CLAAS Combines MEDION 340 330 320 310 MEGA360 350folding cutterbar 4.50m Fitting Instructions Manual

MEDION 340 / 330 / 320 / 310 MEGA 360 / 350

Fitting and Operating Instructions folding cutterbar 4.50 m

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1 Introduction

Introduction

Introduction INTRODUCTION

These instructions describe how to assemble and operate the 4.50 m folding cutterbar together and how to assemble the required accessories on the machine.

You should explain the function, operation and maintenance to the customer on the basis of these instructions.

These instructions are only valid when used in conjunction with the combine harvester operating instructions.

CLAAS Service Department

0299 838.0 - ABA / BA SW klappbar, 4,5 m

1.1.1

Introduction

1.1.2

ABA / BA SW klappbar, 4,5 m - 0299 838.0

2 Table of contents

Table of contents

Table of contents TABLE OF CONTENTS 1. Introduction Introduction ............................................................................ 1.1.1

2. Table of contents Table of contents ................................................................... 2.1.1

3. Preface Attention! ................................................................................ 3.1.1 Special note ........................................................................... 3.2.1 Type plate / serial number ..................................................... 3.3.1

4. Safety rules Safety rules ............................................................................ 4.1.1 Identification of warning and danger signs ...................... 4.1.1 Correct use of the vehicle ................................................ 4.1.1 General safety and accident prevention regulations ....... 4.1.1 Safety Locks .......................................................................... 4.1.3 Cylinder safety lock ......................................................... 4.1.3 Reel supports .................................................................. 4.1.4 Insert the reel supports .................................................... 4.1.4 Remove the reel supports and store them away ............. 4.1.4 Safety decals with pictorials ................................................... 4.2.1

5. Specifications Weights / Dimensions / Safety devices ..................................

Weights / Dimensions ......................................................

Safety feature: .................................................................

Setting the slipping clutch ................................................

5.1.1 5.1.1 5.1.1 5.1.1

6. Prior to operation Carry out prior to initial operation ........................................... 6.1.1 Driving lights for road use ...................................................... 6.2.1 Driving lights for road use ................................................ 6.2.1 Switching over the driving lights ...................................... 6.2.1 Cutterbar cylinder ............................................................ 6.2.1

7. Ancillary equipment Additional weights .................................................................. 7.1.1 MEDION 340 – 310 / MEGA 360 / 350 ............................ 7.1.1 Liquid filler for the steering axle wheels ........................... 7.1.2 Fitting the cover weights .................................................. 7.1.3 Scope of components - Cover weights ........................... 7.1.3 Scope of components - steering axle weights ................. 7.1.4 Steering axle weights ...................................................... 7.1.5 Fitting the steering axle weights (Additional equipment) ..................................................... 7.1.5

0299 838.0 - ABA / BA SW klappbar, 4,5 m

9. Maintenance Transmissions .......................................................................

Knife drive casing ............................................................

Angle drive for the reel drive ...........................................

Knife drive .......................................................................

Drive chain tensioning .....................................................

Cleaning the guide rail of the locking cylinder .................

Adjusting the double fingers ............................................

9.1.1 9.1.1 9.1.2 9.1.2 9.1.2 9.1.3 9.1.3

10. Lubrication chart Lubricants and notes ........................................................... 10.1.1

11. Index

8. Fitting and Operation Fitting additional equipment ...................................................

Fitting stops in the feeder housing ...................................

Scope of parts - Fitting ....................................................

Fitting the stops ...............................................................

Lock the cutterbar at the sides ........................................

Modifying the cutterbar "Auto-Contour" for machines without Auto-Contour ......................................

Fitting the switching device and the driving lights ............

Shortening the flat key MEGA 360 / MEDION 340 ............................................ 8.1.11 Setting the additional headlights ................................... 8.1.12 Fitting the cutterbar ............................................................... 8.2.1 Tilting the cutterbar from the transport position ............... 8.2.1 Fitting and removing the cutterbar. ................................. 8.2.2 Fitting the cutterbar - folded – (Cutterbar in the transport position) ................................ 8.2.2 Aligning the cutterbar (Cutterbar without Auto-Contour) .................................... 8.2.3 Connecting the hydraulic hoses ...................................... 8.2.4 Connecting the plug ........................................................ 8.2.4 Changing the cutterbar from transport position to operating position ............................................................ 8.2.4 Changing the cutterbar from operating position to transport position ............................................................. 8.2.8 Removing the cutterbar - folded in - .............................. 8.2.10 Fitting the cutterbar - unfolded (Cutterbar in operating position) .................................... 8.2.12 Connecting the universal drive shafts ........................... 8.2.13 Connecting the hydraulic hoses .................................... 8.2.14 Connecting the plug ...................................................... 8.2.14 Removing the cutterbar - unfolded (Cutterbar in operating position) .................................... 8.2.14 Adjustments to the cutterbar ................................................. 8.3.1 Crop dividers ................................................................... 8.3.1 Crop lifters ....................................................................... 8.3.2 Knife ................................................................................ 8.3.3 Reel ................................................................................. 8.3.5 Reel speed ...................................................................... 8.3.6 Intake auger .................................................................... 8.3.7 Cutterbar skids .............................................................. 8.3.10 Malfunction .......................................................................... 8.3.11 Cause or Remedy ............................................................... 8.3.11

8.1.1 8.1.1 8.1.2 8.1.3 8.1.4

Index .................................................................................... 11.1.1

8.1.4 8.1.7

2.1.1

Table of contents

2.1.2

ABA / BA SW klappbar, 4,5 m - 0299 838.0

3 Preface

Preface

Preface

ATTENTION!

On fitting the 4.50 m grain cutting unit, foldable, the operating licence of your combine harvester will become invalid.

For this reason, it will be necessary to request a new operating licence for the combine harvester from the relevant authorities (registration office) upon presentation of a certificate for the combine harvester to the administration (§ 19 Para. 2 StVZO).

The new certificate is issued by the relevant "Technical Monitoring Association" (TÜV).

In order to make the acceptance easier, upon request, CLAAS can produce a sample certificate by stipulating the MD type, the machine number and the year of manufacture, or it can undertake an acceptance together with the TÜV in Hanover. Specific care must be taken with regard to the required weight increase on the steering axle to prevent lifting while braking. If their is no weight increase, then the TÜV might not issue a certificate.

0299 838.0 - ABA / BA SW klappbar, 4,5 m

3.1.1

Preface

Preface SPECIAL NOTE

To prevent accidents, the instructions contained in this manual should be carefully read and observed by all persons involved with the operation, maintenance and inspection of this machine. In particular, read the section on “Safety rules”.

The use of spare parts, accessories and ancillary equipment, which are not originally manufactured by CLAAS, can change the specified design of this CLAAS machine or detract from its functional performance, with a possible adverse effect on the active and/or passive operational safety of the machine and its occupational safety standards (accident prevention).

CLAAS is in no way liable for any damage or personal injury caused through the use of parts other than original CLAAS parts, accessories and ancillary equipment.

The technical details, measurements and weights are stated without obligation. CLAAS reserves the right to make changes subsequently as technical developments continue.

Liability for errors or omissions not accepted.

Front, rear, right and left are always in direction of travel.

3.2.1

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Preface

Preface TYPE PLATE / SERIAL NUMBER The type plate with the cutterbar serial number is located at the back on the left-hand side of the cutterbar crossbeam.

(Fig. 1)

1 When placing orders for spare parts or making technical inquiries please quote the cutterbar serial number.

This is necessary as otherwise, incorrect spare parts may be made.

0299 838.0 - ABA / BA SW klappbar, 4,5 m

3.3.1

Preface

3.3.2

ABA / BA SW klappbar, 4,5 m - 0299 838.0

4 Safety rules

Safety rules

Safety rules SAFETY RULES

Correct use of the vehicle

Before putting the machine into operation, read the Operator's Manual and follow the safety precautions.

The folding cutterbar is to be used exclusively for normal use in agricultural work (correct application).

Identification of warning and danger signs All parts of this manual having to do with your safety or the safe operation of the machine are marked with the following signs. Please pass on all safety instructions to other users, too.

DANGER! Sign to indicate instructions which must be observed. Failure to do so would cause danger to life and limb of the operator and the people around him.

☞ Preventive measures

ATTENTION! Sign to indicate instructions which must be observed. Failure to do so could result in damage to the machine.

☞ Measures to prevent damage to the machine.

NOTE! Sign to indicate instructions for a more efficient and economic use of the machine.

ENVIRONMENT!

Any other use is to be considered as an incorrect application; any damage resulting from this is not the responsibility of the manufacturer; the risk is entirely that of the operator.

Compliance and strict adherence to the operation, service and repair conditions as specified by the manufacturer also constitute essential elements of the intended use.

The folding cutterbar can only be operated, maintained and repaired by personnel who are familiar with these tasks and the associated dangers.

Accident prevention regulations, all other generally recognised regulations on safety and occupational medicine and road traffic regulations must be observed at all times.

Fitting and retrofitting of ancillary equipment which is not originally manufactured by CLAAS, and, in addition, also modifications and changes may only be carried out with the consent of CLAAS, as any such actions may have considerable adverse effects on the safety and operational function of the machine.

Any arbitrary modifications carried out on the cutterbar will relieve the manufacturer of all liability for any resulting damage or injury.

General safety and accident prevention regulations 1. In addition to these operating instructions, please observe the general safety and accident-prevention regulations.

2. Always comply with local traffic regulations when driving on public roads.

Sign to indicate instructions which must be observed in order to avoid damage to the environment.

3. Before starting work, familiarise yourself with all the controls and instruments and their functions. During work or road travel it is too late!

Danger to the environment is caused by irregular handling and incorrect disposal of toxic material (e.g. old oil).

4. Before starting work, check the cutterbar unit for loose parts.

The warning and instruction signs placed on the machine provide important recommendations for safe operation. These instructions involve your safety – observe them at all times!

0299 838.0 - ABA / BA SW klappbar, 4,5 m

5. When working on or around the cutterbar unit, stop the engine and remove the ignition key.

Hydraulic pipes must be depressurised.

6. Only work under the cutterbar and the reel if they are securely supported.

4.1.1

Safety rules 7. On public roads and lanes, the cutterbar must always be folded.

The dividers must be folded.

Switch over the driving lights from the bottom to the top.

Attach protection rail with warming plate and side lights on the front of the cutterbar and connect the lighting.

8. When folding the cutterbar the machine should be secured from rolling away (parking brake, wedges).

9. When actuating the push-button for the folding device of the cutterbar, no persons should be standing between the drive wheels and the cutterbar.

10. When folding the cutterbar no persons should be standing within the swing area.

11. Removing and fitting knives involves a great risk of personal injury particularly when the cutterbar is misaligned and/or very dirty.

12. Knives, cutterbar, intake auger and reel etc. cannot be completely shielded by constructional measures due to their function. For this reason, an adequate safety distance must be maintained from these moving elements during operation!

13. Never operate the universal drive shafts with the guard removed or with a damaged guard.

14. When carrying a cutterbar during travel on public roads and lanes, the finger bar and/or the crop lifters must be covered.

15. Under no circumstances attempt to service, lubricate or clean the machine or to remedy any operational problems unless the drive is disengaged and the engine stopped. Remove the ignition key!

16. When working on the electrical equipment always switch off the battery isolator!

17. Always replace safety guards and shields after carrying out maintenance work.

18. There is danger of injury when fitting the cutterbar to the combine harvester!

19. No person must ever be allowed between the combine harvester and cutterbar unless the parking brake is applied and/or the wheels are chocked so that the vehicle cannot start or move on its own.

Observe all further safety precautions contained in the Combine Operator’s Manual.

4.1.2

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Safety rules

Safety rules SAFETY LOCKS Cylinder safety lock Work under the lifted cutterbar or feed rake only when they are securely supported.

Lift the feeder housing to the highest position.

R

DANGER! Stop the engine and remove the ignition key.

1

Release safety lock (S) on latch (R) and fold onto the hydraulic ram.

(Fig. 1, 2) During combine operation, the safety lock must be secured with latch (R).

(Fig. 1, 2)

S

2

0299 838.0 - ABA / BA SW klappbar, 4,5 m

4.1.3

Safety rules Reel supports A

Insert the reel supports Lift the reel to the top.

DANGER!

H

Stop the engine and remove the ignition key.

Remove the reel supports (A) on the right and left from the frame members (H) of the cutterbar troughs.

3

Insert the reel supports (A) on the right and left sides of the machine and secure each one with a split-pin.

(Fig. 3, 4)

A

H

4

Remove the reel supports and store them away Lift the reel to the top. Remove the reel supports (A) and replace the split-pins in the reel supports.

A

Push the reel supports with their points downwards into the frame members (H) of the cutterbar troughs.

H

(Fig. 5, 6)

5

A

H

6

4.1.4

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Safety rules

Safety rules SAFETY DECALS WITH PICTORIALS

Safety decals are attached to the danger zones of the machine. These safety decals help to alert persons to hazards which can cause personal injury. The pictorials provide instructions to avoid the hazard.

These safety signs, their placement on the machine and a brief explanatory text are shown on the following pages.

The CLAAS part number of every decal is stated ahead of the text.

The figure in ( ) refers to the adjacent picture and indicates the correct location of the decal on the machine.

Safety decals that are damaged or cannot be recognised any more must be replaced immediately by new ones.

When parts that have decals are replaced, always make sure to install the relevant new decals with each new part.

0299 838.0 - ABA / BA SW klappbar, 4,5 m

4.2.1

Safety rules

Safety rules

31

22

1

2 0516 039.0 (22) Do not remove the safety guards when the engine is running.

22 31

3

4 0516 040.0 (31) Danger - do not approach the feed unit of the harvest attachment until the drive is switched off and the ignition key has been removed. Wait for all mechanisms to stop and only then attempt to correct any problems.

4.2.2

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Safety rules

4

5

6 0516 042.0 (4) Do not enter the danger area between the front attachment and the machine.

0299 838.0 - ABA / BA SW klappbar, 4,5 m

4.2.3

Safety rules

4.2.4

ABA / BA SW klappbar, 4,5 m - 0299 838.0

5 Specifications

Specifications

Specifications WEIGHTS / DIMENSIONS / SAFETY DEVICES Weights / Dimensions Cutterbar type

Weight

Working width

Transport width

Cutterbar 4.50 m (15’)

1620 kg

5060 mm

3000 mm

Overall length see combine harvester operating instructions

Safety feature: Setting the slipping clutch Cutterbar type

Reel

Intake auger

Cutterbar 4.50 m (15’)

200 ± 40 Nm*

300 ± 40 Nm

0299 838.0 - ABA / BA SW klappbar, 4,5 m

5.1.1

Specifications

5.1.2

ABA / BA SW klappbar, 4,5 m - 0299 838.0

6 Prior to operation

Prior to operation

Prior to operation CARRY OUT PRIOR TO INITIAL OPERATION

1. Take off all wired parts and / or extra parts packages and unpack.

2. Remove the transport brackets from the reel carrier arms.

3. Check all oil levels in the gearboxes and refill if necessary.

4. Check all safety guards and correctly position them, if required.

0299 838.0 - ABA / BA SW klappbar, 4,5 m

6.1.1

Prior to operation

Prior to operation DRIVING LIGHTS FOR ROAD USE Driving lights for road use The normal front driving lights of the combine harvester are covered by the cutterbar when it is in folded position for transport.

When driving on public roads and lanes the lighting must therefore be switched to the top headlights (A).

A

A

(Fig. 1)

1 Switching over the driving lights 12

Switch on the driving lights as usual. This means turning the switch (12) to position (2).

13

Turn the switch (13) to the right-hand position . The driving light (A) is switched on.

(Fig. 1, 2)

2 Cutterbar cylinder Right cutterbar cylinder: The right cutterbar cylinder must be located in the right bracket (R).

(Fig. 3) R

3

6.2.1

ABA / BA SW klappbar, 4,5 m - 0299 838.0

7 Ancillary equipment

Ancillary equipment

Ancillary equipment

ADDITIONAL WEIGHTS MEDION 340 – 310 / MEGA 360 / 350 For road use, with fitted 4.50 m cutterbar, foldable, the StVZO requires an increase in weight on the steering axle, in order to prevent lifting up during braking.

The following combinations fulfil this requirement Combine harvester type

Medion 340*

Medion 330* Medion 320* Medion 310*

MEGA 360*

MEGA 350*

permissible steering axle tyres

Straw chopper

4- Trac Weight increase driven steering steering axle wheels axle (tyre fill see following table) kg

Steering axle weights kg

Cover weights kg

14.9/80-24

+

+

320

-

-

14.9/80-24

+

-

320

-

480

14.9/80-24

+

-

-

-

600

500/60 - 22.5

+

+

400

-

-

500/60 - 22.5

+

-

400

-

300

500/60 - 22.5

+

-

-

-

600

14.5/75-20

+

-

290

-

480

14.5/75-20

+

-

-

400

300

14.9/80-24

+

+

320

-

-

14.9/80-24

+

-

320

480

14.9/80-24

+

-

-

600

500/60 - 22.5

+

+

400

-

500/60 - 22.5

+

-

400

300

500/60 - 22.5

+

-

-

14.9/80-24

+

+

320

600

14.9/80-24

+

+

-

300

14.9/80-24

+

-

320

480

14.9/80-24

+

-

-

600

500/60 - 22.5

+

+

400

-

500/60 - 22.5

+

+

500/60 - 22.5

+

-

-

-

300 400

480

500/60 - 22.5

+

-

-

14.5/75-20

+

-

290

-

600 480

14.5/75-20

+

-

-

400

300

14.9/80-24

+

+

320

-

-

14.9/80-24

+

+

-

300

14.9/80-24

+

-

320

480

14.9/80-24

+

-

-

600

500/60 - 22.5

+

+

400

-

500/60 - 22.5

+

+

500/60 - 22.5

+

-

400

480

500/60 - 22.5

+

-

400

480

300

* Only with driven axle tyres 620/75 R 30 161 A8 or 650/75 R 32 167 A8 or 800/75 R 32 167 A8 Please observe the relevant TÜV road traffic and registration regulations applicable in your area + present - not present

0299 838.0 - ABA / BA SW klappbar, 4,5 m

7.1.1

Ancillary equipment

Liquid filler for the steering axle wheels In order to ensure frost resistance of the water in the tyres of the steering axle down to -20C, the following amounts of magnesium chloride should be added to the water in the tyres.

The quoted quantities refer to both wheels on the steering axle.

7.1.2

Steering axle tyres

Magnesium chloride

Water litre / kg

Total fill weight

14.5/75 - 20

110

180

290

14.9/80-24

120

200

320

500/60-22.5

150

250

400

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Ancillary equipment Fitting the cover weights Unscrew the cover plates (E) on both sides to allow fitting the brackets (1).

C

C

Screw on the brackets (1) using hexagonal head bolts (2) at (A) and (3) at (B).

A

A

1 B

C

Drill all holes on the brackets (C) 12.5 mm. Screw the weights (5) in position using hexagonal head bolts (6) at (D). Replace the cover plates (E).

B

C

(Fig. 1, 2) 1

E

D

5

D

E

2 Scope of components - Cover weights Scope of components

number

1 Bracket, left approx. 10 kg ...................................1 Bracket, right approx. 10 kg .................................1 2 Hexagonal head bolts M 8 x 30 DIN 933-8.8 ......6 Hexagonal nuts M 8 ............................................6 Contact washer A 8 .............................................6 3 Hexagonal head bolt M 12 x 35 DIN 933-8.8 ......2 Contact washer B 12 ...........................................2 4 Hexagonal head bolt M 12 x 40 DIN 933-8.8 ......6 Washer 12.2 x 30 x 3 .........................................12 Lock-nut VM 12....................................................6 5 Weight each approx. 28 kg 130 kg ..................................................................4 300 kg ...............................................................10 480 kg ................................................................16 600 kg ................................................................20 6 Hexagonal head bolt at: 130 kg – M 12 x 120 DIN 933-8.8 ........................6 300 kg – M 12 x 220 DIN 933-8.8 ........................6 480 kg – M 12 x 330 DIN 931-8.8 ........................6 600 kg – M 12 x 430 DIN 931 ..............................6 Washer 12.2 x 30 x 3 ........................................12 Lock-nut VM 12....................................................6 (Fig. 1, 2)

0299 838.0 - ABA / BA SW klappbar, 4,5 m

7.1.3

Ancillary equipment

5

5

2

4

3

1

3

4

Scope of components - steering axle weights Scope of components

3

number

1 Lower weight plate 2 Upper weight plate 3 Hexagonal head bolt M 14 x 220 DIN 931-8.8 Lock-nut VM 14 4 Hexagonal head bolt M 16 x 360 DIN 931-8.8 Lock-nut VM 16 5 Mounting plates

2 4 2 2 4 4 2

(Fig. 3)

7.1.4

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Ancillary equipment Steering axle weights Fitting the steering axle weights (Additional equipment) When fitting the steering axle weights they should be supported by wooden packers.

CAUTION! Total weight of plates = 400 kg The weight plates (1 and 2) must first be screwed into position using two hexagonal head bolts (3).

4

Lift the weights under the axle using a secure lifting device (fork-lift truck or similar).

Screw the weights centrally under the steering axle using four hexagonal head bolts (4) and two mounting plates (5).

Tightening torque for bolts: Hexagonal head bolt (3) = 122 Nm Hexagonal head bolt (4) = 195 Nm (Fig. 3, 4, 5)

5 Check free running of the steering axle: Lift the back of the machine slightly to remove the load from the steering axle wheels.

Turn the steering axle wheels all the way to both sides and check the free-running on the track rod and the steering cylinder. If required, adjust the position of the steering axle stops accordingly.

(Fig. 3, 4, 5, 6)

6

0299 838.0 - ABA / BA SW klappbar, 4,5 m

7.1.5

Ancillary equipment

7.1.6

ABA / BA SW klappbar, 4,5 m - 0299 838.0

8 Fitting and Operation

Fitting and Operation

Fitting and Operation FITTING ADDITIONAL EQUIPMENT Fitting stops in the feeder housing D

When fitting the folding cutterbar for the first time, the supplied support brackets must be fitted to both sides of the feeder housing, (if they are not already fitted). In order to fit them, holes must be drilled in accordance with the stated dimensions (if they are not already present).

C

E B F

E E

1 Stated dimensions: A = 26.5 mm B = 46.0 mm C = 74.0 mm D = 162.0 mm E = Ø 13mm F = Support for the cutterbar cylinder shown on the left, the right is the mirror image (Fig. 1)

0299 838.0 - ABA / BA SW klappbar, 4,5 m

8.1.1

Fitting and Operation

2

Scope of parts - Fitting Scope of parts

Quantity

1 Stop left Stop right 2 Hexagonal head bolts M 12 x 80 DIN 931-8.8 Contact washer A 12 Hexagonal nuts M 12 3 Spacer D 50 x 41.5 4 Guide * 5 Mushroom head screw M 12 x 30 * Contact washer A 12 * Hexagonal nut M 12 * Hexagonal head bolt M 12 x 35 DIN 933-8.8 ** Contact washer A 12 ** 6 Holding plate ** 7 Hexagonal head bolt M 12 x 20 DIN 933-8.8 ** Contact washer A 12 ** Hexagonal nut M 12 **

1 1 4 4 4 4 4 8 8 8 8 8 2 2 2 2

* with Auto-Contour ** without Auto-Contour (Fig. 2)

8.1.2

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Fitting and Operation Fitting the stops Remove the guides (F) with Auto-Contour or the holding plates (P) with Contour from the feeder housing.

(Fig. 3, 4)

F

3

P

4 Machine with Auto-Contour: On both sides of the feeder housing, fit the stops (1) using hexagonal head bolts (2) and spacers (3) at (E).

Insert the guides (4) on the insides of the housing frame. Screw the guides (4) and stops (1) in position at (G) using mushroom head screws (5).

G

(Fig. 2, 5) E

1 5 Machine without Auto-Contour: On both sides of the feeder housing, fit the stops (1) using hexagonal head bolts (2) and spacers (3) at (E).

Apply the holding plates (6) to the outsides and screw in position using hexagonal head bolts (5).

G

E

(Fig. 2, 6)

1 6

0299 838.0 - ABA / BA SW klappbar, 4,5 m

8.1.3

Fitting and Operation Lock the cutterbar at the sides "Cutterbar without CLAAS Auto-Contour“ For this, the cutterbar should be lifted using the machine and then centralised with respect to the feeder housing.

Subsequently, the cutterbar should be locked on both sides each using one hexagonal head bolt (7).

(Fig. 2) Modifying the cutterbar "Auto-Contour" for machines without Auto-Contour In the event that Auto-Contour cutterbars are to be used on machines without Auto-Contour, all the items from 5 to 10 on figure 7, and all the items from 2 to 39 on figure 8 are to be removed; these parts are not required.

8.1.4

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Fitting and Operation

7

8

0299 838.0 - ABA / BA SW klappbar, 4,5 m

8.1.5

Fitting and Operation

14

7

12

8 9

12 13

11 10 5

6 2 6

1

4

3

Scope of parts - fitting (additional driving lights for the folding attachment on the machine)

9

1 Holder.................................................................. 1 2 Cable set ............................................................. 1 3 Cap screw M 5 x 35............................................. 3 Hexagonal nut M 5 .............................................. 3 Spring washer 5 .................................................. 3 4 Pipe clamp 12/20................................................. 3 5 Hexagonal head bolt M 8 x 25 ISO 4017-8.8 ...... 3 Contact washer A 8 ............................................. 3 Hexagonal nut M 8 .............................................. 3 6 Cable tape 7.6 x 282 ........................................... 6 Cable tape 3.6 x 150 ........................................... 3 7 Push button green ............................................... 1 8 Push button red ................................................... 1 9 Push button green ............................................... 1 10 Sticker Operation................................................. 1 11 Warning decal ..................................................... 1 12 Lamp ................................................................... 2 13 Cable set ............................................................. 2 14 Rotary switch....................................................... 1 (Fig. 9)

8.1.6

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Fitting and Operation For the ground operation of the cutterbar (fold and unfold the cutterbar), the electrical switching components is to be mounted on the right hand side of the operator's platform.

Fitting the switching device and the driving lights DANGER! Remove the cable from the negative pole of the battery!

Remove the guard (A).

(Fig. 10)

A

10 Screw the holder (1) to the lower 7 pole plug socket holder using the screws provided.

Screw the red 7 pole plug socket from the cable set (2) to the holder (1) using the cap screws (3).

Fix the cable set (2) to the holder (1) using the pipe clamp (4) and hexagonal head bolt (5).

4

Fix the cable set (2) on the feeder housing with the pipe clamp (4) and the hexagonal head bolt provided.

2 4

(Fig. 9, 11)

1 11

Lay the cable set up to operator's platform and secure using cable ties (6).

(Fig. 12)

6

6 12

0299 838.0 - ABA / BA SW klappbar, 4,5 m

8.1.7

Fitting and Operation Connect the cable set (2) under the operator's platform.

D

Connect the 6 pole plug at (D) and the 2 pole plug at (C) to the existing cable set.

4

Fix the cable set (2) to the brace using the pipe clamp (4) and hexagonal head bolt (5).

C

(Fig. 9, 13)

2

13 Replace the guard (A).

Remove the three blind plugs (B) on the operator's platform.

(Fig. 14)

B

A 14 Fitting the push button: Fit the push buttons (7, 8 and 9) and screw in position.

8 7

Connect the existing cable in accordance with the cable connections.

9

(Fig. 15)

15 Cable connections Push button 7 = pink / green brown Push button 8 = violet / green black Push button 9 = red / green brown (Fig. 15)

8.1.8

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Fitting and Operation Sticker (10) and warning decal (11) to be fitted to the operator's platform.

11

10

(Fig. 16)

16 Fitting the upper driving lights: Screw the lamps (12) in position on both sides, on the rail.

12

Connect the cable sets (13) to the lamps (12).

Lay the cable sets (13) down to the operator's platform and secure to the rail using the cable ties (6).

13

(Fig. 17, 18)

17

12 13

18

0299 838.0 - ABA / BA SW klappbar, 4,5 m

8.1.9

Fitting and Operation Connect the cable sets (13) to the existing cable sets under the operator's platform.

13

(Fig. 19, 20)

19

13

20 Release the fixing screws for the shield (B) and pull the shield forwards slightly.

(Fig. 21) B

21 Remove the blind plugs (S).

(Fig. 22)

S 22

8.1.10

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Fitting and Operation Fit the rotary switch (14) and screw in position.Connect the existing cable set to the rotary switch (14). Fit the rotary knob (D).

(Fig. 23)

14

D 23 Replace the shield (B).

(Fig. 24)

B

24

Shortening the flat key MEGA 360 / MEDION 340 X

When fitting the folding cutterbar for the first time, the flat key (P) on the intermediate drive shaft on the left hand side must be shortened. Grind off the flat key 8 mm dimension (X) until the shaft diameter.

P

(Fig. 25)

25

0299 838.0 - ABA / BA SW klappbar, 4,5 m

8.1.11

Fitting and Operation

Setting the additional headlights

26

1. Check the tyres for correct inflation pressure.

2. Locate the machine at right angles to a vertical wall at a distance (X = 15 metres).

3. Adjust the headlights so that the top edge of the light/dark sections on the wall is at half the height of the headlight.

S1 = ½ height of headlight S2 = height of headlight L = light cone W = wall (Fig. 26)

8.1.12

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Ancillary equipment

Fitting and Operation FITTING THE CUTTERBAR Tilting the cutterbar from the transport position DANGER! When fitting front attachments, there is a danger of injury!

No persons are permitted in the danger area!

1

Before operating the cutterbar for the first time, it should be tilted from the vertical to the horizontal position (if required).

To do this, proceed as follows: Lift the cutterbar onto the transport support with a suitable lifting device. At the same time, hold the cutterbar in place on the opposite side with a suitable lifting device (fork-lift truck or similar). Protect the forks with a pallet or similar to ensure that the cutterbar is not damaged.

If there is no suitable lifting device available on site, large tyres can be used instead.

(Fig. 1, 2)

2

0299 838.0 - ABA / BA SW klappbar, 4,5 m

8.2.1

Fitting and Operation Fitting and removing the cutterbar.

The cutterbar can be fitted and removed in both the transport position (cutterbar folded in) and in the operating position (cutterbar unfolded).

We will show you both versions.

Fitting the cutterbar - folded – (Cutterbar in the transport position) DANGER! When fitting front attachments on the combine harvester (cutterbar etc.) there is danger of injury!

Remove the lower locking pins (V) on both sides.

(Fig. 3)

V 3 Cutterbar with Auto-Contour: H

Move the lever (H) for locking the locating spigots (F) at open position. To do this, release the lever (H) and move it upwards.

F

(Fig. 4)

V

8.2.2

4

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Fitting and Operation Drive the combine harvester into the cutterbar until the locating spigots (F) of the hydraulic cylinders on the feeder housing are located under the locating holes of the upper cutterbar beam.

Lift the cutterbar by actuating the hydraulic control unit.

(Fig. 4) Cutterbar with Auto-Contour: Lock the locating spigots using the lever (H). To do this, move the lever (H) downwards and secure with the linch pin.

(Fig. 5)

H

5 Lock the cutterbar at the bottom on both sides. Insert the locking pins (V) and secure. In doing this, rotate the locking pins so that the lever is located behind the straps (L).

(Fig. 6) Caution, make sure that the cutterbar is securely locked at the bottom and at the top.

L

V

6 Aligning the cutterbar (Cutterbar without Auto-Contour)

F

Before using the combine harvester for the first time, check the cutterbar for horizontal alignment and correct if necessary.

Move the combine harvester and cutterbar to a flat horizontal area. Put the cutterbar down. Adjust the height of the locating spigots (F) of the feeder housing until the cutter beam is parallel to the flat ground.

S

7

0299 838.0 - ABA / BA SW klappbar, 4,5 m

Release the fixing bolts (S) to allow adjustment of the locating spigots. Retighten the fixing bolts after setting.

(Fig. 7)

8.2.3

Fitting and Operation

P

Lock the cutterbar at the bottom on both sides. Insert the locking pins (V) and secure. In doing this, rotate the locking pins so that the lever is located behind the straps (L). If necessary, release the hexagonal head bolts (R) and adjust the holding plates (P) until the locking pins (V) can be inserted.

R L

After adjustment, retighten the hexagonal head bolts (R) securely.

R V

(Fig. 8)

8 Connecting the hydraulic hoses B

When connecting the hydraulic quick-fit couplings, the colour codes must be observed.

E F

B = colourless

reel lift / lower

E = red

fold cutterbar

F = blue

horizontal reel adjustment

(Fig. 9)

9 Connecting the plug Plug (A) for reel speed adjustment Plug (C) for CLAAS-Auto-Contour Plug (U) for lighting and control of the 6/2-way solenoid valve on the cutterbar

A

The plugs are designed in such a way that they cannot be misconnected.

C U

CAUTION! Plug (C) can only be connected to machines with Auto-Contour.

(Fig. 10) 10 Changing the cutterbar from transport position to operating position Lift the cutterbar.

The cutterbar should not come into contact with the ground when folding. Observe the sensing band!

Disengage the gear. Apply the brake.

S

Secure the machine from rolling away.

L

Remove crop lifter guard or cutter guard.

11

8.2.4

Extract the plug (S) for the lighting and remove the protection rail (L).

(Fig. 11)

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Fitting and Operation Push button functions.

2

1

3

1

=

Function only with push button 2 or 3

2

=

Reel forwards

3

=

Reel backwards

1 3 1 2

}

=

}

=

Cutterbar folding in operating position Cutterbar folding in transport position

(Fig. 12) 12

1 2

DANGER!

3

When folding the cutterbar no persons should be within the danger area.

Actuate push buttons (1 and 3). The cutterbar unfolds.

Unfold the cutterbar completely to the end position.

13

Move the reels forwards slightly by actuating the push button (2).

(Fig. 13)

CAUTION! The machine may only be moved if the cutterbar is completely folded or unfolded.

0299 838.0 - ABA / BA SW klappbar, 4,5 m

8.2.5

Fitting and Operation Connecting the right hand universal drive shaft: To do this, pull back the sleeve (Q) of the QS coupling and push on the universal drive shaft.

Close the guard (S).

(Fig. 14, 15)

Q 14

S

15 Unfold the right hand divider, followed by the left hand divider. To do this, retract the lock (R) and swing out the dividers to the end positions.

Caution, make sure that the lock is securely located in the end position.

R

(Fig. 16, 17)

16

R

17

8.2.6

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Fitting and Operation Fold in the safety bracket to limit the back position of the reel: If the safety bracket (N) is folded in, the reel cannot be pushed backwards completely. This prevents damage to the universal drive shafts of the reel drive when the reel is in the top position. For this reason, the safety bracket must be folded in during operation.

(Fig. 18) N 18 Cutterbar with Auto-Contour:

Lock the cutterbar by pushing the lever (M) downwards.

(Fig. 19, 20)

M 19 Cutterbar without Auto-Contour:

M

20 Connecting the left hand universal drive shaft: To do this, pull back the sleeve (Q) of the QS coupling and push on the universal drive shaft.

S

Fold down the guard (S).

(Fig. 21) Q DANGER! 21

0299 838.0 - ABA / BA SW klappbar, 4,5 m

Never engage the universal drive shafts if the guard is not fitted!

8.2.7

Fitting and Operation Changing the cutterbar from operating position to transport position Lower the reel completely.

Move the reel all the way to the front.

Lift the cutterbar until the sensing band no longer touches the ground.

Remove the universal drive shaft from the intermediate drive shaft on the left hand side and place in the holder on the cutterbar.

22

(Fig. 22) Unlock the cutterbar. To do this, swing the lever (M) upwards.

M

CAUTION! Only swing the lever (M) to the vertical position until a resistance is experienced.

(Fig. 23)

23 Unfold the safety bracket (N) to limit the back position of the reel.

(Fig. 24)

N

24

8.2.8

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Fitting and Operation Fold the left hand divider, followed by the right hand divider. To do this, retract the lock (R) and swing out the dividers to the end positions.

Caution, make sure that the lock is securely located in the end position.

(Fig. 25, 26) R

25

R

26 Remove the universal drive shaft from the intermediate drive shaft on the right hand side and place in the holder on the cutterbar.

(Fig. 27)

27 Retract the reel to the end position by actuating the push button (3).

(Fig. 28) 3

28

0299 838.0 - ABA / BA SW klappbar, 4,5 m

8.2.9

Fitting and Operation Fold in the cutterbar to the end position by simultaneously actuating the push buttons (1 and 2).

1

(Fig. 29)

2 DANGER! When folding the cutterbar no persons should be within the danger area.

Take care to ensure that the lock is correctly engaged.

29

Apply the protection rails with warning plates to the front of the folded-in cutterbar. Insert the plug (S) for the lighting.

Also fold in the left hand divider.

(Fig. 30)

30 Removing the cutterbar - folded in Lower the cutterbar completely.

Remove the cable plugs (A, C and U) from the feeder housing and place on the cutterbar beam.

A

(Fig. 31, 32)

C U

31

32

8.2.10

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Fitting and Operation Disconnect the hydraulic hose quick couplings. Close the quick couplings with the dust-tight protection caps.

Place the hydraulic hoses in the bracket on the feeder housing.

(Fig. 33)

33 Remove the locking pins (V) on both sides.

(Fig. 34)

V

34 Unlocking the location spigots: (Cutterbar with Auto-Contour) Unlocking the location spigots. To do this, release the lever (H) and move it upwards.

H

Lower the feeder housing slightly and carefully move the machine backwards.

(Fig. 35)

35

0299 838.0 - ABA / BA SW klappbar, 4,5 m

8.2.11

Fitting and Operation Fitting the cutterbar - unfolded (Cutterbar in operating position) DANGER! When fitting front attachments to the combine harvester (cutterbar etc.) there is danger of injury!

Remove the locking pins (V) on both sides.

(Fig. 36)

V 36 Cutterbar with Auto-Contour: H

Move the lever (H) for locking the locating spigots (F) to open position. To do this, swing the lever (H) upwards.

F

(Fig. 37)

37

8.2.12

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Fitting and Operation Drive the combine harvester into the cutterbar until the locating spigots (F) of the hydraulic cylinders on the feeder housing are located under the locating holes of the upper cutterbar beam. Lift the cutterbar by actuating the hydraulic control unit.

(Fig. 37) Locking the locating spigot: (Machine with Auto-Contour) Lock the locating spigots (F) using the lever (H). To do this, move the lever (H) downwards and secure using the linch pin.

H

(Fig. 37, 38)

38 Lock the cutterbar at the bottom on both sides. Insert the locking pins (V) and secure. In doing this, rotate the locking pins so that the lever is located behind the straps (L).

(Fig. 39)

V L 39

Connecting the universal drive shafts Connect the universal drive shafts on both sides.

Retract the sleeves (Q) of the QS couplings and push on the universal drive shafts. Take care to ensure that the QS couplings are securely located in the grooves of the intermediate drive shaft.

(Fig. 40)

Q

40

0299 838.0 - ABA / BA SW klappbar, 4,5 m

8.2.13

Fitting and Operation Close the guards (S) and lock in position.

(Fig. 41) DANGER! Never engage the universal drive shafts if the guard is not fitted!

S

41 Connecting the hydraulic hoses When connecting the hydraulic quick-fit couplings, the colour codes must be observed.

B

B = colourless reel lift / lower

E

E = red fold cutterbar F = blue horizontal reel adjustment

F

(Fig. 42)

42 Connecting the plug Plug (A) for reel speed adjustment Plug (C) for CLAAS-Auto-Contour Plug (U) for lighting and control of the 6/2-way solenoid valve on the cutterbar

A C

The plugs are designed in such a way that they cannot be misconnected.

U

CAUTION! Plug (C) can only be connected to machines with Auto-Contour.

(Fig. 43) 43 Removing the cutterbar - unfolded (Cutterbar in operating position) Remove the universal drive shaft from the intermediate drive shaft on both sides and place them in the holders on the cutterbar.

(Fig. 44)

44

8.2.14

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Fitting and Operation Disconnect the hydraulic hose quick couplings. Close the quick couplings with the dust-tight protection caps.

Place the hydraulic hoses in the bracket on the feeder housing.

(Fig. 45)

45 Remove the cable plugs (T) from the feeder housing and place on the cutterbar beam.

(Fig. 46)

T

46 Unlocking the location spigots: (Machine with Auto-Contour)

H

Unlocking the location spigots. To do this, release the lever (H) and move it upwards.

(Fig. 47)

47 Remove the locking pins (V) on both sides. Lower the feeder housing slightly and carefully move the machine backwards.

(Fig. 48)

V 48

0299 838.0 - ABA / BA SW klappbar, 4,5 m

8.2.15

Fitting and Operation

8.2.16

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Ancillary equipment

Fitting and Operation ADJUSTMENTS TO THE CUTTERBAR DANGER! Knives, cutterbar, intake auger and reel etc. cannot be completely shielded by constructional measures due to their function. For this reason, an adequate safety distance must be maintained from these moving elements during operation!

When undertaking any work on the elevated cutterbar it must be adequately propped up.

Crop dividers

B

The crop dividers consist of divider plates (A) and inner deflectors (B). The outer deflector (C) can also be fitted to the right hand crop divider. The crop dividers can be fitted to the cutterbar using quick-fit couplings.

A

(Fig. 1, 2)

1

0299 838.0 - ABA / BA SW klappbar, 4,5 m

8.3.1

Fitting and Operation Adjusting the crop divider:

A

Push the divider plates (A) as close as possible to the reel, after releasing the bolts (2).

2 B

Caution, make sure that the reel does not collide.

5

6

C

Position left-hand divider centre plate (A) in the middle of the slot. Push the right-hand divider centre plate (A) completely to the right-hand side.

L = Left-hand crop divider R = Right-hand crop divider 2

Adjust the inner deflector (B) so that the reel shafts do not wind and the reels do not collide.

Adjust the height of the outer deflector (C) after releasing the toggle bolt (5) and the star-wheel (6) so that the straws are pushed into the vertical stack.

3

Adjust the height of the crop divider on the setting slide (1) after releasing the screws (3) so that the points of the crop divider do not continuously scrape on the ground, and in the case of uneven ground do not dig in.

1

(Fig. 2, 3, 4)

3

R

L

2 37341

2 4

Crop lifters The number of crop lifters to be fitted depends on the condition of the crop. In the case of down grain and green through growth the crop lifter should be set at every fourth to sixth cutterbar finger, and in the case of short standing grain and with hanging down crops, it should be closer.

(Fig. 5)

5

8.3.2

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Fitting and Operation Fitting the crop lifter: When fitting the crop lifter start in the centre of the cutterbar. Fit the first crop lifter on both sides next to the three fingers without finger contact.

2

Slacken the nut (1). Slide the crop lifter between the washer and the upper nut, at the same time placing the lifter opening (2) over the finger tip. Then retighten the nut securely.

1

Leave the outer three cutterbar fingers free.

6

CAUTION! Before using the crop lifter for the first time adjust until the support surfaces are parallel to the ground.

(Fig. 5, 6)

Knife Removing the knife: Place the knife in the outer deadpoint. Release the hexagonal head bolts (N) and pull out the knife.

N

(Fig. 7, 8)

G M 7

DANGER! Wear gloves in order to prevent cuts when removing and fitting the knife.

Take special care when pulling out the knife if the knife beam is distorted or very dirty.

(Fig. 8) 8 Fitting the knife: Push the knife into the knife beam and fix using the fixing screws (N). Make sure that the groove is clean and the carrier key (M) is completely located in position.

(Fig. 7)

0299 838.0 - ABA / BA SW klappbar, 4,5 m

8.3.3

Fitting and Operation Adjusting the height of the knife: Adjust the swing lever (G) after releasing the clamping screw (K) so that there is a gap of 0.5 to 1 mm between the first knife blades and the double finger supports. After the adjustment retighten the clamping screw.

(Fig. 9)

K

G 9 Adjusting the knife clip: Adjust the knife clip (M) by adding or removing packing plates until the knife is guided smoothly. Gap between the knife clip and the knife blade approx. 1.5 mm

M

(Fig. 10)

10 Spare knife: On both sides of the cutterbar a spare knife can also be guided into the holders (H).

Secure the knives on both sides with the locks (R).

(Fig. 11) H

R 11

8.3.4

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Fitting and Operation Reel The height of the reel can be adjusted using the hydraulic control unit from the operator's platform.

Fine height adjustment:

B

The height of the reel can be adjusted using the eyebolts (B) on the hydraulic cylinders. This is required if the reel teeth come into contact with the knife beam when the reel is at its lowest position.

E

When adjusting the eyebolts, the internal lock-nuts (D) must also be adjusted accordingly.

12

(Fig. 12, 13)

D

13

0299 838.0 - ABA / BA SW klappbar, 4,5 m

8.3.5

Fitting and Operation Checking the function of the limit switch (E).

After adjusting the height of the reel, lower it completely and move backwards.

Check the switching points of the limit switch.

Caution, make sure that the limit switch is not jammed.

Swing the cutterbar. If the cutterbar cannot be swung, adjust the limit switch upwards in the elongated holes.

(Fig. 12) Reel tines: B

A vertical setting of reel teeth, or slightly forward is best in normal harvesting conditions. For heavy down grain or very short-strawed crops, the reel teeth should be set backward to grip position by relocating lever (B) in the perforated segment (C).

C

(Fig. 14) CAUTION! Adjusting the reel teeth too much to the rear causes the reel to wrap.

14 Safety feature: The reels are protected from overload by slipping clutches (R).

Do not set the slipping clutches so tight that they act as fail-safe devices.

Slipping clutch torque = 200 Nm

R

(Fig. 15)

15

Reel speed The speed of the reel can be adjusted infinitely from the operator's platform using two electric motors and regulating gearboxes.

Speed range = 12 – 47 rpm.

8.3.6

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Fitting and Operation Balancing the speed of the reels: If different reels speeds are produced, for example by extension of the V-belts, they can be balanced again.

To do this, remove one of the plugs (M) on the adjustment motor when the diesel engine is at standstill.

M

Then, with the machine running, actuate the reel speed adjustment in accordance with the speed variation. Stop the machine again and insert the plug.

(Fig. 16) 16

Intake auger Adjusting the distance to the bottom plate: S

The distance between the auger spirals (S) of the intake auger and the bottom plate of the cutterbar trough should be approx. 15 mm. See also the threshing table in the operating instructions for the combine harvester.

F

17

When taking in very thick swathes, to relieve the intake auger, and with large volume threshing material, to reduce the short straw constituent, the intake auger should be set higher.

(Fig. 17) The controlled fingers (F) pull the threshing material fed by the spirals of the auger (S) to the centre, under the intake auger to the feed rake.

Damaged fingers should be replaced immediately.

(Fig. 17)

0299 838.0 - ABA / BA SW klappbar, 4,5 m

8.3.7

Fitting and Operation The height adjustment of the intake auger can be undertaken on the setting screws (C) on both outer sides and in the middle of the cutterbar. Release all the retaining screws (4) on the outer sides and in the middle before each adjustment. Always adjust equally on each side.

C

After adjusting, retighten all screws.

(Fig. 18, 19) 4 18

C 4

19

8.3.8

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Fitting and Operation

20

Adjusting the position of the auger fingers:

The position of the intake fingers (F) can be adjusted by rotating the plate (T) after removing the screws (3).

A = right hand intake auger B = left intake auger G = direction of travel At equal adjustment of the intake fingers, the arrangement of the stamped-in letters (L and R) is opposite between the two intake augers.

M = the middle position CAUTION! Do not use the position (L) on the right hand intake auger (A) and do not use the position (R) on the left hand intake auger!

After adjustment, replace and retighten the screws.

T

T

Adjustment can only take place with the cutterbar in the transport position.

(Fig. 20, 21)

3

3

21

0299 838.0 - ABA / BA SW klappbar, 4,5 m

8.3.9

Fitting and Operation Cutterbar skids The cutterbar skids (V) are adjustable in height.

Proper positioning of skids depends on the size of the tyres. The skids should be set outwards as far as possible, particularly when using CLAAS Auto-Contour.

V

Adjust the skids equally on both sides.

(Fig. 22)

22 Safety feature: The intake augers are protected by slipping clutches (R). Do not set the slipping clutches so tight that they act as fail-safe devices.

R

Slipping clutch torque = 300 Nm (Fig. 23)

23

8.3.10

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Fitting and Operation MALFUNCTION

CAUSE OR REMEDY All work on or in the cutterbar must only be undertaken when the combine harvester is shut down and at standstill. When undertaking any work under the cutterbar, it must be safety propped up - danger of accident!!

Cutterbar cannot be swung

1. Locking lever not opened correctly.

The lever must be vertical.

– see page 8.2.8. (Fig. 23) The limit switch must be actuated.

2. Limit switch (interlock) faulty.

Replace switch.

3. Reel not fully retracted.

Retract reel fully.

The limit switch must be actuated.

4. Limit switch (back reel position) faulty.

Replace limit switch.

5. Reel not fully lowered.

Lower the reel completely.

6. Limit switch (bottom reel position) faulty.

Replace limit switch.

Limit switch not set correctly.

Set limit switch.

7. Push button on machine faulty.

Replace the push button.

Cutterbar cannot be mechanically locked

1. Hydraulic swing device not actuated long enough.

After the cutterbar troughs come together, continue to hold the push button for a further 3 seconds, approximately.

2. The stops on the feeder housing are set incorrectly.

The locking pins must be located centrally in the openings and be free to move when the cutterbar is in the elevated position.

Unequal reel speeds

1. Whilst the machine is running, turn back the speed of the reels to the stop. Reset the required speed.

If this method is insufficient, remove one of the plugs on the electric motors. See text and figure 16, page 8.3.7.

NOTE: Balancing the reel speeds can also be undertaken on the linkages of the regulating disc adjustment.

See also the operating instructions of the combine harvester

0299 838.0 - ABA / BA SW klappbar, 4,5 m

8.3.11

Fitting and Operation

8.3.12

ABA / BA SW klappbar, 4,5 m - 0299 838.0

9 Maintenance

Maintenance

Maintenance TRANSMISSIONS Knife drive casing Oil filling:

E

per gearbox 0.85 Litre Oil type: Gearbox oil to (MIL-L-2105) API-GL-4-90 E = Oil filling screw A = Oil drain screw (Fig. 1, 2) 1

DANGER! Dispose of the used oil properly!

Oil change:

A

In order to change the oil, remove the inner deflector (D). Before filling with oil, retighten the drain screw and refit the inner deflector.

(Fig. 2) 2 Check the oil level: Put the gearbox for the knife drives into a horizontal position by lifting the cutterbar. Remove the oil filling screw (E) to check the oil level.

The oil level can be checked with a wire.

Details of the wire: Overall length approx. 300 mm Dip depth approx. 210 mm At 220 mm bend slightly.

Dip the wire slightly at an angle to perform the check.

Correct level = 80 mm above the end of the wire.

Replace the oil filling screw after checking the oil level.

The oil level should be checked every 50 operating hours.

(Fig. 1)

0299 838.0 - ABA / BA SW klappbar, 4,5 m

9.1.1

Maintenance Angle drive for the reel drive Oil filling: per gearbox (4 off) 0.25 litre Oil type: Gearbox oil to (MIL-L-2105) API-GL-4-90 (Fig. 3, 4)

3

4

Knife drive K

Adjusting the spring cylinder:

D

Adjust the cylinder body after releasing the back-nut (K) so that the end of the measuring rod (D) is at the same level when the back-nut is tightened down. The length of the spring is then 100 mm.

(Fig. 5)

5

Drive chain tensioning Chain tensioner: The chain tensioners (S) can be used to tension the chains for the drive of the reels and the intake augers, after releasing the clamping screws.

S

The chains should not be tightened too much: After tensioning, re-tighten the clamping screws.

(Fig. 6) 6

9.1.2

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Maintenance Cleaning the guide rail of the locking cylinder Blow out the guide rails daily, if possible using compressed air.

The guide rails of the rear cylinder at (M) are accessible in operating position.

The guide rails of the front cylinder at (V) are accessible in transport position.

(Fig. 7, 8) M 7

V 8

Adjusting the double fingers 12

S

13

1

2

14

3

4

15

5

16

6

3

17

18

In order to ensure perfect overlap of the double fingers (15 and 16), the double fingers (13 – 16) can be adjusted in height using the packers (S, 11 x 21 x 0.5).

Numbers 1 – 6 = Number of packers

3

When fitting the double fingers (15 and 16), please note: Push the double finger (15) all the way back.

M 9

Pull the double finger (16) and the mulch finger (M) all the way forwards.

(Fig. 9)

0299 838.0 - ABA / BA SW klappbar, 4,5 m

9.1.3

Maintenance

9.1.4

ABA / BA SW klappbar, 4,5 m - 0299 838.0

10 Lubrication chart

Lubrication chart

Lubrication chart

LUBRICANTS AND NOTES

Grease brand name Examples: Manufacturer Description FINA ARAL FUCHS SHELL DEA AVIA FAG SKF

Move component in direction of arrow to obtain better grease distribution.

»Marson EPL 2« »Aralub HLP 2« »Renolit EP 2« »Retinax EP 2« or »Alvania G3« »Glisando EP2« »Avilup Special grease EP« »Arcanol L 135 V« LGEP2

Every 10 working hours

Every 100 working hours

Every 50 working hours

Once per year (500 operating hours)

0299 838.0 - ABA / BA SW klappbar, 4,5 m

10.1.1

Lubrication chart

Lubrication chart

1

2

1

2 L

10.1.2

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Lubrication chart

2

1

1

0299 838.0 - ABA / BA SW klappbar, 4,5 m

2

10.1.3

Lubrication chart

2

3

4

5

7

1

10.1.4

6

1

2

3

4

6

7

5

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Lubrication chart

9

8

8

0299 838.0 - ABA / BA SW klappbar, 4,5 m

9

10.1.5

Lubrication chart

10

11

10

10.1.6

11

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Lubrication chart

3

1

2

5

6

4

3

1

2

4

5

6

0299 838.0 - ABA / BA SW klappbar, 4,5 m

10.1.7

Lubrication chart

10.1.8

ABA / BA SW klappbar, 4,5 m - 0299 838.0

11 Index

Index

Index INDEX A Additional weights .................................................................. 7.1.1 Adjusting the double fingers ................................................... 9.1.3 Adjustments to the cutterbar .................................................. 8.3.1 Aligning the cutterbar (Cutterbar without Auto-Contour) ........................................... 8.2.3 Angle drive for the reel drive .................................................. 9.1.2 Attention! ................................................................................ 3.1.1 C Carry out prior to initial operation ........................................... 6.1.1 Cause or Remedy ................................................................ 8.3.11 Changing the cutterbar from operating position to transport position ................................................................... 8.2.8 Changing the cutterbar from transport position to operating position .................................................................. 8.2.4 Cleaning the guide rail of the locking cylinder ........................ 9.1.3 Connecting the hydraulic hoses ........................................... 8.2.14 Connecting the hydraulic hoses ............................................. 8.2.4 Connecting the plug ............................................................. 8.2.14 Connecting the plug ............................................................... 8.2.4 Connecting the universal drive shafts .................................. 8.2.13 Correct use of the vehicle ...................................................... 4.1.1 Crop dividers .......................................................................... 8.3.1 Crop lifters .............................................................................. 8.3.2 Cutterbar cylinder ................................................................... 6.2.1 Cutterbar skids ..................................................................... 8.3.10 Cylinder safety lock ................................................................ 4.1.3 D Drive chain tensioning ............................................................ 9.1.2 Driving lights for road use ...................................................... 6.2.1 Driving lights for road use ...................................................... 6.2.1 F Fitting additional equipment ................................................... 8.1.1 Fitting and removing the cutterbar. ........................................ 8.2.2 Fitting stops in the feeder housing ......................................... 8.1.1 Fitting the cover weights ........................................................ 7.1.3 Fitting the cutterbar - folded – (Cutterbar in the transport position) ....................................... 8.2.2 Fitting the cutterbar - unfolded (Cutterbar in operating position) .......................................... 8.2.12 Fitting the cutterbar ................................................................ 8.2.1 Fitting the steering axle weights (Additional equipment) ........................................................... 7.1.5 Fitting the stops ..................................................................... 8.1.3 Fitting the switching device and the driving lights .................. 8.1.7

K Knife ...................................................................................... 8.3.3 Knife drive ............................................................................. 9.1.2 Knife drive casing .................................................................. 9.1.1 L Liquid filler for the steering axle wheels ................................ 7.1.2 Lock the cutterbar at the sides .............................................. 8.1.4 Lubricants and notes ........................................................... 10.1.1 M Malfunction .......................................................................... 8.3.11 MEDION 340 – 310 / MEGA 360 / 350 ................................. 7.1.1 Modifying the cutterbar "Auto-Contour" for machines without Auto-Contour ............................................ 8.1.4 R Reel ....................................................................................... 8.3.5 Reel speed ............................................................................ 8.3.6 Reel supports ........................................................................ 4.1.4 Remove the reel supports and store them away ................... 4.1.4 Removing the cutterbar - folded in - .................................... 8.2.10 Removing the cutterbar - unfolded (Cutterbar in operating position) .......................................... 8.2.14 S Safety decals with pictorials .................................................. 4.2.1 Safety feature: ....................................................................... 5.1.1 Safety Locks .......................................................................... 4.1.3 Safety rules ........................................................................... 4.1.1 Scope of components - Cover weights ................................. 7.1.3 Scope of components - steering axle weights ....................... 7.1.4 Scope of parts - Fitting .......................................................... 8.1.2 Setting the additional headlights ......................................... 8.1.12 Setting the slipping clutch ...................................................... 5.1.1 Shortening the flat key MEGA 360 / MEDION 340 .................................................. 8.1.11 Special note ........................................................................... 3.2.1 Steering axle weights ............................................................ 7.1.5 Switching over the driving lights ............................................ 6.2.1 T Tilting the cutterbar from the transport position ..................... 8.2.1 Transmissions ....................................................................... 9.1.1 Type plate / serial number ..................................................... 3.3.1 W Weights / Dimensions / Safety devices ................................. 5.1.1 Weights / Dimensions ............................................................ 5.1.1

G General safety and accident prevention regulations .............. 4.1.1 I Identification of warning and danger signs ............................. 4.1.1 Insert the reel supports .......................................................... 4.1.4 Intake auger ........................................................................... 8.3.7 Introduction ............................................................................ 1.1.1

0299 838.0 - ABA / BA SW klappbar, 4,5 m

11.1.1

Index

11.1.2

ABA / BA SW klappbar, 4,5 m - 0299 838.0

Following the policy of CLASS KGaA mbH to improve their products as technical developments continue, CLASS reserve the right to make alterations which must not necessarily correspond to text and illustrations contained in this publication, and without incurring obligation to alter any machines previously delivered.

Technical data, dimensions and weights are given as an indication only. Responsibility for errors or omissions not accepted.

Reproduction or translation of this publication, in whole or part, is not permitted without the written consent of the CLAAS KGaA mbH. All rights under the provision of the Copyright Act are reserved.

CLAAS KGaA mbH 33426 Harsewinkel Germany

Our contribution to the environment: CLAAS have printed this manual on 100 % chlorine free paper.

CLAAS KGaA mbH Postfach 1163 33426 Harsewinkel Tel. +49 (0)5247 12-0 www.claas.com

0299 838.0 ABA / BA SW klappbar, 4,5 m EN - 03.05 Printed in Germany