CLAAS CONSPEED 12 CONSPEED 8 CONSPEED 6 LEXION MEDION MEGA Assembly & Operator's Manual

CONSPEED 12 CONSPEED 8 CONSPEED 6 LEXION / MEDION / MEGA

Assembly and operator's manual

Re

ad an df o ll ow th es afe ty

in s

tru

cti

on

s!

EC Declaration of Conformity according to EC Directive 89/392/EEC

CLAAS Saulgau GmbH

We

Zeppelinstraße 2

D-88348 Bad Saulgau

declare under their sole responsibility that the product

Maize picker - model 913 “CONSPEED 12” LEXION Maize picker - model 907 / 912 “CONSPEED 8” LEXION Maize picker - model 908 / 911 / 919 “CONSPEED 6” LEXION Maize picker - model 909 / 914 “CONSPEED 6” MEDION / MEGA to which this declaration refers corresponds to the pertinent basic safety and health requirements of EC Directive 89/392/EEC, and to the requirements of the other pertinent EC Directives:

-/-

For the correct implementation of the safety and health requirements mentioned in the EC Directives, the following standard(s) and/or technical specification(s) has (have) been applied:

EN 632 - 1995

Bad Saulgau, July 07, 2005 Product Development (Rauch)

Supply Chain Management (Fetscher)

Quality management (Switalski)

Introduction

Introduction

1 Introduction INTRODUCTION This manual provides information on how to use, adjust and service the CLAAS maize picker.

Please note that in the following chapters, the CLAAS maize picker is also referred to as front attachment/ machine.

Follow the advice on correct maintenance and servicing in order to ensure maximum performance and a long service life of your machine.

Also, have assembly of your machine and regular inspections carried out by your specialist workshop.

Failure to carry out maintenance work, or incorrect operation will result in poor machine efficiency and loss of valuable time.

By ensuring correct operation, and carrying out maintenance and service work with care, you will be able to make full use of state-of-the-art technology and of the experience with which your machine has been designed.

Your CLAAS Service Department

1.1

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Introduction VALIDITY This operator's manual is valid for all maize pickers: CONSPEED 12-75 C – LEXION Model 913 from serial no. 913 0 1001 onwards CONSPEED 8-75 FC – LEXION CONSPEED 8-70 FC Model 907 from serial no. 907 0 1001 onwards CONSPEED 8-75 FC – LEXION CONSPEED 8-75 F CONSPEED 8-70 FC CONSPEED 8-70 F Model 912 from serial no. 912 0 1001 onwards CONSPEED 6-80 FC – LEXION CONSPEED 6-75 FC CONSPEED 6-70 FC Model 908 from serial no. 908 0 1001 onwards CONSPEED 6-80 FC – LEXION CONSPEED 6-80 F CONSPEED 6-75 FC CONSPEED 6-75 F CONSPEED 6-70 FC Model 911 from serial no. 911 0 1001 onwards CONSPEED 6-75 C – LEXION CONSPEED 6-70 C Model 919 from serial no. 919 0 1001 onwards CONSPEED 6-80 FC – MEDION / MEGA CONSPEED 6-80 F CONSPEED 6-75 FC CONSPEED 6-70 FC CONSPEED 6-70 F Model 914 from serial no. 914 0 1001 onwards CONSPEED 6-75 C – MEDION / MEGA CONSPEED 6-70 C Model 909 from serial no. 909 0 1001 onwards

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

1.2

Table of contents

Table of contents

2 Table of contents 1. Introduction Introduction ............................................................................... 1.1 Validity ...................................................................................... 1.2

2. Table of contents .................................................... 2.1 3. Preface Special care .............................................................................. 3.1 Identification plate ..................................................................... 3.2 Transport on public roads ......................................................... 3.3 Special note for CONSPEED C (non-folding) ........................................................................ 3.3 Protective equipment for road transport ............................. 3.4 Driving lights during road transport ..................................... 3.5 Additional weights ............................................................... 3.5

4. Safety rules Identification of warning and danger signs ................................ 4.1 Intended use ............................................................................. 4.1 General safety and safety precaution instructions .................... 4.1 Safety prop ................................................................................ 4.3 Safety decals with pictorials ...................................................... 4.3

5. Specifications Conspeed 12-75 C .................................................................... 5.1 Conspeed 8-75 FC .................................................................... 5.1 Conspeed 8-75 F ...................................................................... 5.1 Conspeed 8-70 FC .................................................................... 5.1 Conspeed 8-70 F ...................................................................... 5.1 Conspeed 6-80 FC .................................................................... 5.2 Conspeed 6-80 F ...................................................................... 5.2 Conspeed 6-75 FC .................................................................... 5.2 Conspeed 6-75 F ...................................................................... 5.2 Conspeed 6-75 C ...................................................................... 5.2 Conspeed 6-70 FC .................................................................... 5.2 Conspeed 6-70 F ...................................................................... 5.2 Conspeed 6-70 C ...................................................................... 5.2

6. Prior to operation Check and observe the following before putting into operation 6.1 Loading/unloading the maize picker ......................................... 6.2 Initial mounting of the maize picker ........................................... 6.2 Mounting the maize picker – LEXION ....................................... 6.3 Mounting to a combine harvester without Auto Contour System .......................................................... 6.3 Mounting on to a combine harvester with Auto Contour System .......................................................... 6.3 Mounting the maize picker .................................................. 6.4 Locking the maize picker .................................................... 6.5 Connect the quick release coupling .................................... 6.5 Connect snapper plate position display .............................. 6.6 Fitting drive shafts ............................................................... 6.7 Connecting the constant velocity joint ................................ 6.8 Removing the maize picker – LEXION ..................................... 6.9 Unlocking the maize picker ............................................... 6.10

2.1

Mounting the maize picker – MEDION ...................................

Preparing the combine harvester for mounting the maize picker ...............................................

Removing angle bars .......................................................

Mounting on to a combine harvester with Auto Contour System .......................................................

Mounting to a combine harvester without Auto Contour System .......................................................

Mounting the maize picker ...............................................

Locking the maize picker ..................................................

Connect the hydraulic hoses ............................................

Connecting the power supply ...........................................

Fitting drive shafts ............................................................

Connecting the universal drive shafts ..............................

Removing the maize picker - MEDION/MEGA .......................

Unlocking the maize picker ..............................................

Chopper ..................................................................................

Engaging the chopper ......................................................

Stands ....................................................................................

Sheet metal covers .................................................................

Mounting and adjusting the gathering points ....................

Vertical adjustment of the gathering points ......................

Stop gathering points (only CONSPEED – 8 rows folding) .................................

Locking and unlocking the sheet metal covers .................

Raising the sheet metal covers ........................................

Snapper plates .......................................................................

Adjusting the limit stops of the snapper plates .................

6.12 6.12 6.12 6.13 6.14 6.15 6.16 6.16 6.17 6.17 6.18 6.19 6.20 6.22 6.22 6.22 6.23 6.23 6.24 6.25 6.26 6.27 6.28 6.28

7. Operation Using the maize picker ............................................................. 7.1 Work and transport position ............................................... 7.2 Working position ................................................................. 7.2 Transport position ............................................................... 7.3 Adjusting the snapper plates hydraulically ......................... 7.4 Engaging/disengaging the chopper .................................... 7.5 Cut-out clutch for reaper unit drive ..................................... 7.5 Optional equipment .................................................................. 7.6 Intake auger attachment ..................................................... 7.6 Cover elevation (B07 0030) ................................................ 7.6 CLAAS Autopilot (LEXION) (R05 0050, R05 0060) ........... 7.7 CLAAS Auto-Contour (R09 0010) (only CONSPEED model 907/908/909/911/912/914) ........ 7.8 Sliding blocks ..................................................................... 7.8 Stubble attachments (B07 0040) ........................................ 7.8 Stripper angles ................................................................... 7.8 Down maize auger (only for LEXION) (B05 0020) ............. 7.9 Rubber ram stops ............................................................... 7.9 Rubber ram stop screw mounting ...................................... 7.9 Rubber ram stop plug mounting ....................................... 7.10 74-tooth sprocket .............................................................. 7.10 CONSPEED – speed matching ........................................ 7.11 Shear bar for chopper (B07 0080) .................................... 7.12 Additional lighting - combine harvester (B07 0010) .......... 7.12 Fitting kit - Montana (M04 0100) ...................................... 7.13

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Table of contents 8. Maintenance Important Maintenance Instructions .......................................... 8.1 Spare Parts ......................................................................... 8.1 Hydraulic system ................................................................ 8.1 Bolts .................................................................................... 8.1 Lubrication .......................................................................... 8.1 Guards ................................................................................ 8.1 Drive systems ........................................................................... 8.2 Angle drive gearbox ............................................................ 8.3 Special note for CONSPEED C (non-folding) ....................................................................... 8.4 Picker and chopper gearbox ............................................... 8.5 Drive shaft .......................................................................... 8.7 Clutches .................................................................................... 8.7 Chain clutch ........................................................................ 8.8 Overload clutches ............................................................... 8.8 Universal drive shaft ................................................................. 8.9 General information concerning universal drive shafts ..... 8.10 Universal drive shaft - fitting LEXION 470 / 430 Montana ............................................. 8.10 Chains ..................................................................................... 8.12 Cleaning the finger chains ................................................ 8.12 Tensioning the finger chains ............................................. 8.12 Lubricating the drive chain ................................................ 8.13 Tensioning the drive chain ................................................ 8.13 Scraper plates ......................................................................... 8.14 Adjusting the scraper plates ............................................. 8.14 Picker rollers ........................................................................... 8.15 Attaching the picker rollers ............................................... 8.15 Checking the setting of the picker roller knives. ............... 8.15 Snapper plates ........................................................................ 8.15 Basic adjustment of snapper plates .................................. 8.16 Chopper knife ......................................................................... 8.16 Changing the chopper knife .............................................. 8.16 Hydraulic system ..................................................................... 8.19 Hydraulic hose connections .............................................. 8.19 Swivel device for sheet metal covers ................................ 8.19 Fixing elements ....................................................................... 8.20 Screw connections ........................................................... 8.20 Connection elements ........................................................ 8.20 Winter Storage ........................................................................ 8.20 Lubricant table ........................................................................ 8.21 Malfunctions ............................................................................ 8.22

9. Lubrication chart Safety rules ............................................................................... 9.1 Lubricants ................................................................................. 9.1 Lubrication ................................................................................ 9.1

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

2.2

Preface

Preface

3 Preface SPECIAL CARE The instructions set forth in this manual must be read carefully and followed by all persons concerned with the operation, maintenance, repair or inspection of this machine in order to prevent accidents.

Pay particular attention when reading the sections “Safety rules” and “Prior to operation” in the operator's manual CLAAS LEXION, CLAAS MEDION and CLAAS MEGA. The use of spare parts, accessories and additional equipment which is not originally manufactured, and checked and released by CLAAS can have its negative effect on specific design features of the CLAAS machine or on its operability, thereby impair active and/or passive operating safety, as well as safety at work (accident prevention).

CLAAS will in no way be liable for damage or personal injury caused by the use of other than original CLAAS parts, accessories and additional equipment.

Technical data, dimensions and weights are understood with the usual tolerances. Subject to technical modifications and errors.

Front, rear, right and left refer to the direction of travel.

3.1

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Preface IDENTIFICATION PLATE When placing all orders for spare parts, and in the event of technical enquiries, always state the machine number (Fz-Ident-Nr.) (2), the model and the serial number. This is necessary in order to ensure correct delivery of spare parts.

The identification plate (1) with the machine number (Fz-Ident-Nr.) (2) is located on the right hand side wall.

1

(Fig. 1, 2) 1 1

912

xxx

xxx

91201001

xxxx

2

2

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

3.2

Preface

Preface TRANSPORT ON PUBLIC ROADS

LEXION

DANGER! When driving on public roads with the maize picker in the raised position, – master safety switch (25) or in the case of the MEDION/MEGA, – master safety switch (65) must be switched off and be secured against falling down!

3 MEDION/MEGA

Before leaving the combine harvester, lower the maize picker completely.

– Switch the engine off.

– Remove the ignition key.

– Switch off the battery master switch!

(Fig. 3, 4)

• The applicable laws and regulations must be observed when travelling on public roads!

• In the Federal Republic of Germany observe the 4

“Road Traffic Approval Regulations” (StVZO).

• In other countries observe the relevant national or state regulations.

Special note for CONSPEED C (non-folding) DANGER! Because of the load width, the front attachment must not be transported on public roads in the mounted position. For transporting on public roads, the front attachment must be disassembled and moved with the aid of a suitably-dimensioned transporting device.

– Disassemble the front attachment, load onto the transporting device and secure.

– Observe the maximum load width.

– Elevate the hoods and interlock – see Raising the sheet metal covers, page 6.27.

– Attach guard to feeder housing.

3.3

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Preface Protective equipment for road transport The following requirements must be fulfilled for road transport: 1. Maize picker swung into transport position – see Work and transport position on page 7.2.

2. Chopper (6) protruding on the left disengaged (with maize picker swung into transport position!)

– see Engaging/disengaging the chopper on page 7.5.

2

5

3. Safety bar with lighting (2) attached and mounted with the spring hooks.

4. Side safety guards (3) hung into suspension points (4) provided and fastened with spring hooks (5).

3

5. Cable for lighting inserted in socket (7).

4

6. Driving lights switched over – see Driving lights during road transport on page 3.5.

(Fig. 5, 6, 7, 8)

5

6

6 7

7

8

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

3.4

Preface 7. In order not to obstruct the driver's field of vision, the maize picker must be raised so that the front edge of the feeder housing on the combine harvester is about 600 mm above the ground.

(Fig. 9)

600 mm

9 Driving lights during road transport The normal front driving lights of the combine harvester are covered by the maize picker when it is swung into transport position.

A

When driving on public roads and paths, the driving lights therefore must be switched to the headlights (A) located at a higher position and the limit and flashing lights.

A

(Fig. 10) 10

Additional weights Combine harvesters with attached maize picker head must be additionally equipped with weights according to the traffic regulations of your country for transport on public roads and ways. This is necessary so that the machine does not lift at the rear during braking and when driving on slopes.

The necessary additional weights can be: LEXION:

• Attachments at the rear of the machine (e.g. straw chopper...)

• Fluid in the steering axle wheels • Additional weights on the steering axle.

MEDION/MEGA:

• Fluid in the steering axle wheels • Rear weights in the rear hood.

The load on the steering axle wheels should be 20% of the machine weight with mounted maize picker.

3.5

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Safety rules

Safety rules

4 Safety rules Before putting the machine into operation, read the operator's manual and follow the safety precautions!

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 all safety instructions on to other users, too.

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

– Preventive measures.

INTENDED USE The maize picker is designed for the usual applications in agriculture only (intended use).

Use in any other way is considered as contrary to the intended use. The manufacturer does not accept any liability for such use; the user accepts all risk arising from such use.

Intended use also includes observing the service, maintenance and repair conditions as prescribed by the manufacturer.

The maize picker may be used, serviced and repaired only by persons which are familiar with the machine and which have been informed of the risks.

Observe the pertinent accident prevention regulations and other generally acknowledged regulations regarding safety and occupational health, as well as the regulations and standards relevant to motor vehicles and traffic.

Modifications of the maize picker without proper authority exclude the manufacturer's liability for damage resulting from any such modifications.

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.

GENERAL SAFETY AND SAFETY PRECAUTION INSTRUCTIONS 1. In addition to the information set forth in this operator's manual, also follow the general instructions for safety and accident prevention.

2. Follow the regulations in force as you use public roads!

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

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

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

The warning and instruction signs on the machine provide important recommendations for safe operation.

These instructions involve your safety – observe them at all times!

3. Before starting work familiarise yourself with all actuation equipment and its function, as it will be too late once you have set off.

4. Before starting, check the maize picker for any loose parts on the machine.

5. Always stop the engine, remove the ignition key and switch off the battery master switch before working in or on the maize picker. All control levers must be in their neutral position and the hydraulic lines must not be under pressure.

6. Carry out work under the raised maize picker only after having propped it safely.

7. The maize picker must always be in transport position on public roads and paths.

Attach protective bar with warning signs and side lights at the maize picker front and connect lighting.

8. Secure machine against rolling away (parking brake, wheel chocks) when swivelling the maize picker.

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

4.1

Safety rules 9. Make sure no-one is between the drive wheels and the maize picker when pressing the rocker switch or tip switch for the maize picker swinging device.

10. Make sure no-one is in the swinging range when swivelling the maize picker.

11. Increased risk of injury when installing and removing the knives.

12. Intake augers, intake discs and similar cannot be fully secured by design measures because of their function. Therefore, keep an adequate safety distance from these moving parts during operation.

13. Never start drive shafts turning without appropriate protection.

14. Always switch off the drive and the engine before carrying out troubleshooting, and for repair, maintenance and cleaning work.

– Remove the ignition key!

– Switch off the battery master switch!

15. Always switch off the battery master switch before starting work on the electrical system!

16. Reinstall protective devices after maintenance work!

17. Mounting the maize picker onto the combine harvester involves risk of injury!

18. Make sure no-one is between the combine harvester and the maize picker without securing the vehicle with the parking brake and/or wheel chocks, to prevent it from rolling away!

Follow all other safety rules in the operator's manual for the combine harvester.

4.2

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Safety rules

Safety rules SAFETY PROP DANGER! Carry out all work under the raised maize picker or feeder housing only after having propped it safely.

– Position safety prop (1)!

1 1

Raise the feeder housing to the highest position.

Loosen safety prop (1) and swing it onto the hydraulic piston.

(Fig. 1)

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.

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

4.3

Safety rules

1

2

3 Warning symbol 516 039.0 (1) Do not open or remove safety device while the engine is running.

(Fig. 2, 3)

2

4

2 6 Warning symbol 514 898.1 (2) Keep clear of the swivelling range of the operating machine.

(Fig. 4, 5, 6) 5

4.4

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Safety rules

3

7

9 Warning symbol 516 040.0 (3) Keep a safe distance from the harvesting attachment.

Before starting service work or clearing blockages – switch off drive, stop engine and remove ignition key.

3

(Fig. 7, 8, 9) 8

4

10

4 12 Warning symbol 516 042.0 (4) Never enter the danger area between front attachment and machine.

(Fig. 10, 11, 12) 11

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

4.5

Safety rules

5

13

14 Warning symbol 514 877.1 (5) Keep clear of the knife while it is operating.

(Fig. 13, 14)

6

15

16 Warning symbol 514 878.0 (6) Do not touch machine components before they are completely stopped.

(Fig. 15, 16)

4.6

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Specifications

Specifications

5 Specifications NOTE! Technical specifications, dimensions and weights are understood with the usual tolerances.

CONSPEED 12-75 C Working position Width:

mm

9130

mm

9130

kg

4200

Transport position Width: Weight

CONSPEED CONSPEED 8-75 FC 8-75 F Working position Width:

mm

6059

6059

mm

3000

3000

kg

2900

2730

Transport position Width: Weight

CONSPEED CONSPEED 8-70 FC 8-70 F Working position Width:

mm

5709

5709

mm

3000

3000

kg

2865

2695

Transport position Width: Weight

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

5.1

Specifications

CONSPEED CONSPEED 6-80 FC 6-80 F Working position Width:

mm

4800

4800

mm

3250

3250

kg

2430

2300

Transport position Width: Weight

CONSPEED CONSPEED CONSPEED 6-75 FC 6-75 F 6-75 C Working position Width:

mm

4550

4550

4550

mm

3000

3000

4550

kg

2360

2230

2100

Transport position Width: Weight

CONSPEED CONSPEED CONSPEED 6-70 FC 6-70 F 6-70 C Working position Width:

mm

4300

4300

4300

mm

3000

3000

4300

kg

2330

2200

2070

Transport position Width: Weight

5.2

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Prior to operation

Prior to operation

6 Prior to operation DANGER! Carry out work under the raised front attachment only after having propped it safely.

– see Safety prop on page 4.3.

Always carry out work on the maize picker and/or combine harvester with the drive switched off and the engine at a standstill.

– Remove the ignition key!

– Switch off the battery master switch!

In addition, when working on the chopper of the maize picker: – Disconnect the universal drive shaft!

CHECK AND OBSERVE THE FOLLOWING BEFORE PUTTING INTO OPERATION 1. Check oil level in the gearboxes.

– see Drive systems on page 8.2 2. Thoroughly lubricate the maize picker before putting it into operation.

– see Lubrication chart on page 9.1 3. Check bolts for tightness.

4. Check finger chains for correct tension.

– see Tensioning the finger chains on page 8.12 5. Check drive chains for correct tension.

– see Tensioning the drive chain on page 8.13 6. Secure universal drive shaft gear against rotating by hanging in the chains.

7. Check protective bar for wear and damage.

8. Mount and lock all protective devices.

– see Guards on page 8.1 9. Check vehicle for any loose parts before moving off. Firmly attach or cover parts which can fall off during travel.

10. Make sure no-one is in the area of danger. Immediately switch off the machine if persons approach the area of danger.

11. Never let the machine run without proper supervision.

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

6.1

Prior to operation LOADING/UNLOADING THE MAIZE PICKER DANGER! Loading and transporting the maize header incorrectly involves a risk of accidents!

– Load the maize picker only by hitching it onto the left and right hoisting points (A) (Fig. 1)!

A

– Make sure the slings are sufficiently dimensioned!

Maize picker weight – see Specifications on page 5.1.

1

INITIAL MOUNTING OF THE MAIZE PICKER 1. Check the scope of delivery against the delivery note.

2. Remove the lashing of the mounting parts and remove the mounting parts.

3. Open lashing (B) of the maize picker on the transport pallet and remove the lashing straps completely.

4. Unlocking B 2

LEXION: – see Locking the maize picker on page 6.5.

MEDION/MEGA: – see Locking the maize picker on page 6.16.

(Fig. 2)

6.2

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Prior to operation

Prior to operation MOUNTING THE MAIZE PICKER – LEXION

LEXION

DANGER! Mounting the maize picker involves risks of injury!

– Make sure there is no-one between the combine harvester and the maize picker.

1

3

ATTENTION! Make sure the lock mechanisms (1) are open before lifting the maize picker (Fig. 3).

– see Unlocking the maize picker on page 6.10

Mounting to a combine harvester without Auto Contour System

LEXION

F

On machines without Auto Contour System, standard coupling hook (F) must be replaced by a longer coupling hook.

Order no.:

coupling hook

0174 473.0

(Fig. 4)

4 Mounting on to a combine harvester with Auto Contour System Extend both coupling hook cylinders on the feeder housing of the combine harvester by about 40 mm (middle position) before mounting the maize picker.

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

6.3

Prior to operation Mounting the maize picker

LEXION

2

NOTE! Make sure the universal drive shafts of the maize picker are flush on both sides of the machine with the drive shafts of the combine harvester.

3

5 LEXION 452 - 468

1. Move the combine harvester towards the maize picker so that coupling hooks (3) on the feeder housing are below coupling pins (2) of the upper picker crossbar.

2. Press the tip switch on the multifunction lever to lift the maize picker.

4 = lift.

– see also the operator's manual for the combine harvester.

3. Check that the universal drive shaft connections are aligned with the drive shafts, and if necessary correct the adjustment of the coupling hooks.

4 NOTE! 6 LEXION 541 - 548, 580 - 586, 589

If necessary, the position of the maize picker can be changed by shifting washers (E) below coupling hook (F). Two washers (43x53x3) are delivered ex works.

STOP

A

Proceed as follows: 4. Move the combine harvester with the maize picker to an even, horizontal and firm location.

ON

5. Switch the maize picker off

4

– see Removing the maize picker – LEXION on page 6.9.

7

72511 LEXION

F

7. After removing the washers, screw the coupling hook back on and mount the maize picker.

R

8. If this is not yet sufficient, the washers removed on the opposite side can be added.

(Fig. 5, 6, 7, 8)

E

%## %

6.4

6. First take out washers (E) underneath coupling hook (F) on the higher side. Unscrew hexagon head bolt (R) and slightly lift the coupling hook.

8

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Prior to operation Locking the maize picker

LEXION

1. On the right hand side, pull out safety pin (6) before actuating lever (5).

5

2. Push lever (5) downwards in order to lock the maize picker onto the feeder housing.

6

• 1The lock pins on the left and right are connected with a linkage rod.

1

3. Make sure that lever (5) is engaged after locking with safety pin (6).

(Fig. 9) 9

Connect the quick release coupling

LEXION, to front attachment no.: 911 0 1393, 912 0 1185, 914 0 1085

7 8

ATTENTION!

9

Dirt on the quick release coupling or hydraulic coupling sockets can contaminate the hydraulic system.

– Always clean the male couplings of the hydraulic hoses and the hydraulic coupling sockets before connecting them.

– Beware of friction and jamming!

10 LEXION, from front attachment no.: 907 0 1001, 908 0 1001, 911 0 1394, 912 0 1186, 914 0 1086, 919 0 1001

7

1. Remove protective cap (9) on the maize picker.

2. Remove quick release coupling (7) on the feeder housing and mount to maize picker.

9

3. Screw tight quick release coupling with hand wheel (8).

4. Attach protective cap (9) to feeder housing.

(Fig. 10, 11)

8

11

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

6.5

Prior to operation Connect snapper plate position display When the quick coupler is connected the snapper plate position display is also connected.

NOTE! The connection for the snapper plate position display is factory-set to socket VS1.

The socket depends on the combine harvester.

If an error message is received (– see operator's manual for the combine harvester) check the socket.

Either the snapper plate position display or Auto Contour can be connected up to LEXION model 452 - 468.

Socket for the snapper plate position display:

LEXION 452 - 468

LEXION 452 - 468

VS2

– Snapper plate position display or auto contour on socket VS2.

VS1

– Autopilot (option) in socket VS3.

LEXION 541 - 548, 580 - 586, 589 – Snapper plate position display at socket VS1.

– Auto Contour (option) at socket VS2.

VS3

– Autopilot (option) in socket VS3.

12

(Fig. 12, 13)

LEXION 541 - 548, 580 - 586, 589

VS1

VS3

VS2

13

6.6

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Prior to operation Fitting drive shafts

LEXION

10

11

DANGER!

12

Never run drive shafts without their guards, or if the guards are damaged.

16

13

– Fit the joint guard and protective tube.

14

– Secure the guard against turning with the shaft!

– Only operate the universal drive shafts if they are in a technically perfect condition.

15 74783

14 1. Fit the universal drive shaft guard (12) with washer (10) and contact washer (11) to the gearbox.

2. Grease gear profile (16) of the universal drive shaft.

3. Insert toothed profile (16) (external profile) of the universal drive shaft into the bore (hollow shaft) on the bevel gearbox.

4. Attach the universal drive shaft to the angle drive with the flanged bushing (13) (42x28) and cheese-head screw (14) (M12x40).

CAUTION! Protective cap 15) cannot be removed without destroying it. Before fitting the protective cap, tighten screw (14).

5. Fitting protective cap (15). The rubber-lined side (black) faces outwards.

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

6.7

Prior to operation Connecting the constant velocity joint

LEXION

1. Swing down guard (10) on the feeder housing.

2. Push double joints (12) on both sides of the maize picker on drive shafts (11) of the feeder housing until locking pin (13) engages.

3. Close guard (10) on feeder housing.

(Fig. 15, 16) 10 15 LEXION

11

12

13 16

6.8

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Prior to operation REMOVING THE MAIZE PICKER – LEXION

LEXION 452 - 468

ATTENTION! Set the maize picker down on firm and level ground only!

– Move combine harvester back slightly in transport position when setting down the maize picker and make sure that the points do not stick into the ground.

1

17 NOTE!

LEXION 541 - 548, 580 - 586, 589

The maize picker can be removed in working or transport position. The sequence is identical in both cases.

STOP

A

DANGER! Carry out work on the maize picker only with the drive switched off and the engine at a standstill.

ON

1

18

72511

– Remove the ignition key!

– Switch off the battery master switch!

LEXION

Set the maize picker down as follows: 1. Press the tip switch on the multifunction lever to lift the maize picker.

1 = lift.

– see also the operator's manual for the combine harvester.

2. Pull off the double joint on both sides. To do this: • Open guard (5) (Fig. 20, 21)

2

• Press locking pin (2).

19

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

Continue with pos. 3.

6.9

Prior to operation 3. Unscrew quick release coupling (4) from the maize picker and screw it onto the feeder housing.

LEXION, to front attachment no.: 911 0 1393, 912 0 1185, 914 0 1085

3

4. Attach protective cap (3) to the maize picker.

4

Continue with pos. 5.

(Fig. 17, 18, 19, 20, 21)

5

20 LEXION, from front attachment no.: 907 0 1001, 908 0 1001, 911 0 1394, 912 0 1186, 914 0 1086, 919 0 1001

4

3

5

21

Unlocking the maize picker

LEXION

5. Open the locking mechanism of the maize picker with lever (6). To do this: pull out retainer (7) and move lever (6) upwards.

7

6. Pull out both stands (9) and secure with pins (8) in lower position.

6

Start engine and fully lower feeder housing of the combine harvester on the multifunction lever.

Continue with pos. 7.

(Fig. 22, 23) 22 LEXION

8 9

23

6.10

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Prior to operation 7. Press the tip switch on the multifunction lever.

LEXION 452 - 468

10 = Lower cutterbar.

11 = Slowly lower cutterbar.

– see also the operator's manual for the combine harvester.

10

(Fig. 24) 11 ATTENTION! 24 LEXION 541 - 548, 580 - 586, 589

Make sure the coupling hooks do not get caught in the coupling pins before you reverse with the combine harvester!

8. Carefully reverse the combine harvester.

STOP

A

10 ON

11

72511

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

25

6.11

Prior to operation

Prior to operation MOUNTING THE MAIZE PICKER – MEDION

MEDION/MEGA

DANGER! 1

Mounting the maize picker involves risks of injury!

– Make sure there is no-one between the combine harvester and the maize picker.

26

ATTENTION!

MEDION/MEGA

Make sure the upper and lower lock mechanisms (1, 2) are open before lifting the maize picker.

2

– see Unlocking the maize picker, page 6.20.

(Fig. 26, 27)

27

Preparing the combine harvester for mounting the maize picker

MEDION/MEGA

Removing angle bars

W

Remove the angle bars (W) on the left and right feeder housing.

W

Keep for later use.

(Fig. 28)

28

6.12

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Prior to operation Mounting on to a combine harvester with Auto Contour System

MEDION/MEGA

Extend both coupling hook cylinders on the feeder housing of the combine harvester by about 40 mm (middle position) before mounting the maize picker.

DANGER! Block and switch off the Auto Contour System on the combine harvester.

– Close shut-off cock (R) on the right on the feeder housing by turning lever (H) to pos. (Z) (Fig. 29).

29 MEDION/MEGA

– Switch off rocker switch (54) for the Auto Contour System (Fig. 30).

– For safety reasons, disconnect the cable to the switch on the left cutterbar cylinder at cable coupling (C) (Fig. 31).

(Fig. 29, 30, 31) Screw on adapter plate (G) with 4 hexagon head bolts M 12x80.

30

MEDION/MEGA

NOTE! When mounting the adapter plate, ensure that the semicircular slot (H) faces up and the V-slot (V) faces forward!

Order no.:

adapter plate hexagon head bolts self-locking nuts washer

0997 760.0 0235 560.0 0238 234.0 0239 389.0

(Fig. 32) 31 MEDION/MEGA

H V

G 32

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

6.13

Prior to operation Mounting to a combine harvester without Auto Contour System

MEDION/MEGA

F

On machines without Auto Contour System, standard coupling hook (F) must be replaced by a longer coupling hook.

Order no.:

coupling hook

0174 462.0

(Fig. 33)

33 Bolt the L-plate (L) to the adapter plate (G).

MEDION/MEGA

Order no.:

L-plate

0765 451.0

(Fig. 34)

L

G 34

6.14

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Prior to operation Mounting the maize picker

MEDION/MEGA

NOTE!

3

Make sure the universal drive shafts of the maize picker are flush on both sides of the machine with the drive shafts of the combine harvester.

F

35 MEDION/MEGA

1. Move the combine harvester towards the maize picker so that the coupling hooks (F) on the feeder housing are below the coupling pins (3) of the upper picker crossbar.

2. Press the tip switch on the multifunction lever to lift the maize picker.

4

4 = lift.

– see also the operator's manual for the combine harvester.

3. Check that the universal drive shaft connections are aligned with the drive shafts, and if necessary correct the adjustment of the coupling hooks.

NOTE! 36 MEDION/MEGA

F R

If necessary, the position of the maize picker can be changed by shifting washers (E) below coupling hook (F). Two washers (43x53x3) are delivered ex works.

Proceed as follows: 4. Move the combine harvester with the maize picker to an even, horizontal and firm location.

E

5. Switch the maize picker off – see Removing the maize picker - MEDION/ MEGA on page 6.19. %## %

37

6. First take out washers (E) underneath coupling hook (F) on the higher side. Unscrew hexagon head bolt (R) and slightly lift the coupling hook.

7. After removing the washers, screw the coupling hook back on and mount the maize picker.

8. If this is not yet sufficient, the washers removed on the opposite side can be added.

(Fig. 35, 36, 37)

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

6.15

Prior to operation Locking the maize picker

MEDION/MEGA

1. First unlock the top locking bolts (6) (left and right) with lever (5) and then slide them back.

• Ensure that the locking bolt (6) is visible in the drilled hole (7).

5

6

2. Slide the bottom locking bolts (9) (left and right) fully in until the locking bracket (10) can be swung forward.

7

3. Swing locking bracket (10) forward and secure with spring clip (8).

38

(Fig. 38, 39)

MEDION/MEGA

9

8

10 39 Connect the hydraulic hoses

MEDION/MEGA

C

A

ATTENTION! Dirt on the quick release coupling or hydraulic coupling sockets can contaminate the hydraulic system.

B

– Always clean the male couplings of the hydraulic hoses and the hydraulic coupling sockets before connecting them.

– Beware of friction and jamming!

40 When connecting the hydraulic hoses to the maize picker quick-release couplings, observe the colour marking.

• A = clear snapper plate adjustment • B = red swing units out • C = blue swing units in Couple hydraulic hoses in accordance with the identification.

(Fig. 40)

6.16

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Prior to operation Connecting the power supply

MEDION/MEGA

11

ATTENTION!

12

Beware of friction and jamming!

13

To front attachment no.: 911 0 1393, 912 0 1185, 914 0 1085 1. Insert plug (11) for snapper plate position display.

41 MEDION/MEGA

2. Fasten flat connector (12) to the cable end (13) with a bolt.

3. Attach cable end to the right lift cylinder on the combine harvester.

4. Replace existing cable (V) with new cable (14) on the potentiometer.

V

From front attachment no.: 907 0 1001, 908 0 1001, 911 0 1394, 912 0 1186, 914 0 1086, 919 0 1001 1. Insert plug (11) for snapper plate position display.

14

2. Attach cable end to the right lift cylinder on the combine harvester.

3. Connect existing cable (V) and new cable (14) to the potentiometer.

42

(Fig. 41, 42) Fitting drive shafts

MEDION/MEGA

15

16

DANGER!

17

Never run drive shafts without their guards, or if the guards are damaged.

21

18

– Fit the joint guard and protective tube.

19

– Secure the guard against turning with the shaft!

– Only operate the universal drive shafts if they are in a technically perfect condition.

20 74784

43 1. Fit universal drive shaft guard (17) with washer (15) and contact washer (16) to the gearbox.

2. Grease the gear profile (21) of the universal drive shaft.

3. Insert toothed profile (21) (external profile) of the universal drive shaft into the bore (hollow shaft) on the bevel gearbox.

4. Attach the universal drive shaft to the angle drive with the flanged bushing (18) (42x28) and cheese-head screw (19) (M12x40).

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

6.17

Prior to operation

CAUTION! Protective cap 20) cannot be removed without destroying it. Before fitting the protective cap, tighten screw (19).

5. Fitting protective cap (20). The rubber-lined side (black) faces outwards.

Connecting the universal drive shafts

MEDION/MEGA

6. Lift guard (S).

7. Push the opposite end of universal drive shaft (22) onto the drive shafts on the feeder housing.

22

Universal drive shaft with slide pin connection (A): – Push the slide pin and push the universal drive shaft onto the p.t.o. shaft of the machine until the connection engages into the ring groove.

Universal drive shaft with QS connection (C): 44

– Retract the slide sleeve until it stops in the opened state.

– Push the universal drive shaft onto the p.t.o. shaft of the machine until the QS connection automatically engages into the ring groove.

A C

Universal drive shaft with AS connection (D): – Retract the slide sleeve and push the universal drive shaft onto the p.t.o. shaft of the machine until the connection engages into the ring groove.

D

8. Check to make sure that the connection is securely engaged.

74145

45

9. Reinstall guard (S).

10. Tighten the universal drive shaft guard so it cannot rotate with the shaft.

(Fig. 43, 44)

6.18

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Prior to operation REMOVING THE MAIZE PICKER - MEDION/ MEGA

MEDION/MEGA

ATTENTION! 1

Set the maize picker down on firm and level ground only!

– Move combine harvester back slightly in transport position when setting down the maize picker and make sure that the points do not stick into the ground.

46

MEDION/MEGA

C

NOTE!

A

The maize picker can be removed in working or transport position. The sequence is identical in both cases.

2 B

DANGER! Carry out work on the maize picker only with the drive switched off and the engine at a standstill.

47

– Remove the ignition key!

– Switch off the battery master switch!

MEDION/MEGA

3

Set the maize picker down as follows: 1. Press the tip switch on the multifunction lever to lift the maize picker.

3 = lift.

– see also the operator's manual for the combine harvester.

2. Pull off the universal drive shafts on both sides. To do this: 48

• Raise universal drive shaft guard (S) (Fig. 46) • Push the safety pin (1) or retract the slide sleeve.

3. Disconnect hydraulic hoses (A, B, C) on the maize picker.

4. Attach the protective caps for the hydraulic quick release couplings on the maize picker.

5. Disconnect power supply (2) at the socket.

Continue with pos. 6.

(Fig. 46, 47, 48)

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

6.19

Prior to operation Unlocking the maize picker

MEDION/MEGA

6. First slide the top locking bolts forward with lever (4) and then clamp lever (4).

7. Release spring clip (5) and swing locking bracket (7) back.

4

8. Slide bottom locking bolts (6) right out.

9. Swing locking bracket (10) forward and secure with spring clip (5).

• Ensure that the bottom locking bolts (6) are slid fully outward.

49 MEDION/MEGA

Continue with pos. 10.

(Fig. 49, 50, 51)

6

5

7 50 MEDION/MEGA

7

51

6.20

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Prior to operation 10. Pull out both stands (9) and secure with pins (8) in lower position.

8

11. Start engine and fully lower feeder housing of the combine harvester on the multifunction lever.

9

(Fig. 52) 12. Press the tip switch on the multifunction lever.

10 = Lower cutterbar.

52

– see also the operator's manual for the combine harvester.

(Fig. 53)

MEDION/MEGA

ATTENTION! Ensure that the coupling hooks do not catch on the coupling pins when reversing the combine harvester!

10

– see Unlocking the maize picker, page 6.20.

53

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

13. Carefully reverse the combine harvester.

6.21

Prior to operation

Prior to operation CHOPPER DANGER! Carry out work on the maize picker only with the drive switched off and the engine at a standstill.

– Remove the ignition key!

2 2

– Switch off the battery master switch!

1 54

Engaging the chopper 1. Remove guard (2) before engaging the chopper (1).

2. Engaging the chopper – see Engaging/disengaging the chopper on page 7.5.

(Fig. 54)

STANDS Push up stands (1) on both sides and secure with pins (2).

(Fig. 55)

1 2 55

6.22

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Prior to operation SHEET METAL COVERS DANGER! Carry out work on the maize picker only with the drive switched off and the engine at a standstill.

H

– Remove the ignition key!

– Switch off the battery master switch!

56

Carry out work under the raised maize picker head only after having propped it safely.

– see Safety prop on page 4.3.

Mounting and adjusting the gathering points ATTENTION! Make sure the sheet metal covers are completely closed and locked before putting the maize picker into operation.

57

Proceed as follows to mount the gathering points: 1. Swing maize picker into working position – see Work and transport position on page 7.2.

2. Screw gathering points with two hexagon head bolts M 12x35, spacer bushings and contact washers at position (H) to the sheet metal covers.

Hexagon head bolts, spacer bushings and contact washers are present in the sheet metal covers.

3. Adjust and align gathering points after mounting – see Vertical adjustment of the gathering points on page 6.24.

(Fig. 56, 57)

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

6.23

Prior to operation Vertical adjustment of the gathering points 2

Rough adjustment:

3

1. Remove retainer (2) from pin (4).

2. Pull pin (4) out of holder (3).

3. Adjust point support (1) in the desired drilled hole in holder (3) with pin (4).

4

4. After the adjustment of the desired height, secure pin (4) with retainer (2).

1 58 Final adjustment of central gathering points: Perform final adjustment with screw (5). Loosen lock nut (6) and turn screw (5).

5

right:

higher

left:

lower

6 59 Final adjustment of outer gathering points: Perform final adjustment with screw (7). Hold nut (8) and turn screw (7).

7

right:

higher

left:

lower

(Fig. 58, 59, 60) 8

60

6.24

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Prior to operation Stop gathering points (only CONSPEED – 8 rows folding) ATTENTION! In the folded position, the points of the central sheet metal covers on the outer units can push into the ground. This can cause damage to the sheet metal covers or to the cover framework.

– Adjust the stop screws accordingly.

1. Swing maize picker into transport position – see Work and transport position on page 7.2.

The central sheet metal covers (10) of the outer units swing downwards.

2. Lower the maize picker onto the ground carefully whilst driving backwards slowly so that the gathering points (9) cannot push into the ground.

10

3. Check to ensure that the gathering points (9) do not touch the ground.

9 61

4. If necessary, adjust the position of the stop screw (11) in the slotted hole of the sheet metal cover framework.

(Fig. 61, 62)

11

62

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

6.25

Prior to operation Locking and unlocking the sheet metal covers Lift gathering point and move lever (12).

A

left (Pos. B):

locked

right (Pos. A):

unlocked

(Fig. 63, 64)

B 12

63

12

A B 64

6.26

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Prior to operation Raising the sheet metal covers The sheet metal covers can be raised for maintenance and cleaning work.

DANGER! Risk of crushing when raising the sheet metal covers!

– Do not work under the raised sheet metal cover unless it is securely supported.

65

1. First unlock sheet metal covers – see Locking and unlocking the sheet metal covers on page 6.26.

2. Open sheet metal covers by pulling strongly on the gathering points.

14

3. Move sheet metal covers (14) upwards and hook into the point support (13).

13

4. Secure sheet metal covers (14) with linch pin (15). (only CONSPEED C – non-folding) ATTENTION! 15

Make sure the sheet metal covers are completely closed and locked before putting the maize picker into operation.

66

(Fig. 65)

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

6.27

Prior to operation SNAPPER PLATES Adjusting the limit stops of the snapper plates

1

When fitting the maize picker for the first time or when changing the cutterbar on the maize picker, the limit stops of the snapping plates (1) must be “relearned”.

LEXION:

• Press the tip switch on the multifunction lever 3 = reduce distance between snapper plates.

67 LEXION 452 - 468

4 = increase distance between snapper plates.

MEDION/MEGA:

4

3

• Press the tip switch on the multifunction lever 5 = increase distance between snapper plates.

6 = reduce distance between snapper plates.

NOTE! The tip switch (6) also swings the maize picker into working position.

68

Before learning the limit stops, set the snapping plates to 3/4 open.

LEXION 541 - 548, 580 - 586, 589

4

“Learning” the limit stops:

STOP

A

– see Combine Harvester Operator's Manual.

3

Other adjustments: – see Adjusting the snapper plates hydraulically on page 7.4.

ON

– see Basic adjustment of snapper plates on page 8.16.

69

72511

(Fig. 67, 68, 69, 70)

MEDION/MEGA

5

6

70

6.28

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Operation

Operation

7 Operation USING THE MAIZE PICKER DANGER! Risk of injury!

– If excessive vibrations occur, switch the maize picker off immediately and determine and eliminate the cause!

1

1

Carry out work on the chopper of the maize picker only with the drive switched off and the engine at a standstill.

– Remove the ignition key!

– Switch off the battery master switch!

– disconnect the universal drive shaft!

Risk of accidents!

– Switch the maize picker off whenever outside the field!

1. Remove protective bar (1) and safety guards.

2. Engage chopper (2) – see Engaging/disengaging the chopper on page 7.5.

2 2

3. Start the engine.

4. Swing maize picker into working position – see Work and transport position on page 7.2.

5. Switch on the maize picker at idle speed before driving into the crop.

6. Lower the maize picker to working height.

7. Increase to working speed and drive into the crop.

NOTE! If necessary, adapt snapper plates to the crop and adjust the height of the points.

– see Adjusting the snapper plates hydraulically on page 7.4.

– see Vertical adjustment of the gathering points on page 6.24.

Set ground speed according to the working conditions (ground conditions, quality of crop).

(Fig. 1, 2)

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

7.1

Operation Work and transport position DANGER! Carry out work on the chopper of the maize picker only with the drive switched off and the engine at a standstill.

– Remove the ignition key!

– Switch off the battery master switch!

– disconnect the universal drive shaft!

Working position 1. Engage chopper (2) before swinging the maize picker into working position.

– see Engaging/disengaging the chopper on page 7.5.

2. Swing maize picker into working position.

LEXION: • Press rocker switch (3) on the instrument panel.

MEDION/MEGA:

2 3 LEXION

• Press the tip switch (6) on the multifunction lever.

3 NOTE! Pressing the tip switch (6) also reduces the snapping plate gap. Adjust snapping plates before use.

After the maize picker has been opened into working position and no visible movements can be detected, hold the following switch down for about 3 seconds longer to close the cover securely: 4 MEDION/MEGA

LEXION: rocker switch (3).

MEDION/MEGA: tip switch (6).

• Adjusting snapping plates – see Adjusting the snapper plates hydraulically on page 7.4.

(Fig. 3, 4, 5)

6

5

7.2

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Operation Transport position

LEXION

1. Swing maize picker into transport position:

3

LEXION 470 Montana / 430 Montana: ATTENTION! If they are swung together with universal drive shafts attached they will be damaged with the LEXION 470 Montana / 430 Montana.

– Disconnect universal drive shafts.

6 MEDION/MEGA

Before swinging together: • Disconnect right and left universal drive shafts.

5

• Place universal drive shafts in the bracket on the maize picker.

LEXION: • Press rocker switch (3) on the instrument panel.

4

MEDION/MEGA: • Press the tip switch (4+5) on the multifunction lever.

7

2. Disengage chopper (2) – see Engaging/disengaging the chopper on page 7.5.

(Fig. 6, 7, 8)

2 8

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

7.3

Operation Adjusting the snapper plates hydraulically The snapper plates (P) located above the reaper drums (R) can be hydraulically adjusted to the thickness of the maize stalks. The snapper plate distance must always be 5 mm wider at the end than at the beginning.

P P

R

R

9

Adjust the snapper plates on the multifunction lever so that the ears are separated cleanly from the stalks, but are not yet husked.

LEXION 452 - 468

4

If the snapper plates are too wide apart, the ear is also pulled into the reaper drums (shelling losses). If the distance between the snapper plates is too narrow, the maize stalk is torn off below the ear and the combine harvester unnecessarily loaded by excessive maize straw.

3

• Press the tip switch on the multifunction lever LEXION: 3 = reduce distance between snapper plates.

4 = increase distance between snapper plates.

MEDION/MEGA: 5 = increase distance between snapper plates.

10

6 = reduce distance between snapper plates.

LEXION 541 - 548, 580 - 586, 589

NOTE! 4

The tip switch (6) also swings the maize picker into working position.

STOP

A

3 If necessary, check the basic setting of the snapper plates – see Basic adjustment of snapper plates on page 8.16.

ON

11

72511

(Fig. 9, 10, 11, 12)

MEDION/MEGA

5

6

12

7.4

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Operation Engaging/disengaging the chopper A

E

DANGER! Carry out work on the chopper of the maize picker only with the drive switched off and the engine at a standstill.

1

– Remove the ignition key!

– Switch off the battery master switch!

2

– disconnect the universal drive shaft!

13 The chopper can be engaged and disengaged separately for every picking row by turning hexagon screw (1) with screwdriver (2) (included).

Mark on hexagon screw (1) To the rear (E) = engaged (switched on).

To the front (A) = disengaged (switched off).

(Fig. 13)

Cut-out clutch for reaper unit drive The reaper units are protected against overload by cut-out clutches (1).

Switch off the picker attachment when the clutches respond. The slip clutches then switch on again automatically.

(Fig. 14) 1 14

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

7.5

Operation OPTIONAL EQUIPMENT DANGER! Carry out work under the raised front attachment only after having propped it safely.

– see Safety prop on page 4.3.

Always carry out work on the maize picker and/or combine harvester with the drive switched off and the engine at a standstill.

– Remove the ignition key!

– Switch off the battery master switch!

Intake auger attachment 1

The intake auger can be extended up to the middle with the intake auger attachment (1) when winding problems occur. The intake blades first must be removed.

Order no.:

0994 236.0

(Fig. 15)

15

Cover elevation (B07 0030) 2

For high crop conditions or high maize ear position on the stalk we recommend that you install the sheet metal cover raising device (2) on top of the outer screw divider tips and sheet metal covers. This prevents losses on the picker sides.

Order no.:

0998 196.0

(Fig. 16)

16

7.6

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Operation CLAAS Autopilot (LEXION) (R05 0050, R05 0060) The maize picker can be equipped with an autopilot for the automatic control of the combine harvester through the maize rows.

Order no.: To LEXION 452 - 468: analogue:

0997 779.0

From LEXION 541 - 548, 580 - 586, 589: digital:

0998 965.0

LEXION 452 - 468

VS2

NOTE! The electric connections on the central plug must be connected as follows if the autopilot is mounted as well.

VS1

LEXION 452 - 468: – Snapper plate position display or Auto Contour on socket VS2.

VS3

– Autopilot on socket VS3.

17 LEXION 541 - 548, 580 - 586, 589

VS1

VS3

Up to LEXION 452 - 468 either the snapper plate position display or Auto Contour can be connected.

LEXION 541 - 548, 580 - 586, 589: – Snapper plate position display at socket VS1.

– Auto Contour at socket VS2.

VS2

– Autopilot on socket VS3.

18

Adjust sensing bands so that distance (X) is 20 mm (tolerance+5/-15 mm) in rest position.

A = rest position B = swivelled in (Fig. 17, 18, 19)

19

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

7.7

Operation CLAAS Auto-Contour (R09 0010) (only CONSPEED model 907/908/909/911/912/914) The CLAAS Auto Contour system ensures optimum adaptation of the maize picker to the ground conditions.

Order no.:

0998 520.0

(Fig. 20)

20

Sliding blocks To prevent the gathering point from sticking into soft ground, sliding blocks (1) can be mounted on the points.

ATTENTION! Sliding blocks (1) must be mounted on every gathering point.

1 21

Order no.:

0997 517.0

(Fig. 21)

Stubble attachments (B07 0040) Unfavourable slant of the mown maize stalks (stubble) can damage the tyres of the combine harvester.

To prevent damage, stubble attachments (2) can be mounted instead of the stands.

Order no.:

0496 155.0

(Fig. 22) 2 22

Stripper angles Undergrowth in the crop can cause winding problems on the reaper drum.

3

This can be prevented by mounting stripper angles (3) on the left and right of the reaper drums.

Order no.:

23

7.8

Left

0997 771.0

Right

0997 772.0

(Fig. 23)

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Operation Down maize auger (only for LEXION) (B05 0020) The side cover can be replaced by a down maize auger (4) for easier harvesting of down maize.

Order no.: 4

CONSPEED Model 913

0496 241.0

CONSPEED Model 907/908/919

0998 875.0

(Fig. 24) 24

Rubber ram stops If piston losses occur, the small rubber ram stops on the middle gathering points can be replaced with a rubber ram stop that covers the entire sheet metal cover.

Rubber ram stop screw mounting 6 5

7

Order no. per gathering point: Rubber ram stop (5) for row width

8

80 cm 75 cm 70 cm EJOT-PT screw (6) Mounting plate (7)

9 7 10 71683

25

1x 1x 1x 2x 1x

0496 212.0 0496 174.0 0496 200.0 0214 537.0 0995 751.1

Proceed as follows for fitting of the large screw mounting rubber ram stops: 1. Lower maize picker onto firm ground.

2. Remove left and right rubber ram stops (10); to do this unscrew bolts (8) and remove contact washer (9) and mounting plate (7).

3. Attach new rubber ram stop (5) with the same bolts (8), contact washer (9) and mounting plate (7) to the gathering point.

4. Mark the top fastening holes for the EJOT-PT bolts (6) (2x) with the new rubber ram stops (5) and the additional mounting plate (7).

5. Drill fastening holes with 4 mm diameter drill.

6. Attach EJOT-PT screws (6) and mounting plate (7).

(Fig. 25)

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

7.9

Operation Rubber ram stop plug mounting Order no. per gathering point:

8

7

Rubber ram stop (11) for row width 80 cm 75 cm 70 cm Spring clip (12) Mounting plate (13)

9 10

26

74788

1x 1x 1x 2x 2x

0496 215.0 0496 178.0 0496 202.0 0665 666.0 0496 175.0

Proceed as follows for fitting of the large plug mounting rubber ram stops: 1. Lower maize picker onto firm ground.

2. Remove left and right rubber ram stops (10); to do this unscrew bolts (8) and remove contact washer (9) and mounting plate (7).

11 12

3. Attach new mounting plate (13) with same bolts (8), contact washer (9) to the gathering point.

4. Push new rubber ram stop (11) onto the mounting plates and secure with spring clips (12).

(Fig. 26, 27)

13 27

74787

74-tooth sprocket The speed of the intake auger can be reduced by replacing the sprocket.

The standard sprocket with 66 teeth is replaced by the optional sprocket with 74 teeth.

Order no.:

0998 835.0

Proceed as follows to replace the sprocket:

14

1. Lower maize picker onto firm ground.

28

2. Remove guard (14).

3. Remove drive chain.

4. Unscrew hexagon head bolt (18) and remove with contact washer (17).

15

5. Remove flanged bushing (16).

16

6. Remove sprocket (15) and mount new sprocket.

7. Mount drive chain, extend if necessary.

17

8. Tension drive chain – see Tensioning the drive chain on page 8.13.

(Fig. 28, 29)

18 71685

7.10

29

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Operation CONSPEED – speed matching

LEXION

Speed matching to harvest conditions takes place on the combine harvester. By fitting a relevant set of V-belt pulleys, the speed can be reduced or increased.

19

Reducing the speed: grain loss or cob loss of sensitive maize plants Possible speed see table.

20

Increasing the speed: poor chop quality 21 30

74775

– Changing V-belt pulley set, consisting of two V-belt pulleys (19, 20) and set of V-belts/power band belts (21).

LEXION: Front attachments' drive 1st Stage

MEDION/MEGA

MEDION/MEGA: Front attachments' drive – Retain the removed parts for later re-use.

For further information see operator's manual combine harvester.

19

(Fig. 30, 31)

20

21 31

74774

Combine harvester

Equipment

LEXION

Series1 Variator2

MEDION 932 up to serial no. 914 01144

MEDION 932 from serial no. 914 01145

MEDION 934 MEGA 845 up to serial no. 914 01144

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

Speed [rpm]

Variant No.

Order no.:

686 458 - 664

Conversion kit

566

0749 812.0

Series1

583

Conversion kit

689

B07 0050

0667 284.0

Conversion kit

635

only part no.3

0744 898.0

Series1

548

Conversion kit

646

B07 0050

0667 284.0

Conversion kit

598

only part no.3

0744 898.0

Series1

595

Conversion kit

684

B07 0060

0667 285.0

Conversion kit

635

only part no.3

0744 899.0

7.11

Operation Combine harvester

Equipment

MEDION 934 MEGA 845

Series1

558

Conversion kit

from serial no. 914 01145

MEGA 835 up to serial no. 914 01144 MEGA 835 from serial no. 914 01145

Speed [rpm]

Variant No.

Order no.:

641

B07 0060

0667 285.0

Conversion kit

598

only part no.3

0744 899.0

Series1

583

Conversion kit

635

only part no.3

0744 992.0

Series1

548

Conversion kit

598

only part no.3

0744 992.0

1. Combine harvester standard equipment 2. Order with combine harvester 3. only part no.: The conversion kit can only be obtained from the CLAAS spare parts department.

Shear bar for chopper (B07 0080) Fitting the shear bar means: – The stems cannot move out of the way when chopping.

22

– Improvement of the chop quality.

Order no.: 23 32

CONSPEED – 8-rows Kit 8 CONSPEED – 6-rows Kit 6 CONSPEED – 12-rows Kit 6

0496 248.0 0496 249.0 2x

0496 249.0

• Fit the shear bar (22) with bolts (23) (M12x30MK), washer (13x40x3) and contact washer (A12) onto the picker gearbox.

(Fig. 32) Additional lighting - combine harvester (B07 0010) For travelling on public roads and tracks, the higher headlights (A) and the side lights and flashing lights are required – see Driving lights during road transport, page 3.5.

A

Order no.:

A

LEXION MEDION/MEGA

0496 070.0 0997 511.0

(Fig. 33) 33

7.12

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Operation Fitting kit - Montana (M04 0100) For fitting the CONSPEED Model 908/911 (6 rows) to the LEXION 470 Montana / 430 Montana the fitting kit is required.

Order no.:

0905 798.0

(Fig. 34)

34

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

7.13

Maintenance

Maintenance

8 Maintenance IMPORTANT MAINTENANCE INSTRUCTIONS DANGER! Always switch off the drive and the combine harvester for troubleshooting, and for repair, maintenance and cleaning work.

– Remove the ignition key!

Check hydraulic lines at regular intervals, and replace them in the case of damage or ageing! Replaced hydraulic lines must correspond to the technical requirements of the equipment manufacturer!

Repair work on the hydraulic system may be carried out by authorised specialised workshops only.

Bolts Check all bolts for tightness and retighten if necessary.

Check that all split pins and roll pins are in place.

– Switch off the battery master switch!

Lubrication DANGER! Carry out repair, maintenance and cleaning work on or under the raised maize picker or feeder housing only if it is safely propped.

– see Safety prop, page 4.3

Observe the oil change intervals and the oil quality specified by the manufacturer. Lubricate the machine only with brand-name grease or oil of good quality.

Clean the grease nipples before applying the grease gun. Grease all points that require lubrication, observing the intervals specified in the lubrication chart.

The lubrication intervals stated apply to normal service conditions only. Lubricate more frequently if the machine is used in severe conditions.

Spare Parts As a minimum, the spare parts must comply with the technical requirements established by the equipment manufacturer! This can, for example, be ensured by using original spare parts.

Hydraulic system DANGER! Always depressurise the hydraulic system before working on it.

Fluid escaping under high pressure (hydraulic oil etc.) can penetrate the skin and cause serious injuries.

Immediately consult a doctor in case of injury, otherwise serious infections can set in.

ENVIRONMENT! Dispose of oil and grease according to regulations!

Guards Open folding guards only with the drive switched off and the engine at a standstill.

– Remove the ignition key!

– Switch off the battery master switch!

Mount the complete guards again after all maintenance and repair work.

Regularly check safety guards.

Replace worn or damaged safety guards by new ones.

ENVIRONMENT! Dispose of oil and grease according to regulations!

8.1

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Maintenance

Maintenance DRIVE SYSTEMS DANGER! Always carry out work on the maize picker and/or combine harvester with the drive switched off and the engine at a standstill.

– Remove the ignition key!

– Switch off the battery master switch!

– Disengage the universal drive shaft on the left and right!

ATTENTION! Set the maize picker down on firm and level ground only!

1. Swing maize picker into transport position.

2. Unlock maize picker – see Unlocking the maize picker on page 6.10 and set down on the cutterbar skids and stands.

3. Switch off the drive and the engine.

4. Secure combine harvester against rolling away.

ENVIRONMENT! Dispose of drained oil according to regulations.

Use only the prescribed gearbox oil for lubricating the gearbox.

Filling capacity and type of lubricant – see Lubricant table, page 8.21.

Service intervals: Unless otherwise indicated, change all gearbox oils every 500 operating hours - but at the latest after each season.

Check all gearboxes every week for leaks, if necessary check the oil level.

Check oil level of the gearboxes every 50 working hours.

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

8.2

Maintenance

1

2

3 1

2 3 1

Angle drive gearbox 1

1 Oil filler cap 2 Oil level check plug 3 Oil drain plug

x

Oil level check of upper angle drive gearbox: 1. Screw out oil level check plug (2).

2. Insert a clean screw driver through the inspection opening (2) at a right angle to the gearbox until it touches the inside.

2 2

3. Take out screw driver.

• It should be covered with oil to about 10 mm (x).

4. Top up oil as required.

(Fig. 2, 3)

3

3

8.3

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Maintenance Oil level check of lower angle drive gearbox: 1. Screw out oil level check plug (2).

1

• The oil level must be up to the bottom edge of the inspection opening.

2. Top up oil as required.

(Fig. 4, 5)

4

2 3

5 Special note for CONSPEED C (non-folding) DANGER!

4

Do not work under the raised sheet metal cover unless it is securely supported.

– Secure sheet metal cover with linch pin.

– see Raising the sheet metal covers, page 6.27.

5 6

The oil filler cap is under the first sheet metal cover from the outside. Proceed as follows to add oil to the bottom angle drive: 1. Raise sheet metal cover (4) and secure with linch pin (5).

6

2. Loosen bolts (6) and pull cover (7) forward.

3. The oil filler cap (1) is now accessible.

7

1

(Fig. 6, 7)

7

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

8.4

Maintenance Picker and chopper gearbox max

1

DANGER!

min

Carry out work under the raised maize picker head only after having propped it safely.

– see Safety prop on page 4.3.

Carry out work on the picker and chopper gearbox only with the drive switched off and the engine at a standstill.

8

– Remove the ignition key!

– Switch off the battery master switch!

– Disengage the universal drive shaft on the left and right!

1 Oil filler cap with oil level dipstick 2 Oil drain plug

2

9 Oil change: Perform the first oil change after 50 working hours, then once a year or every 500 working hours.

1. Swing maize picker into working position.

2. Fully lift out and safely support maize picker – see Safety prop on page 4.3.

3. Switch off the drive and the engine.

4. Secure combine harvester against rolling away.

5. Remove guard on the bottom/rear.

6. Unscrew oil drain plug (2) and collect oil.

7. Fill in oil and check – see Check oil level on page 8.6.

ENVIRONMENT! Dispose of drained oil according to regulations.

(Fig. 8, 9)

8.5

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Maintenance Check oil level

1

max

1. Swing maize picker into working position.

min

2. Unlock maize picker and set down on cutterbar skids and stands – see Unlocking the maize picker on page 6.10.

3. Switch off the drive and the engine.

4. Secure combine harvester against rolling away.

10

5. Raise sheet metal cover (4) and secure with linch pin (5)– see Raising the sheet metal covers, page 6.27.

6. Unscrew oil filler cap with oil level dipstick (1).

7. Wipe the oil level dipstick.

8. Screw in the oil level dipstick.

9. Unscrew the oil level dipstick again.

10. Check oil level on oil level dipstick: • between min/max = OK • below min = top up oil • above max = drain oil.

(Fig. 10)

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

8.6

Maintenance Drive shaft M

DANGER! Carry out work under the raised maize picker head only after having propped it safely.

– see Safety prop on page 4.3.

Carry out work on the drive shafts only with the drive switched off and the engine at a standstill.

– Remove the ignition key!

11

– Switch off the battery master switch!

– Disengage the universal drive shaft on the left and right!

ATTENTION! Check the position of the joint when assembling the universal drive shaft! If the joints are twisted, the drive will be unbalanced and may damage the maize picker!

– Note marks (M) (arrow) on the universal drive shaft halves!

(Fig. 11)

CLUTCHES DANGER! Carry out work under the raised front attachment only after having propped it safely.

– Use safety prop, see Safety prop on page 4.3.

Carry out work on the maize picker only with the drive switched off and the engine at a standstill.

– Remove the ignition key!

– Switch off the battery master switch!

– Disengage the universal drive shaft on the left and right!

8.7

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Maintenance Chain clutch The chain clutches (1) must be cleaned and lubricated every 500 working hours, at least once a year. Proceed as follows: 1

1. Pull rubber cover (2) aside.

2. Open chain lock (7) and remove chain (4).

3. Clean chain (4) and sprockets (3).

4. Check rubber cover (2) for wear or damage and replace if necessary.

12

2

3

4 5

5. Slide hub (5) aside and grease hexagonal shaft (6) with lubricant. Slide the hub (5) back and forth several times to lubricate the hexagonal hole with paste too.

6. Lubricate the chain (4) and gearwheels (3) with lubricant.

6

7. Re-install chain (4).

8. Re-install chain lock (7).

9. Pull rubber cover (2) over the chain clutch.

Lubricant: – see Lubricant table, page 8.21

7

(Fig. 12, 13) 13

Overload clutches The clutches should be opened and serviced in a specialist workshop in accordance with the operator's manual of the clutch manufacturer every 500 operating hours - at the latest after each second season.

ATTENTION! The set clutch torque must not be altered, since otherwise considerable damage to the universal drive shaft, gearbox etc. can be caused.

• Check for signs of wear and replace any worn parts as necessary.

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

8.8

Maintenance Over-run clutch (8) (Drive intake auger) Torque setting: 900 Nm (Fig. 14) 8

14

74776

Over-run clutch (9) (Drive picker gearbox) Torque setting: 600 +60 Nm (Fig. 15) 9

74777

15

UNIVERSAL DRIVE SHAFT DANGER! Carry out work on the feed units only with the drive switched off and the engine at a standstill.

– Remove the ignition key!

– Switch off the battery master switch!

Never run drive shafts without their guards, or if the guards are damaged.

– Fit the joint guard and protective tube.

– Secure the guard against turning with the shaft!

– Only operate the universal drive shafts if they are in a technically perfect condition.

Lubrication intervals and lubricants see Lubrication chart, page 9.1.

Service the universal drive shaft in accordance with the instructions of the manufacturer of the universal drive shaft - see operator's manual of the universal drive shaft manufacturer.

Observe the manufacturer's safety regulations!

8.9

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Maintenance General information concerning universal drive shafts DANGER! Never run drive shafts without their guards, or if the guards are damaged.

– Fit the joint guard and protective tube.

– Secure the guard against turning with the shaft!

– Only operate the universal drive shafts if they are in a technically perfect condition.

Damaged or missing protective tubes, universal drive shaft guards and fixing chains should be replaced immediately.

Protect the universal drive shafts from the effects of weather.

After the season, thoroughly clean the universal drive shafts in all components and lubricate.

In the event of winter operation, the protective tubes should be greased to prevent them from freezing up.

After standstills for longer periods of time, the universal drive shafts must be re-greased when starting work again and their correct function should be checked.

Universal drive shaft - fitting LEXION 470 / 430 Montana In order to dismantle the universal drive shaft, and for lubrication of the joints, slide and protection tubes, the universal drive shaft guard must be removed.

Lubrication intervals and lubricants – see Lubrication chart, page 9.1.

(Fig. 16)

16

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

8.10

Maintenance Proceed as follows to remove the universal drive shaft guard:

1

• Release sleeve (2) from the universal drive shaft

3

guide (1) with a tool (e.g. screwdriver).

• Unscrew the fixing bolts (3) (6x).

(Fig. 17)

2 17

• Pull the universal drive shaft guard off.

(Fig. 18)

18 Proceed as follows to mount the universal drive shaft guard:

• Push the universal drive shaft guide on and position over the cams so that bolt holes (8) are visible in cut-outs (8).

(Fig. 19)

8 19

• Fit fixing bolts (3) (6x).

(Fig. 20)

3

20

8.11

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Maintenance • Fit the sleeve onto the universal drive shaft guide with a tool (e.g. screwdriver).

(Fig. 21)

21

CHAINS 1 DANGER! Risk of crushing when raising the sheet metal covers!

Risk of injury!

Carry out work on the feed units only with the drive switched off and the engine at a standstill.

1

– Remove the ignition key!

22

– Switch off the battery master switch!

– Disengage the universal drive shaft on the left and right!

Cleaning the finger chains To ensure correct function of the maize picker, the finger chains (1) must be cleaned as required.

In doing this, move the covers upwards and secure – see Raising the sheet metal covers, page 6.27.

(Fig. 22)

Tensioning the finger chains 3

4

The finger chain is tensioned correctly if notch (6) on spring guide (7) is flush with holder (2).

5

Proceed as follows to tension the finger chain:

2

1. Loosen lock nut (4).

2. Adjust spring tension with hexagon head bolt (5) while holding hexagon nut (3).

7

• Clockwise rotation = increase spring tension 6 23

• Counter-clockwise rotation = reduce spring tension (Fig. 23)

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

8.12

Maintenance Lubricating the drive chain Remove plastic cover (9) for lubrication. Turn out hexagon head bolt (8) with fork wrench only until plastic cover (9) can be removed by hand.

After maintenance, reinstall plastic cover (9) and screw in hexagon head bolt (8).

8

(Fig. 24) 9

CONSPEED – 8 rows 24

CONSPEED – 8 rows

For lubrication work, hinge cover (11) backwards, after releasing bolts (10, 12).

After the maintenance work, cover (9) should be closed again and bolts (10, 12) should be re-tightened.

(Fig. 25)

10 11

12 25

Tensioning the drive chain Remove side panel. Tension steel roller chain (E) for intake auger with jockey sprocket (R). The steel roller chain is at its correct tension when its slack side, with the tight side slightly under load, can be pulled down with the thumb by about 2% of the centre distance between the sprockets. Check the tension more frequently when using new chains.

E

R

Example: centre distance 500 mm = pulled down on slack side by about 10 mm (Fig. 27).

26

(Fig. 26, 27)

27

8.13

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Maintenance SCRAPER PLATES 2

Adjusting the scraper plates

3

DANGER!

3

Safely prop the raised maize picker – see Safety prop on page 4.3!

Carry out work on the scraper plates only with the drive switched off and the engine at a standstill.

1 28

– Remove the ignition key!

– Switch off the battery master switch!

– Disengage the universal drive shaft on the left and right!

Loosen screws (3) to position scraper plates (1 and 2) so close to the reaper drum that the clearance (x) to the highest tooth is at least 1 mm. Turn the reaper drums to check whether the clearance is ensured for every blade.

x

(Fig. 28, 29) 29

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

8.14

Maintenance PICKER ROLLERS Attaching the picker rollers After repair, the picker rollers should be re-fitted with fixing bolts (1) (M16) and a new lock edge ring.

Tighten the fixing bolts of the picker rollers with a torque of 195 Nm. (Fig. 30) 1

30

Checking the setting of the picker roller knives.

2

2 ATTENTION!

3

Under no circumstances should knives (3) collide when turning over!

3

– Check gap “x” between the knives (3) of the picker rollers.

x

2

– Release bolts (2) and set gap “x”.

2 31

Gap “x” = 0.5 - 2 mm (Fig. 30)

SNAPPER PLATES DANGER! Risk of crushing when raising the sheet metal covers!

Risk of injury!

Carry out work on the feed units only with the drive switched off and the engine at a standstill.

– Remove the ignition key!

– Switch off the battery master switch!

– Disengage the universal drive shaft on the left and right!

8.15

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Maintenance Basic adjustment of snapper plates When leaving the factory, the separation between the snapping plates at the start (A) is 17 mm and at the end (E) is 22 mm. The snapping plates must always be about 5 mm closer at the start than at the end.

NOTE! Looking from the centre, the outer snapper plates are always fixed. The inner snapper plates are hydraulically adjustable.

E

A 1

32 Perform basic adjustment as follows: 1. Use the hydraulic snapper plate adjustment to always move to the narrowest position – see Adjusting the snapper plates hydraulically on page 7.4.

2. Switch off combine harvester and remove ignition key.

3. In doing this, move the covers upwards and secure – see Raising the sheet metal covers, page 6.27.

4. Loosen screws (1) of the fixed snapper plate.

5. Set distance at the beginning (A) to 17 mm and at the end (E) to 22 mm.

If a different setting is required, the distance of 5 mm between beginning (A) and end (E) must be observed.

(Fig. 32)

CHOPPER KNIFE Changing the chopper knife DANGER! Carry out work on the knives or their attachment only with the drive switched off and the engine at a standstill.

– Remove the ignition key!

– Switch off the battery master switch!

– Disengage the universal drive shaft on the left and right!

Wear gloves when working on the knives.

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

8.16

Maintenance

ATTENTION! Unbalanced components damage the maize picker!

– Immediately replace damaged or broken knives or put chopper out of operation – see Engaging/disengaging the chopper on page 7.5!

– Check the knives before every use and after driving against an obstacle!

– Check correct seating of the knife!

– Both knives must always be fitted per knife holder!

– Always turn or exchange both knives on the knife holder!

Blunt knives can be turned and attached to the same knife holder again, so that chopping is performed with the second knife blade. The use of blunt knives increases power requirements and reduces chopping quality.

Replacement knives must meet the CLAAS technical requirements as a minimum. This is guaranteed with the use of original CLAAS chopper knives!

Changing the knives: 1. Loosen screws (1).

2. Change knives (2).

1

1

3. Reinstall screws (1).

(Fig. 33) Tightening torque for knife fastening screw = 78 Nm

2

33 The chopper knives must be replaced in the following cases:

• When the chopper knives have cracks or are deformed.

Never try to repair a deformed chopper knife.

• When the chopper knives are worn.

• When the drilled hole of the chopper knife has been widened. In this case, the bushes also must be replaced.

(Fig. 34) 65801F

8.17

34

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Maintenance Also check the attachment parts of the chopper knives before every use.

The knife securing screws must be replaced in the following cases:

• Visible deformation of the securing screw (e.g. after driving against an obstacle).

• Missing or ineffective thread coating, caused by water, oil or dirt.

• Severe wear of screw head.

NOTE! 35

75536

Always ensure proper seating when installing the securing screws.

(Fig. 35)

The knife securing nuts must be replaced in the following cases:

• When the nut is so worn that dimension a = H/2.

(Fig. 36)

a

H

65803F

36 The knife carriers must be replaced in the following cases:

• When the knife carriers are damaged (e.g. after driving against an obstacle).

• When the drilled holes for the knife securing screws have been widened (Fig. 37).

• When knives damaged by unbalanced running have caused cracks.

(Fig. 37) 75538

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

37

8.18

Maintenance HYDRAULIC SYSTEM Repair work on the hydraulic system must be carried out by authorised workshops, if possible your CLAAS partner.

Hydraulic hose connections Check hydraulic hoses before putting the machine into operation for the first time and afterwards at least once a year.

Exchange hydraulic hoses when damaged or aged!

38

NOTE! Hydraulic hoses may be used for a maximum period of 6 years after production.

The production date (month and year) is shown on the hydraulic hose.

Example: “2 Q 02” identifies production in the second quarter of 2002.

(Fig. 38)

Swivel device for sheet metal covers The sheet metal covers at the swivelling positions are swung hydraulically to the respective position. If the sheet metal covers no longer fully close (– see Using the maize picker on page 7.1) hydraulic cylinder (3) must be readjusted. Proceed as follows:

1

1. Swing maize picker into working position.

2

2. Raise the sheet metal covers.

3

3. Loosen attachment (1) of hydraulic cylinder (3).

39

4. Adjust attachment (1) in the slot of the holder (2) so that the sheet metal cover fully closes again.

(Fig. 39)

8.19

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Maintenance FIXING ELEMENTS Screw connections After 10 operation hours, all screws and nuts of the machine must be rechecked and tightened. Check on a regular basis!

Connection elements All safety relevant connection elements such as bolts, screws, pins etc. should be regularly checked for wear and deformation.

If necessary, the connection elements should be replaced by new ones.

WINTER STORAGE 1. Clean the dirt off the front attachment.

2. Drain the oil from the gearboxes and refill with new oil up to the prescribed level.

3. Grease all lubrication points thoroughly until oil comes out of the bearings (see Lubrication chart, page 9.1). Run the front attachment for a short period.

4. Check the front attachment for wear and damage and repair as necessary.

5. Clean rust spots and repair paint damage.

6. Store the front attachment in a dry, weather-protected room where no commercial fertiliser is stored.

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

8.20

Maintenance LUBRICANT TABLE Component

Fill quantity

Lubricant type Specification

Viscosity/SAE Change times/ Class Check

Gearbox Upper Angle drive gearbox 1.5 litres Lower Angle drive gearbox 1.2 litres Picker and chopper gearbox (CONSPEED FC with chopper) Picker and chopper gearbox (CONSPEED F/C without chopper) Chain clutch

Approx.

4.0 litres

Gearbox oil API-GL-5-90

SAE 90

(MIL-L-2105)

see Drive systems, page 8.2.

Approx.

2.2 litres Fitting paste “Anti-Seize“ Order no.: Can about 150g

0136 571.0

Lubrication points Grease nipples

High quality multipurpose grease DIN 51825 - K2K CLAAS multipurpose grease EP2 KP 2K-30 Order no.: 400g Cartridge

Other lubrication point

0147 451.0

bio-degradable lubrication oil CEC-L-33-A-93 > 80% CLAAS roller chain oil BIO HEES 46 Order no.: 5 ltr. PE-Kan.

8.21

see Lubrication chart.

see Lubrication chart.

0147 457.0

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Maintenance

Maintenance MALFUNCTIONS Malfunction Jammed reaper units

Cause or remedy 1. Check basic setting of picker clearance and correct, if necessary (at the end 5 mm wider than at the beginning).

2. Adjust (increase) picker clearance according to the knot formation of the maize stalks.

Insufficient performance

1. Speed too low due to loose drive belt. Tension drive belt on combine harvester as specified.

2. Replace worn chopper knives.

3. Replace worn or damaged reaper drums.

4. Adjust picker clearance correctly.

5. On combine harvester with variator, increase the drive speed.

Stubble too high

1. Speed too low.

2. Adjust gathering points so that maize picker can be closer to the ground.

3. Move into crop as planted.

Poor chopping of maize stalks

1. Replace worn knives.

2. Fit the shear bar.

Swinging sheet metal cover does not close fully

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

1. Check setting of hydraulic cylinders.

8.22

Lubrication chart

Lubrication chart

9 Lubrication chart SAFETY RULES DANGER! Lubricate the maize picker only with the drive switched off and the engine at a standstill.

– Remove the ignition key!

– Switch off the battery master switch!

LUBRICANTS Brand-name grease, e.g.

FINA

“Marson EPL 2”

ARAL

“Aralub HLP 2”

FUCHS “Rendit TEP 2” SHELL

“Retinax EP 2” or “Alvania G3”

DEA

“Glissando EP”

FAG

“Arcanol L 135 V”

SKF

“LGEP2”

Specifications: – see Lubricant table, page 8.21

LUBRICATION

Lubricate these grease points every 8 working hours.

Lubricate these grease points every 50 working hours.

Lubricate these grease points every 100 working hours.

Lubricate these grease points every 250 working hours.

9.1

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Lubrication chart

Lubrication chart

NOTE! Only when fitting to LEXION 470 / 430 Montana!

1

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

9.2

Lubrication chart

2

2

2

2

2

2

2

2

NOTE! Do not oil the finger chain on sandy ground!

2

9.3

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Lubrication chart

5 4 3

6 7

5 4 3

6 7

3

4

5

6

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

7

9.4

Lubrication chart

9 8

10

11 12

11 12

9 8

10

NOTE! fig. 8 valid from serial no.: 911 0 1393, 912 0 1185, 914 0 1085

8 NOTE! fig. 9 valid from serial no.: 907 0 1001, 908 0 1001, 911 0 1394, 912 0 1186, 914 0 1086, 919 0 1001 9 CONSPEED - 12 Row

LEXION

MEDION/MEGA

74178

10 74781

9.5

11

74782

12

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Lubrication chart

17 16 14

15

13

13

13

13 CONSPEED - 12 Row

17 16 14

13

13

15

13

13

13

14 LEXION

MEDION/MEGA

74178

15 74781

0298 345.5 - ABA/BA CONSPEED 12 / 8 / 6

16 74782

17

9.6

Lubrication chart

9.7

ABA/BA CONSPEED 12 / 8 / 6 - 0298 345.5

Following the policy of CLAAS KGaA mbH of continuous product improvement to keep abreast of technical development, we reserve the right to make modifications which must not necessarily correspond to the text and illustrations contained in this operator's manual, and this without assuming the obligation to modify any machines previously delivered.

Technical specifications, dimensions and weights are understood with the usual tolerances. Responsibility for errors and omissions not accepted.

Reproduction or translation, in whole or part, only with written authorization by CLAAS KGaA mbH. All rights under the provision of the Copyright act are reserved.

CLAAS KGaA mbH 33426 Harsewinkel Germany

911 0 1393, 912 0 1185, 914 0 1085 907 0 1001, 908 0 1001, 911 0 1394, 912 0 1186, 914 0 1086, 919 0 1001

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

0298 345.5 ABA/BA CONSPEED 12 / 8 / 6 EN - 07.05 Printed in Germany