Ziegler CORN CHAMPION 5S Operating And Assembly Instructions Manual Download Page 40

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MAINTENANCE AND CARE

6.1 Accident protection / operating safety

DANGER! – The cornheader could start up unexpectedly during maintenance
work

Impact: Danger to life or of serious injuries.



Lower the cornheader completely



Switch off the combine harvester completely, remove the ignition key and
secure the machine against reactivation (operating Instructions of the com-
bine harvester)



Wear cut-proof protective gloves



Raise the protective hood of the cornheader and secure against it shutting.



Persons must not be in the danger area.



Never operate the cornheader without all the safety equipment fitted and
closed.

DANGER! – Over-travel of the cornheader for 2 min.

Impact: Danger to life or of serious injuries.



Start with maintenance work 2 minutes after shutdown at the earliest

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. 61

Safety cover on the cornheader

Check the rubber safety cover for completeness and

integrity before every commissioning. Locate the

reason for any damage.

Check



The completeness and integrity of the chop-

per blade



The balancing / concentric run of the chop-

per



Sufficient ground clearance

Replace any damaged or lost protection immediate-

ly.

Summary of Contents for CORN CHAMPION 5S

Page 1: ... 0 Fax 49 0 82 53 99 97 47 Web www ziegler harvesting com EDV Nr 12 080507A EN Vers 02 Last update 07 2018 The information contained herein is subject to change without notice Keep the operating instructions Original Operating and Assembly Instructions Fixed cornheader CORN CHAMPION S ...

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Page 4: ...s 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 7 EN 12965 Tractors and machinery for agriculture and forestry EN ...

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Page 6: ...ill 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 ...

Page 7: ...s not liable for any damage resulting from this type of use This Warranty does not apply to damage resulting from a malicious act damage resulting from the Event of Force Majeure e g floods fires effects of hostilities etc damage resulting from the use of non original components spare parts and auxiliary equipment damage resulting from the unauthorized changes made by the end user in the machine s...

Page 8: ...draulic system 14 2 10 Maintenance 16 2 11 Unauthorized conversions and production of spare parts 16 2 12 Impermissible operation 16 2 13 Safety information on the machine 16 2 14 The meaning of the safety labels 17 TECHNICAL DATA AND DESIGNATION 18 3 3 1 Type plate 18 3 2 Information for inquiries and orders 18 3 3 Intended use 18 3 4 Technical data 19 3 5 Overview of the machine 19 INSTALLATION ...

Page 9: ... Commissioning important information 36 5 3 Cross auger feed 38 5 4 Cross auger 39 MAINTENANCE AND CARE 40 6 6 1 Accident protection operating safety 40 6 2 Lubricants general information disposal 41 6 3 Maintenance care inspection 42 Decommissioning and dismantling 46 7 FAULTS AND TROUBLESHOOTING 47 8 OPTIONS 49 9 9 1 Sunflower kit 49 9 2 Down maize auger 53 Extraction torque for screws 63 10 ...

Page 10: ... manual also refers to the cornheader 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 appl...

Page 11: ... use The Ziegler CORN CHAMPION S cornheader is a harvest front attachment for mounting to a forage harvester combine harvester and serves the harvesting of corn and other bulky forage crops Modifications to the corn stalk chopper combine harvester are required to harvest other plants such as sunflowers Please consult your stockist regarding such modifications 1 2 Validity These operating instructi...

Page 12: ...ication 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 re sponsibility 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...

Page 13: ...s 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 ...

Page 14: ... 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 safe ty 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 a...

Page 15: ...osite 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 replace ment 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 caus...

Page 16: ...erating 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 b...

Page 17: ...ce 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 attach ment Before perform ing maintenance work or removing block ages switch off the harvest front attach ment and the motor and remove the igni tion key Never reach into the rotating auger Maintain sufficient distance from the rotat...

Page 18: ...of liability for the resulting damage Take the corresponding article numbers for the spare parts list 3 3 Intended use The CORN CHAMPION cornheader 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 con...

Page 19: ...ows 75 cm 8 rows 70 cm 8 rows 75 cm 12 rows 70 cm 12 rows 75 cm Length mm 2820 2820 2820 2820 2820 2820 2820 2820 Total width 3700 3900 4550 4800 5950 6300 8690 9240 Working width mm 3500 3750 4175 4350 5545 5850 8400 9000 Height mm 1220 1220 1220 1220 1220 1220 1220 1220 Weight kg 1932 kg 1990 kg 2529 kg 2640 kg 4100kg 4450kg Hydraulic connec tions 1xDW 1xDW 1x DW 1x DW 1x DW 1x DW 1xDW 1xDW 3 5 ...

Page 20: ...y form of seal 4 1 General transport Fig 4 Transport on a HGV When transporting the cornheader on a HGV al ways use the ZIEGLER transport frame Secure the cornheader against falling down using tensioning belts in accordance with the locally valid regulations Ensure that the machine has a steady position Fig 5 Fig 6 Fig 7 Transporting the machine on the company premises with a crane The cornheader ...

Page 21: ...rt frame See also transporting the machine on the company premises with a crane 4 2 Unpacking the cornheader Fig 10 Scope of delivery state of delivery The cornheader 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...

Page 22: ...the transport frame Fig 12 Further use of the transport frame We recommend using the transport frame for any post season service work Load handling attachments may only be used in accordance with their intended purpose All changes or the use with other machines is forbid den The machine may only be transported by a forklift truck using the Ziegler transport frame Fig 13 Fig 14 Placing down the cor...

Page 23: ...icker R in accordance with the settings performed by the harvester Caution The lock can vary according to the model of combine harvester Fig 17 Additional lift cylinder Depending on the size and weight of the cornhead er one or two additional hydraulic cylinders Z could be required Corresponding sets are held ready by the manufac turer of the combine harvester Depending on the design of the cornhe...

Page 24: ...at the pivotally arranged plate F also reaches the stubble once the picker has been pulled out 4 4 Cornheader drive Fig 20 Drive shaft The cornheader is driven with a drive shaft Ensure that the drive shaft guard is secured against revolution by a chain K If the combine harvester is fitted with an angling blade check the cover when it is swung out Remove and read the special instructions for the d...

Page 25: ...also be fitted with a multicoupling The correct coupling is included in the scope of de livery Operation is performed in accordance with the regu lations and instructions of the manufacturer of the combine harvester Connection via the control valve coupling Some brands of combine harvesters require a con trol valve coupling to connect a header The corresponding pickers are fitted with the requi si...

Page 26: ...rements of environmental pro tection Hydraulic actuation Reel Lifting and lowering Open and close snapping plates Caution Some brands of combine harvester are fitted with a separate electrical operating system in the opera tor s platform Read the operating instructions of the combine har vester Check the quantity of hydraulic oil in the harvester store 4 6 Fitting the divider tips Fig 25 Putting u...

Page 27: ...e shaped setting is very important for the function of the picker Operation is performed via the harvester hydraulics Depending on the combine harvester model this can be performed via the function raise lower reel Fig 28 Snapping plates It is not possible to rule out soiling resulting from the operation Open and close the snapping plates L a minimum of once a day to ensure that they are free and ...

Page 28: ...lates are to be readjusted first bring the hydraulic adjustment into the most tight fitting position possible Then check the conical position of the snapping plates Setting see Fig 27 Set an even snapping plate clearance via the ad justment lever H if necessary Setting the speed of the snapping plates The throttle valve A can be used to set the speed of the snapping plate adjustment Turn in slowly...

Page 29: ...laced if it is damaged by foreign bodies Caution Take into account the degree of wear on the fore guide wheel Fig 31 Removing the draw in chains Loosen screw A and slide the idler sprocket B backwards Now dismantle the chain Clearance 1m Worn 3 5cm Unscrew A Unscrew C Slide B t the rear 4 9 Settings and reference dimensions Fig 32 Scraper on the picker cylinders Highly effective scrapers are locat...

Page 30: ...as taken place or if a fault has detect ed on a picking row check the clearance A Contact your contact partner following larger colli sions 4 10 Snapping roller Fig 34 Dismantling the snapping roller 1 Undo the screws and remove the support runner 2 Undo the screws and remove the guard plate 3 Remove the bracket by loosening the screws When refitting Grease the profile shaft and ensure the equal t...

Page 31: ...rdance with the prescriptions of the operating instructions on page 53 Switch off the motor and activate the lowering lock before commencing any work on the ma chine Caution Blades over travel for two minutes Wear the corresponding protective cloth ing Fig 38 Switching the chopper on and off Unscrew the holding screws H and move the lever to the desired position it may be necessary to turn the cho...

Page 32: ... Fig 40 Blade replacement When fitting a new blade check the blade bushing M for wear and renew if necessary Important The blades must only be replaced in pairs Fig 41 Chopper blade Change the chopper blade immediately if If the drillhole D has an even slightly oval form If strong wear is found in the area V force requirement chopper quality If the blade is bent or has fissures Only fit an equal b...

Page 33: ... B corresponds with the works specifica tions The rotation speed is easy to calculate using the following formula CH rotation speed x upper gear wheel lower gear wheel picker rotation speed The reduction increase is performed by changing one or both of the sprockets The connection chain may require shortening or lengthening 4 14 Connection coupling between the picking rows Fig 43 Duplex chains Sub...

Page 34: ...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 cornheader DANGER Ejected parts Impact Danger to life or of serious injuries When the motor is running and the drive is activated maintain sufficient clearance to the chopper blade 5 1 Test run Fig 44 Reducing the starting torque Reduce th...

Page 35: ...ver x for completeness and integrity before every commissioning Should you locate any damage replace the safety cover immediately and locate and rectify the cause of the damage Check The completeness and integrity of the blade of the rotary type stalk chopper The balancing concentric run of the chop per Sufficient clearance from the ground Fig 47 Safety information Rapidly rotating blade Danger fo...

Page 36: ...dictates that a rotation speed of 700 U 1 min may not be exceeded To ensure a sufficiently favourable rotation speed ratio the rotation speed of 550 U 1 min may not be exceeded with the harvesting of corn Subsequent damage resulting from failure to comply with the rotation speed range is not covered by the guarantee Fig 50 Testing the lateral inclination compensation Check the function of the angl...

Page 37: ...utter bar skid and the floor must amount to min 15cm Fig 52 Clean the air filter and other sensitive parts on a daily basis Development of dust It is impossible to prevent the development of a cer tain layer of dust with horizontal action choppers working in close proximity to the ground Depending on its quality cut material thrown about in the air can hinder some of the functions of the harvester...

Page 38: ...ording to the model of picker and depend on the feeder channel width of the respective harvester It is important that the transport claws are only fitted in front of the channel opening Fig 57 Auger drive up to 8 picking rows The auger drive is performed from the opposite side to the main drive The rotation speed is dependant on the main shaft of the picker and is thus preset Subject the chain ten...

Page 39: ...d friction cou plings have been fitted to the machine to ensure its secure operation Should these systems activate deactivate the picking front attachment immediately Switch off the diesel motor and secure the picker against unintended lowering Locate the fault Remedy the problem Never attempt to reactivate the picker through activation and deactivation Fig 60 Cross auger friction coupling If the ...

Page 40: ...ety equipment fitted and closed DANGER Over travel of the cornheader for 2 min Impact Danger to life or of serious injuries Start with maintenance work 2 minutes after shutdown at the earliest 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 fur...

Page 41: ...lopment of dust It is impossible to prevent the development of a cer tain layer of dust with horizontal action choppers working in close proximity to the ground Depending on its quality cut material thrown about in the air can hinder some of the functions of the harvester It is therefore important to subject air filters and other sensitive parts hydraulic cylinder pistons etc to regular cleaning 6...

Page 42: ...tion 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 6 3 Maintenance care inspection Fig 66 Cleaning after the harvest season After the end of a predominantly dry harvest season we recommend d...

Page 43: ...oiled or greased Fig 69 Feeder chains We recommend protecting the feeder chains against rust when storing the machine Either choose the correct storage or protect the chains against rust with suitable oil In the following season the chain should be fitted right left swapped in order to achieve equal wear See page 29 Fig 70 Picking row drives Lift the cornheader into its work position and switch of...

Page 44: ...tachments may only be used for their intended purpose All changes or the use with other machines is forbidden Do not store the cornheader on the com bine harvester when raised Avoid unnecessary loading of the har vester tyres Fig 73 Picking row drives Should the picking cylinder shafts G be dismantled these are to be greased with conventional graphite grease when refitted Clean the gear ventilator...

Page 45: ...MAINTENANCE AND CARE 45 Lubrication plan Perform the first check before commissioning the cornheader Fig 74 ...

Page 46: ... 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 ac cordance with the applicable regulations Fig 75 Decommissioning If the cornheader or its components reach the end of useful life and require scrapping the components must be se...

Page 47: ...eck the drive shaft 20 The drive shaft coupler does not engage Locking impossible check the cou pling halves for full engagement 20 The coupling does not en gage Check the alignment make the shifter piece passable 21 The picker remains stationary during op eration The V belt is not tightened Check the drive CH handbook Overload Adapt the working speed CROSS AUGER Fault Cause Remedy Page Cross auge...

Page 48: ...23 Loss of corn cobs Working speed Adjust speed Row clearance Adapt the machine to the conditions Grain loss Snapping plates Adjust closer together Recirculation of feeder channel chain Set the covering above the cross au ger lower 28 Working speed Increase until the picker is better filled with material Corn stubble too long Horizontal cutting blade worn Replace blade if necessary 33 Divider tips...

Page 49: ...njury from sharp blade Impact Injuries When replacing the cutting tools use tools appropriate to cutting tools and wear suitable gloves Fig 77 Loosen the chain and the chain tensioner Fig 78 Remove the chain Remove the chain tensioner Fig 79 Unscrew the screws ...

Page 50: ... the back Fig 81 Bring the sunflower kit into position and fix with screws Fig 82 Tighten the fixed blade Fig 83 Check the distance between the fixed and rotating blade The distance must be 1mm If the distance is wrong please have a look on the next picture Fig 84 ...

Page 51: ... with shims If you need more space you have to re move the shims or if you want to reduce the space you have to add shims For this work you have to remove the sprocket Caution Danger of injury from sharp blade Fig 85 Place on the chain Fig 86 Tighten the chain Fig 87 Unscrew the screws form the stalk roller ...

Page 52: ...OPTIONS 52 Fig 88 Remove the stalk roller to the top Remove the stalk roller to the top Fig 89 Put on the stalk roller cover and fix it To return everything proceed in the reverse fashion ...

Page 53: ...Fitting the down maize auger Maintain the sequence with fitting and dismantling Remove the cover of the drive gearbox Fig 91 Loosen the chain tensioner Fig 92 Open the chain lock remove the chain disman tle the document roll and fit outside ...

Page 54: ...circlip using pliers Remove the drive collar with the puller if necessary then remove the feather key Remove the screws on the flange bearing on both sides of the drive gearbox Remove the bearing and the shaft Fig 94 Removing the drive shaft completely Remove the sprocket Fig 95 Remove the protective ring Fig 96 Lock collar loosen the grub screw e g hook wrench ...

Page 55: ...irclip using pliers Fig 98 Remove the drive collar with the puller if neces sary then remove the feather key Fig 99 Remove the screws on the flange bearing on both sides of the drive gearbox Fig 100 Remove the bearing and the shaft ...

Page 56: ...on the outside of the shaft Fig 103 Please note place on the inner bearing with the lock collar side facing towards the inside of the picker Install the flange bearing on the left hand side starting on the inside first introduce the 6 KT screw into the cavity from inside then secure the flange bearing on the right hand side Fig 104 Tighten the bearing screws crosswise ...

Page 57: ...shaft bringing into position with light blows se curing with the circlip Fig 106 Maintain the clearance of the drive collar to the drive gearbox 30 065144 Fig 107 Tighten the lock collar with the grub screw Fig 108 Apply the sprocket from outside and fix with screws ...

Page 58: ...OPTIONS 58 Fig 109 Check the alignment of the sprocket Fig 110 Fit the chain and the chain lock set the chain tensioner The chain must not hang through Fig 111 Dismantle the lid ...

Page 59: ...OPTIONS 59 Fig 112 Unscrew the bracket Fig 113 Screw on the down maize auger Fig 114 Screw on the down maize auger Fig 115 Screw on the erasing blade ...

Page 60: ...116 Cut out the pre lasered area Fig 117 Install the pump with console Tighten the screws lightly Fig 118 Place on the chain tension slightly and the tight en Fig 119 Place the fully fitted tank and fix with 4 screws ...

Page 61: ...ulic hoses A B C on the right hand side After installing remove the centre of the three flat headed screws in the side hood E and fit the hose clamps see Fig 122 and Fig 120 Fig 123 Install the hydraulic hoses divide the hose clamps equally set the drillholes and screw on the hydraulic hoses with hose clamps B A A B A D C E B B B ...

Page 62: ... 62 Fig 124 Connect the hydraulic hoses C and D on the left hand side After installing remove the centre of the three flat headed screws in the side hood E and fit the hose clamps see Fig 122 and Fig 120 E C D ...

Page 63: ... Strength class 12 9 M4 2 7 3 8 4 6 M5 5 4 7 6 9 1 M6 9 2 13 0 15 5 M8 22 0 31 0 37 5 M8 x 1 24 0 33 5 40 0 M10 43 5 61 0 73 5 M10 x 1 25 46 0 65 0 77 5 M10 x 1 50 0 70 0 84 0 M12 76 0 106 0 127 0 M12 x 1 5 79 0 111 0 133 0 M12 x 1 25 82 5 116 0 139 0 M14 120 0 168 5 202 0 M14 x 1 5 130 0 183 0 219 0 M16 187 0 262 0 314 0 M16 x 1 5 198 0 278 0 333 0 M18 257 5 362 0 433 0 M18 x 2 272 0 382 0 457 5 ...

Page 64: ... 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 jurisdic tion Aichach Tax no 102 168 10401 Managing director M Ziegler Dipl BW FH Производитель ZIEGLER GmbH Schrobenhausener Straße 74 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 Aug...

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