CLAAS DIRECT DISC 520 Contour DISC 520 JAGUAR 900 890 870 850 830 Typ 493 492 Operator’s manual -

DIRECT DISC 520 Contour DIRECT DISC 520 JAGUAR 900, 890, 870, 850, 830 Typ 493 / 492

Operator’s manual

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EC Declaration of Conformity according to EC Directive 98/37/EC

CLAAS Saulgau GmbH

We

Zeppelinstrasse 2

D - 88348 Bad Saulgau

declare under their sole responsibility that the product

Cutter bar - Type 426 “DIRECT DISC 520 / 520 Contour“ to which this declaration refers corresponds to the pertinent basic safety and health requirements of EC Directive 98/37/EEC,1 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 745 - August 1999

Bad Saulgau, 18.02.2005 Product Development (H. Rauch)

Supply Chain Management (A. Fetscher)

Quality Management (J. Switalski)

Introduction

Introduction

1 Introduction INTRODUCTION This operator's manual provides information on the use, adjustment and operation of the CLAAS “DIRECT DISC” cutter unit.

Note that in the following chapters the CLAAS “DIRECT DISC” cutter unit is also referred to as the front attachment.

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

Also, have assembly of your front attachment 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 front attachment has been designed.

Your CLAAS Service Department

Validity This operator's manual applies to all cutter units: DIRECT DISC 520 / 520 Contour Type 426 From serial No. 426 0 1001.

1.1

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Contents

Contents

2 Contents 1. Introduction

7. Prior to operation

Introduction ............................................................................... 1.1 Validity ................................................................................ 1.1

DIRECT DISC 520 / 520 Contour ............................................. 5.1

Check and observe the following before putting into operation 7.1 Attaching front attachment ....................................................... 7.2 Open lock ........................................................................... 7.3 Attach front attachment ...................................................... 7.3 Close lock ........................................................................... 7.4 Connecting hydraulics ........................................................ 7.5 Positioning v-belts for mower drive .................................... 7.6 Connecting electrics ........................................................... 7.8 Mounting universal drive shaft ........................................... 7.9 Setting the paddle roller ................................................... 7.11 Hydraulic paddle roller adjustment (Additional equipment only DIRECT DISC 520 Contour) . 7.12 Adjusting cutter bar skids ................................................. 7.13 Setting cutter bar inclination ............................................. 7.13 Working and transport position ............................................... 7.14 Transport position ............................................................ 7.14 Working position ............................................................... 7.14 Removing and storing the front attachment ........................... 7.15

6. Assembly

8. Operation

Loading and unloading the front attachment ............................. 6.1 Attaching the front attachment for the first time ........................ 6.2 Front attachment ....................................................................... 6.3 Installing cutter bar skids .................................................... 6.3 Attaching and removing prop stands .................................. 6.4 Adjustments on forage harvester .............................................. 6.5 Additional weight ................................................................ 6.5 Required additional weights ............................................... 6.5 Order numbers – additional weights ................................... 6.6 Matching – forage harvester JAGUAR 900 - 830 Type 492 ............................................. 6.7 Scope of supply fitting kit forage harvester Type 492 (M04/0030) ......................................................................... 6.7 Fitting drive disc “DIRECT DISC” ....................................... 6.9 Raising potentiometer ......................................................... 6.9 Installing additional hydraulic connections ....................... 6.11 Fitting bracket for belt guard ............................................. 6.13 Mounting belt cover .......................................................... 6.14 Fit wiring harness for ESR Module ................................... 6.14 ESR Module ..................................................................... 6.16 Matching – forage harvester JAGUAR 900 - 830 Type 493 ........................................... 6.17 Scope of supply fitting kit forage harvester Type 493 (M04/0040) ....................................................................... 6.17 Fitting the belt guard ......................................................... 6.19 Fitting the guard ................................................................ 6.19 Fitting bracket for belt guard ............................................. 6.20 Installing additional hydraulic connections ....................... 6.20 Fitting belt pulley guard .................................................... 6.21 Fit wiring harness for drive monitoring .............................. 6.22 Removing the dog clutch .................................................. 6.23 Setting the lowering speed (JAGUAR 900 - 830) ........................................................ 6.25 Conversion valve for front attachments (Additional equipment chopper) ........................................ 6.26

Operation ..................................................................................

Raising and lowering the front attachment .........................

Operating front attachment ................................................

Instructions for mowing ......................................................

Difficult application conditions ............................................

Adjusting cutting height ......................................................

Lock/unlock the pendulum frame (DIRECT DISC 520 Contour) .............................................

Adjusting length of cut ........................................................

Additional equipment ................................................................

Hydraulic paddle roller adjustment (R03/0100, only DIRECT DISC 520 Contour) ....................

Feed hats (D03/0080) ........................................................

Additional damping (R05/0060) ..........................................

Laser pilot (R03/0090) ........................................................

3. Preface Of special importance ............................................................... 3.1 Type plate ................................................................................. 3.2 Road transport .......................................................................... 3.3 Protective equipment for road transport ............................. 3.3

4. Safety rules Designated use ......................................................................... 4.1 Identification of warnings and danger signs .............................. 4.1 General safety and accident prevention instructions ................ 4.1 Safety decals with pictorials ...................................................... 4.3 Safety support ........................................................................... 4.8

5. Specifications

0299 924.3 - BA DIRECT DISC 520 / 520 Contour

8.1 8.1 8.2 8.4 8.5 8.5 8.6 8.7 8.8 8.8 8.9 8.9 8.9

9. Maintenance Important maintenance instructions .........................................

Hydraulic system ................................................................

Bolts ...................................................................................

Lubrication ..........................................................................

Guards ...............................................................................

Drive systems ...........................................................................

Gearbox .............................................................................

Intake auger gearbox (A) ...................................................

Angle drive – drive intake auger (B) ...................................

Angle drive - mower drive (C) ............................................

Clutches (D, E) ...................................................................

Chains ......................................................................................

Lubricating the drive chain .................................................

Tensioning drive chain .......................................................

V-belts ......................................................................................

Checking V-belts ................................................................

Tensioning V-belts .............................................................

9.1 9.1 9.1 9.1 9.1 9.2 9.2 9.3 9.4 9.4 9.5 9.6 9.6 9.6 9.7 9.7 9.7

2.1

Contents V-belt guide (only JAGUAR 900 - 830 Type 492) ................................... 9.8 Spring adjustment ..................................................................... 9.9 Spring tension of intake auger ............................................ 9.9 Pendulum frame (only DIRECT DISC 520 Contour) ........... 9.9 Universal drive shafts .............................................................. 9.10 Servicing the universal drive shaft .................................... 9.10 General information on universal drive shafts .................. 9.10 Mower beam ........................................................................... 9.11 Oil level check ................................................................... 9.12 Oil change ......................................................................... 9.13 Draining oil ........................................................................ 9.13 Mower blades .......................................................................... 9.14 Replacing mower blades .................................................. 9.14 Attaching mower blades ................................................... 9.16 Cutting discs ........................................................................... 9.17 Replacing cutting discs ..................................................... 9.17 Electrical ................................................................................. 9.18 Sensor adjustment ............................................................ 9.18 Hydraulic system ..................................................................... 9.18 Hydraulic hose connections .............................................. 9.18 Guards .................................................................................... 9.19 Sheet metal cover ............................................................. 9.19 Side guards ....................................................................... 9.20 Top side guards ................................................................ 9.20 Lock ........................................................................................ 9.21 Adjusting lock .................................................................... 9.21 Adjusting locking pins ....................................................... 9.22 Screw connections .................................................................. 9.22 Connection elements .............................................................. 9.22 End of season storage ............................................................ 9.23 Malfunctions ............................................................................ 9.23

10. Lubrication Chart Safety rules ............................................................................. 10.1 Lubricants ............................................................................... 10.1 Lubrication .............................................................................. 10.1

2.2

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Preface

Preface

3 Preface OF SPECIAL IMPORTANCE Note that in the following chapters the CLAAS “DIRECT DISC” cutter unit is also referred to as the front attachment.

The instructions in this operator's manual must be read carefully and followed by all persons concerned with the operation, maintenance, repair or inspection of this front attachment in order to prevent accidents.

Some safety guards and covers have been removed for illustration in this manual. All safety shields and covers must be attached before the front attachment is put into operation.

In particular, read the sections “Safety rules” and “Prior to operation” in the operater's manual CLAAS JAGUAR 900, 890, 870, 850, 830.

The use of spare parts, accessories and additional equipment which is not originally manufactured, and checked and released by CLAAS can have negative effects on specific design features of the CLAAS machine or on its operability, and 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 parts, accessories and additional equipment that are not original CLAAS. Technical specifications, dimensions and weights are understood with appropriate tolerances.

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

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

3.1

Preface TYPE PLATE The machine number (Fz-Ident-Nr) (2), the model and the serial number are required with all orders for spare parts and technical inquiries. 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 affixed on the back panel on the right side.

(Fig. 1, 2) 1 1 1

426

xxx

xxx

xxxx

42601001 2

2

3.2

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Preface

Preface ROAD TRANSPORT DANGER! The front attachment must not be transported on public roads when attached. The front attachment must be removed for transport on public roads and carried on a vehicle of suitable size.

– Remove front attachment and load it on the vehicle and secure it.

3

– Attach guard to feeder housing.

Before leaving the forage harvester: – Lower front attachment completely!

– Switch off engine!

– Remove the ignition key!

– Switch off the battery master switch!

ATTENTION! Do not exceed approved axle load of towing vehicle!

The trailer is not approved for towing with the following forage harvesters.

JAGUAR Type 492 up to serial no. 492 0 5405 – with standard steering axle and • 16.9-24 tires • 700/50-26.5 tires – with driven steering axle and • 16.9-24 tires An additional towing vehicle is required for transport.

Protective equipment for road transport The following requirements must be fulfilled for road transport: 1. Front attachment removed and loaded and secured on a suitable vehicle– see Transport position, page 7.14.

2. Safety guard attached to feeder housing and secured – see forage harvester operator's manual.

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

3.3

Safety rules

Safety rules

4 Safety rules

ATTENTION!

Before putting the machine into operation, read the operator's manual and follow the safety precautions.

Sign to indicate instructions which must be observed. Failure to do so could result in damage to the front attachment.

DESIGNATED USE

– Measures to prevent danger to the front attachment.

The front attachment is designed for the usual applications in agriculture only (designated use).

The cutter bar is designed for cutting standing or slightly inclined crops close to the ground to a stalk height of 1.50 m. Its application is restricted to land with a smooth surface and no scattered stones that could damage the machine.

Any use other than this is considered to be designated use; the manufacturer accepts no responsibility for any resulting damage; the risk of this is entirely that of the operator.

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

The front attachment may be used, serviced and repaired only by persons who are familiar with the machine and who 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 front attachment without proper authority exclude the manufacturer's liability for damage resulting from any such modifications.

IDENTIFICATION OF WARNINGS 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 the instructions which must be observed. Failure to do so could cause danger to the life and limb of the operator and to the people around him.

– Preventive measures.

NOTE! Sign to indicate instructions for a more effective 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 placed on the front attachment provide important recommendations for safe operation. These instructions involve your safety – observe them at all times!

GENERAL SAFETY AND ACCIDENT PREVENTION INSTRUCTIONS Always check the front attachment and the carrier vehicle for traffic and operating safety before operation!

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

2. The fitted warning and advice signs provide important information for danger-free operation; These instructions involve your safety – observe them at all times!

3. Follow the regulations in force when using public roads!

4. On public roads the front attachment must always be loaded and secured on a suitable transport vehicle.

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

6. Before starting, check the front attachment for any loose parts on the machine.

4.1

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Safety rules 7. Always stop the engine, remove the ignition key and switch off the battery master switch before working in or on the front attachment. All control levers must be in their neutral position and the hydraulic lines must not be under pressure.

22. The guards on the cutter bar, such as canvas and sheet metal covers, are protection against flying stones and similar objects and also block access to danger zones. For this reason they must be placed in safety position before starting work!

8. Perform work under the raised front attachment only after having supported it safely.

23. Intake augers, cutting 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.

9. Wear close-fitting clothing when working on the front attachment. Do not wear loose clothing!

10. Keep the machine clean to prevent fire!

11. Before starting and before putting it into operation, check the area around the machine (children!).

Ensure that you have sufficient vision!

12. Passengers must not be carried on the machine while working or during transport!

13. Safe operation of the cutter bar can only be guaranteed with correctly installed mower blades.

14. There is an increased risk of injury when installing and removing the mower blades - wear gloves!

15. Check cutter bar for damaged, missing and worn mower blades before every use and replace mower blades if required – see Replacing mower blades, page 9.14!

16. Replace missing and damaged mower blades in sets only as specified by the manufacturer to prevent danger resulting from imbalance – see Replacing mower blades, page 9.14!

17. Check fasteners on every mower blade as specified by the manufacturer and replace if necessary!

24. Before putting into operation and while working, the glide discs must be in contact with the ground!

25. Stones and similar objects may be thrown up during correct operation of the cutter bar. Therefore, no-one should be in the danger zone. Special care is required when working near roads and buildings!

26. The cutter bar tools may run on after switching off the drive. Do not approach them until they have stopped.

27. After running into an obstacle, switch off the cutter bar immediately and check it for damage!

28. Never start drive shafts turning without appropriate protection.

29. Secure universal drive shaft gear against rotating by hanging in the chains.

30. Always switch off the drive and the engine before troubleshooting, and before repair, maintenance and cleaning work.

– Remove the ignition key!

– Switch off battery master switch.

18. It is very important to check the wear of the mower blade retaining bolts caused by the mower blade at the internal radius. After the wear limit has been reached – see Attaching mower blades, page 9.16 the mower blade retainer must be replaced by a new blade with an unused mower blade retaining bolt.

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

19. The riveted joints of the mower blade bolt in the mower blade retainer and the wear of the mower blade retainer at the outer edge must also be checked. If necessary, all mower blade retainers of the cutting discs must be replaced with new mower blade retainers.

34. Make sure no-one is between the carrier vehicle and the front attachment unless the vehicle is secured to prevent it from rolling away with the parking brake and/or wheel chocks!

32. Reinstall protective devices after maintenance work!

33. Mounting the front attachment onto the carrier vehicle involves danger of injury!

Observe all other safety instructions in the operator's manual for the carrier vehicle.

20. Some safety guards and covers have been removed for illustration in this manual. All safety shields and covers must be attached before the front attachment is put into operation.

21. The safety guards must be checked regularly and worn or damaged safety guards must be replaced!

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

4.2

Safety rules

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

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

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

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

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

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

1

2

1

2 Pictorial 514 946.1 (1) Before putting the machine into operation, read the operator's manual and follow the safety precautions.

(Fig. 1, 2)

4.3

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Safety rules

1

2

3

4 Pictorial 514 895.1 (2) Before carrying out maintenance and repair work switch off engine and remove ignition key.

(Fig. 3, 4)

3

5

6 Pictorial 516 029.0 (3) Do not enter the danger area unless the cutter bar cylinder safety lock is in position.

(Fig. 5, 6)

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

4.4

Safety rules

6

7

4

7

8 9 7

Pictorial 514 042.0 (4)

6

Never enter the danger area between front attachment and machine.

4

(Fig. 7, 8, 9) 8

DIRECT DISC 520

5

7

6

10 DIRECT DISC 520

12 Pictorial 514 876.1 (5) 6

7

Keep clear of danger posed by flying parts when the engine is running.

5

(Fig. 10, 11, 12)

11

4.5

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Safety rules

6

7

4

13

8 17 Pictorial 514 877.1 (6) 7

6

Maintain distance from the knife when the drive is switched on and the engine is running.

(Fig. 13, 14, 15, 16, 17)

4 14 DIRECT DISC 520

5

7

6

15

STOP

DIRECT DISC 520

18 Pictorial 514 878.0 (7) Do not touch machine components before they have stopped completely.

6

7

5

(Fig. 13, 14, 15, 16, 18)

16

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

4.6

Safety rules

8

19

20 Pictorial 516 039.0 (8) Never open or remove guards when the engine is running.

(Fig. 19, 20)

4.7

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Safety rules

Safety rules SAFETY SUPPORT 2 DANGER! There is a danger of injury when working on or under the elevated front attachment.

– Never work under the raised front attachment without safe support.

1

– Provide secure support/propping for the front attachment.

– Use suitable supporting elements.

1

– Extend support prop.

• Raise front attachment to the highest position.

• Pull out locking pin (2) and lower support prop (1) to come into contact with the ground.

• Secure the support prop (1) in the next possible drilled hole.

(Fig. 1)

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

4.8

Specifications

Specifications

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

DIRECT DISC 520 / 520 Contour Width:

mm

5175

Length:

mm

2440

Height:

mm

1440

Weight

kg

2700

5.1

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Assembly

Assembly

6 Assembly LOADING AND UNLOADING THE FRONT ATTACHMENT

up to serial no. 426 0 1110

1 DANGER! Incorrect loading and transport of the front attachment involves risk of accidents!

1 2

– Suspend the front attachment for loading only from the lifting points (1) on the left, right and in the centre!

1

up to serial no. 426 0 1111

– Make sure the slings are sufficiently dimensioned!

Weight of the front attachment – see Specifications, page 5.1.

NOTE! Up to serial no. 426 0 1110, the front attachment is only fitted with three lifting points. The centre lifting point is under the sheet metal cover (2).

Remove sheet metal cover (2) for loading.

1

1 The lifting points are marked with the symbol (3).

2

(Fig. 1, 2, 3)

3

3

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

6.1

Assembly ATTACHING THE FRONT ATTACHMENT FOR THE FIRST TIME 1. Check the scope of delivery against the delivery note.

2. Match to the forage harvester – see Adjustments on forage harvester, from page 6.5.

Note the different fitting sets for the forage harvesters JAGUAR 900 - 830 Type 492 and Type 493.

3. Open lock – see Open lock, page 7.3.

4. Attach front attachment – see Attach front attachment, page 7.3.

5. Close lock – see Close lock, page 7.4.

6. Lift front attachment from the transport frame with the forage harvester hydraulics.

7. Attach cutter bar skids – see Installing cutter bar skids, page 6.3.

8. If required, insert the prop stands– see Attaching and removing prop stands, page 6.4.

If the front attachment is to be removed from the chopper again after removing from the transport frame, then the support feet must be fitted.

Otherwise there could be problems when refitting the front attachment.

9. Lower front attachment.

10. Connect the hydraulic lines – see Connecting hydraulics, page 7.5.

11. Mount V-belt for cutting disk drive – see Positioning v-belts for mower drive, page 7.6.

12. Connect power supply – see Connecting electrics, page 7.8.

13. Mount universal drive shaft – see Mounting universal drive shaft, page 7.9.

JAGUAR 900 - 830 Type 493 For fitting the front attachment, the dog clutch must be removed – see Removing the dog clutch, page 6.23.

6.2

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Assembly FRONT ATTACHMENT Installing cutter bar skids DANGER! Never work under or on the raised front attachment without safe support.

1

– Lower the safety lock down to the ground and lock in position – see Safety support, page 4.8.

3

2 4

ATTENTION! Adjust cutter bar skids to the same height on each side – if a cutter bar skid is set higher it will be subject to increased wear!

Proceed as follows to attach the cutter bar skids (2):

3

• • • •

1 2 3 5

Raise front attachment completely.

Switch off the engine and remove the ignition key.

Switch off the battery master switch!

Lower the safety lock down to the ground and lock in position – see Safety support, page 4.8.

• Loosen bolts (3).

• Turn straps (1) down.

• Set the minimum cutting height – see Adjusting cutter bar skids, page 7.13.

• Replace bolts (3).

• Tighten all bolts.

(Fig. 4, 5)

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

6.3

Assembly Attaching and removing prop stands 4 DANGER! Never work under or on the raised front attachment without safe support.

– Lower the safety lock down to the ground and lock in position – see Safety support, page 4.8.

6

5

ATTENTION! Under difficult conditions (e.g. max. cutting height) the front attachment can only be refitted with great difficulty.

6

– Attach the prop stands to the cutter bar before unhitching or removing them.

7

Proceed as follows to attach the prop stands:

4 7

• • • •

Raise front attachment completely.

Switch off the engine and remove the ignition key.

Switch off the battery master switch!

Lower the safety lock down to the ground and lock in position – see Safety support, page 4.8.

• Remove prop stands (4) from the bracket by pulling prop stands backwards and removing them upwards.

9

NOTE!

8

The prop stands (4) are held in place only with the aid of two magnets (5).

4 8

• Prop stands (4) left and right to be inserted outside on the mower head, by inserting the nose (7) in the recess (8) on the mower head.

Push the prop stand upwards whilst inserting the side straps (6) into the recesses (9).

• Make sure that the magnets hold firmly; clean contact surfaces it necessary.

Remove prop stands and attach them to the brackets before every use.

(Fig. 6, 7, 8)

6.4

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Assembly ADJUSTMENTS ON FORAGE HARVESTER The front attachment is for operation on the forage harvester JAGUAR 900 - 830 Type 492 and Type 493.

When operating the front attachment, it is to be recommended that the forage harvester be fitted with the “additional damping” for medium duty front attachments (DIRECT DISC). This ensures that the Contour-System works properly and that the front attachment presses down on the ground with the preset pressure.

Order No.: Additional damping

(R05/0060) 0495 510.0

Before attaching the front attachment, make the following adjustments to the forage harvester.

Additional weight Additional weight must be attached to the forage harvester for operation with the front attachment. This is necessary so that the machine does not lift at the rear during braking and when driving on slopes.

The load on the steering axle wheels should be 20% of the machine weight with the front attachment fitted.

Attaching the additional weights – see operator's manual for forage harvester.

Required additional weights Forage harvester JAGUAR 900 - 830 Type 492:

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Number

JAGUAR Model 492 with 540/65-R24 tyres and standard steering axle:

7

JAGUAR Model 492 with 540/65-R24 tyres and rear wheel drive (RWD):

5

JAGUAR Model 492 with 700/50-26.5 tyres and rear wheel drive (RWD):

3

JAGUAR Model 492 with 16.9-24 tyres and standard steering axle:

8

JAGUAR Model 492 with 16.9-24 tyres and rear wheel drive (RWD):

6

6.5

Assembly Forage harvester JAGUAR 900 - 830 Type 493:

Number

JAGUAR Model 493 with 540/65-R24 tyres and standard steering axle:

7

JAGUAR Model 493 with 540/65-R24 tyres and rear wheel drive (RWD):

5

JAGUAR Type 493 with 700/50-26.5 tyres and standard steering axle:

5

JAGUAR Model 493 with 700/50-26.5 tyres and rear wheel drive (RWD):

3

JAGUAR Model 493 with 16.5/85-24 tyres and standard steering axle:

8

JAGUAR Model 493 with 16.5/85-24 tyres and rear wheel drive (RWD):

6

NOTE! The required ballasting on the rear axle can also be achieved by other means, e.g. by filling the tyres with water.

Order numbers – additional weights Quantity Designation Weight

6.6

Order No.

3 additional weights 336 kg

(S09 0025) 0709 708.0

5 additional weights 558 kg

(S09 0040) 0709 718.0

6 additional weights 670 kg

(S09 0045) 0709 709.0

7 additional weights 780 kg

(S09 0050) 0709 721.0

8 additional weights 892 kg

(S09 0060) 0709 719.0

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Assembly Matching – forage harvester JAGUAR 900 - 830 Type 492

JAGUAR 900 - 830 Type 492

Scope of supply fitting kit forage harvester Type 492 (M04/0030) Fitting set complete

0495 730.0

1 Drive pulley: 1 0987 861.1 drive pulley (1x) 2 0905 110.0 cover (1x) 9

(Fig. 9, 10)

JAGUAR 900 - 830 Type 492

2

10 Belt cover:

JAGUAR 900 - 830 Type 492

3

4 5

6 7

14 13

8

12

9 72783_01

11

10 11

3 4 5 6 7 8 9 10 11 12 13 14

0214 062.0 serrated lock bolt M8 (3x) 0905 356.0 guard (1x) 0233 503.0 truss-head screw M8x25 (3x) 0237 874.0 6 hex bolt M10x35 (1x) 0905 354.0 retainer (1x) 0239 388.0 contact washer A10 (1x) 0239 171.0 6 hex nut M10 (1x) 0905 355.0 retainer (1x) 0239 170.0 6 hex nut M8 (3x) 0239 387.0 contact washer A8 (3x) 0236 173.0 6 hex nut M16 (2x) 0215 898.0 6 hex bolt M16x160 (1x)

(Fig. 11)

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

6.7

Assembly Potentiometer conversion for preselection of cutting height:

JAGUAR 900 - 830 Type 492

15 16 17 18 27

19 20

29 28

21

25 26

25

22

24

23

72782_02

12

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

0236 475.0 truss-head screw M16x16x10 (4x) 0905 042.0 strap (1x) 0239 386.0 contact washer A10 (4x) 0236 169.0 6 hex nut (4x) 0905 043.0 strap (1x) 0609 353.0 Split pin plug (2x) 0235 109.0 Split pin 2x12 (2x) 0234 222.0 Washer 6.2x15 (2x) 0905 045.0 connecting rod (1x) 0237 216.0 6 hex nut M5 (2x) 0236 910.2 washer ø5.3 (4x) 0986 246.0 spacer bushing (2x) 0242 047.0 cheese-head screw M5x30 (2x) 0238 500.0 plug D9,4 (1x) 0495 505.0 guard (1x)

(Fig. 12)

Auxiliary hydraulic connectors:

JAGUAR 900 - 830 Type 492

30

31 32 33

30 31 32 33 34 35 36 37 38 39 40

34

39

37

40

38

36

39 35

72784_01

13

41 42 43 44 45 46 47 48 49 50 51

43

41

44 45 46 51

73754

6.8

(Fig. 13)

Wiring harness - ESR Module:

JAGUAR 900 - 830 Type 492

42

0237 461.0 6 hex bolt M12x30 (1x) 0697 909.0 washer blue (1x) 0239 390.0 contact washer A12 (1x) 0236 172.0 6 hex nut M12 (1x) 0986 329.0 hose (2x) 0239 280.0 L union (2x) 0238 788.0 W union (1x) 0905 144.0 retainer (1x) 0697 908.0 washer red (1x) 0697 905.0 screw plug (2x) 0697 902.0 screw socket (2x)

50

47 48 49

14

0014 296.0 wiring harness (1x) 0236 170.0 6 hex nut M8 (1x) 0239 387.0 contact washer A8 (1x) 0215 403.0 pipe clamp (1x) 0236 200.0 6 hex bolt M8x20 (1x) 0237 216.0 6 hex nut M5 (3x) 0236 490.1 lock washer ø5 (3x) 0236 910.2 washer ø5.3 (3x) 0242 047.0 cheese-head screw M5x30 (3x) 0744 607.0 fastener strap (1x) 0755 646.0 self-locking strap (5x)

(Fig. 14)

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Assembly Fitting drive disc “DIRECT DISC”

JAGUAR 900 - 830 Type 492

DANGER! Never work under the raised front attachment without safe support.

– Raise the forage harvester with an appropriately sized jack.

1

– Support the forage harvester with suitable stands!

15

The new 8-groove drive pulley (1) is installed on the right side of the chopper to drive the cutting disks of the “DIRECT DISC”.

(Fig. 15)

Proceed as follows for installation:

JAGUAR 900 - 830 Type 492

• Remove the wheel on the right side of the forage

A

harvester.

B C

16

• • • • • • •

Remove the connecting rod (A).

Mark the position of the lever (B) and remove it.

Loosen screw (C) and remove it.

Disassemble tension ring and remove drive pulley.

Install new drive pulley with V-belt in place.

Lightly grease tension ring before installation.

Tighten bolt (C) with a torque wrench.

Torque: 300 Nm (Fig. 16)

Raising potentiometer

JAGUAR 900 - 830 Type 492

When the new drive pulley is installed, the potentiometer for preselection of the contour system cut height must be raised, as follows:

h

• Pull the plug-in connection (D) from the potentiometer (F).

• Remove the potentiometer (F) on the holder (h).

D F

17

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

6.9

Assembly • • • • •

JAGUAR 900 - 830 Type 492

F 16

29

Mount the potentiometer (F) on the strap (16).

Fix new strap (19) on potentiometer.

Fix the strap (16) on the guard (29).

Fit the plug (28).

Suspend new connecting rod (23) in bottom hole of strap (19) and secure it.

19

28 23 73756

18

• Position drilled hole (G) on lever (B) at

JAGUAR 900 - 830 Type 492

distance (x) (Fig. 19) and drill a 6.5 mm hole.

Distance (x) = 60 mm

x

G

B 72235

19

• Mount the pre-assembled unit (potentiometer,

JAGUAR 900 - 830 Type 492

strap (16) and guard (29) with the spacing bushes (26) and longer bolts on the holder (h). In doing this, lay the connection cable between the two fixings (arrows).

16

h 29

26 20

• Connect plug-in connection (D) again.

JAGUAR 900 - 830 Type 492

D 19

21

6.10

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Assembly • Install lever (B) at top front (Fig. 22).

• Turn the strap (19) (Fig. 22) upwards.

• Fix connecting rod (23) in the drilled hole (G) in

JAGUAR 900 - 830 Type 492

23 B

the lever (B) and secure.

G

(Fig. 17-22)

22 Installing additional hydraulic connections

JAGUAR 900 - 830 Type 492

The additional hydraulic connections are used for connecting the cutter bar drive.

DANGER! J

I

Always depressurise the hydraulic system before working on it!

K ENVIRONMENT! 23

Catch leaking hydraulic oil and dispose of it correctly!

JAGUAR 900 - 830 Type 492

At the top and bottom connection of the hydraulic cylinder (J): a

36

b

34

• • • •

35

a

J b

Loosen existing hose (I or K).

Mount L-unions (36) on hydraulic cylinder (J).

Mount L-unions (35) on top connection.

Connect hose (I and K) to straight outlet (a) of the L-union (35).

• Connect new hoses (34) to the second outlet (b) 71791_01

24

JAGUAR 900 - 830 Type 492

of the L-union (35).

• Fasten retainer (37) to frame with M12x30 hex bolt, A12 contact washer and M12 nut.

31

37

38

40 39

NOTE! If a hydraulic connection is already installed in the top drilled hole:

40 39

Disassemble hydraulic connection and fasten retainer with the help of the existing hydraulic connection.

25

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

• Install screw sockets (40) with blue (31) or red (38) washer and dust plug (39) on retainer (37).

6.11

Assembly

ATTENTION! Beware of friction and jamming!

NOTE! Observe label, because otherwise the mower drive will not work!

Red connection = top hydraulic connection Blue connection = bottom hydraulic connection

• Lay out hose (34) from top hydraulic cylinder connection to screw socket (40) with the red washer (38) to the top and connect it.

• Lay out hose (34) from bottom hydraulic cylinder connection to screw socket (40) with the blue washer (31) to the top and connect it.

• Fasten hose with self-locking straps.

(Fig. 23, 24, 25)

• Install guard (2).

JAGUAR 900 - 830 Type 492

(Fig. 26)

2

26

6.12

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Assembly Fitting bracket for belt guard

JAGUAR 900 - 830 Type 492

7

• Remove screws (K) on feeder housing.

• Hand tighten retainer (7) on feeder housing with

K

screws (K).

• Mark hole (T).

T

ATTENTION! When drilling the holes, be careful not to damage any lines underneath!

– If necessary loosen lines and move to one side.

27

• Remove retainer (7) and drill 11 mm hole (T).

(Fig. 27)

• Fasten retainer (7) to feeder housing with

JAGUAR 900 - 830 Type 492

screws (K) and bolt (6), contact washer (8) and hex nut (9).

7 K

• Fasten retainer (10) to retainer (7) with bolts (5), contact washer (12) and hex nuts (11).

10

(Fig. 28) 6 5

8

12

9

11 28 Fit the guide for V-belt by:

JAGUAR 900 - 830 Type 492

• fitting hex bolt (14) with hex nut (13) to the holder (10).

• Adjust the V-belt – see V-belt guide (only JAGUAR 900 - 830 Type 492), page 9.8.

(Fig. 29)

10

14 13 29

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

6.13

Assembly Mounting belt cover

JAGUAR 900 - 830 Type 492

• Mount guard (4) with retaining screws (3).

4

(Fig. 30)

3

30 Fit wiring harness for ESR Module

• Open right control panel in the cab – see forage

JAGUAR 900 - 830 Type 492

harvester operator's manual.

• • • •

Lift central terminal compartment.

Remove front cover.

Remove retainer (M) on floor on cab.

Remove socket from wiring harness.

(Fig. 31) M 31

• Lay out wiring harness (41) from top to the right

JAGUAR 900 - 830 Type 492

wing.

43 44

ATTENTION!

45

Beware of friction and jamming!

• Attach cable gland to cab floor.

• Fasten wiring harness (41) to cab floor with pipe

M

clamp (44), hex bolt (45) and contact washer (43).

41 32

6.14

• Mount retainer (M) on cab floor again.

(Fig. 32)

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Assembly • Insert cable gland (O) into wing.

• Connect socket (N) to wiring harness (41) again.

JAGUAR 900 - 830 Type 492

O N

41

Clamp

Wire colour

31

brown

53

white/red

54

black/red

33

• Fasten socket and wiring harness (41) to fender

JAGUAR 900 - 830 Type 492

with retaining strap (50), cheese-head screw (49), washer (48), lock washer (47) and nut (46).

41

• Fasten wiring harness with self-locking strap.

(Fig. 33, 34) 50 49 O

48 47 46 34

• Connect wiring harness to central electric system

JAGUAR 900 - 830 Type 492

as follows: • At socket (H1) remove plug (xH1-1) (green).

xH1-1

• Insert plug (xH1) (green) into the free socket (H1) in the wiring harness.

• Insert plug (xH1-1) in the branch (P) (green) of the wiring harness.

H1

• Pull out plug (xC1-1) (blue) at the socket (C1) (blue).

xH1 P 35

• Insert plug (xC1) (blue) into the free socket (C1) in the wiring harness.

• Insert plug (xC1-1) (blue) in the branch (Q) (blue) of the wiring harness.

JAGUAR 900 - 830 Type 492

• Connect central electrics again.

C1

(Fig. 35, 36)

xC1

Q xC1-1 36

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

6.15

Assembly ESR Module

JAGUAR 900 - 830 Type 492

NOTE! P The ESR module monitors the drive train for the cutting discs of the cutter bar “DIRECT DISC”.

As soon as the cutting discs stop, the ESR module switches off the forage harvester feeder drive within 0.5 sec.

R

CAUTION!

37

For operating the front attachment, the ESR Module Index 3 or higher is required. From forage harvester machine No. 492 0 2210, the ESR module Index 3 is fitted as standard. If a lower Index, e.g. 0014 213.2 is fitted, then the ESR Module needs to be changed. The new ESR Module can be obtained from the CLAAS Spare Parts Service.

Order No.:

ESR module 0014 213.3

Check the part number of the ESR Module which is fitted and if required, replace the ESR Module. Changing the ESR Module:

• • • •

Remove retainer (R).

Replace ESR module (P).

Install retainer (R) again.

Close right control panel.

(Fig. 37)

6.16

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Assembly Matching – forage harvester JAGUAR 900 - 830 Type 493

JAGUAR 900 - 830 Type 493

1

2

Scope of supply fitting kit forage harvester Type 493 (M04/0040)

3

Fitting set complete 5

0495 732.0

Drive pulley:

5

4 38

74862

1 2 3 4 5

0211 581.1 hex head bolt M12x240 (6x) 0998 453.0 belt pulley (1x) 0905 428.0 adapter (1x) 0238 234.0 locknut M12 (6x) 0239 389.0 contact washer A12 (12x)

(Fig. 38)

Belt cover:

JAGUAR 900 - 830 Type 493

9

6 7 8 9 10 11 12 13 14

8 10 7 11

6

15 16

12 13 14 39

74863

0214 062.0 locking screw M8x20 (3x) 0905 356.1 guard (1x) 0236 514.0 truss-head screw M10x30 (3x) 0495 559.0 retainer (1x) 0236 503.0 truss-head screw M8x25 (2x) 0906 883.1 retainer (1x) 0239 388.0 contact washer A10 (3x) 0237 947.0 locknut M10 (3x) 0905 355.1 retainer (1x) 0215 913.0 rivetting nut M8 (2x) pre-assembled 15 0239 387.0 contact washer A8 (2x) 16 0239 170.0 hex nut M8 (2x) (Fig. 39)

Auxiliary hydraulic connectors:

JAGUAR 900 - 830 Type 493

17 18 19 20 21 22 23 24 25 26

17 18 23

22

19

26 25

18 21

24

20

22 74864

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

0994 121.1 hose (2x) 0239 479.0 reducer L10/8 (2x) 0238 890.0 L union (1x) 0239 039.0 T union (1x) 0697 902.0 screw socket (2x) 0697 905.0 screw plug (2x) 0697 909.0 washer blue (1x) 0697 908.0 washer red (1x) 0239 390.0 contact washer A12 (2x) 0244 442.0 hex nut M14x1,5 (2x)

(Fig. 40) 40

6.17

Assembly Protection:

JAGUAR 900 - 830 Type 493

27 28 29 30 31 32 33 34 35 36 37

27 28 29 30

31

36

37

35

32

34 33

74865

41

0236 475.0 truss-head screw M16x16x10 (4x) 0495 505.0 guard (1x) 0239 386.0 contact washer A10 (8x) 0236 169.0 hex nut M16 (4x) 0905 042.1 retainer (1x) 0237 216.0 hex nut M5 (3x) 0236 490.1 spring ring 5 (3x) 0986 246.0 spacer bushing (2x) 0236 910.2 washer ø5.3 (3x) 0242 047.0 cheese-head screw M5x30 (3x) 0238 500.0 cap plug D9,4 (1x)

(Fig. 41)

Wiring harness – drive monitor:

JAGUAR 900 - 830 Type 493

38 0495 558.0 wiring harness (1x) 39 0218 356.0 cable tie 4.7x140 (2x) (Fig. 42)

39 38

42

74866

Universal drive shaft guard, pre-assembled, consisting of:

JAGUAR 900 - 830 Type 493

40

42 51 52 50

41

43 47

44

49 48

45 46

74867

43

40 41 42 43 44 45 46 47 48 49 50 51 52

0495 530.0 support (1x) 0631 056.0 tension spring (1x) 0967 149.0 hinge (2x) 0237 465.0 hex bolt M6x16 (4x) 0235 088.0 split pin (1x) 0495 544.0 guard (1x) 0633 109.0 ball knob (1x) 0236 200.0 hex bolt M8x20 (4x) 0239 386.0 contact washer A10 (8x) 0236 169.0 hex nut M6 (4x) 0237 439.0 hex head bolt M8x16 (1x) 0239 170.0 hex nut M8 (4x) 0239 387.0 contact washer A8 (4x)

(Fig. 43)

6.18

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Assembly Fitting the belt guard

JAGUAR 900 - 830 Type 493

DANGER! Never work under the raised front attachment without safe support.

A

– Support the forage harvester with suitable stands!

3

2

44

The fitting of the 4 groove belt pulley (2) on the right hand side of the forage harvester serves to drive the mower discs of the “DIRECT DISC”.

• Mount the belt pulley (2) and adapter (3) to the

JAGUAR 900 - 830 Type 493

belt pulley (A) of the forage harvester.

1

2

(Fig. 44, 45) 3

5

5

4 45

74862

Fitting the guard

JAGUAR 900 - 830 Type 493

• Fix the strap (31) on the guard (28).

• Fit the plug (37).

• Mount the pre-assembled guard (31) and

27 28 29 30

guard (28) with spacer bush (34) and screws (36) onto the bracket (h).

(Fig. 46, 47)

37

31

36 35

32

34 33

74865

46

JAGUAR 900 - 830 Type 493

31

h

28

34 47

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

6.19

Assembly Fitting bracket for belt guard

JAGUAR 900 - 830 Type 493

• Fix the bracket (9, 13) to the infeed chute with

9 8

screws (8), contact washers (12) and hex nuts (13).

10

• Fasten retainer (14) to retainer (13) with

11

bolts (10), contact washer (15) and hex nuts (16).

(Fig. 48, 49)

12

15

13

16

14 48

74870 JAGUAR 900 - 830 Type 493

14 11

9 49 Installing additional hydraulic connections

JAGUAR 900 - 830 Type 493

The additional hydraulic connections are used for connecting the cutter bar drive.

I

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

J

K

ENVIRONMENT! 50

Catch leaking hydraulic oil and dispose of it correctly!

JAGUAR 900 - 830 Type 493

17 19

At the top and bottom connection of the hydraulic cylinder (J):

18

17

J

• Loosen existing hose (I or K).

• Mount the L union (19) and reducer (18) to the upper connection.

I

• Mount the T union (20) and reducer (18) to the

18

lower connection.

20 K 74873

6.20

51

• Fit hose (I or K) in accordance with fig. 51.

• Connect the new hoses (17) each to the reducers (18).

(Fig. 50, 51)

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Assembly • Install screw sockets (21) with blue (23) or

JAGUAR 900 - 830 Type 493

red (24) washer and dust plug (22) on retainer (9).

17o ATTENTION! 23

Beware of friction and jamming!

22

17u

NOTE!

21

24

Observe label, because otherwise the mower drive will not work!

22 52

74864

Red connection = top hydraulic connection

JAGUAR 900 - 830 Type 493

Blue connection = bottom hydraulic connection 17u

23

• Lay out hose (17o) from top hydraulic cylinder

17o

connection to screw socket (21) with the red washer (24) to the top and connect it.

• Lay out hose (17u) from bottom hydraulic cylinder 9

connection to screw socket (21) with the blue washer (23) to the top and connect it.

24

• Fasten hose with self-locking straps.

(Fig. 52, 53) 53 Fitting belt pulley guard

JAGUAR 900 - 830 Type 493

• Cut out the section (B) at the perforations (C) from

C

the existing guard (D).

• Deburr the cut edge.

B

(Fig. 54) D

54

• Install guard (D).

JAGUAR 900 - 830 Type 493

(Fig. 55)

D

55

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

6.21

Assembly • Mount guard (7) with retaining screws (6).

JAGUAR 900 - 830 Type 493

(Fig. 56)

6

7

56 Fit wiring harness for drive monitoring

JAGUAR 900 - 830 Type 493

• Open the guard on DIRECT DISC – see Sheet metal cover, page 9.19.

ATTENTION! E Beware of friction and jamming!

• Replace the existing wiring harness (E) with the new wiring harness (38).

• Secure the wiring harness (38) with cable 57 JAGUAR 900 - 830 Type 493

ties (39).

(Fig. 57, 58)

39 38

74866

6.22

58

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Assembly Removing the dog clutch In order to fit the front attachment, the dog clutch (F) on the JAGUAR 900 - 830 Type 493 must be removed.

JAGUAR 900 - 830 Type 493

G NOTE! Retain the parts removed for later use.

F

• Remove the hex head bolts (G) (4x M10x20) from

G

the guard.

• Remove guard.

G

(Fig. 59) 59

• Remove cover (H) from the back of the gearbox.

• Unscrew the locking screw (L) (M12x45) of the

JAGUAR 900 - 830 Type 493

dog clutch.

(Fig. 60) H L

60

• Remove dog clutch (F).

JAGUAR 900 - 830 Type 493

(Fig. 61)

2.

1.

F 61

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

6.23

Assembly • Unscrew bolts (N) (M12x45).

• Remove guide (M).

JAGUAR 900 - 830 Type 493

(Fig. 62)

M

N

62

• Fit the pre-assembled universal drive shaft

JAGUAR 900 - 830 Type 493

guard (O) (individual parts see fig. 43) with screws (N) (M12x45) and hex head bolts (G) (2x M10x20).

O

(Fig. 63)

N

G

63

6.24

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Assembly Setting the lowering speed

Jaguar 900, 890, 870, 850, 830

(JAGUAR 900 - 830) ATTENTION! E

Conversion of the lowering speed “heavy front attachment” must be done before the front attachment is fitted, otherwise the shifting linkage may become damaged.

S

If the front attachment has already been fitted:

L

67443

64

Jaguar 900, 890, 870, 850, 830

– Lower the front attachment to the ground and depressurise the hydraulic cylinder.

The drop rate of the front attachment can be changed by adjustment of the knurled screw (V) on the flow divider.

First the switching linkage (E) of the conversion valve for front attachments must be changed to position (S).

Note: Lift the star wheel to change – do not rotate.

V

Position (S) = heavy front attachment

65

With the hydraulic oil at operating temperature set the knurled screws so the front attachment lowers to the ground in 5 to 6 seconds from a fully raised position.

Drop rate: Faster = screw knurled screw (V) in Slower = screw knurled screw (V) out Further information – see operator's manual of forage harvester under “medium heavy to heavy front attachments” (Fig. 64, 65)

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

6.25

Assembly Conversion valve for front attachments

Jaguar 900, 890, 870, 850, 830

V

(Additional equipment chopper) A

h

ATTENTION! The conversion valve can only be switched before the front attachment is fitted.

B

If the front attachment has already been fitted: – Lower the front attachment to the ground and depressurise the hydraulic cylinder.

66 As an option, the chopper can be fitted with a pressure balancing system for light, medium heavy and heavy front attachments. If the chopper is fitted with this, the lever (h) of the valve (V) must be changed to position (A).

Further information – see operator's manual of forage harvester under “medium heavy front attachments” (Fig. 66)

6.26

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Prior to operation

Prior to operation

7 Prior to operation DANGER! Work on the front attachment and/or the forage harvester should only ever be undertaken when the drive is disconnected and the motor is at standstill.

– Remove the ignition key!

– Switch off the battery master switch!

CHECK AND OBSERVE THE FOLLOWING BEFORE PUTTING INTO OPERATION 1. Check oil level in the gearboxes – see Gearbox, page 9.2.

2. Lubricate front attachment thoroughly before putting into operation – see Lubrication Chart, page 10.1.

3. Check bolts for tightness.

4. Check that the mower blades are properly fastened.

5. Secure universal drive shaft gear against rotating by attaching the chains.

6. Check safety guards and safety bar for wear and damage.

7. Mount and lock safety equipment completely – see Guards, page 9.1.

8. Removing prop stands from cutter bar – see Attaching and removing prop stands, page 6.4.

9. JAGUAR 900 - 830 Type 493 For fitting the front attachment, the dog clutch must be removed – see Removing the dog clutch, page 6.23.

10. Check vehicle for any loose parts before moving off. Firmly attach or cover parts which can fall off during travel.

11. Make sure no-one is in the area of danger. If any person approaches the danger area, switch off the front attachment immediately.

12. Never let the front attachment run without proper supervision.

13. Switch on the front attachment only in working position and at idle speed – see Working position, page 7.14.

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

7.1

Prior to operation ATTACHING FRONT ATTACHMENT DANGER! Danger of injury while attaching the front attachment!

– Nobody must stand between the forage harvester and the front attachment.

Never work under or on the raised front attachment without safe support.

– See Safety support on page 4.8.

Never work on the front attachment unless the drive is switched off and the engine has stopped.

– Remove the ignition key!

– Switch off the battery master switch!

ATTENTION! Ensure that the lock is open before attaching the front attachment.

Proceed as follows to attach the front attachment: 1. Adjust drop rate – see Setting the lowering speed (JAGUAR 900 - 830), page 6.25.

2. Open lock – see Open lock, page 7.3.

3. Attach front attachment – see Attach front attachment, page 7.3.

4. Close lock – see Close lock, page 7.4.

5. Check that the front attachment is safely locked, if necessary adjust lock – see Adjusting lock, page 9.21.

6. Connect hydraulic hoses – see Connecting hydraulics, page 7.5.

7. Fit the V-belts – see Positioning v-belts for mower drive, page 7.6.

8. Connect power supply – see Connecting electrics, page 7.8.

9. Attach universal drive shaft – see Mounting universal drive shaft, page 7.9.

10. Removing prop stands from cutter bar – see Attaching and removing prop stands, page 6.4.

7.2

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Prior to operation Open lock

• Remove the spring clip (2).

• Push the lever (1) downwards.

2

(Fig. 1)

1

1

Attach front attachment 3

DANGER! 4 Danger of injury while attaching the front attachment!

– Nobody must stand between the forage harvester and the front attachment.

ATTENTION!

2

Ensure that the lock is open before attaching the front attachment.

• Move the chopper towards the front attachment until the location spigots (4) of the feed are located below the location pockets (3) of the front attachment.

• Lift the front attachment with the chopper hydraulics.

(Fig. 2)

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

7.3

Prior to operation Close lock ATTENTION!

5

Machines which are not locked/secured can come loose from the retainer during the journey.

6

– Close lock.

– Ensure that the front attachment is securely locked to the coupling shaft (1)!

3

• Lift lever (5) on the front attachment upwards and secure with the spring clip (6).

NOTE! The locking pins must be adjusted to allow the pretensioned coupling hooks (11) to surround the coupling shaft (10) from the feeder housing of the forage harvester.

10

11

• Adjust lock mechanism if necessary 4

– see Adjusting lock, page 9.21 or adjust locking pins – see Adjusting locking pins, page 9.22.

(Fig. 3, 4)

7.4

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Prior to operation Connecting hydraulics

JAGUAR 900 - 830 Type 492

15 ATTENTION! The hydraulic system may be contaminated by dirty hydraulic connectors or hydraulic coupling sockets.

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

16

– Beware of friction and jamming!

5

• Switch off the engine and remove the ignition key.

JAGUAR 900 - 830 Type 493

NOTE! 16

If the hydraulic lines are connected wrong, the mower drive will not function!

Note the colour coding on the hydraulic lines and sockets.

• Connect the hydraulic hoses (16) for the V-belt 15 6

tensioning cylinder to the hydraulic plug connections (15) on the forage harvester.

Only with DIRECT DISC 520 Contour:

• If required, connect the hydraulic hoses for the hydraulic paddle roller adjustment (Additional equipment) – see Hydraulic paddle roller adjustment (R03/0100, only DIRECT DISC 520 Contour), page 8.8.

(Fig. 5, 6)

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

7.5

Prior to operation Positioning v-belts for mower drive 17 DANGER! Fingers may be jammed when positioning v-belts.

– Use appropriate tools.

18 19

ATTENTION! 7

Ensure that belts are aligned!

Replace defective v-belts in sets only.

19 Open the guard (18) by:

• turning the bolts (17) of the interlock towards the inside and opening the guard towards the front.

20

Remove the V-belt guard (19) by:

• Releasing the bolts (20) and lifting the V-belt guard upwards and removing it.

8

NOTE! When the motor is running, the V-belt tensioning cylinder is immediately extended and remains extended in order to tension the V-belts. The V-belts cannot be fitted whilst the motor is running.

• If necessary, switch off the engine and remove the ignition key.

7.6

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Prior to operation

CAUTION! Before fitting the V-belts, clean the grooves in the V-belt pulleys (arrows) and the running surface of the tensioning roller (arrows).

9

10

• First position V-belts (24) (2 units) on the drive 23

pulley on the forage harvester and header.

21

• Lift the tensioning roller (23) up as far as possible

22

and push the V-belt (24) under the tensioning roller (23).

CAUTION! Only JAGUAR 900 - 830 Type 492: The V-belt guide (22) protects the adjusting motor 21) from damage by the V-belts.

24 11

• Only JAGUAR 900 - 830 Type 492: Check to make sure that the V-belts are under the V-belt guide (22).

• Check V-belt alignment.

• Let the motor run for a short period of time to tension the V-belts.

• Switch off the engine again and remove the ignition key.

• Check to make sure that the V-belts do not rub continually on the V-belt guide – see V-belt guide (only JAGUAR 900 - 830 Type 492), page 9.8.

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

7.7

Prior to operation • Reinstall V-belt guard (19).

In doing this, make sure that: • the pull rod (26) runs freely (only JAGUAR 900 - 830 Type 492).

25

• The guard (25) should be in contact with the V-belt cover (19).

26

• Close the guard.

• Check that the lock has securely clicked into 19

position.

12

(Fig. 7-12)

Connecting electrics

JAGUAR 900 - 830 Type 492

27 ATTENTION! Beware of friction and jamming!

• Insert plug (27) for fast shutdown of the mower drive.

JAGUAR 900 - 830 Type 492:

13 JAGUAR 900 - 830 Type 493

– Plug socket for wiring harness for the ESR-Module – see Fit wiring harness for ESR Module, page 6.14.

JAGUAR 900 - 830 Type 493: – Auto-Contour plug socket – see operator's manual forage harvester.

(Fig. 13, 14)

27

14

• Connect plug (28) for clearance lights (USA only), if required.

(Fig. 15)

28

15

7.8

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Prior to operation • If required, insert plug (29) for the laser pilot (additional equipment).

– Autopilot plug socket – see operator's manual forage harvester or laser pilot.

29

(Fig. 16)

16

Mounting universal drive shaft DANGER! Never run drive shafts without their guards, or if the guards are damaged.

– The universal drive shafts must only be operated when in good condition.

Never work under or on the raised front attachment without safe support.

– Lower the safety lock down to the ground and lock in position – see Safety support, page 4.8.

• Switch off the engine and remove the ignition key.

• Switch off the battery master switch!

JAGUAR 900 - 830 Type 492:

JAGUAR 900 - 830 Type 492

NOTE! JAGUAR 900 - 830 Type 492: It is easier to install the universal drive shaft if the drive for the front attachment is switched off.

For this, set lever (H) at position 0 (Fig. 17).

17

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

7.9

Prior to operation • Open cover (31).

JAGUAR 900 - 830 Type 492

31 18

• First place universal drive shaft (30) on the PTO

JAGUAR 900 - 830 Type 492

shaft of the front attachment. Press in locking pin and slide universal drive shaft on to the PTO shaft of the gearbox and reverser gear.

30

• Ensure that the locking pin clicks are securely in place.

• Close cover (31).

(Fig. 17, 19, 18)

31 19 JAGUAR 900 - 830 Type 493:

JAGUAR 900 - 830 Type 493

NOTE! In order to fit the front attachment, the dog clutch must be removed – see Removing the dog clutch, page 6.23.

• Open cover (32).

• Grease universal shaft (34) and profiled

32

shaft (35).

20 JAGUAR 900 - 830 Type 493

• Grease the connection spigot (33).

• Firstly push the profiled shaft (35) into the hole in the reversing gearbox (36).

36

32

• Push the universal drive shaft onto the PTO stub of the front attachment.

35 33

• Ensure that the locking pin clicks are securely in

34

place.

• Close cover (32).

(Fig. 20, 21)

21

7.10

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Prior to operation Setting the paddle roller The height of the paddle roller (37) above the mower head must be adjusted to suit the fodder level, the fodder conditions and the usage conditions. Four holes (Fig. 22) are available for adjustment.

Hole A = short fodder Hole B = normal fodder conditions 37

Hole C/D = long fodder (longer than about 80 cm) DANGER!

22

72794

38

D 42

B

– Switch off the battery master switch!

C

40

41

A

– Remove the ignition key!

39

D

Never work on the front attachment unless the drive is switched off and the engine is stopped.

Both sides must be adjusted. To adjust the paddle roller (37) proceed as follows:

D 43

23

• • • •

Lower front attachment to the ground.

Switch off the engine and remove the ignition key.

Switch off the battery master switch!

Open the side cladding and secure in position – see Guards, page 9.19.

• Remove bolts (42, 43, 41).

• Loosen lock nut (39) on the adjusting screw (38).

NOTE! When using hole (D), the chain must be extended with an offset link.

• Using the adjusting screw (38) and the nut (40) bring the paddle roller to the desired position.

• Replace all screws and tighten them.

• Close side guard.

Order No.:

offset link (L-12 A-1)

0767 147.0

(Fig. 22, 23)

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

7.11

Prior to operation Hydraulic paddle roller adjustment

A

(Additional equipment only DIRECT DISC 520 Contour)

44

Setting the stroke limits Y

The straps (44) serve as stroke limiters for the adjustment plates. The straps (44) can be fitted in two different positions, depending upon the application.

X

Position A – low clearance height For low or down crops.

Stroke Y = 60 mm 24

Position B – high clearance height For tall crops.

Stroke X = 90 mm

• Move the paddle roller to the lowest position

Trough left – Position A

– see Hydraulic paddle roller adjustment (R03/0100, only DIRECT DISC 520 Contour), page 8.8.

A 44

• Fit the straps (44) using hex bolts (45) (M12x35MK) and Contact Washers (46) in the corresponding position (A or B).

B

45 46

CAUTION! The straps must be mounted in the same positions on both sides!

25 Trough left – Position B

(Fig. 24, 25, 26)

A

B

44

45 46

26

7.12

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Prior to operation Adjusting cutter bar skids DANGER! Never work under or on the raised front attachment without safe support.

48

– Lower the safety lock down to the ground and lock in position – see Safety support, page 4.8.

47 49 48 27

ATTENTION! Adjust cutter bar skids to the same height on each side – if a cutter bar skid is set higher it will be subject to increased wear!

The minimum cutting height is set by the cutter bar skids (49) as follows:

• • • •

Raise front attachment completely.

Switch off the engine and remove the ignition key.

Switch off the battery master switch!

Lower the safety lock down to the ground and lock in position – see Safety support, page 4.8.

• Loosen bolts (48).

• Set minimum cutting height with the straps (47) and holes.

• Replace bolts (48).

(Fig. 27)

Setting cutter bar inclination

51

The cutter bar inclination can be set 3º steeper by removing the wedges (50) and packing wedges (51).

This is advisable in extreme operating conditions.

Keep chocks for later use.

50

51

(Fig. 28)

50 72790

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

51

28

7.13

Prior to operation After removal or installation of the wedges and chocks adjust the safety bar (54) on both sides as follows: 52

• Unfasten bolt (53).

• Release bolts (52).

• Fix safety bar (54) in the appropriate hole.

A B

– Hole (A) = flatter 53

54

– Hole (B) = steeper

• Tighten all bolts again.

(Fig. 29) 29

WORKING AND TRANSPORT POSITION Transport position NOTE! The front attachment must be removed and loaded and secured on a suitable vehicle for transport on public roads and tracks. Install and fasten safety guards to feeder housing – see Road transport, page 3.3.

30

• Raise front attachment completely for transport – see Raising and lowering the front attachment, page 8.1.

Only with DIRECT DISC 520 Contour:

• Lock the pendulum frame – see Lock/unlock the pendulum frame (DIRECT DISC 520 Contour), page 8.6.

(Fig. 30)

Working position

• Remove safety guard on feeder housing – see operator's manual for forage harvester.

• Attach front attachment – see Attach front attachment, page 7.3.

• Removing prop stands from cutter bar 2

– see Attaching and removing prop stands, page 6.4.

1

• If necessary, slide safety stand (1) up as far as possible and secure it with the pin (2).

31

7.14

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Prior to operation Only with DIRECT DISC 520 Contour:

• If necessary unlock the pendulum frame – see Lock/unlock the pendulum frame (DIRECT DISC 520 Contour), page 8.6.

• Lower front attachment to working height – see Raising and lowering the front attachment, page 8.1.

(Fig. 31)

REMOVING AND STORING THE FRONT ATTACHMENT DANGER! Never work under or on the raised front attachment without safe support.

– see Safety support, page 4.8.

Never work on the front attachment unless the drive is switched off and the engine has stopped.

– Remove the ignition key!

– Switch off the battery master switch!

ATTENTION! Place the front attachment on firm and level ground only!

Under difficult conditions (e.g. max. cutting height) the front attachment can only be refitted with great difficulty.

– Before removal, attach prop stands to cutter bar.

Proceed as follows to store the front attachment:

• Switch off the engine and remove the ignition key.

• Switch off the battery master switch!

• Attach prop stands (1) to cutter bar to ensure that the front attachment can always be reattached – see Attaching and removing prop stands, page 6.4.

• Lock the pendulum frame – see Lock/unlock the pendulum frame (DIRECT DISC 520 Contour), page 8.6.

1 32

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

• Lower front attachment to the ground.

7.15

Prior to operation • Open cover (3) and remove universal drive

JAGUAR 900 - 830 Type 492

shaft (2) by pressing the locking pin.

2

3 33 JAGUAR 900 - 830 Type 493

3

2 34

• Remove V-belts (7) (2x) as follows: 5

• Open the cover – see also Positioning v-belts for mower drive, page 7.6.

4

6

• Remove V-belt guard – see also Positioning v-belts for mower drive, page 7.6.

NOTE!

7 35

When the motor is running, the V-belt tensioning cylinder is immediately extended and remains extended in order to tension the V-belts. The V-belts cannot be removed whilst the motor is running. Only remove the hydraulic hoses for the hydraulic tensioning cylinder on the forage harvester when the tensioning cylinder (6) has fully retracted.

• Push the tensioning roller (5) upwards to fully retract the tensioning cylinder (6).

• Remove the V-belt pulley (7) under the tensioning roller (5) and the V-belt guide (4) (only JAGUAR Type 492).

• Remove V-belts (7) from the V-belt pulley on the header and forage harvester.

7.16

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Prior to operation • Detach hydraulic hoses (8) at the quick release

JAGUAR 900 - 830 Type 492

couplings.

8

36 JAGUAR 900 - 830 Type 493

8 37 Only with DIRECT DISC 520 Contour:

• If necessary, disconnect the hydraulic hoses for the hydraulic paddle roller adjustment at the quick-fit couplings (additional equipment) – see Hydraulic paddle roller adjustment (R03/0100, only DIRECT DISC 520 Contour), page 8.8.

NOTE! Lay out hydraulic hoses to prevent the quick release couplings from becoming dirty.

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

7.17

Prior to operation • Remove the electrical plug (9) for drive monitoring

JAGUAR 900 - 830 Type 492

from the forage harvester.

9

38 JAGUAR 900 - 830 Type 493

9

39

• Disconnect plug (10) for clearance lights (USA only).

10

40

• If required, insert plug (11) for the laser pilot (additional equipment).

NOTE!

11

Lay out cables to prevent the plugs from becoming dirty.

41

7.18

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Prior to operation • Unlock front attachment – see Open lock, page 7.3.

• Lower forage harvester feeder housing completely.

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

• Cautiously reverse the forage harvester.

(Fig. 32-41)

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

7.19

Operation

Operation

8 Operation OPERATION DANGER! Nobody must stand in the danger area while the front attachment is being raised or lowered.

– Direct all persons away from the danger area!

Raising and lowering the front attachment

Jaguar 900, 890, 870, 850, 830

With the multifunction lever: – Press push switch (1a) – lower front attachment.

R

1c

– Press push switch (1b) – raise/extend front attachment.

1a

– Switch on the “Contour System” by pushing the push switch (1d) –.

1d

– Switch on the “Cut height adjustment” by pushing the push switch (1c) –.

1b 70798A

1

NOTE! By pushing the push switch (1a, 1b) the “Contour-System” and the “Cut height adjustment” is switched off.

Set the working height or cut height – see Adjusting cutting height, page 8.5.

(Fig. 1)

8.1

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Operation Operating front attachment DANGER! Danger from flying objects.

– Direct all persons away from the danger area!

– If necessary, switch off front attachment immediately!

Danger of injury when working on the mower blades or their fasteners!

Only work on the mower blades or their fasteners if the drive and cutting disks are at standstill!

– Switch off mower drive.

– Switch off engine.

– Do not leave the forage harvester until the cutting disks have come to a complete stop!

– Remove the ignition key!

– Switch off the battery master switch!

– Remove universal drive shaft!

– Wear gloves!

ATTENTION! Keep the area to be mowed free of foreign objects!

Before operation and after driving into an obstacle check the header for damaged, missing or worn mower blades and check the mower blade fasteners.

– Check that the mower blades are correctly seated – see Mower blades, page 9.14.

Extended overloading of the drive shaft coupling will burn out the clutches.

– Avoid frequent extended overloading of the drive shaft clutches.

1. Undertake the working tasks “Before commissioning” – see Check and observe the following before putting into operation, page 7.1.

2. Bring the front attachment into working position and check – see Working position, page 7.14.

0299 924.3 - BA DIRECT DISC 520 / 520 Contour

8.2

Operation 3. If necessary, unlock the pendulum frame – see Lock/unlock the pendulum frame (DIRECT DISC 520 Contour), page 8.6.

4. Start the engine.

5. Switch on front attachment as follows:

Jaguar 900, 890, 870, 850, 830

• Safety switch (2) and

2

• main drive (push button 3) to be switched on (Fig. 2).

3

6. Check drop rate of front attachment and adjust if necessary – see Setting the lowering speed (JAGUAR 900 - 830), page 6.25.

4

7. Set the cutting height – see Adjusting cutting height, page 8.5.

37171

2

8. Before moving into the forage, switch on the front attachment at idle speed.

9. Lower front attachment to working height – see Raising and lowering the front attachment, page 8.1.

10. Accelerate to working speed.

NOTE! The whistling noise of the cutting discs at high speed is completely normal and is generally muffled during actual mowing.

11. Move into the forage.

12. Set the ground speed as required for the working conditions (ground conditions, density, height and quality of the forage).

(Fig. 2)

8.3

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Operation Instructions for mowing DANGER! Clearing blockages or removing foreign objects: – Switch off mower drive.

– Switch off engine.

– Do not leave the forage harvester until the cutting disks have come to a complete stop!

– Remove the ignition key!

– Switch off the battery master switch!

– Wear gloves!

After extended operation, the cutter bar can reach temperatures up to approx. 80° C. – Danger of burns!

– Do not touch the bar!

• Reduce ground speed when working in dense or downed forage and when mowing around a curve.

• Adjust the height of the paddle roller above the mower head to the application conditions – see Setting the paddle roller, page 7.11.

• The cutter bar cannot mow backwards. Raise cutter bar when moving backwards.

• Do not mow on rocky ground!

• During extended work on slopes, particularly when working across the slope (contouring), do not work only in one direction, rather work in both directions alternately.

0299 924.3 - BA DIRECT DISC 520 / 520 Contour

8.4

Operation Difficult application conditions DANGER! Be particularly cautious when working in difficult conditions or on uneven ground. To prevent flying objects note the following points: – Direct all persons away from the danger area!

– If necessary, switch off front attachment immediately!

– Increase cutting height – see Adjusting cutting height, page 8.5.

– If necessary, set cutter bar flatter – see Setting cutter bar inclination, page 7.13.

– Reduce ground speed.

– Check that the mower blades can swing back if they hit an obstacle.

Adjusting cutting height The cutting height is adjusted with the forage harvester contour system. Two operating modes are available:

• Cutting height preselection and • Contour system (automatic ground pressure control); a ground pressure of about 470 kg is recommended (potentiometer level 3).

NOTE! To allow the “Contour System” (automatic ground pressure control) to operate, it is recommended to fit the “additional damping”. Further information – see Additional damping (R05/0060), page 8.9.

For more information, see operator's manual forage harvester – Contour System or cutting height preselection.

The minimum cutting height is set by the cutter bar skids – see Adjusting cutter bar skids, page 7.13.

8.5

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Operation Lock/unlock the pendulum frame (DIRECT DISC 520 Contour) When using the DIRECT DISC 520 Contour with Contour-System the pendulum frame can also be unlocked, thus ensuring better adjustment to the ground conditions.

DIRECT DISC 520 Contour

5

Unlock the pendulum frame: A

• Turn lever (5) to position (A).

NOTE! When using “cutting height preselection”, the pendulum frame must be locked.

3 Lock the pendulum frame.

DIRECT DISC 520 Contour

• Turn lever (5) to position (B).

• Check that the frame is locked, if necessary move the front attachment up and down slightly.

(Fig. 3, 4)

5

B 4

0299 924.3 - BA DIRECT DISC 520 / 520 Contour

8.6

Operation Adjusting length of cut DANGER!

I

II

Work on the front attachment and/or the forage harvester should only be undertaken when the drive is disconnected and the motor is at standstill.

6

– Remove the ignition key!

– Switch off the battery master switch!

5 To adjust the length of cut, the universal drive shaft (6) (Fig. 5) can be changed on the gearbox for the intake auger. The gearbox affects the speed of the intake auger only.

7

NOTE! With the model 492 forage harvester the lever group switch (7) (Fig. 6) can also influence the speed of the front attachment.

The following lengths of cut can be set: 6

4-7 mm, 9 mm, 14 mm and 17 mm (Fig. 5, 6, 7)

7

72789

8.7

7

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Operation ADDITIONAL EQUIPMENT Hydraulic paddle roller adjustment (R03/0100, only DIRECT DISC 520 Contour) The height of the paddle roller above the mower head must be adjusted to suit the fodder level, the fodder conditions and the usage conditions. The hydraulic paddle roller adjustment allows adjustment also whilst in operation without any problems. This is particularly important when the operation conditions vary greatly.

Necessary settings before operation – see Hydraulic paddle roller adjustment (Additional equipment only DIRECT DISC 520 Contour), page 7.12.

8

1 ATTENTION! The hydraulic system may be contaminated by dirty hydraulic connectors or hydraulic coupling sockets.

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

9 NOTE! If the hydraulic lines are connected wrong, the mower drive will not function!

Note the colour coding on the hydraulic lines and sockets.

Connect the hydraulic hoses to the quick-fit couplings (1).

The operation takes place using the multifunction lever.

Jaguar 900, 890, 870, 850, 830

Lift or lower the paddle roller by actuating the switch (2).

Position (s) = lowering paddle roller 2

Position (h) = lifting paddle roller Further information – see operator's manual for the forage harvester.

h

Order No.: 70799

Retrofitting set

s

0299 924.3 - BA DIRECT DISC 520 / 520 Contour

10

0495 508.0

(Fig. 8, 9, 10)

8.8

Operation Feed hats (D03/0080) To improve the crop infeed, the cutter discs can be fitted with feed hats. Proceed as follows:

• Remove cap 4).

• Fit feed hats (3) in accordance with fig. 11.

3

Order No.: 4

Fitting set

0495 509.0

(Fig. 11) 11

74001

Additional damping (R05/0060) When operating the front attachment, it is recommended that the forage harvester be fitted with the “additional damping” for medium duty front attachments (DIRECT DISC). This ensures that the Contour-System works properly and that the front attachment presses down on the ground with the preset pressure.

If the front attachment is operated only with the “cutting height preselection”, this additional equipment is not required.

Order No.: Retrofitting set

0495 510.0

Laser pilot (R03/0090) For optimisation of the use of the full working width and for relieving the driver of a task, the DIRECT DISC can be fitted with the Laser pilot (5) to help with steering. The Laser pilot automatically guides the DIRECT DISC along the edge of the crop. The driver monitors the machine and needs to take action only at the headland or in the event of a malfunction.

5

Order No.: Retrofitting kit 12

8.9

0495 424.0

(Fig. 11)

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Maintenance

Maintenance

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

Lubrication Observe the oil change intervals and the oil quality specified by the manufacturer. Use only good quality grease or oil to lubricate the front attachment. 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 front attachment is used in severe conditions.

– Remove the ignition key!

– Switch off the battery master switch!

ENVIRONMENT! Dispose of oil and grease according to regulations!

DANGER! Carry out repair, maintenance and cleaning work on or under the raised front attachment or feeder housing only when they are securely supported.

NOTE! The quoted fill quantities are approximate values, the oil level check is always decisive for the correct oil level.

– see Safety support, page 4.8.

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

Guards Open folding guards only when the drive is switched off and the engine is at standstill.

– Remove the ignition key!

– Switch off the battery master switch!

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

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.

Regularly check safety guards.

Replace worn or damaged safety guards by new ones.

ENVIRONMENT! Dispose of oil and grease according to regulations!

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

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

Bolts Check all bolts for tightness and retighten if necessary.

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

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

9.1

Maintenance

Maintenance DRIVE SYSTEMS Gearbox DANGER! Support the raised front attachment safely!

– see Safety support, page 4.8.

Work on the front attachment and/or the forage harvester should only be undertaken when the drive is disconnected and the motor is at standstill.

– Remove the ignition key!

– Switch off the battery master switch!

– Uncouple the universal drive shaft!

NOTE! When checking the oil levels of all gearboxes, the front attachment must be lowered to the working position.

The quoted fill quantities are approximate values, the oil level check is always decisive for the correct oil level.

1. Swing front attachment into working position – see Working position, page 7.14.

2. Secure forage harvester against rolling away.

3. Switch off drive and engine.

4. Remove the ignition key.

5. Switch off battery master switch.

ENVIRONMENT! Dispose of drained oil according to regulations.

Use only SAE 90 (MIL-L-2105) API-GL-4-90 as gear oil.

Unless specified otherwise, change all gear oils every 500 working hours - at the end of every season at the latest. Check all gearboxes for leaks once a week and check the oil level if necessary.

9.2

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Maintenance

A

1 Intake auger gearbox (A) Gearbox capacity: 3.5 litres

1

1 = oil filler cap 2 = oil level check plug 3 = oil drain screw (Fig. 1, 2, 3) 2

2

3 3

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

9.3

Maintenance

B

C

C

4 Angle drive – drive intake auger (B) Gearbox capacity: 1.2 litres 4 = oil filler and oil level check plug 5 = oil drain screw (Fig. 4, 5)

4

5

5 Angle drive - mower drive (C) Gearbox capacity: 1.2 litres

6

6 = oil filler cap 7 = oil level check plug 8 = oil drain screw The universal drive shaft guard and the top side guards – see Top side guards, page 9.20 must be removed to change the oil or to check the oil level.

7 8

(Fig. 4, 6) 6

9.4

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Maintenance

D

E

7

Clutches (D, E) The friction clutch (E) and the cam-type cut-out clutch (D) must be opened and serviced by a dealer as specified by the clutch manufacturer every 500 working hours - at the end of every second season at the latest.

ATTENTION! The clutches are designed for a torque of 1400 Nm ±8% and this must not be changed, because otherwise the universal drive shaft, gearbox, etc. may be damaged.

Check friction plates regularly for wear and replace if necessary.

NOTE! After extended downtime the clutches must be ventilated before operating the front attachment again – clutch manufacturer's operator's manual.

(Fig. 7)

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

9.5

Maintenance CHAINS Lubricating the drive chain DANGER! Never work on the front attachment unless the drive is switched off and the engine has stopped.

1

– Remove the ignition key!

– Switch off the battery master switch!

8

Open and secure the side guards (1) to lubricate the drive chains – see Guards, page 9.19.

(Fig. 8)

Tensioning drive chain

DIRECT DISC 520

The front attachment is fitted with an automatic chain tensioning device.

Check the indicator on the chain tensioning device regularly.

3

Possible positions of the mark (3): Chain tension

Mark

Remedy

between 5°/15°

O K.

less than 5°

too low

replace or shorten chain

greater than 15°

too high

extend or replace chain

9

(Fig. 9)

9.6

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Maintenance V-BELTS DANGER! Never work on the front attachment unless the drive is switched off and the engine has stopped.

– Remove the ignition key!

– Switch off the battery master switch!

Checking V-belts Check the V-belts of the mower drive regularly for wear, breakage and other damage and replace if necessary.

NOTE! Replace V-belts in sets only.

Tensioning V-belts The V-belts of the mower drive are tensioned hydraulically. Adjustments are not required. The hydraulic cylinders are extended and retracted when the forage harvester feeder is switched on. If the V-belts are not correctly tensioned, the problem can be found in the forage harvester hydraulic system.

NOTE! If a V-belt breaks the forage harvester feeder drive and thus the cutter bar are shut down immediately!

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

9.7

Maintenance V-belt guide (only JAGUAR 900 - 830 Type 492) After first commissioning the front attachment or changing the V-belts, the setting of the V-belt guard (hex bolt) should be checked after the first 10 operating hours.

1 2

3 Y

If necessary, correct.

4

After this, check at regular intervals.

Check V-belt guide, for that:

• Remove the front attachment completely and connect the hydraulic hoses for the V-belt tensioning cylinder.

10

• Run the motor for a short period – The V-belts are tensioned in this way.

• Switch off the engine again and remove the ignition key.

• Check distance (Y) between the tensioned V-belt and the V-belt guide (hex bolt) and adjust if necessary.

CAUTION! The V-belt guide (2) protects the adjusting motor (4) from damage by the V-belts.

• Check the wear of the hex bolt (2).

– Replace hex bolt (2) if it is badly worn.

Order No.:

hex bolt

0215 898.0

Set the V-belt guide, by:

• Releasing hex nuts (3) on the holder (1).

• Move the hex bolt (2) in the elongated hole until the set measurement (Y) between the tensioned V-belt and the V-belt guide (hex bolt) is reached.

• Hex nuts (3) on the hex bolts (2) to be retightened.

Adjustment dimension Y: 2 mm (Fig. 10)

9.8

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Maintenance SPRING ADJUSTMENT Spring tension of intake auger 1

The intake auger is pressed on to the crop on the left with springs (3). The pressure is regulated by spring tension. Proceed as follows:

X

• Open the side cladding and secure in position – see Guards, page 9.19.

• Loosen lock nut (2).

• Adjust bolt (1) until the adjustment dimension X is

3

2

reached.

3 11

• Tighten lock nut (2) again.

Adjustment dimension X: 30 mm (Fig. 11)

Pendulum frame (only DIRECT DISC 520 Contour) Z

4

The pendulum frame is held horizontal with the springs (4). The position of the front attachment is adjusted using spring tension. Proceed as follows:

• Open the hood and secure – see Guards, page 9.19.

5

• Loosen lock nut (5).

• Adjust bolt (6) until the adjustment dimension Z is reached.

12

• Tighten lock nut (2) again.

Adjustment dimension Z: 82.5 ± 2.5 mm (Fig. 12, 13)

6

13

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

9.9

Maintenance UNIVERSAL DRIVE SHAFTS Servicing the universal drive shaft DANGER! Work on the universal drive shafts only when the drive and engine are switched off.

– Remove the ignition key!

– Switch off the battery master switch!

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

– Mounting shaft guard and protective tube.

– Fasten them to prevent them rotating!

– The universal drive shafts must only be operated when in good condition.

For lubrication intervals and lubricants see Lubrication Chart, page 10.1.

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

Observe the safety instructions of the manufacturer!

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

– Mounting shaft guard and protective tube.

– Fasten them to prevent them rotating!

– The universal drive shafts must only be operated when in good condition.

Immediately replace damaged or missing protective tubes, universal drive shaft guards and securing chains.

Protect the universal drive shafts against the weather.

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

The protective tubes must be greased to prevent freezing during winter.

After long periods of non-use, lubricate the universal drive shafts before using them again and check their functioning.

9.10

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Maintenance

9 9

F G

h

12

11

10

10

14

MOWER BEAM DANGER! After extended operation, the cutter bar can reach temperatures up to approx. 80° C. – Danger of burns!

– Do not touch the bar!

– Wear safety gloves!

NOTE! If the maintenance instructions are observed there is no reason to worry if the cutter bar becomes very hot, so long as the cutting disks can still be easily rotated manually with the warm machine. An operating temperature of approx. 60° C must be considered normal.

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

9.11

Maintenance Use only EP SAE 90 gear oil to lubricate the cutting disk gearbox. Check the oil level in the gearbox daily and add oil if necessary.

Gearbox capacity: Mower beam (G) = 4.0 Litre Mower beam (F) = 4.0 Litre 9 = oil filler and oil level check plug 10 = oil drain screw

Oil level check DANGER! Support the raised front attachment safely!

– see Safety support, page 4.8.

Work on the front attachment and/or the forage harvester should only be undertaken when the drive is disconnected and the motor is at standstill.

– Switch off mower drive.

– Switch off the engine and do not leave the forage harvester until the cutting disks have come to a complete stop.

– Remove the ignition key!

– Switch off the battery master switch!

NOTE! Only undertake the oil level check on solid flat ground!

• Warm up front attachment for 8 - 10 minutes.

• Drive the right-hand wheel (11) of the forage harvester onto a ramp (12) of height h = 280 mm (wood block or similar) (Fig. 14).

• Lower the front attachment so that the mower beam is horizontal in the direction of travel (Fig. 15).

• • • • • 74892

9.12

15

Secure forage harvester against rolling away.

Switch off drive and engine.

Remove the ignition key.

Switch off battery master switch.

Lower the support prop to the ground and lock in position – see Safety support, page 4.8.

• Wait approx. 10 - 15 minutes before checking the oil level to allow the oil to collect.

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Maintenance • Check oil level through the opening (9).

X

90°

NOTE! The scale must be perpendicular to the cutter bar to measure the correct oil level. If the oil level cannot be determined exactly, all oil must be drained and the specified amount of fresh oil must be added.

9

Oil level: X = 18 - 20 mm 71969/01

16

(Fig. 14, 15, 16)

Oil change DANGER! Never work on the front attachment unless the drive is switched off and the engine has stopped.

– Switch off mower drive.

– Switch off engine.

– Do not leave the forage harvester until the cutting disks have come to a complete stop!

– Remove the ignition key!

– Switch off the battery master switch!

After initial operation or after an overhaul of the cutter bar, the first oil change must be made after 50 working hours, then every 200 working hours and at the latest after every season.

Draining oil ENVIRONMENT! Dispose of drained oil according to regulations.

• Lower the front attachment until the mower beam is tilted slightly backwards in the direction of travel.

• Warm up front attachment for 8 - 10 minutes.

• Drive the right-hand wheel (11) of the forage harvester onto a ramp (12) (wood block or similar) (Fig. 14).

• Drain oil through the opening of the magnetic plug (10) (Fig. 14). Clean the magnetic plug before reinstalling it.

(Fig. 14)

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

9.13

Maintenance MOWER BLADES Replacing mower blades DANGER! The safety guard of the cutter bar must only be opened when the drive has stopped and the engine and cutting discs are switched off!

Only work on the mower blades or their fasteners when the drive has stopped and the engine and cutting discs are switched off.

– Switch off mower drive.

– Switch off engine.

– Do not leave the forage harvester until the cutting disks have come to a complete stop!

– Remove the ignition key!

– Switch off the battery master switch!

– Wear gloves when working on the mower blades!

ATTENTION! Always check the mower blades before operation and after driving into an obstacle!

– Always check that the mower blades are correctly seated!

– Worn, damaged or bent blades must be replaced immediately.

– Both mower blades on every cutting disc must be attached or replaced, because otherwise the cutter bar may be damaged by unbalanced blades.

Use only original CLAAS mower blades for best results!

NOTE! Use only sharp mower blades for neat cutting.

Use of blunt blades requires more power and reduces the cutting quality.

Blunt blades can be reversed and fastened to the same disk so the other blade is used for cutting.

9.14

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Maintenance Replacing mower blades R

1. To replace blades first clean the seat of the nut (1) and loosen the nut with the socket wrench.

2. Mount new blades with the cutting edge downwards.

L

NOTE! Note the direction of rotation when mounting new mower blades!

17

71855

3. The direction of rotation of the disc is marked with an arrow on the blade ATTENTION!

1

After each nut is released, they need to be relocked using single component fluid DELO ML 5328 (Order No. 201 802.1) or Loctite Type 242 (Order No. 666 285.0).

4. Replace bolt and nut (1).

72187

120 Nm

18

Tightening torque of the mower blade securing bolt = 120 Nm (Fig. 17, 18)

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

9.15

Maintenance The mower blades must be replaced under the following conditions: – If the blades are cracked or bent.

10 mm

Never attempt to straighten a bent blade.

B

– If the blades are worn.

Bn

The width (B) of the blade measured 10 mm from the edge of the disc should be at least 3/4 of the standard width (Bn) (Fig. 19).

– If the drilled hole in the blade is widened.

61622

19

Maximum allowable widening of the drilled hole of Ln = 18 mm to L = 20 mm (Fig. 20).

(Fig. 19, 20)

L

Ln 61623

20

Attaching mower blades The attachment parts of the mower blades must be checked before every use.

ATTENTION! Always ensure proper seating when installing the securing screws.

61625

21

The mower blade securing bolts must be replaced under the following conditions: – Visible deformation of the securing bolt (e.g. after running into an obstacle).

D

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

Dn

– In case of serious wear of the bolt, head to the blade surface (Fig. 21).

– If the bolt shaft is worn from Dn = 18 mm to D = 15 mm (Fig. 22).

(Fig. 21, 22)

61624

9.16

22

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Maintenance The knife securing nuts must be replaced in the following cases: 2

– If the spring contact washer (2) has lost its elastic properties or has become detached from the nut.

– If the nut has worn so much that dimension a = H/2.

(Fig. 23)

H

a

61626

23

CUTTING DISCS Worn or damaged cutting discs must be replaced immediately.

90

Replacing cutting discs ATTENTION!

61628

The discs must be arranged so the long dimension is at right angles to the adjacent disc. The discs must always be arranged like this to prevent the mower blades from colliding.

24

2

(Fig. 24)

1

The cutting discs are fastened to one flange each.

The bolts (1) for securing the cutting discs must be tightened as specified.

Tightening torque: Bolts (1) = 80 Nm Nuts (2) = 350 Nm (Fig. 25)

71806

25 Ensure that the drainage opening (3) at the bottom of the conveyor cones is always open. This is the only place for draining water that has collected here (e.g. high-pressure steam cleaning).

(Fig. 26)

3 26

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

9.17

Maintenance ELECTRICAL 1 4

Sensor adjustment The distance x between the sensor (4) and the sensor wheel (3) must not decrease.

2

Proceed as follows to adjust the sensor: 3 x

27

• • • •

Remove cover.

Loosen lock nut (1) on sensor.

Use the nuts (2) to adjust the distance (x).

Tighten lock nut (1) again.

Adjustment dimension x: 2 mm (Fig. 27)

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.

Replace hydraulic hoses when damaged or aged!

28

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” indicates that the date of manufacture is the 2nd quarter of 2002.

(Fig. 28)

9.18

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Maintenance GUARDS DANGER! Never remove the guards unless the drive is switched off and the engine has stopped.

– Remove the ignition key!

– Switch off the battery master switch!

Sheet metal cover To open the sheet metal cover (1):

1

• Turn lock mechanism (4) to left and open sheet metal cover.

• Remove support (3) from bracket (5) and prop sheet metal cover with support (3).

To close the sheet metal cover (1): 4

• Remove support (3) from retainer (2) and secure in bracket (5).

29

• Close sheet metal cover.

• Check that the sheet metal cover is securely locked.

(Fig. 29, 30)

2

3

5

30

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

9.19

Maintenance Side guards To open the side guards (6):

• Remove screws (7) • Turn screw (8) to the back and open side guards.

• Secure side guards with bracket (9) in

7

retainer (10).

6

To close the side guards (6):

• Remove bracket (9) from retainer (10) and close

8

side guards.

31

• Check that the lock mechanism has securely clicked into position.

• Replace bolts (7).

(Fig. 31, 32)

10

9 32

Top side guards Remove top side guards (11) as follows:

11

• • • •

12

Open the side cladding and secure in position.

Loosen screws (13), Slide top side guards (11) towards back and remove upwards.

Installing top side guards (11):

13 33

9.20

Loosen bolts (12).

• Install in reverse order of removal.

(Fig. 33)

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Maintenance LOCK Adjusting lock

1

If the lock cannot be closed, adjust the cast iron bearing (3) on the front attachment.

DANGER!

2

Never work under or on the raised front attachment without safe support.

– Raise front attachment to the highest position.

3 34

– Lower the safety lock to the ground and lock in position – see Safety support, page 4.8.

To adjust the lock: 1. Loosen screws (2), 2. Adjust cast iron bearing (3) in the slotted holes, 3. Tighten screws (2).

Check the lock adjustment after the first 10 working hours and adjust if necessary. After this, check at regular intervals.

(Fig. 34)

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

9.21

Maintenance Adjusting locking pins NOTE! The locking pins must be adjusted to allow the pretensioned coupling hooks (5) to surround the coupling shaft (4) from the feeder housing of the forage harvester.

4

5 If necessary readjust the locking pin (8). Proceed as follows: 35

1. Loosen yoke (9) on the lever (6).

2. Loosen lock nut (7).

3. Screw the yoke (9) in or out from the pin.

6

4. Tighten yoke (9) on the lever (6).

9

5. Tighten lock nut (7).

Check the lock adjustment after the first 10 working hours and adjust if necessary. After this, check at regular intervals.

7 8

(Fig. 35, 36)

36

SCREW CONNECTIONS Check all screws and nuts of the entire front attachment again after 10 working hours and retighten if necessary.

After this, check at regular intervals.

CONNECTION ELEMENTS Check all safety relevant connection elements such as bolts, screws, pins etc. regularly for wear and deformation.

If necessary, replace the connection elements.

9.22

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Maintenance END OF SEASON STORAGE 1. Clean dirt from the front attachment.

2. Drain oil from all gearboxes and refill with fresh oil to the specified levels.

3. Lubricate all grease points thoroughly until the grease comes out of the bearings (see Lubrication Chart, page 10.1). Run the front attachment for a short time.

4. Check front attachment for wear and damage and have it repaired.

5. Clean rust off and repair paint damage.

6. Store front attachment in a dry weatherproof space away from synthetic fertiliser.

MALFUNCTIONS Malfunction

Remedy

Cause

Vibration

• Clean the feeder drum.

– Feeder drum dirty.

Cutter bar does not run

• Check V-belts.

• Check hydraulic connection for

– V-belt defective.

V-belt tension.

• Check forage harvester feed drive.

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

– Hydraulic connections on forage harvester reversed.

– ESR module has shut off drive.

9.23

Lubrication Chart

Lubrication Chart

10 Lubrication Chart SAFETY RULES DANGER! Never lubricate the front attachment unless the drive is switched off and the engine has stopped.

– Remove the ignition key!

– Switch off the battery master switch!

LUBRICANTS Propriety lubrication 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”

Brand name gear oil SAE90 - API GL 5

LUBRICATION

Lubricate these grease points every 50 working hours.

Lubricate these grease points every 250 working hours.

10.1

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Lubrication Chart

Lubrication Chart

3

4

1

5

2

6 7

72802 DIRECT DISC 520 Contour - Additional equipment

1

2

3

4

5

DIRECT DISC 520 Contour - Additional equipment

6

0299 924.3 - BA DIRECT DISC 520 / 520 Contour

7

10.2

Lubrication Chart

8

10

11

12

9

13

72802

10.3

8

9

10

11

12

13

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Lubrication Chart

16

14

17

15

14

74017 DIRECT DISC 520 Contour

DIRECT DISC 520 Contour

14 DIRECT DISC 520 Contour

15 DIRECT DISC 520 Contour

16

0299 924.3 - BA DIRECT DISC 520 / 520 Contour

17

10.4

Lubrication Chart

23 24

21 22

18 20

18

18 19

23 24

72800

18

19 JAGUAR 900 - 830 Type 942

20

JAGUAR 900 - 830 Type 943

21

22

NOTE! Remove cover (A) to lubricate the universal drive shaft (23).

71741

10.5

23

A

24

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

Lubrication Chart

27 25

28 26

30 26

29 25

72800

25 DIRECT DISC 520 Contour

26 DIRECT DISC 520 Contour

27 DIRECT DISC 520 Contour

28 DIRECT DISC 520 Contour

29

0299 924.3 - BA DIRECT DISC 520 / 520 Contour

30

10.6

Lubrication Chart

10.7

BA DIRECT DISC 520 / 520 Contour - 0299 924.3

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

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

0299 924.3 BA DIRECT DISC 520 / 520 Contour EN - 02.06 Printed in Germany