Ziegler Pickup ZPU Operating 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,
We,
ZIEGLER GmbH
Schrobenhausener Straße 56
D-86554 Pöttmes
Erklären in alleiniger Verantwortung, dass das Produkt
declare, and takes sole responsibility for declaring, that the product
Maschine:
Modell:
Typ:
ab Seriennummer:
ZIEGLER Pickup
PICK UP
ZPU, ZPU +
4200000
auf das sich diese Erklärung bezieht, den einschlägigen grundlegenden Sicherheits- und Gesundheitsanforderungen der EG-Richtlinie 2006/42/EG entspricht. Zur sachgemäßen Umsetzung der in den EG-Richtlinien genannten 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
EN ISO 4254-1
EN ISO 4254-5
EN ISO 4254-7
EN ISO 4254-12
EN 12965
EN 60204-1
Safety of machines
Agricultural machinery - Safety - Part 1
Agricultural machinery - Safety - Part 5
Agricultural machinery - Safety - Part 7
Agricultural machinery - Safety - Part 12
Tractors and machinery for agriculture and forestry
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 declaration.
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
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
10
FOREWORD
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 maintenance, 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 medicalsafety 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 replacement. Please state the number on the next page.
We wish the best of success with your pickup.
Ziegler GmbH
11
INTRODUCTION
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 commissioning 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 hydraulic pump and tank.
As soon as the pick-up system is connected, all further processes are controlled from the driver's position 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 completed, the covers must be properly attached again.
The
attachment
to
all
common
combine
uncomplicated thanks to a suitable removable frame.
harvester
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: +49 (0) 8253/9997-0 (switchboard)
Fax: +49 (0) 8253/9997-47
e-mail: [email protected]
Internet: www.ziegler-harvesting.com
12
models
is
quick
and
SAFETY
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 specifications of the operating instructions.
Repair work not described in these operating instructions may only be performed by an authorized specialist 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
13
SAFETY
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
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In addition to the information contained in these operating instructions, comply with all the generally-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 sufficient 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 necessary, 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, engage 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 instructions.
14
SAFETY
2.7 Attached devices
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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 removed. 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
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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).
15
SAFETY
2.9 Hydraulic system
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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 / combine 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 performing any work on the hydraulic system.
16
SAFETY
2.10 Maintenance
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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 ignition 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 appropriate
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 replacement.
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.
2.11 Unauthorized 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 machine. Using other parts can invalidate the liability for the resulting consequences.
2.12 Impermissible 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.
2.13 Safety 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 replacements from the supplier and install on the intended locations. The position and meaning are described 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 otherwise 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 provide information for the special danger areas on the machine.
17
SAFETY
2.14 The meaning of the safety labels
Read and comply
with the operating instructions and the
safety information before 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 machine
Persons are only permitted to be in the
danger area if the
safety supports are
engaged.
Maintain sufficient
safety clearance to
the harvest front attachment. Before performing maintenance
work or removing
blockages, switch off
the harvest front attachment and the motor and remove the ignition key.
Never reach into the
rotating auger.
Be careful with escaing high-pressure
fluid. Observe the note
in the technical manual.
Do not open or remove the safety equipment when the motor
is running
QR manual and spare parts list
Quality check sticker
18
TECHNICAL DATA AND DESIGNATION
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 machine. 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.
19
TECHNICAL DATA AND DESIGNATION
3.4 Technical data
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.
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)
20
INSTALLATION
INSTALLATION
DANGER! – The machine can tip!
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Impact: Danger to life or of serious injuries.
Apply the transport lock
Secure the machine correctly with tension belts
Ensure that the machine has a steady position and let it down slowly.
Ensure sufficient chain tension.
Switch off the motor and activate the lowering lock before commencing
any work on the machine
Persons must not be in the danger area.
Use sufficient lifting gear
Comply with the regulations for lifting gear
PLEASE NOTE – Fit seals
Impact: Seals not tight
➢ Comply with the correct sequence before fitting any form of seal
4.1 General transport
Transport on a HGV
When transporting the pickup on a HGV, always use the ZIEGLER transport frame.
Secure the pickup against falling down using tensioning belts in accordance with the locally-valid regulations.
Ensure that the machine has a steady position.
Transporting the machine on the company premises with a crane
The pickup can only be transported from above with a crane. Use the suspension points intended for suspending the load. Ensure that the picker is always in balance and that the load is distributed evenly.
Use only suitable lifting gear to perform the transport.
Switch off the motor and activate the lowering lock before commencing any work on the
machine.
Persons must not be in the danger area.
Fig. 3
21
INSTALLATION
Transporting the machine on the company
premises with a forklift truck
The transport frame is designed in such as way
that the pickup can be secured to the frame so as
to prevent it falling out.
You can use the ZIEGLER transport frame to
transport the pickup with a forklift truck.
We recommend driving at a walking pace.
You will require a crane in order to set the pickup in
the transport frame.
(See also “transporting the machine on the company premises with a crane”).
Fig. 4
Transport with the combine harvester
The pickup can be attached securely to the combine harvester and be transported using the ZIEGLER header trailer.
Fig. 5
4.2 Unpacking the pickup
Scope of delivery / state of delivery
The pickup is delivered upright on a
transport frame.
Every dispatch is accompanied by a delivery slip.
Remove the shrink wrap and the packaging pieces from the front attachment device.
Check the scope of delivery.
Check the delivered row clearance
Ensure that the machine is located in a steady position
22
INSTALLATION
4.3
Pickup 3m: Mount the conveyor belt in the working position.
Delivery condition
Attache hydraulic screw connection,
put on.
Move, fasten with enclosed screws (dispose
of old screws)
Secure wheel
23
INSTALLATION
Fig. 6
Adaptation to the thresher
The pickup is to be parked on the parking supports.
Check the correctness of the adaptation parts.
Drescher approach the pickup.
Pick up the pickup with the feed channel.
Check that the adaptation (A) is correctly seated.
It is not permitted for people to stand
between the threshing machine and the
pickup during the attachment process.
Fig. 7
Lock the machine to the feeder housing.
Fasten the pick-up (R) according to the setup specified by the harvester.
Attention: Depending on the combine model, the
locking mechanism may be different.
Additional weights
Fig. 8
Depending on the weight of the installed pickup, additional weights may be required on the steering
shaft of the harvester.
The dimensions of these additional weights are
specified in the motor vehicle certification of the
combine harvester handbook.
Comply with the certification conditions
for public traffic.
24
INSTALLATION
4.4 Pickup drive
Cardan shaft drive
The pickup is driven by a cardan shaft.
Fig. 9
It is essential to protect the drive shaft with a chain
(K) secure against turning.
If the combine is equipped with a swivel blade,
check the overlap when it is swung out.
Remove and read the special instructions for cardan shafts before commissioning!
Grease the shaft profile of the cardan shaft connection once a year.
Check protective devices (S) before commissioning.
Do not open or remove these during operation.
Switch off the diesel engine for all work
on the machine!
Secure the cardan shaft guards against
turning! Replace damaged protection immediately!
4.5 Hydraulic connections
Multicoupling
If the combine harvester is equipped with a multicoupling, the pickup should also be equipped in
the same way.
The correct coupling is included in the scope of delivery.
Operation is performed in accordance with the regulations and instructions of the manufacturer of the
combine harvester.
Connection via the control valve coupling
Some brands of combine harvesters require a control valve coupling to connect a header.
The corresponding pickers are fitted with the requisite technology on a serial basis.
Operation is performed in accordance with the regulations and instructions of the manufacturer of the
combine harvester.
Fig. 10
Avoid the danger area when performing
a functional check. Check for leaks.
Should you find a leak, comply with all
the requirements of environmental protection. Wear the corresponding protective clothing.
25
INSTALLATION
4.6 Electric plug
Fig. 11
Electric plug
The electric plug must be connected to the electric
socket of the platform, see position 2.
Avoid danger area during function test!
Check tightness!
In the event of leaks, observe the environmental protection regulations! Wear appropriate
protective clothing!
4.7 Pump
Fig. 12
Pump (on models with mechanical reel drive)
Level gauge, position “2”- check every 100 hours
of operation. Refill by removing the cap, position
3. Change the oil every 400 hours using SAE
90/100 or equivalent.
If the pump, item 1, reaches a high operating temperature, there is a risk of
serious burns. Before you start any
work, let it cool down first.
4.8 Motor
Fig. 13
Pickup conveyor belt motor
The motor shown in Figure 13 controls the speed
of the conveyor belt. It is maintenance free.
Switch off the diesel engine for all work
on the machine!
26
INSTALLATION
4.9
Conveyor belts
To optimally adjust the band, adjust the screw “x” located on both sides of the band.
Fig. 14
Switch off the diesel engine for all work
on the machine!
Fig. 15
To adjust the tension in the center of the rollers, turn
nut “1” which adjusts rod “2”. Make sure that the distance in the middle between the rollers is also the
same on the sides.
2
Fig. 16
The chain "Y" has a support function during transport
of the pickup.
During operation, with the conveyor belt and wheel
lowered, the chain “Y” of the shock absorber should
be loosened rather than tensioned. The tines of the
conveyor belt should have a ground clearance of approximately 1 to 2 cm during the harvesting process.
Y
Switch off the diesel engine for all work
on the machine!
27
INSTALLATION
4.10 Tank and filter (combine harvesters with a mechanical reel drive)
Fig. 17
The oil level in the tank “1” (fig 1) shall periodically be
checked through the cover “2” and filled up with oil
(see table)
The oil shall totally be replaced every 1200 working
hours.
AGIP
BLASIA
100
FINA
GIRAN
100
TOTAL CARTER EP
100
Fig. 18
The filter shall be replaced every 100 working hours
for the first time and every 400 working hours thereafter.
The tap shall be opened again after a filter replacement and before running the pickup.
Before replacing the filter “1” carefully
close the tap “2”.
28
OPERATION
OPERATION
DANGER! – The pickup could start up unexpectedly during setting work
Impact: Danger to life or of serious injuries.
➢ Lower the pickup completely
➢ Switch off the combine harvester completely, remove the ignition key and
secure the machine against reactivation (operating Instructions of the
combine harvester)
➢ Wear cut-proof protective gloves
➢ Persons must not be in the danger area.
DANGER! – Persons could be in the corn field
Impact: Danger to life or of serious injuries.
➢ Ensure that the field is empty of persons before starting operation; no-one
may per permitted to be in the proximity of the pickup.
DANGER! – Ejected parts
Impact: Danger to life or of serious injuries.
➢ When the engine is running and the drive is switched on, keep a sufficient
distance to the conveyor belts!
5.1 Test run
Reducing the starting torque
Fig. 19
Reduce the startup force by starting the pickup with
a reduced motor rotation speed in the stand gas
position. This will considerably prolong the life-expectancy of the drive couplings and straps.
Ensure that the horizontal chopper does not come
into contact with foreign bodies.
Maintain a safe distance from the machine
Protect yourselves and others against
injury and accidents.
Control the operating rotation speed.
29
OPERATION
5.2
Screw conveyor / feeder
Fig. 20
Auger
K
The screw conveyors are fitted with conveyor fingers (K) in the area of the channel opening to
transport the crop.
The number of conveyor fingers (K) can differ for
the individual pick-up models and depends on the
feed channel width of the respective thresher.
Fig. 21
Screw conveyor drive
The screw conveyor timing chain can be tightened
with a special chain tensioner.
The voltage condition should be checked every 100
hours of operation.
Turn off the engine and remove the ignition key from the combine to perform this operation.
30
MAINTENANCE AND CARE
MAINTENANCE AND CARE
6.1 Accident protection / operating safety
DANGER! – The pickup could start up unexpectedly during maintenance
work
Impact: Danger to life or of serious injuries.
➢ Lower the pickup completely.
➢ Switch off the combine harvester completely, remove the ignition key and
secure the machine against reactivation (operating Instructions of the
combine harvester)
➢ Wear cut-proof protective gloves
➢ Persons must not be in the danger area.
Caution – contact with oils and grease
Impact: Injuries
➢ Avoid skin contact with oil, grease and solvents
➢ Consult a doctor immediately after injuries or burns from oils, cleaning agents
and solvents Follow all further safety information to prevent injury and accident.
Fig. 22
Protective covering of the pickup
Before each start-up, the completeness and integrity of the protective cover must be checked. In the
event of damage, it must first be determined why
the damage occurred.
Replace damaged or lost protection immediately.
Formation of dust
Air filter
and other
sensitive components
clean daily!
Important: Air filters and the like, as well as
other sensitive parts (piston rods of the hydraulic cylinders, etc.) must be cleaned regularly.
31
MAINTENANCE AND CARE
6.2 Lubricants / general information / disposal
Recommended lubrication
Hydraulics:
Following the manufacturer’s specifications
General lubrication nipple:
Lubricant Semi-fluid grease EP2
Wear the correct protective clothing Perform an
end control of the lubrication points before
commissioning of the pickup.
Fig. 23
General instructions
All moving parts should be lubricated and cared for
to a degree usual for a machine construction context.
Regular cleaning and the removal of deposits serves
the value-retention and operating safety.
Components subject to regular or irregular movement also require periodic oiling or greasing.
Fig. 24
All bare machine parts require reliable rust-protection after the conclusion of the harvest.
Lubricant Oil (conventional)
Storage
Recommendation:
Clean the machine thoroughly after the conclusion of
the harvest and remove all harvest material and
other residue.
The cleaning hatches and service apertures are to
be kept open during the storage period, in order to
prevent damage to the cables by rodents.
Fig. 25
32
MAINTENANCE AND CARE
6.3 Maintenance / Care / Inspection
Fig. 26
Post-harvest cleaning
After a largely dry harvest campaign, dry cleaning,
e.g. exclusively with compressed air, is recommended.
If the machine is exposed to high levels of moisture
and soiling due to harvesting conditions, cleaning
with a high-pressure cleaner is essential.
Inspection after the harvest season
During the regular inspection (after the harvest season), the following components must be checked
and replaced if necessary:
• Protection device of the PTO shaft
• Hydraulic hoses and hydraulic fittings
Fig. 27
Fig. 28
Roller chains
The mounted roller chain for the auger drive must
be kept rust-free during storage.
Otherwise, the relevant recommendations for roller
chain care apply.
Warehousing
Fig. 29
It is best to store the pickup in a well-ventilated hall.
All bare metal parts should be protected from rust.
Load handling equipment may only be
used as intended. Any modification or
use with other machines is prohibited.
33
MAINTENANCE AND CARE
6.4 Decommissioning and dismantling
DANGER! – The machine can tip!
➢
➢
➢
➢
➢
➢
➢
➢
➢
➢
Impact: Danger to life or of serious injuries.
Apply the transport lock
Secure the machine correctly with tension belts
Ensure that the machine has a steady position.
Lower slowly
Ensure sufficient chain tension.
Switch off the motor and activate the lowering lock before commencing
any work on the machine.
Persons must not be in the danger area.
Use sufficient lifting gear
Comply with the regulations for lifting gear
Caution – contact with oils and grease
Impact: serious injury or damage to the machine
➢ Avoid skin contact with oil, grease and solvents
➢ Consult a doctor immediately after injuries or burns from oils, cleaning
agents and solvents
Follow all further safety information to prevent injury and accident.
Environment
PLEASE NOTE – Oil or grease enters the environment.
Impact: Pollution
➢ Dispose of oils and grease in an environmentally friendly fashion and in
accordance with the applicable regulations.
Decommissioning
If the pickup or its components reach the end of
useful life and require scrapping, the components
must be separated according to material and disposed of in an environmentally safe manner. Comply with the applicable regulations.
Fig. 30
Disposal
Ensure the correct and environmentally friendly disposal of the operating and auxiliary materials
Ensure that no operating materials (oil, grease or
other operating materials which endanger the
groundwater) are able to sink into the groundwater
or the soil.
Fig. 31
Please address any questions to the local disposal
specialists.
Always wear personal protective equipment when
performing the disposal.
34
MAINTENANCE AND CARE
FAULTS AND TROUBLESHOOTING
HYDRAULIK
Malfunction
Pickup cannot be
raised
The hydraulic functions of the pickup do
not work
Cause
Remedy
Insufficient amount of hydraulic oil
Refill oil
Lifting power too low
Additional lifting cylinder required
Hydraulic connections have no flow
Check connections/couplings/screw connections
Lack of pressure in the hydraulic system
Check pressure, increase if permitted
Insufficient amount of hydraulic oil
Refill oil
DRIVE
Malfunction
The drive is switched
on, but the conveyor
belt is not turning.
Pickup stops during
use
Cause
Remedy
Hydraulic connections have no flow
Check connections/couplings/screw connections
Lack of pressure in the hydraulic system
Check pressure, increase if permitted
Insufficient amount of hydraulic oil
Refill oil
Overload
Adjust working speed
AUGER
Malfunction
Cause
Remedy
Overload
Reduce amount of material straw
percentage too high
Drive
Check chain and clutch
Original combine harvester splash panel
mounted in front of the intake channel
Remove splash panel
Conveyor screw stops
35
OPTIONS
OPTIONS
8.1 Protective grid
Fig. 32
Protective grille assembly
Pay attention to the sequence during assembly and
disassembly.
➢
Screw the grille to the designated attachment
points using the supplied screws.
➢
Observe the torque!
8.2 Performance-Damping
Fig. 33
Performance-Damping
The optionally available performance damping improves the ground following, which increases the harvesting speed by up to 4 km/h. In addition, the machine runs more smoothly and wear is reduced.
36
EXTRACTION TORQUE FOR SCREWS
EXTRACTION TORQUE FOR SCREWS
Tightening torque for galvanized screws
Strength
class
5.6
8.8
10.9
12.9
Strength
class
Tightening
torque
Nm
M3
M4
M5
M6
M7
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
M33
M36
M39
Nm
0.56
1.28
2.50
4.3
7.1
10.5
21
36
58
88
121
171
230
295
435
590
800
1030
1340
ft/lb
0.41
0.94
1.84
3.1
5.2
7.7
15
26
42
64
89
126
169
217
320
435
590
759
988
Nm
1.28
2.90
5.75
9.9
16.5
24
48
83
132
200
275
390
530
675
995
1350
1830
2360
3050
ft/lb
0.94
2.14
4.24
7.3
12.1
17.7
35
61
97
147
202
287
390
497
733
995
1349
1740
2249
Nm
1.80
4.10
8.1
14
23
34
67
117
185
285
390
550
745
960
1400 1900
2580
3310
4290
ft/lb
1.33
3.02
5.97
10.3
16.9
25
49
86.2
136
210
287
405
549
708
1032 1401
1902
2441
3163
Nm
2.15
4.95
9.70
16.5
27
40
81
140
220
340
470
660
890
1140
1680 2280
3090
3980
5150
ft/lb
1.59
3.65
7.15
12.1
19.9
29
59
103
162
250
346
486
656
840
1239 1681
2278
2935
3798
NOMINAL DIAMETER - NORMAL THREAD
Tightening
torque
Nm
NOMINAL DIAMETER - FINE THREAD
M8 x 1
M10 x 1.25
M12 x 1.25
M14 x 1.5
M16 x 1.5
M18 x 1.5
M20 x 1.5
M22 x 1.5
Nm
25
49
88
140
210
305
425
570
720
ft/lb
18
36
64
103
154
224
313
420
531
Nm
ft/lb
35
25
68
50
125
92
195
143
295
217
425
313
600
442
800
590
1000
737
Nm
42
82
150
235
350
510
720
960
1200
ft/lb
30
60
110
173
258
376
531
708
885
8.8
10.9
12.9
37
M24 x 2
Hersteller:
ZIEGLER GmbH
Schrobenhausener Straße 56
D-86554 Pöttmes
Tel: +49 (0) 82 53 / 99 97-0
Fax: +49 (0) 82 53 / 99 97-47
Web: www.ziegler-gmbh.com
Amtsgericht Augsburg HR-NR. B 17559
Erfüllungsort Pöttmes, Gerichtsstand Aichach
Steuer-Nr. 102/168/10401
Geschäftsführer: M. Ziegler, Dipl. BW (FH)
Manufacturer:
ZIEGLER GmbH
Schrobenhausener Straße 56
86554 Pöttmes
Germany
Phone: +49 (0) 82 53 / 99 97-0
Fax: +49 (0) 82 53 / 99 97-47
Web: www.ziegler-gmbh.com
Local Court of Augsburg, commercial register no.
HRB 17559
Place of performance: Pöttmes, Place of jurisdiction: Aichach
Tax no. 102/168/10401
Managing director: M. Ziegler, Dipl. BW (FH)
Производитель:
ZIEGLER GmbH
Schrobenhausener Straße 56
D-86554 Pöttmes
Tel: +49 (0) 82 53 / 99 97-0
Fax: +49 (0) 82 53 / 99 97-47
Web: www.ziegler-gmbh.com
Amtsgericht Augsburg HR-NR. B 17559
Erfüllungsort Pöttmes, Gerichtsstand Aichach
Steuer-Nr. 102/168/10401
Geschäftsführer: M. Ziegler, Dipl. BW (FH)
Managing director: M. Ziegler, Dipl. BW (FH)