LEMKEN ZIRKON 12 K User manual

OPERATING INSTRUCTIONS
POWER HARROW
ZIRKON 12 K
en-GB | Item no. 17516804 | BA 00/2022-10

Ensure that these instructions are always available when using the machine
and can be accessed by all users..
●
Keep these instructions for the entire service life of the machine.
●
Pass these instructions to all users / owners.
Original instructions
©2022 | This documentation is copyright protected. The copyright remains with LEMKEN GmbH & Co.
KG, Weseler Strasse 5, D-46519 Alpen.
The texts, diagrams and drawings must not be duplicated, distributed or disclosed in any other way,
either in whole or in part, without express approval.

Table of contents
1 About these instructions....................................................................................................................................... 1
1.1 Introduction......................................................................................................................................................... 1
1.2 Target groups...................................................................................................................................................... 3
1.3 Applied presentations..................................................................................................................................... 3
1.3.1 Signal words and hazard statements...................................................................................................... 3
1.3.2 Symbols and text markings........................................................................................................................ 4
1.3.3 Direction specications................................................................................................................................ 4
1.4 Further applicable documents..................................................................................................................... 5
2 Safety.............................................................................................................................................................................. 6
2.1 Intended use........................................................................................................................................................ 6
2.2 Requirements of operators, users and service personnel................................................................... 8
2.3 Hazardous areas................................................................................................................................................. 8
2.4 Workplaces and passengers........................................................................................................................ 13
2.5 Technically perfect condition..................................................................................................................... 13
2.6 Safe handling.................................................................................................................................................... 15
2.6.1 Personal protective equipment.............................................................................................................. 15
2.6.2 Avoid damage to health caused by noise.......................................................................................... 15
2.6.3 Driving the tractor-machine combination......................................................................................... 16
2.7 Safety devices and labels............................................................................................................................. 17
3 Design and description........................................................................................................................................ 18
3.1 Machine overview........................................................................................................................................... 18
3.2 Machine safety................................................................................................................................................. 22
3.2.1 Position of the label.................................................................................................................................... 22
3.2.2 Meaning of the labels................................................................................................................................. 22
3.2.3 Safety devices............................................................................................................................................... 27
3.3 Working tools................................................................................................................................................... 29
3.4 Rollers.................................................................................................................................................................. 30
4 Commissioning........................................................................................................................................................ 32
4.1 Preparing an attachment............................................................................................................................. 32
4.1.1 Check machine for completeness......................................................................................................... 32
4.1.2 Checking suitability of the tractor......................................................................................................... 32
4.1.3 Cardan shaft................................................................................................................................................... 33
4.1.4 Preparing braking system......................................................................................................................... 37
4.2 Attaching the machine................................................................................................................................. 38
4.2.1 Attaching a combination machine........................................................................................................ 43
4.3 Checking machine.......................................................................................................................................... 48
4.4 After initial commissioning.......................................................................................................................... 48
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en-GB | Item no. 17516804 | BA 00/2022-10 I

5 Road travel................................................................................................................................................................. 50
5.1 Information on road travel........................................................................................................................... 50
5.2 Preparing for road travel.............................................................................................................................. 50
5.2.1 Preparing the lighting equipment for road travel........................................................................... 52
5.2.2 Mounting additional trailer...................................................................................................................... 52
5.2.3 Adjusting stop screws................................................................................................................................ 54
6 Operation................................................................................................................................................................... 56
6.1 Basic operation................................................................................................................................................. 56
6.1.1 Folding machine.......................................................................................................................................... 56
6.2 Changing the setup state............................................................................................................................. 58
6.2.1 Changing blade tines................................................................................................................................. 58
6.3 Adjusting the machine.................................................................................................................................. 61
6.3.1 Adjusting working depth.......................................................................................................................... 61
6.3.2 Rotors and gearbox..................................................................................................................................... 67
6.3.3 Adjusting side shields................................................................................................................................ 70
6.3.4 Adjusting rollers........................................................................................................................................... 71
6.4 Working with the machine.......................................................................................................................... 73
6.4.1 Standard procedure.................................................................................................................................... 73
6.4.2 Driving on the headland........................................................................................................................... 75
7 Cleaning and care................................................................................................................................................... 76
7.1 Cleaning with a high-pressure cleaner.................................................................................................... 76
8 Detaching machine................................................................................................................................................ 77
8.1 Detaching machine........................................................................................................................................ 77
8.2 Storing and wintering machine................................................................................................................. 79
9 Maintenance and repair work.......................................................................................................................... 80
9.1 Maintaining the machine properly........................................................................................................... 80
9.1.1 Preparations.................................................................................................................................................. 80
9.1.2 During the maintenance and repair..................................................................................................... 81
9.2 Maintenance..................................................................................................................................................... 81
9.2.1 Maintenance schedule............................................................................................................................... 81
9.2.2 Checking cardan shaft............................................................................................................................... 83
9.2.3 Frame and trailer.......................................................................................................................................... 83
9.2.4 Checking safety devices............................................................................................................................ 85
9.2.5 Hydraulics and gearbox............................................................................................................................. 86
9.2.6 Electrics............................................................................................................................................................ 92
9.2.7 Soil cultivation implements..................................................................................................................... 92
9.2.8 Rollers............................................................................................................................................................... 93
9.3 Lubricating......................................................................................................................................................... 94
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en-GB | Item no. 17516804 | BA 00/2022-10II

9.3.1 Lubrication schedule.................................................................................................................................. 94
9.3.2 Lubricating components via grease nipples..................................................................................... 95
9.3.3 Grease components.................................................................................................................................... 99
9.3.4 Traction increase device............................................................................................................................ 99
9.3.5 Pivot bearing of the headstock............................................................................................................... 99
10 Troubleshooting and error correction...................................................................................................... 100
10.1 Finding and eliminating errors correctly........................................................................................... 100
10.1.1 Before troubleshooting on the machine........................................................................................ 100
10.1.2 When troubleshooting and eliminating errors............................................................................ 100
10.2 Error - Cause - Remedies at a glance................................................................................................... 101
11 Shutdown and disposal.................................................................................................................................... 103
11.1 Shutdown...................................................................................................................................................... 103
11.2 Disposal.......................................................................................................................................................... 103
12 Technical data....................................................................................................................................................... 104
12.1 Dimensions................................................................................................................................................... 104
12.2 Machine weights........................................................................................................................................ 104
12.3 Permissible mass and loads.................................................................................................................... 104
12.4 Performance data....................................................................................................................................... 104
12.5 Connection data......................................................................................................................................... 106
12.5.1 Electrical connections........................................................................................................................... 106
12.5.2 Hydraulic connections.......................................................................................................................... 107
12.6 Noise, airborne sound.............................................................................................................................. 107
12.7 Operating materials................................................................................................................................... 107
12.8 Tyres and wheels........................................................................................................................................ 108
12.9 Connecting systems at the machine................................................................................................... 108
12.10 Permitted roller types............................................................................................................................ 108
Index.......................................................................................................................................................................... 109
Appendix................................................................................................................................................................. 114
A Type plate variants.......................................................................................................................................... 115
B Tightening torques screws .......................................................................................................................... 117
C Calculation of axle load and ballasting for mounted machines..................................................... 122
D Cross shaft overview....................................................................................................................................... 126
Table of contents
en-GB | Item no. 17516804 | BA 00/2022-10 III

Table of contents
en-GB | Item no. 17516804 | BA 00/2022-10IV

1 About these instructions
1.1 Introduction
These operating instructions are important and belong to the
machine's scope of delivery.
These operating instructions must be available to the user at the place
of use.
nAlways read chapter "Safety" before using the machine for the rst
time.
nRead chapter "Operation - Basic operation" before using the
machine for the rst time.
nBefore starting work, also read the relevant steps in the operating
instructions.
INFORMATION
In other documents and in sections of these operating
instructions, the machine is also referred to as an imple‐
ment.
About these instructions
en-GB | Item no. 17516804 | BA 00/2022-10 1

These operating instructions describe operation of the machine after
initial commissioning by the LEMKEN sales partner and handover to the
operator.
Prior to operation, initial commissioning and instruction in operation,
setting/adjustment and maintenance must have been carried out.
These instructions describe the machine in combination with a tractor.
If the requirements placed on the tractor are also met by other
machines or vehicles, the respective description can also be applied
in these cases.
Operation of the tractor, including its relevant functions, is not part of
these operating instructions. The operator and the user are responsible
for observing the operating instructions of the tractor.
For an unambiguous assignment of this document to the machine,
transfer the following data from the type plate of the machine:
Designation on the type plate Enter the machine data here:
Series
Type designation
Model year
Serial number
Year of manufacture
INFORMATION
Position of the type plate on the machine:
Ä Chapter 3 ‘Design and description’ on page 18
Explanation of the full type plate content:
Ä Appendix A ‘Type plate variants’ on page 115
The machines can be equipped dierently at the factory.
Standard components, special equipment or optional accessories are
not marked separately.
The contents of these operating instructions, e.g. illustrations, may
therefore dier from the equipment of the machine.
Depending on the equipment, additional documents may be required
for operation.
Validity range
Equipment variants
About these instructions
en-GB | Item no. 17516804 | BA 00/2022-102

1.2 Target groups
The target groups of these operating instructions are operators, users
and service personnel of the machine.
The target groups must meet the requirements for the qualication of
the personnel.
Ä Chapter 2.2 ‘Requirements of operators, users and service personnel’
on page 8.
1.3 Applied presentations
1.3.1 Signal words and hazard statements
The following signal words and hazard statements are used to label
warning signs and to warn of residual risks:
Signal word Meaning
DANGER Indicates an immediate hazardous situation
that may result in serious injury or death.
WARNING Indicates a hazardous situation that may
result in injury or death.
CAUTION Indicates a situation that may result in minor
injury.
Signal word Meaning
NOTICE Indicates a situation that may result in mate‐
rial damage.
Signal word Meaning
NOTE Indicates tips and useful information for the
user
ENVIRONMENTAL
PROTECTION
Indicates notices and special measures
regarding environmental protection
Warning of personal injury
Warning of property damage
Other notices and information
About these instructions
en-GB | Item no. 17516804 | BA 00/2022-10 3

1.3.2 Symbols and text markings
Symbol, text
marking
Meaning
In front of and in texts
●Marking for routine maintenance tasks
Activities that demand the help of service
sta.
nListing
[1], , Position numbers
Example: ‘Settings’ Software element
Example: [OK] Softkey, key, switch and button
[kg] Unit
ÄCross reference
In work instructions
√ Preconditions
►nWorking steps in single-step work
instructions
nMeasures for hazard avoidance in safety
information
1.
2.
Working steps in multi-step work instructions
ðResult
In illustrations
Light grey coloured
components
Non-relevant components, visible to facilitate
orientation
Yellow coloured com‐
ponents
Action-relevant components
1.3.3 Direction specications
The direction specications used in the text (left, right, front and rear)
refer to the driving direction of the tractor when moving forwards.
About these instructions
en-GB | Item no. 17516804 | BA 00/2022-104

1.4 Further applicable documents
Documents that are necessary and must be observed for operation:
nOperating instructions of the tractor
nFor partially assembled or disassembled delivery:
Mounting instructions
nSpare parts list
nInstructions for the cardan shaft
INFORMATION
In other documents and in sections of these operating
instructions, the machine is also referred to as an imple‐
ment.
About these instructions
en-GB | Item no. 17516804 | BA 00/2022-10 5

2 Safety
2.1 Intended use
The machine is used for soil cultivation on agricultural land.
It may only be used in accordance with the recognised rules of good
agricultural practice.
The permitted working depth is limited to the cultivatable soil horizons.
Not intended for use in the following cases:
nOn very or deep-frozen soils
nIn soil horizons with unweathered bedrock
nIn soil horizons with loose rock or solid hard rock
►Only suciently qualied personnel may use this machine.
Ä Chapter 2.2 ‘Requirements of operators, users and service personnel’
on page 8
►Only use the machine with a suitable tractor.
Ä Chapter 4.1.2 ‘Checking suitability of the tractor’ on page 32
►When using the machine, observe the permitted loads and weights
for the tractor, machine and tractor-machine combination.
Limitations
Responsible personnel
Tractor
Safety
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The operating instructions are part of the machine. The machine
is intended exclusively for use in accordance with these operating
instructions. Applications of the machine not described in these oper‐
ating instructions may result in personal injury or death or property
damage. If applications other than those described in the operating
instructions are planned, obtain the prior written consent of the manu‐
facturer. This also applies to unauthorised modications and alterations
to the machine.
►Observe the operating instructions and follow the working steps
given therein.
►Clarify questions of comprehension concerning the contents of
these operating instructions before starting work. If necessary, con‐
tact the manufacturer’s sales partner.
INFORMATION
In other documents and in sections of these operating
instructions, the machine is also referred to as an imple‐
ment.
►Operate the machine only in a technically perfect condition.
►Observe the maintenance instructions. Perform all the necessary
tests.
►Use original spare parts or parts approved by the manufacturer.
►Only use the auxiliary and operating materials listed.
►Dispose of auxiliary materials and operating materials in an envi‐
ronmentally responsible manner.
The actual service life of a machine is not limited to a specic time
period as long as the machine is in ecient working order. The ecient
working order of the machine depends to a great extent on the actual
operating conditions and proper maintenance in accordance with the
relevant operating instructions.
Liability and warranty are excluded if personal injury and damage to
property can be traced back to improper use or non-observance of the
operating instructions.
Operating instructions
Technically perfect condition
Service life
Liability and warranty
Safety
en-GB | Item no. 17516804 | BA 00/2022-10 7

2.2 Requirements of operators, users and service personnel
Operators within the meaning of these instructions are obliged to
inform all the users about correct application of the machine and the
respective hazards.
This can be done on the basis of these operating instructions. Opera‐
tors are responsible for ensuring that the operating instructions are
always available at the machine and that the users observe the oper‐
ating instructions.
Operators must also provide users with any necessary personal protec‐
tive gear.
Within the meaning of these instructions, users are persons who drive,
adjust, operate or maintain the machine. Users must be able to use the
machine safely.
This means:
nUsers understand how the machine works.
nUsers know and are able to avoid dangers.
nUsers are physically capable of controlling the machine.
In order to use the machine as intended and in a professional manner,
users must have the required technical (agricultural) knowledge.
Unless otherwise indicated, users may perform all of the activities
described in these operating instructions themselves.
Certain activities should only be performed by service personnel, e.g.
work on braking systems. These activities are indicated in the operating
instructions by the symbol .
Service personnel within the meaning of these instructions are all per‐
sons who maintain and repair safety-relevant components.
Service personnel are qualied for these activities based on their
training and expertise (for example agricultural machine mechanics).
2.3 Hazardous areas
If the hazardous areas are not heeded, this may result in death or
serious injury to personnel.
Only once all persons have left the hazardous areas: Switch on drives
and motors.
Any work required while the motor or drive is running in a hazardous
area requires special attention and precautions. Follow the instructions
for action in these operating instructions exactly.
Operator
Users
Service personnel
Safety
en-GB | Item no. 17516804 | BA 00/2022-108

The hazardous area of the machine during operation.
b
Moving hazardous area
b
The hazardous area includes the area in the direction of travel across
the entire width
b
of the machine.
►NEVER climb out of the tractor while it is moving.
►NEVER allow other persons to board the tractor while it is moving.
►In addition, maintain a safety distance of 2 m from the machine.
►While driving on the eld, observe the entire hazardous area. Stop
if required.
When standing between the tractor and machine, there is a risk due to
tractor movements or sudden machine movements.
►Secure the tractor against rolling away.
►Before operating the linkage: Keep all persons away from the
movement area of the linkage.
Moving hazardous area
Hazardous area between the tractor
and machine
Safety
en-GB | Item no. 17516804 | BA 00/2022-10 9

b
c
Hazardous areas when folding the implement
b
c
Moving parts of the machine
When the machine is folded, persons in the folding range
b
will be
crushed or hit by moving parts of the machine.
►NEVER fold the machine if persons are in the folding range
b
.
►Maintain a safety distance of 2 m to the folding range.
Overhead lines
Lateral parts may, due to their height,
c
touch overhead lines during
the folding processes.
►NEVER fold the machine in and out near overhead lines.
Hazardous areas when folding in and
out
Safety
en-GB | Item no. 17516804 | BA 00/2022-1010

Flashovers cause high electrical voltages on the outside of the tractor-
machine combination. Large voltage dierences occur on the ground
around the tractor-machine combination. Large steps, lying down or
supporting yourself on the ground may cause life-threatening electrical
currents (step voltage).
►Do not leave the cab.
►Do not touch metal parts.
►Do not establish a conductive connection to earth.
►Warn other people: Do NOT approach the tractor-machine combi‐
nation. Electrical voltages on the ground may cause severe electric
shocks.
►Wait for help from professional rescue workers. The overhead line
must be switched o.
If persons have to leave the cab despite a ashover, e.g. because there
is an immediate danger of death due to re:
►Jump away from the tractor-machine combination. Jump into a
safe standing position. Do not touch the tractor-machine combina‐
tion from the outside.
►Move away from the tractor-machine combination in small steps.
The parked machine may overturn. This may result in fatal or serious
injuries.
►Park the machine on rm and level ground only.
►Place a plate (metal, wood, stone) with sucient carrying capacity
under the stands.
Behaviour during ashover of over‐
head lines
Parked machine
Safety
en-GB | Item no. 17516804 | BA 00/2022-10 11

Persons may be entangled, pulled in and seriously injured by the PTO
shaft and the driven components.
Before switching on the PTO shaft:
►Install all the safety guards.
►Move the safety guards to the protective position.
►Check that the speed and direction of rotation of the PTO shaft
correspond to the permitted speed and direction of rotation of the
machine.
►Make sure that nobody is in the hazardous area of the PTO shaft.
►If excessive bending occurs, switch o the PTO shaft.
nThe machine may be damaged.
nScattered components may injure persons.
►If the PTO shaft is not required, switch it o.
Persons may be entangled, pulled in and seriously injured by the
cardan shaft.
►Make sure that the pto shaft guard is tted and fully functional.
►Make sure that nobody is in the hazardous area of the cardan shaft.
►Ensure sucient covering of prole tube and pto shaft guard.
►Let the cardan shaft locks engage.
►To secure the pto shaft guard against moving along, hook in the
chains of the pto shaft guard.
►Observe the operating instructions of the cardan shaft.
The gearbox of the machine may become hot during operation.
Contact with hot components may cause minor burns to hands and
arms.
►Keep away from hot surfaces.
►Wear suitable protective gloves.
►Before working on the machine: Let the machine cool down.
Risk of injury at the PTO shaft
Risk of injury at the cardan shaft
Risk of injury on hot surfaces
Safety
en-GB | Item no. 17516804 | BA 00/2022-1012

2.4 Workplaces and passengers
The main workplace for working with the machine is the driver's seat in
the tractor. Further workplaces are described in the respective instruc‐
tions for action.
Dangerous situations may occur if several persons operate the machine
functions at the same time.
►Observe the hazardous areas.
►Pay attention to other persons in the vicinity of the machine.
Passengers may fall from the machine and seriously injure themselves.
Scattered objects may hit and injure passengers.
►NEVER allow persons to ride along on the machine.
2.5 Technically perfect condition
Operational safety of the machine cannot be guaranteed without
proper preparations in accordance with these operating instructions.
This may result in fatal or serious injuries.
►Use the machine only after proper preparations.
If the technical limit values of the machine are not observed, the
machine will be damaged.
This may result in fatal or serious injuries.
►Observe the machine-specic limit values.
Ä Chapter 12 ‘Technical data’ on page 104
Workplaces
Passengers
Operation only after proper prepara‐
tions
Observe the technical limit values
Safety
en-GB | Item no. 17516804 | BA 00/2022-10 13

Damage to the machine can impair the operational safety of the
machine and cause accidents.
This may result in fatal or serious injuries.
To ensure that the machine is in a safe condition, carry out the fol‐
lowing measures:
►Check the machine according to the maintenance schedule.
Ä Chapter 9.2.1 ‘Maintenance schedule’ on page 81
►Repair damage and eliminate causes of damage immediately.
►Remove coarse dirt.
If safety-relevant damage cannot be repaired in accordance with these
operating instructions:
►Have damage repaired by a qualied specialist workshop.
Structural modications and extensions can impair the functionality
and operational safety of the machine.
This may result in fatal or serious injuries.
Auxiliary equipment and spare parts that do NOT comply with the man‐
ufacturer's requirements may negatively aect the operational safety of
the machine and cause accidents.
►Modications and conversions may only be carried out with the
written consent of the manufacturer.
►Structural modications and extensions must only be carried out
by an authorised specialist workshop.
►Use original spare parts or parts approved by the manufacturer.
►Only use the auxiliary and operating materials listed.
Ä Chapter 12.7 ‘Operating materials’ on page 107
Improper welding work endangers the operational safety of the
machine.
This may result in fatal or serious injuries.
►Have welding work carried out by a qualied specialist workshop.
Danger due to damage to the
machine
Modications at the machine
Welding work
Safety
en-GB | Item no. 17516804 | BA 00/2022-1014