CLAAS DIRECT DISC 520 DIRECT DISC 520 CONTOUR JAGUAR 900 890 870 850 830 Assembly and Operator’s man

DIRECT DISC 520 DIRECT DISC 520 CONTOUR JAGUAR 900, 890, 870, 850, 830

Assembly and Operator’s manual

Pl ea se

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!

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

CLAAS Saulgau GmbH

We

Zeppelinstrasse 2

D-88348 Bad Saulgau

declare under their sole responsibility that the product

Header - Model 426 »DIRECT DISC 520 / 520 Contour« to which this declaration refers corresponds to the pertinent basic safety and health requirements of EC Directive 89/392/EEC, and to the requirements of the other pertinent EC Directives:

-/-

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

EN 745 - 1999

Bad Saulgau, 18.02.2005 Technical Management (Rauch)

Production management (Fetscher)

Quality management (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 operating instruction is valid for all cutter units: DIRECT DISC 520 / 520 Contour Type 426 from machine No. 426 0 1001.

1.1

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

Table of contents

Table of contents

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

2. Table of contents .................................................... 2.1 3. Preface Of special importance ............................................................... 3.1 Type plate ................................................................................. 3.2 Road transport .......................................................................... 3.3 Protective equipment for road transport ............................. 3.4

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 prop ............................................................................... 4.8

5. Specifications DIRECT DISC 520 / 520 Contour ............................................. 5.1

6. Assembly 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 Shipping package forage harvester attachment set ........... 6.6 Installing »DIRECT DISC« drive pulley in forage harvester ................................................... 6.8 Raising potentiometer ......................................................... 6.8 Installing additional hydraulic connections ....................... 6.10 Fit wiring harness for ESR Module ................................... 6.14 ESR Module ..................................................................... 6.16 Adjusting drop rate ........................................................... 6.17 Conversion valve for front attachments (Additional equipment chopper) ........................................ 6.18

7. Before operation 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 ........................................................ 7.4 Positioning v-belts for mower drive ..................................... 7.5 Connecting electrics ........................................................... 7.7 Mounting universal drive shaft ............................................ 7.8 Setting the paddle roller ...................................................... 7.9 Hydraulic paddle roller adjustment (Additional equipment only DIRECT DISC 520 Contour) . 7.10

0299 924.2 - BA DIRECT DISC 520 / 520 Contour

Adjusting cutter bar skids .................................................

Setting cutter bar inclination .............................................

Working and transport position ...............................................

Transport position ............................................................

Working position ...............................................................

Removing and storing the front attachment ...........................

7.11 7.11 7.12 7.12 7.12 7.13

8. Operation 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) ..........................................

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

9. Maintenance Important maintenance instructions ......................................... 9.1 Hydraulic system ................................................................ 9.1 Bolts ................................................................................... 9.1 Lubrication .......................................................................... 9.1 Guards ............................................................................... 9.1 Drive systems ........................................................................... 9.2 Gearbox ............................................................................. 9.2 Intake auger gearbox (A) ................................................... 9.3 Angle drive – drive intake auger (B) ................................... 9.4 Angle drive - mower drive (C) ............................................ 9.4 Clutches (D, E) ................................................................... 9.5 Chains ...................................................................................... 9.6 Lubricating the drive chain ................................................. 9.6 Tensioning drive chain ....................................................... 9.6 V-belts ...................................................................................... 9.7 Checking V-belts ................................................................ 9.7 Tensioning V-belts ............................................................. 9.7 V-belt guide ........................................................................ 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 Cutter bar (F) .......................................................................... 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

2.1

Table of contents 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 Faults ...................................................................................... 9.23

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

2.2

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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 set forth in this manual must be read carefully and followed by all persons concerned with the operation, maintenance, repair or inspection of the 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 operating instructions 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 data, dimensions and weights are given as an indication only.

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

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

3.1

Preface TYPE PLATE The machine number (VIN) (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 type plate (1) with the machine number (VIN) (2) is affixed on the back panel on the right side.

(Fig. 1, 2) 1 1 1

426

xxx

xxx

42601001

xxxx

2

2

3.2

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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 with the front attachment loaded on it must be attached to a forage harvester with trailing tires at the rear axle only.

– With other tires an additional towing vehicle is required for the trailer.

The trailer is approved for towing with the following forage harvesters: JAGUAR Model 492 with standard steering axle and • 540/65-R24 tires JAGUAR Model 492 with rear wheel drive (RWD): • 540/65-R24 tires • 700/50-26.5 tires

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

3.3

Preface The trailer is not approved for towing with the following forage harvesters. An additional towing vehicle is required for transport.

JAGUAR Model 492 with standard steering axle and • 16.9-24 tires • 700/50-26.5 tires JAGUAR Model 492 with rear wheel drive (RWD) and • 16.9-24 tires

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 7.12.

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

3.4

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

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 other use is considered to be as improper use and the manufacturer accepts no responsibility for any damage which may result from this, the risk 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 warning and information plates fitted provide important aids for the operation without danger; observing these instructions will ensure your personal safety.

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.

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4.1

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 risk 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!

4.2

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

(Fig. 1, 2)

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4.3

Safety rules

1

2

3

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

(Fig. 3, 4)

3

5

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

(Fig. 5, 6)

4.4

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Safety rules

6

7

4

7

8 9 7

Warning symbol 514 042.0 (4)

6

Never enter the danger area between front attachment and machine.

4

(Fig. 7, 8, 9) 8

5

7

6

10

12 Warning symbol 514 876.1 (5) 6

7

5

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

(Fig. 10, 11, 12) 11

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4.5

Safety rules

6

7

4

13

8 17 Warning symbol 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

5

7

6

15

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

6

7

5

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

16

4.6

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Safety rules

8

19

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

(Fig. 19, 20)

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4.7

Safety rules

Safety rules SAFETY PROP 2

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

1

ATTENTION! Do not apply any additional load to the cutter bar cylinder safety lock with the hydraulic system of the forage harvester.

1

Raise front attachment to the highest position.

Pull the locking pin (2) in and position the cutter bar cylinder safety lock (1) so it touches the ground.

Secure the cutter bar cylinder safety lock (1) in the next possible drilled hole.

(Fig. 1)

4.8

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Specifications

Specifications

5 Specifications NOTE! Technical data, dimensions and weights are given as an indication only.

DIRECT DISC 520 / 520 CONTOUR Width:

mm

5175

Length:

mm

2440

Height:

mm

1440

Weight

kg

2700

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

5.1

Assembly

Assembly

6 Assembly LOADING AND UNLOADING THE FRONT ATTACHMENT

up to machine 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

from machine No. 426 0 1111

– Make sure the slings are sufficiently dimensioned!

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

NOTE!

1

up to machine 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 2

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

(Fig. 1, 2, 3)

3

3

6.1

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

2. Make adjustments on the forage harvester – see Adjustments on forage harvester, page 6.5.

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 7.4.

11. Mount V-belt for cutting disk drive.– see Positioning v-belts for mower drive, page 7.5.

12. Connect power supply – see Connecting electrics, page 7.7.

13. Mount universal drive shaft – see Mounting universal drive shaft, page 7.8.

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6.2

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 prop, page 4.8.

3

– Do not apply additional loading to the cutter bar cylinder safety lock with the hydraulic system of the forage harvester.

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!

3

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

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 prop, page 4.8.

• Loosen bolts (3).

• Turn straps (1) down.

• Set the minimum cutting height – see Adjusting cutter bar skids, page 7.11.

• Replace bolts (3).

• Tighten all bolts.

(Fig. 4, 5)

6.3

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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 prop, page 4.8.

– Do not apply additional loading to the cutter bar cylinder safety lock with the hydraulic system of the forage harvester.

6

5

6

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

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

7

4

Proceed as follows to attach the prop stands: 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 prop, page 4.8.

• Remove prop stands (4) from the bracket by

9

pulling prop stands backwards and removing them upwards.

8

NOTE! 4 8

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

• 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)

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6.4

Assembly ADJUSTMENTS ON FORAGE HARVESTER The front attachment is designed for attachment to the forage harvester Type 492.

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 type: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

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

6.5

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Assembly Order numbers – additional weights Quantity Designation Weight

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

Shipping package forage harvester attachment set Drive pulley: 1 0987 861.1 drive pulley (1x) 2 0905 110.0 cover (1x) (Fig. 9, 10)

1

9

2

10 3

Belt cover:

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)

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6.6

Assembly Potentiometer conversion for preselection of cutting height:

15 16 17

24

26

18 19 20

25

22

21

23 22

72782_01

12

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

0236 475.0 truss-head screw M16x16x10 (4x) 0905 042.0 strap (1x) 0905 043.0 strap (1x) 0239 386.0 contact washer A10 (4x) 0236 169.0 6 hex nut (4x) 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:

28 29 30

27

31

36

34

35

37

33

36

32 13

72784

27 28 29 30 31 32 33 34 35 36 37

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)

(Fig. 13)

Wiring harness - ESR Module:

39

40

38

41 42 43 48

73754

47

44 45 46

14

38 39 40 41 42 43 44 45 46 47 48

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)

6.7

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

Assembly Installing »DIRECT DISC« drive pulley in forage harvester 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: A

• Remove the wheel on the right side of the forage 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 H

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

• 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 924.2

6.8

Assembly • • • • •

F 16

26

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

Fix new strap (17) on potentiometer.

Fix the strap (16) on the guard (26).

Fit the plug (25).

Suspend new connecting rod (20) in bottom hole of strap (17) and secure it.

17

25 20

18

73756

• Position drilled hole (G) on lever (B) at distance (x) (Fig. 19) and drill a 6.5 mm hole.

Distance (x) = 60 mm

x

G

B 19

72235

• Mount the pre-assembled unit (potentiometer, strap (16) and guard (26) with the spacing bushes (23) and longer bolts on the holder (H). In doing this, lay the connection cable between the two fixings (arrows).

16

H 26

23 20

• Connect plug-in connection (D) again.

D 17

21

6.9

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

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

• Turn the strap (17) (Fig. 22) upwards.

• Fix connecting rod (20) in the drilled hole (G) in

20 B

the lever (B) and secure.

G (Fig. 17-22)

22

Installing additional hydraulic connections 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!

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

32 33

a

31

• • • •

b

J

Loosen existing hose (I or K).

Mount L-unions (32) on hydraulic cylinder (J).

Mount W-unions (33) on top connection.

Connect hose (I and K) to straight outlet (a) of the L-union (32).

• Connect new hoses (31) to the second outlet (b) 24

71791

of the L-union (32) and W-union (33).

• Fasten retainer (34) to frame with M12x30 hex 37 36

28

34

bolt, A12 contact washer and M12 nut.

35

NOTE! 37

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

36

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

25

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

• Install screw sockets (37) with blue (28) or red (35) washer and dust plug (36) on retainer (34).

6.10

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 (31) from top hydraulic cylinder connection to screw socket (37) with the red washer (35) to the top and connect it.

• Lay out hose (31) from bottom hydraulic cylinder connection to screw socket (37) with the blue washer (28) to the top and connect it.

• Fasten hose with self-locking straps.

(Fig. 23, 24, 25)

• Install guard (2).

(Fig. 26)

2

26

6.11

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

Assembly Mount pulley cover as follows:

7

• Remove screws (K) on feeder housing.

• Hand tighten retainer (7) on feeder housing with

K

screws (K).

T

• Mark hole (T).

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

27

– If necessary loosen lines and move to one side.

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

(Fig. 27)

• Fasten retainer (7) to feeder housing with

7

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

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:

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

• Adjust the V-belt – see V-belt guide, page 9.8.

(Fig. 29)

10

14 13 29

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

6.12

Assembly Mounting belt cover

4

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

(Fig. 30) 3

30

6.13

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

Assembly Fit wiring harness for ESR Module

• Open right control panel in the cab – see forage 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 (38) from top to the right wing.

40 41

42

ATTENTION! Beware of friction and jamming!

M

• Attach cable gland to cab floor.

• Fasten wiring harness (38) to cab floor with pipe

38

clamp (41), hex bolt (42) and contact washer (40).

32

• Mount retainer (M) on cab floor again.

(Fig. 32)

• Insert cable gland (O) into wing.

• Connect socket (N) to wiring harness (38) again.

O N

38

Clamp

Wire colour

31

brown

53

white/red

54

black/red

33

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

6.14

Assembly • Fasten socket and wiring harness (38) to fender with retaining strap (47), cheese-head screw (46), washer (45), lock washer (44) and nut (43).

38

• Fasten wiring harness with self-locking strap.

(Fig. 33, 34)

47 46 O

45 44 43 34

• Connect wiring harness to central electric system 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.

• Connect central electrics again.

C1

(Fig. 35, 36)

xC1

Q xC1-1 36

6.15

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

Assembly ESR Module 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 chopper 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)

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

6.16

Assembly Adjusting drop rate

Jaguar 900, 890, 870, 850, 830

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

E

S

If the front attachment has already been fitted:

L

67443

38

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

Jaguar 900, 890, 870, 850, 830

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.

Position (S) = heavy front attachment

V

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.

39

Drop rate: Faster = screw knurled screw (V) in Slower = screw knurled screw (V) out Further information – see operating instructions of forage harvester under “medium heavy to heavy front attachments”.

(Fig. 38, 39)

6.17

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

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.

40 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 operating instructions of forage harvester under “medium heavy front attachments”.

(Fig. 40)

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

6.18

Before operation

Before operation

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

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

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

12. Switch on the front attachment only in working position and at idle speed – see Working position, page 7.12.

7.1

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

Before 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 prop on page 4.8.

Never work on the front attachment unless the drive is switched off and the engine is 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 Adjusting drop rate, page 6.17.

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 7.4.

7. Fit the V-belts – see Positioning v-belts for mower drive, page 7.5.

8. Connect power supply – see Connecting electrics, page 7.7.

9. Attach universal drive shaft – see Mounting universal drive shaft, page 7.8.

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

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

7.2

Before 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)

7.3

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

Before operation Close lock ATTENTION!

5

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

6

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

3

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.

• Adjust lock mechanism if necessary

10

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

(Fig. 3, 4)

11 4

Connecting hydraulics

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 5

• Switch off the engine and remove the ignition key.

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

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

7.4

Before operation

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

Note the colour coding on the hydraulic lines and sockets.

(Fig. 5)

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

– Use appropriate tools.

18 19

ATTENTION! 6

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.

7

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.

7.5

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

Before 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).

8

9

• 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! The V-belt guide (22) protects the adjusting motor (21) from damage by the V-belts.

24 10

• 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, page 9.8.

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

7.6

Before operation • Reinstall V-belt guard (19).

In doing this, make sure that: • The connecting rod (26) moves freely.

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

25

• Close the guard.

• Check that the lock has securely clicked into

26

position.

19

(Fig. 6-11) 11

Connecting electrics

27

ATTENTION! Beware of friction and jamming!

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

(Fig. 12) 12

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

(Fig. 13)

28

13

7.7

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

Before operation Mounting universal drive shaft DANGER! Never run drive shafts without their guards, or if the guards are damaged. Never work under or on the raised front attachment without safe support.

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

14

– Do not apply additional loading to the cutter bar cylinder safety lock with the hydraulic system of the forage harvester.

NOTE! 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. 14).

• • • •

30

Switch off the engine and remove the ignition key.

Switch off the battery master switch!

Open cover (31).

First place universal drive shaft (30) on the PTO 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. Ensure that the locking pin clicks are securely in place.

• Close cover (31).

31 15

(Fig. 14, 15, 16)

31 16

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

7.8

Before operation Setting the paddle roller The height of the paddle roller (32) above the mower head must be adjusted to suit the fodder level, the fodder conditions and the usage conditions. Four holes (Fig. 17) are available for adjustment.

Hole a = short fodder Hole B = normal fodder conditions 32

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

17

72794

38

33

D

37

35

a

– Remove the ignition key!

B

– Switch off the battery master switch!

C

36 D

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

D

Both sides must be adjusted. To adjust the paddle roller (32) proceed as follows:

34

18

• • • •

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 (33, 34, 35).

• Loosen lock nut (37) 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 (36) 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. 17, 18)

7.9

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

Before operation Hydraulic paddle roller adjustment

A

(Additional equipment only DIRECT DISC 520 Contour)

39

Setting the stroke limits

Y

The straps (39) serve as stroke limiters for the adjustment plates. The straps (39) 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 19

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 39

• Fit the straps (39) using hex bolts (40) (M12x35MK) and Contact Washers (41) in the corresponding position (A or B).

B

40 41

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

20 Trough left – Position B

A

(Fig. 19, 20, 21) B

39

40 41

21

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

7.10

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

42

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

42 43

– Do not apply additional loading to the cutter bar cylinder safety lock with the hydraulic system of the forage harvester.

42 22

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 (43) 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 prop, page 4.8.

• Loosen bolts (42).

• Set minimum cutting height with the straps (42) and holes.

• Replace bolts (42).

(Fig. 22)

Setting cutter bar inclination

45

The cutter bar inclination can be set 3º steeper by removing the wedges (44) and packing wedges (45).

This is advisable in extreme operating conditions.

Keep chocks for later use.

44

45

(Fig. 23)

44 72790

7.11

45

23

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

Before operation After removal or installation of the wedges and chocks adjust the safety bar (48) on both sides as follows: 46

• Unfasten bolt (47).

• Release bolts (46).

• Fix safety bar (48) in the appropriate hole.

A B

– Hole (A) = flatter 47

48

– Hole (B) = steeper

• Tighten all bolts again.

24

(Fig. 24)

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.

25

• 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. 25)

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

3

– see Attaching and removing prop stands, page 6.4.

• If necessary, slide safety stand (2) up as far as

2

possible and secure it with the pin (3).

26

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

7.12

Before 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. 26)

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

– see Safety prop, 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 27

7.13

• Lower front attachment to the ground.

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

Before operation • Open cover (3) and remove universal drive shaft (2) by pressing the locking pin.

2

3 28

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

• Open the cover – see also Positioning v-belts for mower drive, page 7.5.

4

6

• Remove V-belt guard – see also Positioning v-belts for mower drive, page 7.5.

NOTE!

7 29

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 (7) from under the tensioning roller (5) and V-belt guide (4).

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

8

• Detach hydraulic hoses (10) at the quick release couplings.

10

30

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

7.14

Before operation 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.

• Remove the electrical plug (8) for drive monitoring from the forage harvester.

• Disconnect plug (11) for clearance lights (USA only).

11

31

• 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. 27, 28, 29, 30, 31)

7.15

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

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

– Touch push switch (1d) – switch on the “Contour System”.

1d

– Touch push switch (1c) – switch on the “Cut height adjustment”.

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)

0299 924.2 - BA DIRECT DISC 520 / 520 Contour

8.1

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 7.12.

8.2

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

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 Adjusting drop rate, page 6.17.

4

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

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

37171

2

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)

0299 924.2 - BA DIRECT DISC 520 / 520 Contour

8.3

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 fire!

– 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 7.9.

• 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.

8.4

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

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 7.11.

– 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 operating instructions 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 7.11.

0299 924.2 - BA DIRECT DISC 520 / 520 Contour

8.5

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 or move the front attachment up and down slightly.

(Fig. 3, 4)

5

B 4

8.6

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

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

7

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.

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

0299 924.2 - BA DIRECT DISC 520 / 520 Contour

7

8.7

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 7.10.

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 operation instructions for the forage harvester.

h

Order No.: 70799

8.8

s

Retrofitting set 10

0495 508.0

(Fig. 8, 9, 10)

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

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) 74001

11

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

0299 924.2 - BA DIRECT DISC 520 / 520 Contour

0495 510.0

8.9

Maintenance

Maintenance

9 Maintenance IMPORTANT MAINTENANCE INSTRUCTIONS DANGER!

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.

Always switch off the drive and the forage harvester for troubleshooting, repair, maintenance and cleaning work.

Bolts

– Remove the ignition key!

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

– Switch off the battery master switch!

Lubrication

DANGER!

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.

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

– see Safety prop, page 4.8.

Check all bolts for tightness and retighten if necessary.

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

ENVIRONMENT!

Hydraulic system

Dispose of oil and grease according to regulations!

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

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

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

ENVIRONMENT! Dispose of oil and grease according to regulations!

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

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.

Regularly check safety guards.

Replace worn or damaged safety guards by new ones.

9.1

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

Maintenance

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

– see Safety prop, 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 7.12.

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.

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

9.2

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

9.3

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

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

8

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

(Fig. 4, 6) 6

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

9.4

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)

9.5

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

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): Mark

9

Chain tension Remedy

between 5°/15°

O K.

less than 5°

too low

replace or shorten chain

greater than 15°

too high

extend or replace chain

(Fig. 9)

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

9.6

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!

9.7

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

Maintenance V-belt guide 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 dimensionY: 2 mm (Fig. 10)

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

9.8

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

9.9

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

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 from 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!

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

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.

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

9.10

Maintenance

9 9 F F

h

12

11

10

10

14

CUTTER BAR (F) DANGER! After extended operation, the cutter bar can reach temperatures up to approx. 80° C. – Fire danger!

– 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.

9.11

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

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: 4.0 litres each 9 = oil filler and oil level check plug 10 = oil drain screw

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

– see Safety prop, 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 check oil on level ground!

• Allow front attachment to reach operating temperature.

• 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).

• • • • • •

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

Lower front attachment to the ground.

Secure forage harvester against rolling away.

Switch off drive and engine.

Remove the ignition key.

Switch off battery master switch.

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

9.12

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

NOTE!

X

90°

9

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.

90°

Oil level: X = 15 - 17 mm 71969

15

(Fig. 14, 15)

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 cutter bar to the ground.

• Warm up cutter bar 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)

9.13

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

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.

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

9.14

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!

16

71855

1

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

ATTENTION! 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).

(Fig. 16, 17)

67733

120 Nm

17

9.15

4. Replace bolt and nut (1).

Tightening torque of the mower blade securing bolt = 120 Nm.

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

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. 18).

– If the drilled hole in the blade is widened.

61622

18

Maximum allowable widening of the drilled hole of Ln = 18 mm to L = 20 mm (Fig. 19).

(Fig. 18, 19)

L

Ln 19

61623

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.

20

61625

D

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).

– 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. 20).

– If the bolt shaft is worn from Dn = 18 mm to D = 15 mm (Fig. 21).

(Fig. 20, 21)

61624

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

21

9.16

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. 22)

H

a

22

61626

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

90

Replacing cutting discs ATTENTION! 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.

23

61628

2

(Fig. 23)

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. 24) 24

71806

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. 25)

3 25

9.17

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

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

26

• • • •

Remove cover.

Loosen lock nut (1) on sensor.

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

Retighten lock nut (1).

Adjustment dimension x: 2 mm (Fig. 26)

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!

27

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. 27)

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

9.18

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).

28

• Close sheet metal cover.

• Check that the sheet metal cover is securely locked.

(Fig. 28, 29)

2

3

5

29

9.19

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

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.

30

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

• Replace bolts (7).

(Fig. 30, 31)

10

9 31

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 32

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

Loosen bolts (12).

• Install in reverse order of removal.

(Fig. 32)

9.20

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.

3

– Raise front attachment to the highest position.

33

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

– Do not apply additional loading to the cutter bar cylinder safety lock with the hydraulic system of the forage harvester.

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. 33)

9.21

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

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: 34

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. 34, 35) 35

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.

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

9.22

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.

FAULTS Problem

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.

9.23

– Hydraulic connections on forage harvester reversed.

– ESR module has shut off drive.

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

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.

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

10.1

Lubrication Chart

Lubrication Chart

10

1

11

3

4

2

5

6 7

72802 DIRECT DISC 520 Contour - Additional equipment

1

2

3

4

5

DIRECT DISC 520 Contour - Additional equipment

6

10.2

7

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

Lubrication Chart

8

10

11

12

9

13

72802

8

9

10

11

12

13

0299 924.2 - BA DIRECT DISC 520 / 520 Contour

10.3

Lubrication Chart

16

14

17

15

14

74017 DIRECT DISC 520 Contour

DIRECT DISC 520 Contour

14 DIRECT DISC 520 Contour

16

10.4

15 DIRECT DISC 520 Contour

17

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

Lubrication Chart

23 24

22

19 21

18

19 20

23 24

72800

18

19

20

21

22

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

71741

23

0299 924.2 - BA DIRECT DISC 520 / 520 Contour

A

24

10.5

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

29

10.6

28 DIRECT DISC 520 Contour

30

BA DIRECT DISC 520 / 520 Contour - 0299 924.2

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 924.2 BA DIRECT DISC 520 / 520 Contour EN - 03.05 Printed in Gremany