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www.lely.com
Lely Industries N.V.
460 / 520 Stabilo
LOTUS 520 Stabilo
LELY LOTUS
Operator’s manual
T-H005.0802VT
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EN-1
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OPERATOR’S MANUAL
LELY LOTUS
460 / 520 Stabilo
Th0050802en-tp.fm
English
LOTUS
®
is a registered trademark. The right of exclusive use belongs to the companies of the LELY Group.
©2008. All rights reserved. Nothing from this publication may be reproduced and/or published by printing, photocopying, microfilm or any other way without the prior written permission of LELY INDUSTRIES N.V.
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TABLE OF CONTENTS .......................................................................................................page
PREFACE .........................................................................................................................5
WARRANTY CONDITIONS .............................................................................................5
TYPE AND SERIAL NUMBER OF YOUR MACHINE ........................................................5
SAFETY INSTRUCTIONS ..................................................................................................6
EXPLANATION OF SAFETY DECALS ON THE MACHINE ...............................................7
1 INTRODUCTION..............................................................................................................8
2 LINKAGE TO THE TRACTOR...........................................................................................9
3 TRANSPORT...................................................................................................................10
4 MACHINE ADJUSTMENTS .............................................................................................11
4.1 Tine adjustment.................................................................................................. 11
4.2 Rotor angle and working height.......................................................................11
5 OPERATING THE LOTUS®............................................................................................. 12
5.1 General instructions ...........................................................................................12
5.2 Forward speed and PTO speed ..........................................................................12
5.3 STABILO steering device .................................................................................... 13
5.4 Recommended procedure..................................................................................13
6 DISMOUNTING FROM THE TRACTOR .......................................................................... 14
7 MAINTENANCE ............................................................................................................. 15
7.1 Maintenance after operation ............................................................................15
7.2 Lubrication.......................................................................................................... 15
7.3 Periodic maintenance.........................................................................................16
Supplements:
A OPTIONAL EXTRAS .......................................................................................................18
B TECHNICAL DETAILS ..................................................................................................... 19
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PREFACE
This Operator’s Manual is meant for personnel who operate the machine and are responsible for its daily maintenance.
Kindly read this entire manual prior to starting work.
Instructions relating to your safety and/or that of others are
marked in the margin by a warning triangle containing an exclamation mark. Always observe these instructions with particular care and attention.
Instructions which may lead to serious material damage in
case of non-compliance or incorrect use are indicated in the
margin with an exclamation mark.
The machine described in this manual may contain components
which do not form part of the standard equipment but are available
as optional extras.
This is not indicated in all cases since standard specifications may differ from country to country.
Furthermore, machines and optional extras may be adapted to specific regional conditions and are also subject to permanent research
and innovation.
For this reason, the specifications of your machine may not be consistent with the pictures in this manual.
WARRANTY CONDITIONS
For those parts which 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.
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.
TYPE AND SERIAL NUMBER OF YOUR MACHINE
The type/serial number plate is fitted on the drive line alongside the
central gearbox.
Please specify the type and serial number of your machine in any correspondence and when ordering spare parts.
Complete the box below with these numbers.
!
Type number
Serial number
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SAFETY INSTRUCTIONS
- Use the machine only for the purpose for which it was designed.
- Follow all prevailing safety regulations, including those laid down
in this manual and indicated on the machine.
- Operate this machine in a safe manner.
- The machine should be operated by authorised persons only.
- Be alert and observe all safety precautions.
- Ensure that all safety guards and protection devices are in place.
- Keep out of reach of moving parts.
- Stop the engine, PTO and moving parts before adjusting, cleaning
or lubricating the machine.
- Take care that no-one is within the dangerous zone while the machine is in operation and ensure that people are kept well away
from the machine. This is especially important when working
along roads and near or on fields that are accessible to the public.
- Always use a tractor with a cab.
- Clear the field of any objects that could be thrown up by the machine.
- Observe prevailing legislation for public road transport.
- Use flashing lights or other safety signs, when required.
- Do not stand on the machine.
- Use genuine LELY parts only.
- Remove the pressure from hydraulic systems before starting work
on them and/or before coupling/uncoupling hydraulic hoses.
- Use protective clothing, gloves and/or safety glasses if required.
- Clean the safety decals regularly so that they can be read at all
times.
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EXPLANATION OF SAFETY DECALS ON THE
MACHINE
- Read the operator’s manual carefully before operating the machine. Observe instructions and safety rules during operation.
- Danger! Moving parts.
Stay clear of rotating machine parts.
- Danger: flying objects!
Maintain a sufficient, safe distance from the machine while the
tractor engine is running.
- Danger: rotor segments can fold down!
Keep away from the folding area of the machine.
- Ensure the tractor PTO speed never exceeds 540 r.p.m.
- Danger: moving parts!
Read the operating instructions of the PTO shaft.
Never use a PTO shaft without any protection.
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1 INTRODUCTION
The LELY LOTUS 460 and 520 are rotary tedders that are used for
tedding mown grass and spreading out windrows. The tedders are
equipped with the STABILO steering device.
The LOTUS tedder is equipped with 4 rotors. Each rotor is fitted with
six tine arms featuring double spring steel tines (fig. 1). The special
tine shape ensures that the crop is picked up and spread out with a
minimum loss of material.
Since the rotors can pivot in relation to one another, the LOTUS tedder can follow field undulations with ease.
Ground contours are followed without any problem because the
wheels are positioned closely behind the tines (fig. 2).
Due to the STABILO steering device, the LOTUS tedder behaves like
a trailed machine. The steering device has been designed in such a
way (four pivot points, fig. 3) that any deviations made by the machine are corrected quickly.
Hydraulic controls ensure that the machine can be folded up quickly
and simply.
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EN-9
2 LINKAGE TO THE TRACTOR
Link the machine to the tractor as follows:
- Adjust the tractor’s three-point-hitch arms at an equal height.
- Fit the lower arms to the linkage pins (cat. II) of the three-point
hitch.
- Attach the top link of the tractor to the machine with a category
II top link pin.
- Place the 3 parking jacks in the raised position (fig. 4).
- Secure the tractor’s lower arms with stabilisation chains or rods to
eliminate any sideways movements.
- Check if the PTO shaft telescopes smoothly.
- Fit the PTO shaft to the tractor PTO.
During first assembly or when using another tractor, check
the minimum and maximum overlap of the PTO shaft halves
*
.
Also check whether the PTO shaft remains clear of the headstock
when the smallest possible bend is taken with the tractor. If not,
make allowance for this when manoeuvring and always take generous bends.
- Fit the safety chain of the protection tube to a rigid part of
the tractor.
- Connect the hydraulic hose to a single-acting hydraulic tractor
valve.
Permitted maximum oil pressure: 21.0 MPa (210 bar).
- Place the end of the operating cord of the ram lock in the tractor
cab.
*. Consult the instructions supplied with the PTO shaft
4
!
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3 TRANSPORT
The LOTUS tedder can be transported in the tractor hydraulics.
- Secure the STABILO steering device with the locking pin (fig. 5).
- Adjust the tines of the two inner rotors inwards (fig. 6).
- Fold up the lateral rotors using the tractor hydraulics.
- Block the hydraulic system by adjusting the tractor valve to the
blocked position.
- Check whether the ram has been secured by the locking hook
(fig. 7).
- Adjust the wheel supports of the lateral rotors to the position in
which the wheels protrude as little as possible (fig. 6).
- Lift the machine off the ground.
- Use all lighting and warning signals required by law (or
other regulations prescribed by the authorities).
- For transport on public roads, ensure that the front axle
weight is sufficient (fit front weights, if necessary) and
that the permitted maximum rear axle weight is not exceeded.
The machine is now ready for transport.
Never allow the PTO shaft to rotate when the machine is in
the transport position.
567
!
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4 MACHINE ADJUSTMENTS
Ensure that no-one is near the machine when it is switched
from the transport position to the working position.
Put the machine into the working position as follows:
- Place the wheel supports of the lateral rotors in the same position
as those of the middle rotor segments.
- Lower the machine to the ground.
- Tighten the control cord of the locking hook. Use the hydraulic
valve to gently lower the rotor segments.
- Remove the locking pin from the steering device and place it in
the appropriate hole on top of the headstock (fig. 8).
4.1 Tine adjustment
- Adjust the tines to the outer position (A, fig. 9).
Headland tedding:
Adjust the tines of the rotor on the plot side to the inner position
(B).
4.2 Rotor angle and working height
The wheels have the following preferred setting:
- LOTUS 460 Stabilo: highest/second-to-highest position;
- LOTUS 520 Stabilo: second-to-highest/ middle position.
A more level machine adjustment may be required when handling
light crops or in windy conditions.
- Lift the rotors clear from the ground using the tractor hydraulics.
- Switch off the tractor engine and take the necessary precautions
to ensure the machine does not suddenly lower before you start
adjusting the wheel supports.
Adjust the wheels to the desired position (A, fig. 10).
Headland tedding:
Adjust the rotor on the plot side 1 or 2 positions lower than the
other rotors.
- Lower the rotors.
- Adjust the working angle of the rotors in relation to the ground
via the top link in such a way that the tines gently sweep the
ground ensuring adequate crop pick-up. Rule of thumb: the tines
should touch the ground over a width of approximately 25 cm.
Deep adjustment causes an excessive load, which increases
wear and tear as well as the risk of tine breakage. The crop
will also become contaminated more easily.
8
9
A
B
10
25 cm
A
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5 OPERATING THE LOTUS
®
• Ensure no-one is near the machine at the moment the
PTO is engaged.
• Do not allow anyone to come within a 25 m radius of the
machine during operation.
• Stop the tractor engine before leaving the tractor cab.
• The safety guards are essential protective components of
the machine. For this reason, only operate the tedder if it
these components are duly fitted.
- When using the machine for the first time, carry out the inspection
and maintenance points specified in § 7.3 “Periodic maintenance”
before commencing work.
5.1 General instructions
- Engage the PTO at the lowest possible engine r.p.m.
- Increase the motor speed.
- Drive forward.
Never drive the machine through the crop while the rotors are on
the ground and are not rotating. This may damage the tines and
tine arms.
- Lower the rotors into the crop.
During the early stage of the process in particular, fast and airy tedding twice a day at a low r.p.m. rate is better than intensive tedding
at a high rotor speed.
The LOTUS tedder behaves like a trailed machine. It can continue
tedding in bends without any problem.
When the machine is lifted, the STABILO steering device is secured in
the angle at which the machine is positioned behind the tractor (see
§ 5.3).
A locked steering device can be used if the LOTUS tedder sways too
much during crosswise tedding on slopes.
- Secure the steering device with the locking pin (fig. 11).
- Raise the machine if a bend has to be taken.
5.2 Forward speed and PTO speed
Both crop pick-up and spreading depend on the forward speed and
rotor speed.
- Select the highest possible forward speed (up to a maximum of
15 km/h).
- Operate at the lowest possible PTO output (400-450 r.p.m.) so that
the crop is picked up effectively.
- Reduce your PTO output when windrows develop during the tedding operation.
- Adjust the forward speed and PTO speed to field and crop conditions.
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5.3 STABILO steering device
When the machine is lifted, the STABILO steering device is locked automatically. A conical pin is forced into the locking strip B through
the tumbler A (fig. 12) to which the top link is fitted.
Since the strip has several holes, the machine more or less remains in
the angle that is applied at the moment of lifting.
If there is a difference between the angles during lowering and lifting of the machine, the conical pin may not be released from the
hole because of the force exerted on the locking strip.
- If so, steer the tractor in the same angle in which the machine was
lifted or reverse slightly to discharge the locking strip.
5.4 Recommended procedure
- Work the central part of the field by driving up and down. Leave
a strip equal to 1 working width free on all sides of the field (c,
fig. 13).
In windy conditions, drive up and down into the direction of the
wind.
- Adjust the rotor segment that hugs the plot side 1 or 2 positions
lower and adjust the tines of this rotor segment inwards.
- Finish the plot by driving round and round (d).
12
A
B
13
wind direction
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6 DISMOUNTING FROM THE TRACTOR
- Lock the STABILO steering device (fig. 14).
The machine can be stored in two positions; either folded out or
folded up. The folded out position is recommended.
Always place the machine on hard, even ground.
- Storage in folded-out position:
• Adjust all wheel supports in the same position.
• Lower the machine to the ground.
• Use the hydraulic valve to gently lower the lateral rotor seg-
ments.
• Lower the machine onto the ground using the tractor hydrau-
lics.
- Storage in folded-up position:
• Adjust the wheel supports of the middle two rotor segments in
the closest position to the dish (fig. 15). This ensures the most
stable position for the machine.
• Lower the machine onto the ground using the tractor hydrau-
lics.
All other actions for dismounting the machine from the tractor are
identical in both cases.
- Switch off the tractor engine.
- Disengage the PTO shaft from the tractor PTO.
- Place the PTO shaft in the hook (fig. 16).
- Depressurize the hydraulic system and disconnect the hydraulic
hose. Slide the dust cap onto the plug.
- Remove the control cord for the locking hook from the tractor
cab.
- Place the two parking jacks of the headstock in the lowest position.
- Screw in the top link until the parking jacks are on ground level.
- Adjust the rear parking jack in the lowest possible position
(fig. 16).
- Disconnect the top link from the machine.
- Disconnect the lower arms from the machine.
141516
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7 MAINTENANCE
• Correct machine servicing is vital for ensuring reliable
and safe operation.
7.1 Maintenance after operation
- Clean the machine thoroughly.
- Check the tines and tine arms for tightness or any damage.
- Grease the machine with an anti-corrosion agent.
Pay special attention to the tines. Smooth tines without any rust
stimulate an unhampered crop flow.
- Grease the piston rod with an anti-corrosion agent if the machine
will not be used for a long period. Remove the agent before using
the machine again. If not, the ram seal may be affected if the anticorrosion agent hardens.
7.2 Lubrication
All lubrication points of the machine can be greased with a biodegradable grease (Total Biomultis SEP2), unless stated otherwise.
- PTO shafts must be greased every 8 working hours via the grease
nipples on the cross assemblies, protection tubes and slip clutch
(fig. 17).
- Grease the profiled tubes of the PTO shaft every 8 working hours
(fig. 17).
- Grease the cross assemblies of double universal joints every 8
working hours (fig. 18).
- Grease the gears in the gearboxes every 8 working hours (fig. 19)
While greasing, keep turning the rotors bit by bit to ensure the
grease is distributed effectively all over the gears.
- Grease the pivot points of the lateral rotors every 40 working
hours (fig. 19).
!
17
8 h
8 h
18
8 h
19
8 h
40 h
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- Grease the pivots of the STABILO steering device every 40 working
hours (fig. 20).
- Grease or lubricate all remaining pivot points every 40 working
hours.
7.3 Periodic maintenance
Periodic maintenance must be carried out:
• at the start of the haymaking season;
• before prolonged storage of the machine;
• when the machine is used extensively during the season.
- Grease all points of the machine listed in § 7.2 “Lubrication”.
- Grease the spring-loaded locking pins of the yoke lock of the PTO
shaft.
- Check if the PTO shaft telescopes smoothly.
A damaged PTO shaft may cause excessive wear and tear to the
machine and tractor.
- Check the machine for any damage and flaws.
- Check the tyre pressure (fig. 21).
- Check all bolts and nuts for tightness.
Tighten loose bolts/nuts to the torques specified below.
- Check the rotors for sagging (fig. 22).
• Place the machine on a level floor.
• Place the central wheels on an elevation of 60 mm.
• Ensure the machine is horizontal.
• The stop bolts should then only just touch the surfaces of the
stops.
M6 M8 M10 M12 M14 M16 M20 M24
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
20
40 h
21
275 kPa
150 kPa
(2.75 bar)
(1.5 bar)
22
60 mm
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- Check whether all safety decals are on the machine and not damaged (fig. 23).
A (P/N 9.1170.0408.0)
B (P/N 9.1170.0407.6) -4xC (P/N 9.1170.0410.2)
D P/N 9.1170.0420.5)
E P/N 9.1170.0125.4)
F (P/N 16.61.175)
- Check the gearbox for grease leakage.
Change the grease every 500 working hours. Remove the cover on
the rear of the gearbox for this purpose (fig 24).
(Contents 0.25 kg; Shell Alvania WR-0).
When mounting the cover, lubricate the edge of the gearbox and
the bolt holes with a fluid gasket (LOCTITE 574).
23
B
A
B
B C D B
E
F
24
SHELL ALVANIA WR-0
0.25 kg
ABCDE
F
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A OPTIONAL EXTRAS
Extension kit for Stabilo steering device
When the LOTUS Stabilo tedder is pulled behind a tractor with very
wide rear tyres or when the tractor is on a large track width, the tractor's rear tyres may touch the machine when a bend is taken.
To prevent this, extended linkage points are available so that the
machine is coupled further behind the tractor.
Lowering kit for Stabilo steering device
Sometimes the tractor's hydraulics are unable to lift the LOTUS Stabilo tedder high enough over the swaths.
To obtain more lifting height, the Stabilo steering device is fitted
with lowered linkage points for the pull rods of the tractor. These allow the machine to be lifted higher.
Lighting set
While the machine is being transported on public roads, the tractor's
lighting may no longer be properly visible anymore.
The LOTUS Stabilo tedders are therefore equipped with a lighting
set that can be attached to the machine's warning signs.
Spare wheel with support
The LOTUS tedder can be fitted with a support for a spare wheel so
that a flat tyre can be mended quickly in the field.
Supplement A
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B TECHNICAL DETAILS
All details are without engagement and may be
altered without prior notice.
LOTUS® Stabilo
460 520
Working width 4.60 m 5.20 m
Transport width 2.75 m 2.75 m
Transport height 2.50 m 2.60 m
Transport length 2.20 m
Tedding angle ca. 10° - 17°
Number of rotors x tines 4 x 6 double tines
Linkage category II
Hydraulic connections
1 single-acting valve with floating position
(max. oil pressure 21.0 MPa (210 bar))
PTO speed 400 - 450 r.p.m., max. 540 r.p.m.
Overload security K33 radial pin clutch
Operating speed max. 15 km/h
Tyre size 16/6.5-8 6 ply
Power required
37 kW
(50 HP)
40 kW
(55 HP)
Weight approximately 680 kg 695 kg
Supplement B
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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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