LEMKEN GIANT 1000 User manual

Operating Instructions
System Trac
GIANT 1000
Safety is our concern!
Part No. 175 1399
GB-4/06.01
LEMKEN GmbH & Co. KG
Weseler Straße 5, D-46519 Alpen / Postfach 11 60, D-46515 Alpen
Telefon [phone], Telefax (0 28 02) 81-220
eMail: [e-mail], Internet: http://www.lemken.com

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Dear customer!
We would like to thank you for the confidence you have in us when buying this
implement.
The advantages of the implement will be shown, only, when operated and used
with due care.
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.
We hope you will understand that conversion work, 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:
No.:
Please think of using genuine Lemken spare-parts, only. Spurious parts influence
the function of the implement negatively, show a shorter lifetime and increase in
nearly all cases the effort in maintenance.
We hope you will understand that LEMKEN can not take on the guarantee for
operational disadvantages and damage being caused by using spurious parts!

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DEFINED USE
•Please familiarise yourself with the LEMKEN GIANT and its
operations before putting the implement to work. Therefore use this
instruction book with the „General Health- and Safety precautions“!
•The LEMKEN GIANT has 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 GIANT 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 advice as well as the generally accepted
safety technical, working, medical and road traffic rules should be adhered to!
BRAKES
•Without own braking system the GIANT may only be used in the field, if the
combination (tractor with coupled GIANT) is able to reach the prescribed
braking deceleration and the tractor death weight is more than 12.000 kg.
•Without own braking system it is only allowed to park the GIANT on absolutely
level ground with folded-out and fully lowered wing sections and chocks in front
and behind each wheel.
•Without own braking system it is not allowed to transport the GIANT on public
roads.

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CONTENT
DEFINED USE ..................................................................................................................2
CONTENT.........................................................................................................................3
1. TABLE OF VARIATIONS............................................................................................6
2. SAFETY INSTRUCTIONS .......................................................................................... 7
3. WARNING STICKERS..............................................................................................10
3.1 General Instructions ............................................................................................ 10
3.2 Meaning of the stickers ....................................................................................... 10
4. PREPARATION OF TRACTOR................................................................................11
4.1 Tyres......................................................................................................................11
4.2 Hitch Coupling......................................................................................................11
4.3 Brake-System ....................................................................................................... 11
4.4 Hydraulic Assembly.............................................................................................11
4.5 Axle loads ............................................................................................................. 11
5. ATTACHING AND DETACHING THE IMPLEMENT................................................12
5.1 Attaching to the tractor........................................................................................ 12
5.2 Detaching from the tractor .................................................................................. 13
6. FOLDING OF THE WING SECTIONS...................................................................... 14
6.1 Folding-in of the wing sections.......................................................................... 14
6.2 Folding-out of the wing sections........................................................................ 15
7. PENDULUM BALANCE............................................................................................16
8. BRAKING ASSEMBLY.............................................................................................17
8.1 Double-hose-air-pressure brake-system........................................................... 17
8.2 Parking brake........................................................................................................17
9. TYRES ......................................................................................................................18
10. TRANSPORT ON PUBLIC ROADS ...................................................................... 19

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11. ADJUSTMENTS - TERRADISC GIANT ................................................................ 20
11.1 Adjustment of the Three-Point Linkage..........................................................20
11.2 Horizontal Position of the sections.................................................................20
11.3 Depth Adjustment of the Tines........................................................................21
11.4 Depth Adjustment of the Hollow Discs...........................................................21
11.5 Share Position...................................................................................................22
11.6 Shearbolt Device...............................................................................................22
11.7 Depth guiding of the Terradisc sections.........................................................23
11.7.1 Depth wheels as outer depth guiding...................................................... 23
11.7.2 Draw links as inner depth guiding............................................................. 23
11.8 Rollers................................................................................................................24
11.9 Packer roller scrapers.......................................................................................24
11.10Straw harrow STR 80 ........................................................................................25
12. CHANGING OF THE SECTIONS ..........................................................................26
12.1 Top link............................................................................................................... 26
12.2 Drawbar.............................................................................................................. 26
12.3 Horizontal position of the implement sections .............................................. 27
12.4 Parallel position of the implement sections...................................................27
13. ADJUSTMENTS - TERRATILTH GIANT...............................................................28
13.1 Pressure Load on the front Crumbling Rollers..............................................28
13.2 Pressure Load on the rear Rollers...................................................................28
13.3 Pressure distribution on the rear Rollers ....................................................... 28
13.4 Adjustments of the Cutting Bar.......................................................................29
13.4.1 Adjustments by means of an adjuster screw.................................................29
13.4.2 Hydraulic cutting bar adjustment...................................................................29
13.5 Working Depth Adjustment of the Tines.........................................................30
14. BRAKING DEVICE ................................................................................................31
14.1 Connection of braking hoses........................................................................... 31
14.2 Adjusting the brake........................................................................................... 31

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14.3 Maintenance of the Braking Device................................................................. 31
14.3.1 De-watering valve .........................................................................................31
14.3.2 Greasing........................................................................................................31
14.3.3 Brake-shoe linings.........................................................................................31
14.3.4 Filter..............................................................................................................31
14.4 Disconnection of the brake hoses................................................................... 31
15 MAINTENANCE ......................................................................................................32
15.1 System trac GIANT............................................................................................ 32
15.2 Terradisc sections............................................................................................. 33
15.3 Terratilth sections.............................................................................................33
16. LIGHTING EQUIPMENT AND WARNING BOARDS............................................34
17. NOTES...................................................................................................................34
18. NOISE, AIRBORNE SOUND................................................................................. 34
19. TECHNICAL DATA................................................................................................34
20. PRODUCT REGISTRATION / GUARANTEE........................................................ 34
EC CERTIFICATE OF CONFORMITY............................................................................ 36

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1. TABLE OF VARIATIONS
System trac
Brake system: Double-hose-air-pressure brake-system
Drawbar connection: Drawbar eye D40 (D48)
Drawbar eye D50 (D58)
Tyres: 500/45x22.5
Twin wheels 405/70-20 TL
Terradisc sections
Depth guiding: Depth wheels for outer depth guiding
Draw link for inner depth guiding
Rollers: Tube bar roller D400
Tube bar roller D540
Double roller Tube/Flat D400/400
Double roller Tube/Tube D400/400
Packer roller ZPW 500
Outer discs: with shearbolt device, folding
with overload safety device, folding
Hollow discs: with shearbolt device
with overload safety device
Spring harrow: with 48 harrow units
Terratilth sections
Cutting bar adjustment: by adjuster screw
hydraulic
Crumbling rollers: Flat bar 2xD270
Tube bar 2xD330
Rollers: Tube bar roller D400
Crosskill roller D400
Track looseners: FSÜ with duck-foot shares.
Carrier for track looseners: 1 pair

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2. SAFETY INSTRUCTIONS
•Read and adhere to these "General Health- and Safety
precautions" before putting your implement into operation!
•Before use, always check both the machine and the tractor for
roadworthiness and operational safety.
•Adhere to the general rules of health- and safety precautions as
well as the advice in this instruction manual!
•The implement obtained by you has been designed for the exclusive use of
cultivating agricultural soil!
•Any use beyond the one stipulated above is no longer considered as defined
use. The manufacturer does not accept any responsibility for damages
resulting from this; the operator himself carries the full risk!
•Under "defined use" the manufacturer's prescribed operation-, maintenance
and repair conditions are to be adhered to!
•The implement 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 advice as well as further generally
accepted safety technical, working, medical and road traffic rules should be
adhered to!
•Any damages resulting from unauthorised changes to the machine rule out the
responsibility of the manufacturer!
•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
operation; adhering to these increases your own security!
•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 advised devices!
•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 devices into
the corresponding position (standing safety)!
•Fit weights always as advised to the fixing points provided for that purposes!
•Adhere to the maximum permissible axle loads, total weights and transport
measurements!
•Fit and check transport gear, traffic lights and warning guards!

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•The release ropes for quick coupler should hang freely and in the lowered
position must not release the quick coupling by themselves.
•Never leave drivers seat whilst in motion!
•Moving behaviour, steerability and braking are influenced by mounted
implements, trailers and ballast weights. Check sufficient steerability and
braking!
•When driving round bends note the width of the machine and/or changing
centre 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 slewing area of the implement!
•Do not operate any hydraulic controls while anybody is in the operating area!
•On all pivoting parts actuated by foreign powers (e.g. hydraulics) exists danger
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!
•Lock track markers in transport position!
Mounted implements
•Before coupling and uncoupling implements on/from the three-point linkage,
move the raise / lower control to the position at which unintentional raising or
lowering cannot take place!
•In the case of three-point linkage, ensure that the tractor linkage balls and
implement pins are of the same category.
•There is 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
tractor, in the implement transport position.
•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 services, the pipes must be connected as directed.
•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!

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•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.
•Hydraulic oil escaping at high pressure can penetrate the skin and cause
serious injury!
•Before working on any hydraulic equipment - lower all implements/attachments,
release hydraulic pressure where possible and switch off the tractor engine.
Tyres
•When working on the tyres make sure that the implement has been placed on
the ground safely and that it is secured by chocks against unintentional rolling!
•Fitting tyres requires knowledge and special tools!
•Repairwork on tyres may only be conducted by trained staff and with suitable
tools!
•Check air pressure regularly and adhere to the advised air pressure!
Brakes
•Check function of brakes before each drive!
•The braking systems must be checked regularly!
•Repairwork on brakes may only be conducted by trained staff and with suitable
tools!
Maintenance
•Whenever possible, only carry out work on the implement when it is lowered
onto the ground with the PTO drive disengaged, and the tractor engine at rest
with the ignition key removed.
•Always ensure safety when working on a raised machine by the use of suitable,
secure supports.
•Regularly check all nuts and bolts, and tighten these if necessary.
•Dispose of oil and grease properly.
•In the event of welding being required on the implement ensure that, if a tractor
is attached, its battery/alternator is disconnected.
•Only use genuine or approved replacement parts when repairing the
implement. The warranty could be declared null and void if this is not done.

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3. WARNING STICKERS
3.1 General Instructions
The LEMKEN Giant 1000 is equipped with all devices ensuring a safe operation.
Where danger spots of the implement could not be safeguarded sufficiently,
warning stickers are fitted which point to the remaining danger spots.
3.2 Meaning of the stickers
WARNING: Read and adhere to this instruction book and these
„General Health- and Safety precautions, before
putting the implement to work!
WARNING!
Keep well clear of the working and swinging
area of the implement.
WARNING!
Pinch point.
WARNING!
Keep distance to the folding area of the
implement.

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4. PREPARATION OF TRACTOR
4.1 Tyres
Ensure that all tyres- especially the rear ones - are at identical pressure. For
heavy conditions it may be necessary to add wheel weights and/or water ballast.
(See Manufacturer's Instructions).
4.2 Hitch Coupling
The system trac GIANT must only be used with tractors equipped with a drawbar
clevis. This must be capable of supporting a 20 KN (2,0 t) load both downwards
and upwards.
The allowed supporting at the is at its highest when the is adjusted to the
shortest position. The must be secured in this position. See tractor
manufacturer's instructions.
4.3 Brake-System
The tractor must be equipped with a double-hose-air-pressure brake-system.
4.4 Hydraulic Assembly
A double acting and a single acting tractor spool valve are required for the system
trac GIANT.
4.5 Axle loads
During reversing on headlands the rear axle of the tractor will be relieved by
approximately 18 kN (1,8 t). The relief of the load on the rear axle must be
considered especially when working in hilly conditions.

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5. ATTACHING AND DETACHING THE IMPLEMENT
5.1 Attaching to the tractor
The system trac GIANT must be parked,
only, with folded in wing sections. The
tractor must be equipped with a which is
designed for upwards and downwards loads
of 20 KN (2,0 t).
The drawbar eye (2) of the system trac
GIANT will be connected to the (1) of the
tractor.
The drawbar eye (2) will be adjusted by the
jack (5), so that it will be coupled easily and
the wear protection washer (VS) out of
plastic is fitted above the drawbar eye.
After connecting the drawbar eye (2) to the
by means of the coupling pin (3), the
coupling pin will be secured by the securing
pin (4) or another securing device. After that
set the jack (5) as high as possible. For that
purpose the pin adjuster (7) is thought which
can be used as a quick adjuster.
If the tractor rear wheels can touch the
stand (6) during reversing on headlands, the
stand (6) can be dismounted and placed into
the holder (HA) of the V-pole (VD).
Fit hydraulic hoses, braking hoses and electric cables.
If it is required to drive on public roads, fit lighting equipment with warning boards.
Finally the wedges (9) will be fitted into the clamp holding and secured.

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5.2 Detaching from the tractor
Park the implement always on firm and
level ground; re-attachment will then be
easier.
It is recommended to park the GIANT
with folded-in wing sections, this saves
space and reduces the effort of attaching
and detaching the warning boards and
the lighting equipment, if it is required to
drive on public roads.
Before detaching the implement the
electric cables, braking hoses and
hydraulic hoses must be detached from
the tractor.
The stand (6) will be lowered until there
is no vertical force of the drawbar eye (2)
on the drawbar clevis (1).
Apply hand brake by winding the crank
(8) clock-wise and prevent unintended
rolling by chocks (9).
The crank (8) of the hand-brake is
positioned at the rear of the chassis axle
or at the right side of the V-pole (VD).
After that the coupling pin (3) must be
drawn out after removing the securing
pin.
•Read and adhere to the
General Safety Instruc-
tions as well as to the
instructions ‘Trailed imple-
ment’!
•Adhere to the maximum allowed load
on the drawbar clevis!
•It must be ensured that the coupling
pin (3) will be secured carefully!
•Attach the implement to a double
lashing drawbar clevis (1), only!
•Before transport, it must be ensured that the lateral frames (11) are locked by
the pin (12) and the three point hydraulics (13) positioned at the lateral frames
(11) are locked against unintentional folding-out by means of the securing pins
(14)!

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6. FOLDING OF THE WING SECTIONS
6.1 Folding-in of the wing sections
Before folding-in the Giant Terradisc, the
pins (18) und (20) of the depth adjustment
(19) must be unlocked, removed and put
into the tool box. If the Giant Smaragd is
equipped with double rollers, additionally
the pins (SS) mut be unlocked, removed,
fitted into the bores (BO) and secured.
−It is allowed to swing-in the wing
sections, only, when the implement is
coupled to the tractor.
−Attention must be paid to the fact that
each handle (15) of the locking pin (12)
stands horizontally, and points to the
top link before the folding-in operation.
−Before the folding-in operation the wing
sections must be lifted fully by means of
the lift linkages (13). Otherwise the
transport width of 3 m will be exceeded
and also it is not possible to fit the
securing pins (14) anymore.
−For the folding-in operation the double
acting spool valve will be used so that
the lateral frames (11) with the wing
sections will be folded upwards first and
then in.
−Hold the spool valve in that position
until the wing sections are folded-in
completely and the securing pins, which
serve as safety devices for transport,
are locked. This happens automatically,
but check that they have engaged
correctly.
−Mount and secure securing pins (14)
(See picture G-12)!
When driving on public roads the lighting
equipment with warning boards
concerned must be fitted!

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6.2 Folding-out of the wing sections
Before folding-out the lighting equipment
with warning boards must be removed
and put into the special holder in the
front.
−Fold-out the wing sections, only, with
the GIANT fitted to the tractor as
prescribed and detached lighting
equipment and warning boards.
−Before folding-out the wing sections
(40), detach the lighting equipment
and warning boards.
−Before folding-out the wing sections the locking pins (12) must be unlocked by
turning them 180° and the securing pins (14) must be detached. For that
purpose the securing pins (14) will be placed in the alternative hole (17).
−Then the wing sections will be folded-out by operating the double acting spool
valve.
−After finishing the folding-out procedure the spool valve must be held in
pressure position for a few seconds so that the hydraulic rams can be filled with
oil fully.
•Read and adhere to the General Safety Instructions as well as to
the Instructions ‘Hydraulic equipment’!
•Transport the GIANT, only, with locked locking pin (12) and locked
lateral frames (11).
•The locking pins and their guidings (16) must be lubricated
sufficiently.
•Ensure that any people keep well clear of the working and swinging area of the
implement.
•Before folding-in, ensure that the handle (15) of the locking pin (12) stands
horizontally = parallel to the lateral frames (11) and that it points to the top link.

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7. PENDULUM BALANCE
The lower links (UL) of the three point hydraulics (13) are equipped with a
pendulum balance (PA), which allows an individual adaption of the implement
sections even in hilly conditions.
On the left and right side of the lower links (UL) the lower link ends (UE) are
positioned pivotably around the eccentric bolts (E). The lower link ends will be
connected directly to the drawbar (36) and secured by means of the securing
lashing (40), bolt (41) and securing pin (42).

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8. BRAKING ASSEMBLY
8.1 Double-hose-air-pressure brake-
system
The Giant must be equipped with a double-
hose-air-pressure brake-system when
public roads are used.
When braking the rod (61) may only open
25 to 40 mm. If the rod openes more than
40 mm, the braking linkage must be
adjusted by the adjuster screw (62) so that
the rod (61) opens 25 to 40 mm, only.
8.2 Parking brake
With all system tracs Giant 1000 Terradisc
with depth guiding device with depth wheels
(SR) and draw links (L) and with all Giant
1000 Terratilth system tracs from the serial
No. 237 640 on, the parking brake (8) is
fitted right outside of the V-pole.
With older Giant 1000 Terratilth system
tracs the parking brake is fitted at the rear of
the axle.

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9. TYRES
The chassis of the Giant is equipped with the tyres 550/45-22,5 with 12PR or with
the twin wheels 405/70-20 TL with 12 PR and the depth wheels for the outer
depth guiding of the Terradisc sections are equipped with the tyres 10.80-12 with
8PR. For work and driving on public roads the following minimum and maximum
air pressures are allowed.
Air pressure
Tyres PR Profile maximum
allowed minimum allowed Recommen- dation
550/45-22,5 12 I-331 2,7 2,3 2,5
405/70-20 TL 12 M27 3,5 2,0 2,0
10/80-12 8 AW 4 2,0 2,5
The stated maximum allowed air pressure value must never be exceeded!
Similarly the tyres must not be used with less than the minimum allowed air
pressure, in order to prevent overload and damage!
•Read and adhere to the General Safety Instructions as well as to
the Instructions ‘Tyres’!
•Tighten wheel nuts of the chassis after the first 20 hours of use
with a torque of 270 Nm! After that check them regularly and
tighten if necessary (at least every 100 working hours)!
•With twin wheels the Giant is 3,45 m wide and may not be transported on
public roads!