LEMKEN Zirkon 10 KA User manual

Operating Instructions
Power Harrows
Zirkon 10 KA
- EN -
Item no. 175_3769
3/02.14
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 rating 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.

Contents
3
CONTENTS
Contents...........................................................................................................................3
1General information................................................................................................10
1.1Liability.........................................................................................................................10
1.2Guarantee.....................................................................................................................10
1.3Copyright .....................................................................................................................11
1.4Optional accessories ..................................................................................................11
2Symbols used in the Operating Instructions........................................................12
2.1Hazard classes ............................................................................................................12
2.2Information...................................................................................................................12
2.3Environmental protection...........................................................................................12
2.4Indication of passages................................................................................................13
3Safety measures and precautions.........................................................................14
3.1Target group................................................................................................................14
3.2Intended use................................................................................................................14
3.3Safety features of the device......................................................................................15
3.4Safety and warning signs...........................................................................................15
3.4.1General information ................................................................................................... 15
3.4.2Meaning of warning signs .......................................................................................... 15
3.4.3Meaning of other symbols.......................................................................................... 18
3.4.4Position of safety and warning stickers...................................................................... 18
3.5Special safety instructions.........................................................................................19
3.6Danger areas................................................................................................................20
3.6.1Danger areas when operating the implement ............................................................ 21
3.6.2Danger area when folding in and out......................................................................... 21
3.7Residual risks..............................................................................................................22
3.7.1Hazard caused by mechanical systems..................................................................... 22
3.7.2Hazard caused by hydraulic systems ........................................................................ 22
3.8Applicable rules and regulations...............................................................................22

Contents
4
3.9Operation on public highways...................................................................................23
3.9.1Lighting system and identification.............................................................................. 23
3.9.2Requirements of the tractor ....................................................................................... 23
3.9.3Permissible transport speed ...................................................................................... 24
3.9.4Check before departure............................................................................................. 24
3.9.5Correct behaviour in road traffic ................................................................................ 25
3.10Obligation of the operator ..........................................................................................25
3.11Operating the device safely........................................................................................26
3.11.1General information................................................................................................ 26
3.11.2Personnel selection and qualifications ................................................................... 27
3.11.3Hydraulic system .................................................................................................... 27
3.11.4Power take-off operation ........................................................................................ 28
4Handing over the device.........................................................................................30
5Layout and description...........................................................................................31
5.1Overview ......................................................................................................................31
5.2Description...................................................................................................................32
5.2.1Drawbar with coupling ............................................................................................... 32
5.2.2Gear trough ............................................................................................................... 32
5.2.3Tines.......................................................................................................................... 32
5.2.4Side blades................................................................................................................ 33
5.2.5Power takeoff shaft drive-through.............................................................................. 33
5.2.6Rollers ....................................................................................................................... 33
5.2.7Levelling beam .......................................................................................................... 33
5.2.8Gearbox..................................................................................................................... 34
5.2.9Feed disc ................................................................................................................... 34
5.2.10Track markers ........................................................................................................ 34
5.2.11Wheel track eliminators .......................................................................................... 34
5.2.12Lighting system ...................................................................................................... 34
5.2.13Three point linkage, hydraulic................................................................................. 35
5.2.14Safety devices ........................................................................................................ 35
5.2.15Braking system....................................................................................................... 35
5.2.16Without brake system............................................................................................. 36
6Using the implement for the first time ..................................................................37

Contents
5
6.1Working depth.............................................................................................................37
6.2Rear levelling bar ........................................................................................................37
6.3Track loosener.............................................................................................................38
6.4Scraper.........................................................................................................................38
7Preparations on the tractor....................................................................................39
7.1Swinging drawbar .......................................................................................................39
7.2Required hydraulic equipment...................................................................................40
7.2.1Mounted implement with separate hydraulic connections.......................................... 41
7.2.2Mounted implement with 6/2-way valve..................................................................... 41
7.2.3Mounted implements with electromagnetic control .................................................... 42
7.2.4Mounted implements with electronic control .............................................................. 43
7.2.5Mounted implements with hydraulic equipment for stand-alone operation ................ 44
7.3Required power sources.............................................................................................44
7.3.1Acoustic drive shaft monitoring.................................................................................. 45
7.4Brake system...............................................................................................................45
7.4.1Air brake system........................................................................................................ 45
7.4.2Hydraulic brake system ............................................................................................. 45
8Preparations on implement....................................................................................46
8.1Final assembly.............................................................................................................46
8.2Drawbar coupling........................................................................................................46
9Coupling and uncoupling implement....................................................................47
9.1Attaching......................................................................................................................48
9.2Detaching.....................................................................................................................53
10Operation .................................................................................................................57
10.1Turning at the headland..............................................................................................57
10.2Power take-off..............................................................................................................57
10.3Drive shaft monitoring................................................................................................58
10.4Retracting/extending...................................................................................................59
10.4.1Retracting............................................................................................................... 59
10.4.2Extending ............................................................................................................... 61

Contents
6
11Adjustments.............................................................................................................62
11.1Tilt.................................................................................................................................63
11.1.1Mechanical ............................................................................................................. 63
11.1.2Hydraulic ................................................................................................................ 63
11.2Working depth.............................................................................................................64
11.3Knife tines with quick-coupling system....................................................................65
11.4Manual gearbox...........................................................................................................66
11.4.1General................................................................................................................... 66
11.4.2Rotor speeds.......................................................................................................... 68
11.5Change in the direction of rotation of the rotors......................................................70
11.6Power takeoff shaft drive-through.............................................................................71
11.7Side blade ....................................................................................................................72
11.8Side blade extension...................................................................................................72
11.9Wheelmark eradicator.................................................................................................72
11.9.1Relocation at the side............................................................................................. 73
11.9.2Adjusting the working depth ................................................................................... 73
11.10Feed discs....................................................................................................................74
11.10.1Relocation at the side.......................................................................................... 74
11.10.2Adjusting the working depth ................................................................................ 74
11.11Protective equipment..................................................................................................75
11.12Stop screws.................................................................................................................76
11.13Levelling beam ............................................................................................................77
11.13.1Rear-mounted levelling beam ............................................................................. 77
11.13.2Forward-mounted levelling beam........................................................................ 77
11.14Track markers..............................................................................................................78
11.14.1Length and angle of attack.................................................................................. 78
11.14.2Shearing protection ............................................................................................. 80
12Rollers......................................................................................................................81
12.1General information ....................................................................................................81
12.2Adjusting the scrapers ...............................................................................................82

Contents
7
12.3Clearance between scraper and roller casing ..........................................................83
12.4Tilt of the roller............................................................................................................84
12.4.1Trapeze rollers TPW and TSW............................................................................... 84
12.4.2Toothed packer rollers ZPW................................................................................... 85
13Hydraulic three-point Linkage ...............................................................................86
13.1Mounting an implement..............................................................................................86
13.2Lowering the implements...........................................................................................86
13.3Dismounting the implement.......................................................................................87
14Semi-mounted devices...........................................................................................88
14.1Tyres.............................................................................................................................88
14.2Brakes ..........................................................................................................................88
15Switching off the device.........................................................................................89
15.1Shutting down the device in an emergency..............................................................89
15.2Disposal .......................................................................................................................89
16Maintenance and repairs........................................................................................90
16.1Special safety instructions.........................................................................................90
16.1.1General................................................................................................................... 90
16.1.2Personnel qualifications ......................................................................................... 90
16.1.3Protective equipment.............................................................................................. 90
16.1.4Immobilise the implement for maintenance and repairs ......................................... 91
16.1.5Working on the hydraulics ...................................................................................... 91
16.1.6Working on the electrics ......................................................................................... 91
16.1.7Working under the raised device ............................................................................ 92
16.1.8Utilised tool............................................................................................................. 92
16.2Environmental protection...........................................................................................93
16.3Maintenance intervals.................................................................................................94
16.3.1After commissioning (within 2 hours)...................................................................... 94
16.3.2Daily check............................................................................................................. 94
16.3.3Weekly check ......................................................................................................... 94
16.4Check the connections to the tractor........................................................................95
16.4.1Hydraulic connections ............................................................................................ 95

Contents
8
16.4.2Electrical connections............................................................................................. 95
16.5Oil changing.................................................................................................................96
16.5.1Lubricants for the manual gearbox and lateral right angle drives ........................... 97
16.6Gear trough..................................................................................................................98
16.7Fans..............................................................................................................................99
16.8Lubrication.................................................................................................................100
16.9Rotor bearings...........................................................................................................102
16.10Bolts ...........................................................................................................................103
16.11Tightening torques....................................................................................................103
16.11.1General information........................................................................................... 103
16.11.2Bolts and nuts made of steel............................................................................. 104
16.11.3Wheel bolts and wheel nuts .............................................................................. 104
16.12Tines...........................................................................................................................105
16.13Scrapers.....................................................................................................................105
16.14Cardan shaft ..............................................................................................................105
16.15Hydraulic hoses.........................................................................................................106
17Troubleshooting....................................................................................................107
17.1.1General information.............................................................................................. 107
17.1.2Electrical equipment ............................................................................................. 107
17.1.3Hydraulic equipment............................................................................................. 107
18Information for driving on public roads..............................................................108
18.1Laws and regulations................................................................................................108
18.2Braking deceleration.................................................................................................108
18.3Transport....................................................................................................................108
18.4Safety devices ...........................................................................................................109
18.5Feed discs..................................................................................................................110
18.6Track markers............................................................................................................110
18.7Allowed transport speed...........................................................................................111
19Technical data .......................................................................................................112

Contents
9
20Type plate...............................................................................................................113
21Noise, Airborne Sound.........................................................................................114
22Notes ......................................................................................................................114
Index .............................................................................................................................115
EU Declaration of Conformity ....................................................................................117

General information
10
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
11
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.

Symbols used in the Operating Instructions
12
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
13
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
14
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
15
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.
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 Meaning of warning signs

Please familiarise yourself with the
meaning of the warning signs.
The following explanations provide detailed
information.
Please read and observe the operating in-
structions and safety instructions before
starting up the implement for the first time.

Safety measures and precautions
16
Before carrying out maintenance or repair
work, switch off the engine and remove
key.
Do not remain in the operating and swivel
area of the implement.
Danger of crushing.
Danger through moving machine parts.
The power takeoff shaft drive-through
runs to the right.
Do not climb onto the implement.

Safety measures and precautions
17
Keep out of the folding area of the device.
Do not touch any moving machine parts.
Wait until they have come to a standstill.
Hot surfaces
Lock the lifting device
Lock the lifting device before travelling
on public roads.
Unlock the lifting device before opera-
tion.

Safety measures and precautions
18
3.4.3 Meaning of other symbols.
Load-securing points
3.4.4 Position of safety and warning stickers