal
of the battery. Pay attention to making good contacts. (It is not possible to connect
the power supply using the cigar lighter as this cannot provide the necessary cur-
rent intensity).
4.2 Power sockets
The following power sources must be available on the tractor for the electrical
consumers of the machine.
Consumer Volts Power socket
Lighting system 12 DIN-ISO 1724
Operating terminal 12 DIN 9680
SPRAYDOS with TRAIL-Control 12 DIN 9680
The power supply tolerance range is between 10 V and 15 V. Overvoltages and
undervoltages result in operating faults and can in certain circumstances destroy
electric and electronic components.
Furthermore, the power supply must have at least a 25 A fuse.

Tractor preparations
18
4.3 Speed sensor
At the EuroLux TLE the speed sensor is to be mounted on the tractor. Please see
also the operating instructions of the on-board computer Spraydos (section „Sen-
sor X“). The speed signal of the tractor (adapter cable) can also be used if pre-
sent.
4.4 Installation of the operating terminal or the on-board computer
Installation of the operating terminal or the on-board computer is done using the
supplied tractor installation kit. Using this, the operating terminal or the on-board
computer can be easily located in the driver’s field of view and work area. If nec-
essary, appropriate holders must be provided. When making the necessary drill
holes, ensure that no electrical cables or liquid conducting lines are damaged. The
operating terminal or the on-board computer power supply is done using the sup-
plied tractor installation kit. This is laid from the tractor cab to the battery. The op-
erating terminal or on-board computer cable can then be connected to the in-
stalled battery connection cable using a plug connector. Connecting the machine
to the operating terminal or on-board computer is then made using the connection
cable on the machine side. This is routed to the tractor cab and connected. The
supplied operating and installation instructions for the operating terminal or on-
board computer with more information about installation must be strictly observed.