LEMKEN Gigant 12S 1400 Heliodor 9 User manual

Operating Instructions
System Trac
Gigant 12S 1400 Heliodor 9
- en -
Item no. 17512358
BA_00/06.18
LEMKEN GmbH & Co. KG
Weseler Straße 5, 46519 Alpen / Germany
Telephone [phone], Fax [phone]
[email protected], www.LEMKEN.com

1
Dear customer,
Thank you for the trust you have placed in us by purchasing this device. The de-
vice can only be used to its full advantage when operated and used properly.
When the device was delivered, you will already have been instructed in opera-
tion, adjustment and maintenance by your dealer. However, this brief instruction is
not a substitute for thorough study of the operating instructions.
These operating instructions will help to familiarise you with the LEMKEN GmbH &
Co. KG device and the options available for using it.
The operating instructions contain important information about how to operate the
device safely, properly and efficiently. Following the instructions will help to pre-
vent hazards, faults and down times and will increase reliability and service life.
Read the operating instructions carefully and attentively before commissioning.
Make sure that the operating instructions are always available at the location
where the device is used.
The operating instructions must be read and followed by anyone who is involved
in carrying out the following work:
Coupling and uncoupling
Adjustments
Operation
Maintenance and repairs
Troubleshooting, and
Final shutdown and disposal.

2
Spare parts ordering
This device is supplied with a specification listing all assemblies that are relevant
for the product. The spare parts list valid for your device includes both those as-
semblies relevant to you and those that are not intended for your device. Make
sure that you only order spare parts that belong to the assemblies that can be
found on your specification or the enclosed print out. When ordering spare parts,
state the type designation and serial number of the device. This information can
be found on the type plate. Enter this data in the fields below so that it is always to
hand.
Type designation:
Serial number:
Remember that you should only use genuine LEMKEN spare parts. Reproduction
parts have a negative influence on the function of the device, have a shorter ser-
vice life and present risks and hazards that cannot be estimated by LEMKEN
GmbH & Co. KG. They also increase the maintenance costs.
Service and spare parts
Information on service and spare parts is available from your local dealer or our
website at www.lemken.com.

3
CONTENTS
1General information..................................................................................................9
1.1 Liability...........................................................................................................................9
1.2 Guarantee ......................................................................................................................9
1.3 Copyright .....................................................................................................................10
1.4 Optional accessories ..................................................................................................10
1.5 Type plate ....................................................................................................................11
2Symbols used in the Operating Instructions........................................................13
2.1 Hazard classes ............................................................................................................13
2.2 Information...................................................................................................................13
2.3 Environmental protection...........................................................................................13
2.4 Indication of passages................................................................................................14
3Safety measures and precautions.........................................................................15
3.1 Target group................................................................................................................15
3.2 Intended use................................................................................................................15
3.3 Safety features of the device......................................................................................16
3.4 Safety and warning signs...........................................................................................18
3.4.1 General information...................................................................................................18
3.4.2 Position of safety and warning stickers......................................................................18
3.4.3 Meaning of warning signs..........................................................................................20
3.4.4 Meaning of other symbols..........................................................................................22
3.5 Special safety instructions.........................................................................................24
3.6 Danger areas................................................................................................................26
3.6.1 Danger areas during implement operation.................................................................26
3.6.2 Danger areas when folding and unfolding .................................................................27
3.7 Residual risks..............................................................................................................28
3.7.1 Hazard caused by mechanical systems.....................................................................28
3.7.2 Hazard caused by hydraulic systems ........................................................................28
3.7.3 Hazard during operation............................................................................................28

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3.8 Applicable rules and regulations...............................................................................28
3.9 Operation on public highways...................................................................................29
3.9.1 Lighting system and identification..............................................................................29
3.9.2 Requirements on the tractor ......................................................................................29
3.9.3 Permitted transport speed .........................................................................................30
3.9.4 Check before departure.............................................................................................31
3.9.5 Correct behaviour in road traffic ................................................................................31
3.10 Obligation of the operator ..........................................................................................31
3.11 Operating the implement safely.................................................................................32
3.11.1 General information................................................................................................32
3.11.2 Personnel selection and qualifications ...................................................................33
4Handing over the Implement..................................................................................34
5Layout and description...........................................................................................35
5.1 Overview ......................................................................................................................35
5.2 Description...................................................................................................................37
5.2.1 Drawbar with drawbar eye.........................................................................................37
5.2.2 Stand.........................................................................................................................37
5.2.3 Folding frame.............................................................................................................37
5.2.4 Three-point hydraulics...............................................................................................37
5.2.5 Traction guide............................................................................................................37
5.2.6 Catch coupler with swing balance system.................................................................37
5.2.7 Adjustable pressure limiting valve .............................................................................37
5.2.8 Mounted implements or working sections..................................................................37
5.2.9 Air brake system........................................................................................................38
5.2.10 Hydraulic braking system .......................................................................................40
6Preparations on tractor ..........................................................................................43
6.1 Tyres.............................................................................................................................43
6.2 Hitch coupling .............................................................................................................43
6.3 Loads and weights......................................................................................................43
6.3.1 Tractor back axle load ...............................................................................................44
6.3.2 Drawbar loads ...........................................................................................................44

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6.4 Power sources required .............................................................................................45
6.5 Required hydraulic equipment...................................................................................46
6.6 Brake system...............................................................................................................47
6.6.1 Air brake system........................................................................................................47
6.6.2 Hydraulic brake system .............................................................................................47
6.6.3 Without brake system................................................................................................48
7Preparations on implement....................................................................................49
7.1 Final assembly.............................................................................................................49
7.2 Spring brake cylinders................................................................................................49
8Coupling and uncoupling implement....................................................................51
8.1 Hydraulic stand ...........................................................................................................51
8.1.1 Installation .................................................................................................................51
8.1.2 Operation...................................................................................................................53
8.1.3 Removal ....................................................................................................................54
8.2 Attaching the implement ............................................................................................55
8.3 Detaching the implement............................................................................................56
8.4 Safety chain.................................................................................................................58
9Driving on public highways ...................................................................................60
9.1 General information ....................................................................................................60
9.2 Preparation for driving on public roads....................................................................60
9.3 Safety guards...............................................................................................................61
9.4 Protective devices for Heliodor working sections ...................................................62
9.5 Transport dimensions.................................................................................................63
10 Folding and unfolding ............................................................................................64
10.1 Safety information for folding and unfolding............................................................64
10.2 Folding .........................................................................................................................65
10.3 Unfolding .....................................................................................................................66

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11 Roller adjustment....................................................................................................67
11.1 General information ....................................................................................................67
11.2 Transport position.......................................................................................................67
11.2.1 Heliodor 9...............................................................................................................67
11.3 Working position.........................................................................................................67
12 Attaching and detaching working sections..........................................................68
12.1 General information ....................................................................................................68
12.2 Cross shaft...................................................................................................................69
12.3 Top links ......................................................................................................................69
12.4 Before making the first attachment ...........................................................................72
12.5 Attaching......................................................................................................................73
12.6 Detaching.....................................................................................................................75
13 Working sections ....................................................................................................76
13.1 Three-point hydraulics................................................................................................76
13.2 Heliodor 9.....................................................................................................................78
13.2.1 Mechanical working depth adjustment ...................................................................78
13.2.2 Setting the roller lowering depth.............................................................................79
13.2.3 Hydraulic working depth adjustment.......................................................................80
13.2.4 Hollow disc adjustment in the tractor track.............................................................81
13.2.5 Lateral limiters........................................................................................................82
13.3 Rollers..........................................................................................................................85
13.3.1 General information................................................................................................85
13.3.2 Knife rollers ............................................................................................................86
13.3.3 Flex ring roller.........................................................................................................88
13.3.4 Flex ring roller scrapers..........................................................................................89
13.3.5 Scrapers on rubber ring roller.................................................................................89
14 Turning at the headland .........................................................................................90

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15 Maintenance/repairs ...............................................................................................91
15.1 Special safety instructions.........................................................................................91
15.1.1 General ..................................................................................................................91
15.1.2 Personnel qualifications .........................................................................................91
15.1.3 Personal protective clothing ...................................................................................92
15.1.4 Shutting down the device for maintenance/repairs.................................................92
15.1.5 Work on the hydraulics...........................................................................................92
15.1.6 Work on the electrical system.................................................................................93
15.1.7 Working under raised device..................................................................................93
15.1.8 Tools used..............................................................................................................94
15.2 Environmental protection...........................................................................................95
15.3 Lubrication...................................................................................................................95
15.3.1 Lubrication chart.....................................................................................................96
15.3.2 Overview of lubricating points.................................................................................96
15.4 Maintenance intervals.................................................................................................98
15.4.1 After commissioning (within 2 hours)......................................................................98
15.4.2 Daily inspection......................................................................................................98
15.4.3 Weekly checks .......................................................................................................99
15.4.4 Annual check..........................................................................................................99
15.5 Tightening torques....................................................................................................100
15.5.1 General ................................................................................................................100
15.5.2 Bolts and nuts made of steel................................................................................100
15.5.3 Wheel bolts and wheel nuts..................................................................................101
15.6 Draining the compressed air tank............................................................................101
15.7Braking system..........................................................................................................101
15.8 Cleaning the filter......................................................................................................102
15.9 Checking and adjusting length of tension struts ...................................................103
15.10 Checking connections to the tractor.......................................................................105
15.10.1 Couplings..........................................................................................................105
15.10.2 Connectors and cables .....................................................................................105

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16 Technical data .......................................................................................................106
16.1 Dimensions................................................................................................................106
16.2 Implement weights....................................................................................................106
16.3 Permitted loads and weights....................................................................................107
16.4 Tractor power ............................................................................................................107
16.5 Tyres / Air pressure...................................................................................................108
16.5.1 Chassis ................................................................................................................108
17 Noise, Airborne Sound .........................................................................................109
18 Notes ......................................................................................................................109
Index .............................................................................................................................110

General information
9
1 GENERAL INFORMATION
1.1 Liability
The "Standard Terms and Conditions of Sales and Delivery" of LEMKEN GmbH &
Co. KG, in particular Section IX, shall apply. Liability. In line with the dimensions
cited in these conditions the LEMKEN GmbH & Co. KG shall not be held liable for
any personal or material damage, when such damage is caused by one or more
of the following reasons:
improper use of the device, see also section entitled "Intended use",
non-compliance with the operating instructions and the enclosed safety instruc-
tions,
unauthorised changes to the device,
inadequate monitoring of parts which are subject to wear,
maintenance work that has not been conducted properly or in good time,
the use of spare parts that are not original LEMKEN GmbH & Co. KG spare
parts,
accidents or damage through outside influences or force majeure
1.2 Guarantee
The "Standard Terms and Conditions of Sales and Delivery" of LEMKEN GmbH &
Co. KG shall apply at all times.
The guarantee period shall be one year from the date of receipt of the implement.
We shall rectify any implement faults in accordance with the LEMKEN guarantee
guidelines.

General information
10
1.3 Copyright
These operating instructions represent a document in terms of the law on unfair
competition.
Copyright is retained by
LEMKEN GmbH & Co. KG
Weseler Strasse 5
D-46519 Alpen, Germany
These operating instructions are intended to be used by the user of the imple-
ment. They contain texts and drawings which must not be
reproduced,
divulged or
communicated in any other way in whole or in part without the express permis-
sion of the manufacturer.
Infringements will result in a claim for damages.
1.4 Optional accessories
LEMKEN implements may be equipped with various accessories. The operating
instructions below describe both series components and optional accessories.
Please note: These accessories will vary depending on the type of equipment.

General information
11
1.5 Type plate
The implement carries a type plate.
The type plate can be found at front right
on the implement.
The operating instructions may apply to
different implement types or variants of the
implement.
The operating instructions indicate infor-
mation which only applies to a specific im-
plement type or a specific variant of the
implement.
The type plate will help you to identify the
implement type and variant.
Layout of the type plate
Illustration: Example of a type plate
Illustration: Example of a type plate, France only

General information
12
1
Series
2
Type designation
3
Serial number
4
Year of manufacture
5
Permissible drawbar load [kg]
6
Permissible axle load [kg]
7
Permissible gross weight [kg]
8
Company logo and address
9
CE marking
(only within the European Union)
10
Name of manufacturer
11
Type, variant, version
12
Type approval date

Symbols used in the Operating Instructions
13
2 SYMBOLS USED IN THE OPERATING INSTRUCTIONS
2.1 Hazard classes
The following symbols are used in the Operating Instructions for particularly im-
portant information:
DANGER
Denotes an imminent hazard with high risk, which will result in
death or severe physical injury, if not avoided.
WARNING
Denotes a possible hazard with medium risk, which could result in
death or severe physical injury, if not avoided.
CAUTION
Denotes a low-risk hazard, which could cause light or medium
physical injury or property damage, if not avoided.
2.2 Information
Denotes special user tips and other particularly useful or important
information for operation and efficient utilisation.
2.3 Environmental protection
Indication of special recycling and environmental protection
measures.

Symbols used in the Operating Instructions
14
2.4 Indication of passages
The following symbols are used for particular passages in the operating instruc-
tions:
Indicates work steps
Indicates enumerations

Safety measures and precautions
15
3 SAFETY MEASURES AND PRECAUTIONS
General safety instructions for the operator are specified in the chapter entitled
«Safety measures and precautions». At the start of some main chapters the safety
instructions, which refer to all work to be carried out in this chapter, are listed to-
gether. Each safety-relevant work step includes other safety instructions specific
to the work step.
3.1 Target group
These operating instructions are restricted exclusively to the use of the device by
trained technicians and instructed persons.
3.2 Intended use
The device is manufactured in accordance with state-of-the-art standards and the
recognised safety rules. However, the use of the device may result in a risk to life
and limb of the user or third parties, or cause damage to the device and other ma-
terial property. The device may be operated in a technically perfect condition only,
in accordance with its designated use and by safety-conscious persons in compli-
ance with the operating instructions.
Intended use also includes:
compliance with the operating instructions and implementation of the work
steps indicated in the operating instructions,
compliance with the safety and warning signs on the device,
observance of the power limits of the tractor and device,
observance of all maintenance specifications and additional checks,
the use of original spare parts,
the use of the listed auxiliary and operating materials as well as their environ-
mentally friendly disposal.
Safe operation is not guaranteed unless all instructions, settings and power limits
applicable to the device are observed.
The machine is only suitable for the usual agricultural use.

Safety measures and precautions
16
3.3 Safety features of the device
To protect the operator and the device, the device is equipped with special safety
features in accordance with country specific requirements.
Always keep all safety devices in working order.
Warning board for slow moving vehicles (depending on
national regulations)
Stand
Side protective devices
Safety chain

Safety measures and precautions
17
Wheel chocks

Safety measures and precautions
18
3.4 Safety and warning signs
3.4.1 General information
The implement features all equipment
which ensures safe operation. If hazardous
areas could not be completely secured
with respect to operational safety, warning
signs are affixed which indicate these re-
sidual risks. Damaged, lost or illegible
warning signs must be replaced immedi-
ately.
3.4.2 Position of safety and warning stickers