Ziegler Pickup ZPU User manual

Pickup ZPU / ZPU +
Date: 17.05.2023
Ziegler-Nr.: 12-054035A Vers.07 Pickup BTA EN

EG-Konformitätserklärung
Entspricht der EG-Richtlinie 2006/42/EG
EC Declaration of conformity
In accordance with the EC directive 2006/42/EC
Wir, ZIEGLER GmbH
We, Schrobenhausener Straße 56
D-86554 Pöttmes
Erklären in alleiniger Verantwortung, dass das Produkt
declare, and takes sole responsibility for declaring, that the product
Maschine: ZIEGLER Pickup
Modell: PICK UP
Typ: ZPU, ZPU +
ab Seriennummer: 4200000
auf das sich diese Erklärung bezieht, den einschlägigen grundlegenden Sicherheits- und Gesundheitsanforde-
rungen der EG-Richtlinie 2006/42/EG entspricht. Zur sachgemäßen Umsetzung der in den EG-Richtlinien ge-
nannten Sicherheits- und Gesundheitsanforderungen wurden insbesondere folgende Normen und technische
Spezifikationen herangezogen:
To which this declaration refers conforms with the applicable basic health and safety requirements of the EC
directive 2006/42/EC. The following standards and technical specifications were applied in order to fulfil the
health and safety requirements of the relevant EC directives:
EN ISO 12100 Safety of machines
EN ISO 4254-1 Agricultural machinery - Safety - Part 1
EN ISO 4254-5 Agricultural machinery - Safety - Part 5
EN ISO 4254-7 Agricultural machinery - Safety - Part 7
EN ISO 4254-12 Agricultural machinery - Safety - Part 12
EN 12965 Tractors and machinery for agriculture and forestry
EN 60204-1 Safety of machinery - Electrical equipment of machine Part 1
Bevollmächtigt zur Zusammenstellung der technischen Unterlagen ist der unterzeichnende Geschäftsführer.
The company officer authorized to compile the technical documentation is the Managing Director (signatory).
Dieses Zertifikat belegt, dass auch einzelne Anbauteile mit den grundlegenden Sicherheitsvorgaben (gemäß
der EU-Richtlinie 2006/42/EG) rechtskonform sind und bei der Montage an Mähdreschern und an anderen
Geräten mit dem CE-Zeichen gekennzeichnet werden dürfen.
This certificate furnishes proof of the conformity of individual attachment parts with the fundamental safety
specifications (in accordance with EU Directive 2006/42/EC) and may be assigned a CE mark when fitted to
combine harvesters and other devices.
Pöttmes, 01.01.2021______
Ort und Datum; Place and date Dipl. BW (FH) M. Ziegler
(Managing Director)

To guarantee the handover of the operating instructions to the end customer and the reseller.
Date of delivery ______________________________
Please a completed copy of this form to
ZIEGLER GmbH, Schrobenhausener Straße 56, D-86554 Pöttmes (Germany)
Address authorized stockist / importer
__________________________________________________
Company
__________________________________________________
Address
_______________________________________________________________________________________________________
Town / postcode Company stamp / date
Customer address
__________________________________________________
Name
__________________________________________________
Address
__________________________________________________
Post code
I hereby declare that I have purchased the machine / set specified below. I also confirm that I was presented with the operating
instructions upon delivery of the machine / set. I undertake to read these operating and installation instructions comprehensively
and carefully before use of the machine / set. Moreover, I undertake to commission and operate the machine / set in accordance
with their contents. I will also include these documents with the machine / set in the event of its resale and inform the buyer of the
obligation to pass on the instructions with the machine. I am aware that a guarantee claim can be made against ZIEGLER GmbH
only after ZIEGLER GmbH have received a completed and signed version of this declaration. Furthermore, I am aware that the
guarantee period begins with the date on which I took receipt of the machine / set, regardless of the date on which this declaration
was returned.
__________________________________________________ ________________________________________________
Machine / set type Machine / set no.
_______________________________________________________________________________________________________
Place / date Customer signature
Guarantee payments can only be made upon provision of a completed and signed handover decla-
ration.

CONTENTS
Page
FOREWORD ....................................................................................................................................................11
INTRODUCTION....................................................................................................................................12
1.1 Intended use...........................................................................................................................................12
1.2 Validity....................................................................................................................................................12
1.3 Contact partner.......................................................................................................................................12
SAFETY .................................................................................................................................................13
2.1 MARKING OF INFORMATION IN THE OPERATING INSTRUCTIONS...............................................13
2.2 MARKING OF THE DANGER WARNINGS...........................................................................................13
2.3 Personnel qualification and training .......................................................................................................13
2.4 Dangers for failure to follow the safety information................................................................................13
2.5 Safety-conscious working.......................................................................................................................14
2.6 Safety and accident-protection regulations............................................................................................14
2.7 Attached devices....................................................................................................................................15
2.8 Drive shaft ..............................................................................................................................................15
2.9 Hydraulic system....................................................................................................................................16
2.10 Maintenance...........................................................................................................................................17
2.11 Unauthorized conversions and production of spare parts......................................................................17
2.12 Impermissible operation .........................................................................................................................17
2.13 Safety information on the machine.........................................................................................................17
2.14 The meaning of the safety labels ...........................................................................................................18
TECHNICAL DATA AND DESIGNATION.............................................................................................19
3.1 Type plate...............................................................................................................................................19
3.2 Information for inquiries and orders........................................................................................................19
3.3 Intended use...........................................................................................................................................19
3.4 Technical data ........................................................................................................................................20
3.5 Overview of the machine........................................................................................................................20
INSTALLATION .....................................................................................................................................21
4.1 General transport....................................................................................................................................21
4.2 Unpacking the pickup.............................................................................................................................22
4.3 Pickup 3m: Mount the conveyor belt in the working position. ................................................................23
4.4 Pickup drive............................................................................................................................................25
4.5 Hydraulic connections ............................................................................................................................25
4.6 Electric plug............................................................................................................................................26
4.7 Pump ......................................................................................................................................................26
4.8 Motor ......................................................................................................................................................26
4.9 Conveyor belts........................................................................................................................................27
4.10 Tank and filter (combine harvesters with a mechanical reel drive)........................................................28
OPERATION ..........................................................................................................................................29
5.1 Test run ..................................................................................................................................................29

CONTENTS
10
5.2 Screw conveyor / feeder.........................................................................................................................30
MAINTENANCE AND CARE.................................................................................................................31
6.1 Accident protection / operating safety....................................................................................................31
6.2 Lubricants / general information / disposal.............................................................................................32
6.3 Maintenance / Care / Inspection.............................................................................................................33
6.4 Decommissioning and dismantling.........................................................................................................34
FAULTS AND TROUBLESHOOTING...................................................................................................35
OPTIONS ...............................................................................................................................................36
8.1 Protective grid.........................................................................................................................................36
8.2 Performance-Damping ...........................................................................................................................36
EXTRACTION TORQUE FOR SCREWS..............................................................................................37

FOREWORD
11
FOREWORD
Dear customer,
In purchasing our pickup, you have decided for a high-quality ZIEGLER product.
As such, we should like to thank you for your expression of trust.
Please read these operating instructions carefully and before use so as to ensure the best possible use of the
pickup.
This manual has been structured in such a way as to provide comprehensive information about the required
activities following the technical sequence. They provide comprehensive information pertaining to the mainte-
nance, the safe operation of the machine, safe working methods, special precautionary measures and the
additional accessories available. Compliance with the specifications contained in this manual is vital so as to
ensure operational safety, reliability and value-conservation of the pickup.
Please note:
This manual also refers to the pickup as the “machine” or “front attachment device”.
Please note:
These operating instructions represent a constituent part of the machine and must be stored in immediate
proximity to it.
Only ever operate the machine after full training and in compliance with the specifications of this manual.
It is imperative that you follow the safety information.
Comply will all the applicable accident prevention regulations and all generally recognized safety and medical-
safety regulations and the applicable highway code.
All the information, diagrams and technical specifications made in these operating instructions correspond to
the latest state of technology at the point of publication.
We reserve the right to make alterations to the design at any time and without the need to specify reasons.
Should these operating instructions become completely or partially unusable, we will provide you with a re-
placement. Please state the number on the next page.
We wish the best of success with your pickup.
Ziegler GmbH

INTRODUCTION
12
INTRODUCTION
These operating instructions contain the basic information which must be followed during the operation
and maintenance of your machine. All personnel must read these operating instructions before commis-
sioning the machine. They are to be always held accessible to personnel.
Follow all the safety information provided in these operating instructions and not just those listed under
the special safety headings.
1.1 Intended use
The pickup is perfect for easy and efficient swath pick-up for e.g. Rapeseed, peas, beans, lentils etc.
The collecting belts are controlled hydraulically and are equipped with safety valves. Each belt has 36
springs, the control is possible directly from the cabin. The collecting auger (diameter of 61 cm) has
several disc clutches. Two support wheels, freely adjustable in height, can optionally also be equipped
with performance damping. With mechanical reel control, the pick-up can be delivered with its own hy-
draulic pump and tank.
As soon as the pick-up system is connected, all further processes are controlled from the driver's posi-
tion of the combine harvester. After that, no additional staff is required.
Covers or protective devices may only be removed in an emergency. In this case, the device must be
disconnected, and the ignition key removed. As soon as the repair or other measures have been com-
pleted, the covers must be properly attached again.
The attachment to all common combine harvester models is quick and
uncomplicated thanks to a suitable removable frame.
1.2 Validity
These operating instructions are valid for the pickup ZPU, ZPU+
1.3 Contact partner
Ziegler GmbH
Schrobenhausener Str. 56
D-86554 Pöttmes (Germany)
Tel: [phone] (switchboard)
Fax: [phone]
e-mail: [e-mail]
Internet: www.ziegler-harvesting.com

SAFETY
13
SAFETY
2.1 MARKING OF INFORMATION IN THE OPERATING INSTRUCTIONS
The safety information provided in these operating instructions (failure to follow them can result in the
endangerment of persons) is marked with general danger symbols:
2.2 MARKING OF THE DANGER WARNINGS
Danger!
DANGER! –Nature and source of the danger!
Impact: Danger to life or of serious injuries.
➢Measures for danger prevention
Warning!
WARNING! –Nature and source of the danger!
Impact: Injury, serious damage to material.
➢Measure for damage limitation
Caution
WARNING –Nature and source of the danger!
Impact: Material damage
➢Measure for damage limitation
Please note
PLEASE NOTE –Nature and source of the danger!
Impact: Economic use of the machine
➢Measures to be performed
Environment
PLEASE NOTE –Nature and source of the danger!
Impact: Pollution
➢Measures to be performed
Warnings placed directly on the machine always require compliance and are to be maintained
in a completely legible manner.
2.3 Personnel qualification and training
The machine may only be used, serviced and repaired by those persons who are familiar with it and
have been informed of the dangers which it presents. The owner is to establish clearly the areas of
responsibility and monitoring of personnel. Personnel lacking any requisite knowledge must be trained
and instructed. The owner is to ensure that the personnel have read and understood entirely the speci-
fications of the operating instructions.
Repair work not described in these operating instructions may only be performed by an authorized spe-
cialist workshop.
2.4 Dangers for failure to follow the safety information
Failure to follow with the safety information can result in hazards for persons, the environment and the
machine itself. Failure to follow the safety information can result in loss of all liability cover.
Non-compliance can result in the following hazards:
➢Hazards to persons through unsecured working areas
➢The failure of important machine functions
➢The failure of the prescribed methods of maintenance and repair
➢The endangerment of persons from mechanical and chemical influences
➢Environmental hazards resulting from the leakage of hydraulic oil

SAFETY
14
2.5 Safety-conscious working
Follow the safety information provided in these operating instructions; any valid accident-prevention
regulations; and any internal working, operating and safety regulations.
The health and safety and accident-prevention regulations of the appropriate professional associations
are binding.
Follow the safety information of the vehicle manufacturer.
Comply with the relevant highway code when driving on public highways
(in Germany StVZO and StVO)
Be prepared for any emergencies. Maintain fire extinguishers and First-Aid kits in the immediate vicinity.
Display the emergency numbers for medical and fire services.
2.6 Safety and accident-protection regulations
➢In addition to the information contained in these operating instructions, comply with all the gener-
ally-valid
safety and accident-protection regulations
➢Warning signs provide important information required for danger-free operation. Compliance with
them serves your safety.
➢Comply with all traffic regulations when using public highways.
➢Please ensure that you familiarize yourself with all the features and operating elements as well as
their function before commencing work. It is too late to do so whilst working!
➢Operating personnel should wear tightly-fitting clothing. Avoid wearing any loose clothing.
➢Keep the machine clean so as to minimize the danger of fire.
➢Check the immediate surroundings before activating and commissioning. (Children!) Ensure suffi-
cient visibility.
➢Travelling on the equipment is forbidden during work.
➢Couple the devices as prescribed and only fix and secure to the prescribed equipment.
➢Bring the support equipment into the respective position during fitting and removal.
➢Exercise especial caution when coupling and uncoupling the pickup to or from the forage harvester
/ combine harvester.
➢Always couple the ballast weights to the foreseen
anchorage points in accordance with the specifications.
➢Comply with the permissible axle loads, total weight and transport dimensions.
➢Check and install the transport equipment such as illumination, warning equipment and if neces-
sary, the
safety equipment.
➢The actuation equipment (rope, chains, rod etc.) of remotely-actuated units must be installed in
such a way that they do not trigger unintended movements in all transport and working positions.
➢Bring the pickup into the prescribed state for road travel and lock in accordance with the relevant
specifications.
➢Never leave the driver's cab during travel.
➢The travel speed must always be adapted to the surrounding conditions. Avoid sudden approaches
to a curve during hill and valley travel and transverses to the slope.
➢Handling, steering and braking is influenced by the installation of the devices and the addition of
ballast weight. Ensure sufficient steerability and brake capacity.
➢Pay attention to the wide projection and / or the oscillating weight of the device when travelling on
curves.
➢Only ever commission the pickup once all safety equipment have been installed and are in
the protection position.
➢Maintain the safety equipment in a good state. Replace missing or damaged parts.
➢Persons are forbidden from remaining in the work area.
➢Do not remain in the turning and pivoting area.
➢The hydraulic folding frame may only be actuated once there is no-one in the
pivoting area.
➢Danger of crushing and shearing at remote-actuated parts (e.g.
hydraulics).
➢Before leaving the forage harvester / combine harvester, set down the pickup on the ground, en-
gage the parking brake, switch off the motor and remove the ignition key.
➢People are prohibited from standing between the forage harvester / combine harvester and pickup
without the parking brake and stop block being activated to stop the vehicle from rolling away.
➢Follow all the further safety information in the forage harvester / combine harvester operating in-
structions.

SAFETY
15
2.7 Attached devices
➢Exercise especial caution when coupling and uncoupling the pickup to or from the forage harvester
/ combine harvester.
➢The pickup may only be attached to the type of forage harvester / combine harvester intended for
the purpose.
➢Work on the pickup may only be performed with the motor switched off and the ignition key re-
moved. All control levers should be in the neutral position and none of the hydraulic lines should
be pressurized.
➢Never work under a raised pickup.
➢The pickup may only be driven on public highways and paths with the transport trailer intended for
the purpose.
➢The pickup must always be placed into the transport position for transport on public highways and
paths. Apply protective sheets with flashing lights and front guards onto the pickup; connect the
illumination. Repairs, maintenance and cleaning work and troubleshooting may only be performed
after the drive and motor have been switched off and the ignition key has been removed.
➢Liquids emerging under pressure (hydraulic oil) can penetrate the skin and cause serious injuries
which are not visible from outside. Consult a hospital immediately after injuries. Danger of infection
➢Dispose of used operating resources such as old oil in the correct fashion.
➢The repairs of the hydraulic installation can only be performed by specialist workshops.
2.8 Drive shaft
➢Only the drive shaft prescribed by the manufacturer may be used.
➢The protective piping, guard cone and power take-off guard - also on the device side - must be
fitted and in good condition.
➢Ensure the prescribed pipe coverings for the drive shaft are used in the transport and
Work position.
➢Only install and dismantle the drive shaft with the power take-off shaft and with the motor switched
off and the ignition key removed.
➢When using a drive shaft with an overload or freewheel coupling which is not covered by the safety
equipment on the tractor, the overload or freewheel couplings are to be installed on the device side.
➢Always ensure the correct installation and securing of the drive shaft.
➢Secure the drive shaft guard by securing the chain against running.
➢Before activating the power take-off shaft, ensure that the rotation speed of the power take-off shaft
of the
forage harvester / combine harvester matches the rotation speed of the device.
➢Before activating the power take-off shaft, ensure that no-one is in the danger area of the
➢device.
➢Never activate the power take-off shaft when the motor is deactivated.
➢No-one may be permitted to remain in the area of the turning power take-off shaft or drive shaft
when working on the power take-off shaft
.
➢Always deactivate the power take-off shaft when too great a level of angular offset means that it is
not required.
➢Caution! Danger from running flywheel mass once the power take-off shaft has been switched off.
Do not enter the device during this time. Work may only performed on the machine once it is at a
complete standstill.
➢Cleaning, lubrication or setting power take-off shaft driven devices or the drive shaft may only be
performed with the power take-off shaft and motor deactivated and the ignition key removed.
➢Place uncoupled drive shafts in the bracket intended for this task.
➢After removing the drive shaft, place on the protection cover on the power take-off stub.
➢Rectify any damage immediately before continuing work with the device.
Please note
Follow the information of the manufacturer of the drive shaft.
(Separate operating instructions).

SAFETY
16
2.9 Hydraulic system
➢The hydraulic system is pressurized.
➢When connecting hydraulic cylinders and motors, ensure that you connect the hydraulic hydraulic
hoses in the correct fashion.
➢When connecting the hydraulic hoses to the hydraulic connections of the forage harvester / com-
bine harvester, ensure that the hydraulics are depressurized on both sides.
➢Given hydraulic function connections between the forage harvester / combine harvester and the
front attachment, ensure that the coupling sleeves and plugs are marked so as to prevent incorrect
operation. Swapping the connections of the opposite functions (e.g. raising and sinking) brings the
DANGER OF ACCIDENT.
➢Subject the hydraulic hose lines to regular checks and replace if damaged or worn. All replacement
hose lines must satisfy the technical requirements of the device manufacturer.
➢Use suitable resources when searching for leaks due to the danger of injury.
➢Liquids emerging under pressure (hydraulic oil) can penetrate the skin and cause serious injuries.
Consult a doctor immediately after injuries. Danger of infection
➢Ensure that the hydraulic system has been depressurized and switch off the motor before perform-
ing any work on the hydraulic system.

SAFETY
17
2.10Maintenance
➢Repair, maintenance and cleaning work and the elimination of malfunctions should only ever be
performed once the drive has been switched off and the motor is at a standstill. - Remove the ig-
nition key.
➢Test all nuts and screws for their security and tighten if necessary.
➢When performing maintenance work on the raised machine, ensure that it is secured with appro-
priate
support elements.
➢Dispose of oils, grease and filters correctly.
➢Always disconnect the electrical system from the power supply before commencing work.
➢Should safety equipment be subject to wear, it is to be subject to regular checks and replace-
ment.
➢When performing electrical welding work on the vehicle and connected devices, disconnect the
power supply via the battery main switch or the cable on the generator and pinch off the battery.
➢The spare parts must correspond with the manufacturer’s technical specifications as a minimum.
This is guaranteed by original ZIEGLER spare parts.
➢When replacing the cutting tools, use tools appropriate to cutting tools and wear suitable gloves.
2.11Unauthorized conversions and production of spare parts
Conversions or changes to the machine are only permitted following consultation with the manufacturer.
ZIEGLER original spare parts and manufacturer-authorized accessories serve the security of the ma-
chine. Using other parts can invalidate the liability for the resulting consequences.
2.12Impermissible operation
The operating safety of the machine is only guaranteed given its intended use in accordance with the
chapter “Introduction Intended use” of the operating instructions. The threshold values specified in the
data sheets must never be exceeded.
2.13Safety information on the machine
The ZIEGLER front attachment device is fitted with all the necessary safety equipment. Not all danger
points on this machine can be secured entirely against function-loss. The corresponding safety warnings
are located on the machine which point to the remaining residual dangers. The danger information has
been presented in the form of so-called warning symbols. The following section provides information
about the position of these warnings.
The safety information on the machine warn against residual dangers. They consist of warning symbols
and work safety symbols. Follow all the safety information Safety information must always be maintained
in a clean and easily-legible state. Should the safety information suffer damage or be lost, order re-
placements from the supplier and install on the intended locations. The position and meaning are de-
scribed in the following section:
DANGER! –Danger area of the machine
Impact. Danger to life or of serious injuries.
➢Replace damaged or illegible labels immediately.
➢Affix the corresponding safety labels to all repaired, replaced or oth-
erwise altered components.
➢Never use a high-pressure jet to clean areas to which a safety label
has been affixed.
➢Familiarize yourself with the meaning of the warning symbols. The
adjacent text and the area on the machine selected for the labels pro-
vide information for the special danger areas on the machine.

SAFETY
18
2.14The meaning of the safety labels
Read and comply
with the operating in-
structions and the
safety information be-
fore commissioning.
Do not remain in the
area of the drive shaft.
Danger of injury!
Never stand in the
danger area between
the front attachment
device and the ma-
chine
Persons are only per-
mitted to be in the
danger area if the
safety supports are
engaged.
Maintain sufficient
safety clearance to
the harvest front at-
tachment. Before per-
forming maintenance
work or removing
blockages, switch off
the harvest front at-
tachment and the mo-
tor and remove the ig-
nition key.
Never reach into the
rotating auger.
Be careful with es-
caing high-pressure
fluid. Observe the note
in the technical man-
ual.
Do not open or re-
move the safety equip-
ment when the motor
is running
QR manual and spare parts list
Quality check sticker

TECHNICAL DATA AND DESIGNATION
19
TECHNICAL DATA AND DESIGNATION
3.1 Type plate
Fig. 1
3.2 Information for inquiries and orders
Year of construction:
SN:
Type
The entire marking is equivalent to an official document and may not be altered or changed beyond
recognition.
Should you have questions about the machine or when ordering spare parts, state the type designation,
serial number and the year of construction of the corresponding machine. We recommend that you enter
this information in the fields above so as to ensure their availability.
Please note
ZIEGLER original spare parts and manufacturer-authorized accessories serve the security of the ma-
chine. The use of spare parts, accessories and other devices not produced, tested or authorized by
ZIEGLER will result in the loss of liability for the resulting damage.
Take the corresponding article numbers for the spare parts list.
3.3 Intended use
The pickup may only be fitted to transport vehicles for which the respective adapter frame has been
authorized (comply with the operating permission of the bearer vehicle). It is exclusively to be used for
conventional agricultural operations (intended use): please consult the chapter introduction “Intended
use”.
Any other form of use exceeding these specifications is classed as non-intended use. The manufacturer
is not liable for any damage resulting from this form of use. The risk is carried by the operator alone.
Intended use includes the maintenance of the operating, maintenance and servicing conditions specified
by the manufacturer.
Unauthorized alterations made to the machine can exert a negative influence on the machine and impair
the orderly function. Unauthorized alterations release the manufacturer from any resulting liability
claims.

TECHNICAL DATA AND DESIGNATION
20
3.4 Technical data
All the information, diagrams and technical specifications made in these operating instructions corre-
spond to the latest state of technology at the point of publication.
We reserve the right to make alterations to the design at any time and without the need to specify
reasons.
Technical Data
working width
belts
tines
width x height x depth
weight
3,0 m
6
6 x 36
3550 x 1400 x 1950 mm
≈860 kg
4,0 m
8
8 x 36
4650 x 1400 x 1950 mm
≈1.190 kg
5,0 m
10
10 x 36
5650 x 1400 x 1950 mm
≈1.550 kg
6,0 m
12
12 x 36
6650 x 1400 x 1950 mm
≈1.900 kg
3.5 Overview of the machine
Fig. 2
1. Drive box
2. Frame
3. Multicoupler
4. Conveyor belt
5. Snail
6. Hydraulics
7. Protective grille (option)
8. Performance dampening (option)