LELY 1250 PROFI Operator's Manual

Lely Lotus
1250 Profi

Operators Manual

T-H021.1301EN

English Original

ii

TRADEMARKS, COPYRIGHT AND DISCLAIMER

Lely, Astronaut, Astri, Atlantis, Attis, AWS, C4C, Calm, Caltive, Commodus,
Compedes, Cosmix, Discovery, F4C, Fertiliner, Gravitor, Grazeway,
Hibiscus, Hubble, Juno, L4C, Lely Center, Lelywash, Lotus, Luna, Nautilus,
Orbiter, Quaress, Qwes, SAE, Shuttle, Splendimo, Storm, T4C, Tigo, Viseo,
Vector, Voyager, Walkway and Welger are registered trademarks of the Lely
Group. The right of exclusive use belongs to the companies of the Lely
Group. All rights reserved. The information given in this publication is
provided for information purposes only and does not constitute an offer for
sale. Certain products may not be available in individual countries and
products supplied may differ from those illustrated. No part of this publication
may be copied or published by means of printing, photocopying, microfilm or
any other process whatsoever without prior permission in writing by Lely
Holding S.à r.l. Although the contents of this publication have been compiled
with the greatest possible care, Lely cannot accept liability for any damage
that might arise from errors or omissions in this publication.

The English language manual is the original manual. Translations into other
languages use the English language manual as the source document. Lely
accepts no liability for discrepancies between the original English language
manual and versions in other languages. If there is a conflict over the
content and accuracy of any translated manual, the English language
manual is the authority document.

T-H021.1301EN

Copyright © 2013 Lely Industries NV
All rights reserved

Lely Industries NV
Weverskade 110
3147 PA Maassluis
The Netherlands
Phone: Tel: [phone]
Fax: Fax: [phone]
Website: www.lely.com

Trademarks, copyright and disclaimer

1

T-H021.1301EN

2 Trademarks, copyright and disclaimer

Manual contents

Warranty conditions

PREFACE

This manual contains the information necessary to operate the Lely Lotus. It
also includes maintenance information that can be done by an operator.

Study and understand this information thoroughly before you operate the
Lely Lotus. Failure to do so could result in personal injury or damage to
equipment. Please consult your local Lely service provider if you do not
understand the information in this manual, or if you need additional
information.

All information in this manual has been compiled with care. Lely shall not be
liable for errors or faults in this manual. The recommendations are meant to
serve as guidelines. All instructions, pictures and specifications in this
manual are based on the latest information that was available at the time of
publication. Your Lely Lotus may comprise improvements, features or
options that are not covered in this manual.

For those parts that fail under normal operating conditions, the factory will
make replacement parts available, free of charge, for a period of 12 (twelve)
months from the date of purchase.

T-H021.1301EN

The warranty shall not apply if the instructions mentioned in this manual
have not been followed, or if they have not been followed completely or
correctly. Nor will the warranty apply if you or third parties modify the
machine without our foreknowledge and/or authorisation.

Preface

1

Registration

The Type and Serial Number Plate is on the top front of the drawbar.

Always include the type and serial numbers of your product when you
contact your local Lely service provider or order spare parts.

We suggest you to complete the table below with the type and serial
numbers of your product. This makes sure you can easily find the
information.

Type number

Serial number

Abbreviations

Figure 1. Type and Serial Number Plate location

This manual uses the following abbreviations:

• HCP = Hydraulic Control Panel

• P = Oil flows to the cylinders

• PTO = Power take-off

• T = Oil flow returns to the tank

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2

Preface

Table of Contents

1. Introduction.........................................................................................................................................1-1

1.1 Optional extras......................................................................................................................... 1-3

1.1.1 Spare Rotor Wheel.................................................................................................................. 1-3

2. Safety...................................................................................................................................................2-1

2.1 Signal words.............................................................................................................................2-1

2.2 Safety instructions....................................................................................................................2-1

2.3 Explanation of the safety decals.............................................................................................. 2-3

2.4 Explanation of remaining decals.............................................................................................. 2-3

2.5 Position of the safety decals.................................................................................................... 2-4

3. Operation.............................................................................................................................................3-1

3.1 Hydraulic control panel.............................................................................................................3-1

3.2 Connect the Lotus to the tractor...............................................................................................3-3

3.3 Disconnect the Lotus from the tractor...................................................................................... 3-6

3.4 Move the Lotus from the transport position to the working position......................................... 3-7

3.5 Move the Lotus from the Working position to the Transport Position.......................................3-9

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3.6 Start Tedding..........................................................................................................................3-11

3.7 Move the Lotus from the working position to the headland position...................................... 3-13

3.8 Stop Tedding..........................................................................................................................3-13

4. Operation adjustments...................................................................................................................... 4-1

4.1 Adjust the Tines....................................................................................................................... 4-1

4.2 Adjust the Height of the Rotor Wheels..................................................................................... 4-2

4.3 Adjust the Rotor Angle............................................................................................................. 4-3

5. Maintenance........................................................................................................................................5-1

5.1 Scheduled maintenance...........................................................................................................5-1

5.1.1 Maintenance after operation.................................................................................................... 5-1

5.1.2 Maintenance every 10 working hours...................................................................................... 5-1

5.1.3 Maintenance every 50 working hours...................................................................................... 5-1

5.1.4 Maintenance every 100 working hours.................................................................................... 5-1

5.1.5 Maintenance every 250 working hours.................................................................................... 5-1

5.1.6 Maintenance Every 6 Year.......................................................................................................5-2

5.1.7 Maintenance before prolonged storage................................................................................... 5-2

5.1.8 Maintenance after prolonged storage...................................................................................... 5-3

5.2 Preventive maintenance...........................................................................................................5-4

5.2.1 Clean the Lotus........................................................................................................................5-4

Table of Contents

iii

5.2.2 Grease the Drive Line.............................................................................................................. 5-5

5.2.3 Grease the pivot points............................................................................................................ 5-6

5.2.4 Grease the PTO shaft.............................................................................................................. 5-7

5.2.5 Replace the Gearbox Grease................................................................................................ 5-11

5.3 Corrective maintenance......................................................................................................... 5-12

5.3.1 Replace the Tine(s)................................................................................................................5-12

5.3.2 Adjust the Deflection of the Rotors........................................................................................ 5-13

6. Diagrams and tables.......................................................................................................................... 6-1

6.1 Diagrams and Schematics....................................................................................................... 6-1

6.2 Bolt and nut torque table.......................................................................................................... 6-2

6.3 Tyre Pressure Diagram............................................................................................................ 6-3

7. Specifications..................................................................................................................................... 7-1

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iv Table of Contents

1. INTRODUCTION

The Lely Lotus 1250 Profi is a pull-type rotary tedder-to ted mown fodder
crops or to wide spread crop swaths.

The working width of the Lotus is 12.50 m (41.01 ft), and can be driven up to
15 km/h. The wheels are positioned closely behind the tines to follow ground
contours accurately.

The Lotus has 10 rotors. A rotor has 7 tine arms with a double spring steel
tine each. The special shaped tines pick up the crop and spread it with a
minimum loss. The rotors can pivot in relation to each other to follow field
undulations accurately.

The Lotus is connected to the tractor hydraulics. The hydraulic control
makes sure the Lotus moves quick and easily to the transport position. The
machine can be transported behind the tractor. The transport width is 2.98 m
(9.77 ft).

A special headstock connects the tedder to the tractor. The headstock has
category II linkage pins. The pivot point of the headstock is positioned further
to the back in relation to traditional pull-type machines to provide a wide turn
circle. A wide turn circle makes the Lotus turn easy in tight bends.

An optional extra is available for the Lotus.

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Introduction

1-1

1. Primary PTO shaft - 2. PTO-support - 3. Front safety guard - 4. Wheel wedge - 5. Drawbar - 6. Hydraulic ram -

7. Secundary PTO shaft - 8. Transport wheel - 9. Lighting set - 10. Rear safety guard - 11. Safety brackets - 12. Tine -

13. Rotor wheel - 14. Rotor - 15. Gearbox - 16. Drive line - 17. Rotor angle adjustment - 18. Headstock - 19. Parking jack

Figure 2. Overview of the Lotus

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1-2

Introduction

1.1 Optional extras

1.1.1 Spare Rotor Wheel

The spare wheel support is installed on the Lotus to carry a spare wheel. So
that a flat tyre can be mended quickly in the field.

1. Spare rotor wheel

Figure 3. Spare Rotor Wheel

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Introduction

1-3

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1-4 Introduction

2.1 Signal words

2. SAFETY

This chapter contains safety instructions you must obey when you use or do
maintenance on your Lely Lotus. It also explains the safety decals on the
Lely Lotus.

Note the use of the signal words DANGER, WARNING and CAUTION. The
signal word for each message uses the following guidelines:

DANGER

WARNING

CAUTION

Note:

2.2 Safety instructions

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Danger: Indicates an imminently hazardous situation that,
if not avoided, will result in death or serious injury.

Warning: Indicates a potentially hazardous situation that, if not
avoided, could result in death, serious injury or product damage, and
includes hazards that are exposed when guards are removed.

Caution: Indicates a potentially hazardous situation that, if not avoided, may
result in minor or moderate injury or damage to the product or property.

Note: This shows extra information that may help the reader.

• Use the Lotus only for the purpose for which it was designed.

• Follow all safety regulations, including those in this manual and
instructions or warnings indicated on the machine.

• Operate the Lotus in a safe manner.

• The Lotus must only be operated by authorised persons.

• Be alert and observe all safety precautions.

• Make sure all safety guards and protection devices are installed and
function correctly.

• Keep people, animals and objects away from moving parts.

• Stop the tractor engine, the Power Take-Off (PTO) and all moving parts
before you do operation adjustments and maintenance on the Lotus.

• Make sure no people are in the danger zone when the Lotus is in
operation. This is especially important when you work near or on areas
that are accessible to the public.

• Always use a tractor with a cab.

• Make sure there are no objects in the field that could be thrown up by the
Lotus before you operate the Lotus.

• Obey local legislation when you drive on a public road.

• Use flashing lights or other safety signs, when necessary.

• Do not remain on the Lotus during operation or transport.

• Only use genuine LELY parts.

Safety 2-1

• Depressurise the hydraulic system before you connect or disconnect
hydraulic hoses.

• Use protective clothing, safety shoes, gloves, safety glasses and ear
protectors, if necessary.

• Clean or replace the safety decals regularly so that they can be read at
all times.

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2-2 Safety

2.3 Explanation of the safety decals

Caution: Read manual

Read the operator's manual carefully before
you operate the Lotus

Danger: Moving parts

Keep away from all moving parts unless they
are locked and cannot move.

Danger: Flying objects

Keep a safe distance from the Lotus when the
tractor engine is on.

Danger: Mowing or rotating parts

Read the operating instructions for the PTO
shaft. Always use the correct safety precautions
and protection when you operate the PTO
shaft.

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2.4 Explanation of remaining decals

Warning: Maximum operating speed

Never operate the Lotus at a PTO speed of
more than 540 rpm

Caution: Risk of damaged machine parts

Make sure to fold down the rear safety guards
before placing the Lotus in transport position.

Danger: Risk of being crushed

Do not sit on the Lotus.

Note: Grease point

This indicates a grease point, read the operator
manual for maintenance instructions.

Safety 2-3

2.5 Position of the safety decals

Figure 4. Position of the Safety Decals

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2-4

Safety

3. OPERATION

3.1 Hydraulic control panel

Note:

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Read the tractor manual for the correct procedures to operate the tractor
hydraulics.

The operator switches the handle(s) or moves the joystick to operate the
Lotus. The following positions of the switches or joystick enable an action to
the hydraulic system:

• Floating (~)

The floating position opens the supply and return valves. The oil pressure is
not available in the system, but passive hydraulic movements are possible.
This position is used when working and disconnecting the machine.

• Neutral (N)

The neutral position closes the supply and return valves. The oil pressure is
available in the system, but no hydraulic movements are possible.

• Forwards/Reverse

The forward/reverse operations activates the hydraulic system. The
hydraulic operation of the Lotus depends on how the hydraulic hoses are
connected to the tractor:

• Oil flows to cylinders,

• Oil flow returns to tank.

1.Neutral (N) - 2. Forwards - 3. Reverse - 4. Floating

Figure 5. Panel hydraulic operation positions

Operation 3-1

CAUTION

The two hydraulic operations (forward/reverse) are depending on how the
connections are made to the tractor.

• Hydraulic system (I)

The blue marked hydraulic system (I) operates the following functions:

• the operation to fold the frame supports with rotors in or out between the
following position:

- the position after operating the hydraulic system II,

- headland position,

- working position.

• the operation floating during tedding.

• Hydraulic system (II)

The white marked hydraulic system (II) operates the following functions:

• the operation to lift the folded frame until it is lifted out of the transport
support.

• the operation to lower the folded frame into the transport support
(transport position).

I Hydraulic system (blue)

II Hydraulic system (white)

Figure 6. Hydraulic system marks and systems

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3-2 Operation

3.2 Connect the Lotus to the tractor

Procedure

1. Ensure the towing vehicle has sufficient capacity to tow the trailer.

DANGER

CAUTION

WARNING

CAUTION

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Do not exceed the maximum hitch load

2. Make sure the tractor is aligned with the Lotus.

3. Reverse the tractor to the Lotus headstock.

4. Make sure the three-point hitch arms of the tractor are at an equal

height.

5. Fit the lower arms to the linkage pins (cat.ll) of the three-point hitch.

The first time you connect the Lotus to each tractor, refer to the instructions
supplied with the PTO shaft and make sure the minimum and maximum
overlap of the two parts of the PTO shaft is correct.

Always connect the safety chain of the PTO shaft to a rigid part of the
tractor.

6. Make sure the Lotus PTO shaft telescopes smoothly.

7. Lift the PTO shaft from the PTO support.

8. Connect the Lotus PTO shaft to the tractor PTO shaft.

9. Set the hydraulic system of the tractor in the floating position.

The first time you connect the Lotus to each tractor, refer to the instructions
supplied with the PTO shaft and make sure the minimum and maximum
overlap of the two parts of the PTO shaft is correct.

WARNING

The maximum pressure of the tractor hydraulic system must not be
more than 21.0 MPa (210 bar).

10. Remove the dust caps from the three hydraulic hoses.

11. Connect the white marked hydraulic hose (II) to a single-acting

hydraulic valve on the tractor.

12. Connect the two blue marked hydraulic hoses (I) to the double-acting

hydraulic valves on the tractor.

13. Connect the lighting electrical cable to the correct socket on the

tractor.

14. Make sure all the lights on the Lotus operate correctly.

15. Remove the wheel wedges (1) (Figure 8, page 3‑5) and attach

them to the support at the front safety guards.

16. Lift the tractor 3-points hitch slightly to release parking jacks from the

ground.

17. Install the 2 parking (2) (Figure 7, page 3‑4) jacks to the top

position and insert the locking pins (1) (Figure 7, page 3‑4).

Operation 3-3

1. Locking pin - 2. Parking jacks

Figure 7. Link the Lotus to the tractor

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3-4

Operation

1. Wheel wedges

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Figure 8. Wheel wedges storage position

Operation

3-5

3.3 Disconnect the Lotus from the tractor

WARNING

Note:

WARNING

Always position the tractor on solid ground before you disconnect the
Lotus from the tractor.

Make sure there are no persons near the Lotus when you disconnect it
from the tractor.

The Lotus can be disconnected from the tractor in the transport position and
in the working position.

Procedure

1. Switch off the tractor engine and release the pressure from the tractor

hydraulic system.

2. Install the wheel wedges in front of the transport wheels and behind

the transport wheels.

3. Position the 2 parking jacks to the lowest position and insert the

locking pins.

Always disconnect the safety chain of the PTO shaft from the tractor.

4. Disconnect the Lotus primary PTO shaft from the tractor PTO.

5. Attach the primary PTO shaft to the PTO support.

6. Disconnect the two lower arms from the linkage pins on the

headstock.

7. Disconnect the three hydraulic hoses from the tractor hydraulic system

(I and II).

8. Install the dust caps on the hydraulic hoses.

9. Attach the hydraulic hoses to the hose support on the Lotus drawbar.

10. Disconnect the lighting electrical cable from the tractor.

11. Attach the lighting electrical cable to the hose support on the Lotus

drawbar.

12. Remove the tractor from the area.

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3-6 Operation

3.4 Move the Lotus from the transport position to the working position

Make sure there are no persons in the area when you move the Lotus to the
headland position.

CAUTION

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Make sure the safety guards are moved to the bottom position. Safety
guards in top position cause damage to the Lotus when moving from
transport position to the working position.

Procedure

1. On both sides of the Lotus, move the safety guard to the bottom
position.

2. Make sure all rotor wheel assemblies are set to the same position.

3. Operate the tractor hydraulic system (II) to lift the folded frame
upwards out of the transport support to position A (Figure 12, page 3‑

10).

4. Operate the tractor hydraulics system (I):

• to move the two outer rotor segments outwards until they are

completely out to position B (Figure 10, page 3‑8).

• to lower the frame and segments to the ground in position C

(Figure 10, page 3‑8).

5. If necessary perform the following steps to:

• adjust the tines (page 4‑1) of the other rotors to the applicable

position according to the spread of the crop,

• adjust the height of the rotor wheels (page 4‑2),

• adjust the rotor angle (page 4‑3),

6. Set the hydraulic valve in the tractor to the floating position.

7. Perform the procedure start tedding (page 3‑11).

A. Bottom position - B. Top position

Figure 9. Move the Safety Guard to the Top or Bottom Position

Operation 3-7

A. Hydraulic system (II) - B.Hydraulic system (I) - C. Hydraulic (I) to the working position

Figure 10. Move the Lotus to the Working Position

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3-8

Operation

3.5 Move the Lotus from the Working position to the Transport Position

WARNING

CAUTION

WARNING

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Make sure the front axle weight of the tractor is sufficient (use front
weights if necessary) and that you do not exceed the permitted axle
load when the Lotus is in the transport position.

Make sure the PTO shaft is not engaged when the Lotus is in the
transport position.

Use all lights and warning signals as defined by your local road traffic
regulations.

Make sure there are no persons in the area when you move the Lotus
to the transport position.

Procedure

1. On both sides of the Lotus, make sure that the safety guards are in
the bottom position (A) (Figure 12, page 3‑10).

2. Operate the tractor hydraulic system (I):

• to lift the frame and segment to position A (Figure 11, page

3‑10).

• to move the rotor segments forwards to position B (Figure 11, page

3‑10).

3. Operate the tractor hydraulic system (II) to move the frame with folded
segment downward for to position C (Figure 11, page 3‑10) between
the transport supports.

4. If necessary, move the two center wheel assemblies to the most inner
position to reduce the transport length.

5. Move the tines of the two center rotors to position A (Figure 14, page
4‑1).

6. On both sides of the Lotus, move the safety guard to the top position
B (Figure 12, page 3‑10).

Operation 3-9

A. Hydraulic (I) from the working position - B.Hydraulic (I) - C. Hydraulic (II)

Figure 11. Move the Lotus to the Transport Position

A. Bottom position - B. Top position

Figure 12. Move the Safety Guard to the Top Position

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3-10

Operation

3.6 Start Tedding

WARNING

Note:

WARNING

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Make sure no persons are near the Lotus when you engage the PTO.

Make sure no persons are within a 25 meter radius of the Lotus during
operation.

Always switch off the tractor engine before you leave the tractor cab.

Do not operate the Lotus without safety guards or covers, or if the
safety guards or covers are damaged.

During the early stage of the process in particular, fast and airy tedding twice
a day at a low rotor speed is better than intensive tedding at a high rotor
speed.

Procedure

1. Operate the tractor hydraulic system to lift the rotors to the headland
position.

2. Carefully engage the PTO at the lowest possible engine speed.

3. Slowly increase the speed of the PTO to 400-450 rpm (max. 540 rpm).

Do not drive the machine through the crop when the rotor is on the
ground and not rotating. This causes damage to the tines and tine
arms.

4. Drive the tractor at a maximum speed of 15 km/h and make sure:

• The hydraulic rams telescope smoothly.

• The PTO speed must not exceed the speed shown on the Lotus.

Operation 3-11

5. Set the tractor hydraulic system to the floating position to lower the
rotors to the ground so the Lotus will follow the contour line of the land
during operation.

6. If necessary, stop the tractor, disengage the tractor PTO and:

a. Adjust the tines (page 4‑1).

b. Adjust the height of the rotor wheels (page 4‑2).

c. Adjust the rotor angle.

7. The following tedding procedure is recommended:

Note:

WARNING

In case of windy weather conditions, drive the tractor up and down against
the wind.

a. Drive the tractor up and down to ted the center part of the field

(1) (Figure 13, page 3‑12). Keep a lane of approximately one
working width free at the sides of the field by using the
headland position.

b. Drive the tractor along the side of the field to ted sides (2)

(Figure 13, page 3‑12). Make sure to adjust the tines
(Figure 14, page 4‑1) of the outer rotors for small spread
tedding.

Slow down the driving speed when taking corners with the rotors on
the ground, this prefents overloading the outer rotors.

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A.Normal condition - B. Windy conditions

Figure 13. Recommended tedding procedure

3-12 Operation

3.7 Move the Lotus from the working position to the headland position

Procedure

1. Operate the tractor hydraulic system to lift the tedder to the headland
position.

The headland position lifts the rotors from the ground, so it is possible:

WARNING

3.8 Stop Tedding

WARNING

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WARNING

Make sure you will not manoeuvre yourself in a dangerously position
when performing adjustments or maintenance. Preferably perform
adjustments or maintenance whilst in transport position.

• to make operation adjustments (page ‑1) after disengage the

tractor PTO, if neccessary.

• to drive to an other position in the field.

• to make a turn at the side of the field.

Procedure

Always switch off the tractor engine before you leave the tractor cab.

1. Stop the tractor.

2. Disengage the PTO shaft.

3. Move the Lotus to the transport position (page 3‑9).

Wait for all moving parts of the Lotus to stop.

4. Switch off the tractor engine.

Operation 3-13

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3-14 Operation

4. OPERATION ADJUSTMENTS

WARNING

Make sure that the PTO shaft is disengaged and the tractor engine is
switched off before adjustments are made.

4.1 Adjust the Tines

Procedure

1. Push the lock (1) down to disengage the lock and move the tine (2) to
the required position (Figure 14, page 4‑1). The lock engages
automatically.

• Use position (A) only for the outer rotor type to ted the side of the

field, to give a small spread of the crop and to make sure that the
crop stays on the field.

• Use position (B) for normal tedding.

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1. Lock - 2. Tine - A. Small spread tedding - B. Normal tedding

Figure 14. Adjust the position of the tines

Operation adjustments 4-1

4.2 Adjust the Height of the Rotor Wheels

Procedure

1. Move the Lotus to the headland position (page 3‑13).

2. Switch off the tractor engine.

3. Make sure the rotors can not move downwards.

4. Remove the pin from the wheel assembly.

5. Adjust the wheel assembly to the required height (Figure 15, page 4‑

2) position:

• Position A is used during transport to create a smaller transport

width.

• Position B is recommended when working with light and short

crops or windy conditions.

• Position C and D are the intermediate positions defined by the

operator.

• Position E is recommended when working with heavy and long

crops.

6. Install the pin in the required hole of the wheel assembly.

7. Secure the pin with the locking pin.

1. Pin - 2. Locking pin - A. Lowest height - B. Second lowest height - C. Middle height -

D. Second highest height - E. Highest height

Figure 15. Adjust the height of the rotor wheels

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4-2

Operation adjustments

4.3 Adjust the Rotor Angle

Procedure

1. Make sure:

a. The Lotus is connected to the tractor (page 3‑3).

b. The Lotus is in the working position (page 3‑7).

c. The hydraulic system is set to the floating position.

d. The rotor wheels are set to the required position.

CAUTION

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Make sure the height adjustment of the tines is not too low. This results in an
excessive load and causes the tines to wear or break.

2. Release the rod out of the clamp

3. Turn the spindle to adjust the rotor angle to the ground by using the
rod

4. Make sure the tines slightly touch the ground and the crop is picked
correctly.

5. Make sure the tines touch the ground over a distance of
approximately 25 cm (10 in).

1. Winding handle - 2. Rod - 3. Clamp

Figure 16. Adjust the Rotor Angle

Operation adjustments 4-3

A. 25 cm (10 in)

Figure 17. The distance over which the tines should touch the ground.

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4-4 Operation adjustments

5. MAINTENANCE

5.1 Scheduled maintenance

5.1.1 Maintenance after operation

• Clean the Lotus (page 5‑4).

• Make sure the tines and tine arms are tight and not damaged.

• Apply anti-corrosion agent to the bare metal parts.

5.1.2

Maintenance every 10 working hours

• Grease the drive line (page 5‑5).

5.1.3 Maintenance every 50 working hours

• Grease the pivot points (page 5‑6).

5.1.4 Maintenance every 100 working hours

• Grease the PTO shafts (page 5‑7).

5.1.5 Maintenance every 250 working hours

• Make sure the hydraulic hoses are not damaged or worn. Replace if

necessary.

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Maintenance

5-1

5.1.6 Maintenance Every 6 Year

• Replace all hydraulic hoses six years after their production date. Refer to

the text on the hoses for their production date.

5.1.7 Maintenance before prolonged storage

• Apply anti-corrosion agent to the bare metal parts.

• Grease the PTO shafts (page 5‑7).

• Replace the gearbox grease (page 5‑11).

• Grease the pivot points (page 5‑6).

• Grease the drive line (page 5‑5).

• Grease the bearings of the transport wheel axles.

• Torque tighten the nuts of the transport wheels to 270 Nm (27 kgm).

• Examine the deflection of the rotors. Adjust the stop bolts if

necessary (page 5‑13).

• Make sure the tyres meet the correct pressure (page 6‑3).

• Examine the Lotus for damage and defects. Repair or replace damaged

parts.

• Examine the hydraulic system for leaks and damaged parts. Repair or

replace damaged parts.

• Examine the gearbox for leaks.

• Make sure all bolts and nuts are torque-tight (page 6‑2).

• Make sure all safety decals are not damaged. Replace if necessary.

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5-2

Maintenance

5.1.8 Maintenance after prolonged storage

• Grease the PTO shafts (page 5‑7).

• Replace the gearbox oil.

• Grease the pivot points (page 5‑6).

• Grease the drive line (page 5‑5).

• Grease the bearings of the transport wheel axles.

• Torque tighten the nuts of the transport wheels to 270 Nm (27 kgm).

• Examine the deflection of the rotors. Adjust the stop bolts if

necessary (page 5‑13).

• Make sure the tyres meet the correct pressure (page 6‑3).

• Examine the Lotus for damage and defects. Repair or replace damaged

parts.

• Examine the hydraulic system for leaks and damaged parts. Repair or

replace damaged parts.

• Examine the gearboxes for leaks.

• Make sure all bolts and nuts are torque-tight (page 6‑2).

• Make sure all safety decals are not damaged. Replace if necessary.

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Maintenance 5-3

5.2 Preventive maintenance

WARNING

5.2.1

WARNING

Make sure that the PTO shaft is disengaged and the tractor engine is
switched off before maintenance is made.

Clean the Lotus

Procedure

1. Make sure the Lotus is in the working position.

2. Use a water jet to thoroughly clean the Lotus.

3. Move the Lotus to the headland position (page 3‑13).

Make sure the tines and tine arms are tight and not damaged.

4. Carefully engage the PTO at the lowest possible engine speed until all
the water is removed from the rotors.

5. Apply anti-corrosion agent to the bare metal parts.

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5-4 Maintenance

5.2.2 Grease the Drive Line

Requirements:

• Grease pump

• Biodegradable grease (Total Biomultis SEP2 or equivalent)

Procedure

1. Grease the drive line on both sides with the grease pump.

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A = Grease after 10 hours.

B = Grease after 40 hours.

1. Housing

2. Housing

3. Coupling shaft

Figure 18. Grease the Drive Line

Maintenance

5-5

5.2.3 Grease the pivot points

Requirements:

• Grease pump

• Biodegradable grease (Total Biomultis SEP2 or equivalent)

Procedure:

1. Grease the pivot points with the grease pump.

A = Grease after 40 hours.

1. Safety guard

2. Wheel frame

3. Head stock pin

4. Pivot frame

Figure 19. Grease the Pivot Points

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5-6

Maintenance

5.2.4 Grease the PTO shaft

Requirements:

• Grease pump with flexible hose.

• Biodegradable grease (Total Biomultis SEP2 or equivalent)

CAUTION

Note:

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Refer to the third party documentation for detailed information to grease the
type of PTO shaft. The important grease point for all the type of PTO-shafts
are described in the next procedure.

Procedure:

1. Verify the types of PTO shafst on the Lotus.

2. Grease the following grease points of the PTO shaft(s) with the
grease pump:

• the grease nipple (A),

• the guard bearing (B),

• the profiled tubes (C).

To grease the headstock PTO shaft, make sure to turn the headstock to the
left or right as far as possible, for easier access.

1. PTO shaft

Figure 20. Headstock PTO shaft

Maintenance 5-7

1. PTO shaft 9-1154-0253-1 (Figure 22, page 5‑9)

2. PTO shaft 9-1154-0283-3 (Figure 23, page 5‑9)

3. PTO shaft 9-1154-0326-0 (Figure 24, page 5‑10)

Figure 21. Grease point PTO shafts

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5-8

Maintenance

Type PTO A B C

W 100. h. 100. h. n.a..

A. Grease nipple - B. Guard bearing - C.Profiled tube

Figure 22. Grease Points PTO Shaft (Type W)

Type PTO A B C

W (P-sealing) 250. h. 100 h. 100 h.

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A. Grease nipple - B. Guard bearings - C. Grease nipple

Figure 23. Grease Points PTO Shaft (Type W - P-sealing)

Maintenance

5-9

Type PTO A B C

W 100. h. 100. h. n.a..

A. Grease nipple - B. Guard bearing - C.Profiled tube

Figure 24. Grease Points PTO Shaft (Type W)

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5-10 Maintenance

5.2.5 Replace the Gearbox Grease

Requirements:

• Shell Gadus S2 V220-AC0

• Loctite 243

• Loctite 574

Procedure

1. Remove the hose clamp (2) and the protection cover (1).

2. Remove the bolts (4) and cover (3).

3. Remove the old grease from the gearbox .

4. Fill the gearbox with 1.2 kg of grease.

5. Put loctite 574 on the edge of the gearbox.

6. Put loctite 243 on the cover bolt holes.

7. Install the cover (3) and bolts (4) on the gearbox.

8. Install the hose clamp (2) and the protection cover (1).

9. Dispose of the old grease according by the rules.

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1. Protection cover - 2. Hose clamp - 3. Cover - 4. Bolt - 5. Fill plug

Figure 25. Replace gearbox grease

Maintenance

5-11

5.3 Corrective maintenance

WARNING

5.3.1

CAUTION

Make sure that the PTO shaft is disengaged and the tractor engine is
switched off before maintenance is made.

Replace the Tine(s)

Purpose

This procedure tells you how to replace the tines, which are liable to wear or
can break by an excessive load.

Procedure

1. Stop the tractor and disengage the tractor PTO.

2. Disengage the lock from the tine.

3. Remove the nut from the bolt on top of the adjustment block.

4. Remove the bolt and bushings from the broken or worn-out tine.

Make sure the replaced tine has the same colour mark used on the rotor or
tine arm (L=Yellow and R=Blue).

5. Put the adjustment block in the centre part of the tine.

6. Slide the tine with the adjustment block on the tine arm.

7. Insert the bushings on both side of the new tine.

8. Insert the bolt through the bushing at the longest tine tooth.

9. Tighten the tine and the adjustment block together on the tine arm

10. Move the tine to the required A or B position (Figure 14, page 4‑1).

If necessary replace the worn-out bushings.

with the nut and the bolt.

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1. Adjustment block - 2. Tine (yellow/blue) - 3. Bolt- 4. Bushings - 5. Nut - 6.Tine arm

Figure 26. Tine replacement

5-12 Maintenance

5.3.2 Adjust the Deflection of the Rotors

Procedure

1. Park the Lotus on a level floor.

2. Place an elevation of approximately 4 cm (1.57 in) under the four
central rotor wheels.

3. Move the Lotus to the working position (page 3‑7).

4. Make sure the Lotus is level.

5. Verify the adjustment of the deflection points on the adjustment-bar on
both sides of the Lotus:

a. Unlock the locking-nut to release the tension on the adjustment-

bar

b. Secure the locking-nut after releasing the tension on the

adjustment-bar.

6. Verify the adjustment of the deflection points at the front and rear side
on both sides of the Lotus:

a. Unlock the locking nuts to release the tension on the stop bolts.

b. Make sure the stop bolts slightly touch the stops.

c. Secure stop bolts by means of counter nuts.

7. Place an elevation of approximately 4 cm (1.57 in) under the next
deflection point.

8. Adjust the next outer deflection point, go to step 6.

9. Remove all elevations at the deflection points.

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Maintenance

5-13

1. Adjustment-bar - 2. Counter nut - 3. Stop bolt - 4. Deflection point - A. 4 cm (1.57 in)

Figure 27. Adjust the Deflection of the Rotors

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5-14

Maintenance

6. DIAGRAMS AND TABLES

6.1 Diagrams and Schematics

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1a. Single-acting ram (transport position) - 1b. Single-acting ram (headland position) - 2. Single-acting bar - 3. Double-acting ram -

4. Single-acting bar - 5. Double-acting ram - 6. Single-acting ram -

B1 (P/T). Blue marked hydraulic hose - B2 (P/T). Blue marked hydraulic hose - W (P/T). White marked hydraulic hose

Figure 28. Mechanically Controlled Hydraulic Schematic

Diagrams and tables

6-1

6.2 Bolt and nut torque table

The following tables specify the standard torque load for all quality bolts on
the Lotus.

Always use a calibrated torque wrench when you torque-tighten bolts and
nuts.

Thread size M6 M8 M10 M12 M14 M16 M20 M24

Bolt quality 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8

Nut quality 8 8 8 8 8 8 8 8

Nm 10 25 50 85 135 215 410 710

kgm 1.0 2.5 5.0 8.5 13.5 21.5 41.0 71.0

Thread size M8 M10 M12 M14 M16 M20

Bolt quality 10.9 10.9 10.9 10.9 10.9 10.9

Nut quality 10.9 10.9 10.9 10.9 10.9 10.9

Nm 35 70 110 190 295 580

kgm 3.5 7.0 11.0 19.0 29.5 58.0

Thread size M12

Bolt quality 12.9

Nut quality 10.9

Nm 75

kgm 7.5

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6-2 Diagrams and tables

6.3 Tyre Pressure Diagram

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A. 100 kPa (1.0 bar) - B. 150 kPa (1.5 bar) - C. 275 kPa (2.75 bar) - D. 300 kPa (3.0 bar)

Figure 29. Tyre Pressure Diagram

Diagrams and tables

6-3

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6-4 Diagrams and tables

7. SPECIFICATIONS

The specifications of the Lotus are defined in the following table:

Working width 12.50 m (41.01 ft)

Transport width 2.98 m (9.77 ft)

Transport height 2.95 m (9.68 ft)

Transport length 6.50 m (21.32 ft)

Approximate tedding angle 10º - 17º

Number of rotors 10

Number of tines per rotor 7 double tines

Linkage Category II

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Note:

Hydraulic connections

Hitch load (static load) 985 kg (2171 lb)

PTO speed 400 - 450 rpm, max. 540 rpm

Security K34B radial pin clutch

Operating speed Max. 15 km/h

Transport speed Max. 40 km/h

Transport tyre size 15.0/55-17 10 ply

Rotor tyre size 16/6.5-8 6 ply

Power requirement 70-95 kW (95-130 HP)

Approximate weight 2945 kg (6493 lb)

All specifications may be changed without prior notice.

• 1 double-action valve with floating
position

• 1 single action valve

Max. oil pressure 21.0 MPa (210 bar)

Specifications 7-1

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7-2 Specifications

INTENTIONALLY BLANK

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LELY INDUSTRIES NV

Weverskade 110
NL-3147 PA Maassluis
Tel +31 (0)10 - 59 96 333
Fax +31 (0)10 - 59 96 444
www.lely.com

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T-H021.1301EN