CLAAS Forage Harvesters JAGUAR 960-930 JAGUAR 900-830 Fitting and Operating Instructions Manual

JAGUAR 960-930 JAGUAR 900-830

Fitting and Operating Instructions Adapter for LEXION front attachments

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40784

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Contents 1 Introduction 1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.1.1 How to use this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.1.2

Validity of instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.1.3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.2 Identification plates and identification numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.2.1 Spare parts and technical questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.2.2

Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 Safety precautions 2.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.1.1 Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.1.2

Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.2 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.2.1 Identification of warning and danger signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.3 Safety decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.3.1 General instructions for warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.3.2

Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3 Package list 3.1 Adapter for LEXION front attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.1.1 Supplementary kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4 Mounting 4.1 Preparing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 4.1.1 Putting the machine out of action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 4.1.2

Check shipping package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.1.3

Installing the hydraulic system (only JAGUAR type 492/493) . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.1.4

Installing the electric system (only JAGUAR type 492/493) . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.1.5

Installing the electric system (only JAGUAR type 494) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.1.6

Cutting the adapter PTO shaft (only JAGUAR type 493/494) . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.1.7

Pre-assembling the multicoupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.1.8

Installing the reel peripheral speed wiring loom (only cutterbar, only type 492/493) . . . . . . . . 38

4.1.9

Prepare and carry out a test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5 Specifications 5.1 JAGUAR - LEXION front attachments adapter - Types 492 / 493 / 494 . . . . . . . . . . . . . . . . . . . . . 41 5.1.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 5.1.2

Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.1.3

Permissible front attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

6 Prior to initial operation 6.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 6.1.1 General warnings prior to putting the machine into operation for the first time . . . . . . . . . . . . 43 6.1.2

Initial operation check list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3

40784

7 Prior to each operation 7.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 7.1.1 General warnings Prior to operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 7.1.2

Checklist for putting the machine into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

8 Mounting/removing front attachment 8.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 8.1.1 General warnings Installing / removing the front attachment . . . . . . . . . . . . . . . . . . . . . . . . . . 45 8.2 Mounting the adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 8.2.1 Connecting the wiring loom (only JAGUAR type 494) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 8.2.2

Removing the quick-release coupler (only JAGUAR type 493/494) . . . . . . . . . . . . . . . . . . . . 46

8.2.3

Mounting the adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

8.3 Fitting the front attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 8.3.1 Mounting CONSPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 8.3.2

Fitting the cutterbar (folding) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

8.4 Removing the adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 8.4.1 Disconnecting the wiring loom (only JAGUAR type 494) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 8.4.2

Removing the adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

8.4.3

Installing the quick-release coupler (only JAGUAR Type 493/494) . . . . . . . . . . . . . . . . . . . . . 59

9 Fieldwork 9.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 9.1.1 General warnings Fieldwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 9.2 Cab / Operator's platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 9.2.1 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

10 Faults and remedies 10.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 10.1.1 General warnings Faults and remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 10.2 Various components / Machine body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 10.2.1 Adjusting the lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

11 Maintenance 11.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 11.1.1 General warnings Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 11.2 General maintenance notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 11.2.1 Fixing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 11.2.2 Maintenance operations after the harvest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 11.2.3 Tightening torques for metric standard threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 11.2.4 Tightening torques for metric fine threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 11.2.5 Tightening torques for hydraulic screw fittings with ferrule according to DIN 3861 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 11.2.6 Tightening torques for hydraulic screw fittings and air conditioner fittings with a sealing cone and O-ring DIN 3865 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 11.3 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 11.3.1 Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 11.4 Lubricants chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 11.4.1 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4

40784

11.5 Gearbox / Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 11.5.1 Checking the drive gearbox oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 11.5.2 Topping up drive gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 11.5.3 Draining drive gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 11.5.4 Checking the output gearbox oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 11.5.5 Topping up output gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 11.5.6 Draining output gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

12 Lubrication chart 12.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 12.1.1 General warnings Lubrication chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 12.2 Lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 12.2.1 Greasing cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 12.2.2 Lubrication points - 100 h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

5

1 Introduction 1.1 General Information 40785

1 Introduction 1.1 General Information 64945

1.1.1 How to use this manual The present fitting and operating instructions are primarily intended for the machine operator and provide information about how to fit and operate the product.

Moreover, they describe how to fit the parts listed in the shipping package chapter.

In the Installation chapter, existing parts are marked by letters and new parts by numbers to provide better orientation.

Provided you follow the advice on care and servicing of your product, you will be rewarded with reliable and long service from your product.

Please have the regular inspections carried out by your CLAAS specialist workshop. Omissions of parts of the maintenance schedule or incorrect operation lead to a drop in performance and cost valuable time.

By correct operation and servicing you can make full use of our sound experience and of the latest technical knowledge with which your product has been designed, thus ensuring reliability of your product.

Texts and figures Pictures and graphics are neutral. Differences are pointed out by notes beneath the figure.

Texts are short and not machine-specific as far as possible. Differences are pointed out by intermediate headings.

Different types of texts can easily be distinguished from one another by their formats. The following formats are distinguished: Formatting

Meaning

Description

Description

Text

Further information on the subject.

Operation

Operations which must be carried out one after the other.

Result

Consequence of operations carried out.

– Instructions Result

References can easily be distinguished by suitable symbols. The following symbols are distinguished: Symbol

6

Meaning

Description

See index

The symbol indicates that further information on this subject can be found at another point in this manual.

See index of the relevant Operator's manual

The symbol indicates that further information on this subject can be found in the Operator's manual of that machine or equipment.

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1 Introduction 1.1 General Information 40785

Document structure based on subassemblies As far as the contents permit, the chapters of this manual are structured according to subassemblies. The structure of these subassemblies is the same in all chapters.

Different product groups have different document structures based on subassemblies. CLAAS always takes care to keep these document structures based on subassemblies identical in any documents.

Search and find The wanted subject can easily be found with the recurring subassembly structure, using the table of contents or the header line of this manual.

In addition, the index of this manual is a useful tool for locating a specific subject. The index can be found on the last pages of this manual.

Directions Text elements such as front, rear, right and left always apply to the direction of travel. In figures, the direction of travel may be indicated by a direction arrow.

Optional equipment and accessories Optional equipment includes equipment variants of the machine where different variants are available, but only one variant can be fitted.

Accessories are equipment items that may be additionally fitted to the machine, but are not included in the standard scope of the machine.

Both terms designate possible variants. Standard scopes and equipment variants may differ in other countries.

Your CLAAS Service Department

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7

1 Introduction 1.1 General Information 40785 65824

1.1.2 Validity of instructions The present Manual applies to the following machine / front attachment: Designation

Type

Serial number from

to

JAGUAR 960 – 930

494

49400011

―

JAGUAR 900 – 830

493

49300011

―

JAGUAR 900 – 830

492

49200011

― 2475

1.1.3 Specifications Technical data, dimensions and weights are given as an indication only. CLAAS reserves the right to make changes subsequently as technical developments continue. Responsibility for errors or omissions not accepted.

8

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1 Introduction 1.2 Identification plates and identification numbers 40785

1.2 Identification plates and identification numbers 16907

1.2.1 Spare parts and technical questions All orders for spare parts and technical questions must include an indication of the associated identification number.

This is necessary, as otherwise incorrect spare part deliveries may result.

The identification number is located on the respective identification plate.

65827

1.2.2 Identification plate The identification plate (1) with the identification number is fitted on the left side above the housing.

1

1 22292

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9

2 Safety precautions 2.1 General Information 40786

2 Safety precautions 2.1 General Information 65539

2.1.1 Important information The information provided in this document must be read and observed by all persons concerned with the operation, maintenance and inspection of this product in order to prevent hazards.

Especially the "Safety“, "Prior to initial operation“ and "Prior to putting into operation“ chapters of the Operator's manual of the machine / front attachment must be read.

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

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

65530

2.1.2 Intended use This product has been constructed exclusively for usual applications in agricultural operations (intended use).

Any use beyond the above is considered as being outside of the intended use; the manufacturer will not be liable for any damage resulting from such use; the risk lies entirely with the user.

The intended use also includes the respect of the operating, maintenance and repair conditions specified by the manufacturer.

This product may be used, serviced and repaired only by persons who are familiar with it and who have been informed about the hazards.

The relevant accident prevention regulation as well as the other generally recognised rules in the fields of safety, occupational medicine and road traffic regulations shall be complied with.

Unauthorised modifications on this product will exclude any liability by the manufacturer for the resulting damage.

10

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2 Safety precautions 2.2 Safety rules 40786

2.2 Safety rules Before putting the machine into operation, read and follow the Operator's manual and the safety instructions!

67075

2.2.1 Identification of warning and danger signs In the present document, we have provided all texts concerning your safety and product safety with the signs below. Please pass all safety instruction on to other users as well.

Danger!

Nature and source of danger Consequences: death or serious injury – Countermeasures Warning!

Nature and source of danger Consequences: injuries – Countermeasures Caution!

Nature and source of danger Consequences: material damage – Countermeasures Note!

Nature and source of information Consequences: enhanced machine economy or easy assembly – Measures Environment!

Nature and source of danger Consequences: damage to the environment – Countermeasures

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11

2 Safety precautions 2.3 Safety decals 40786

2.3 Safety decals 67078

2.3.1 General instructions for warning signs The danger zones on this product which cannot be eliminated by design or protective measures, are identified by safety decals. These safety decals help to alert persons to hazards which can cause personal injury.

The safety decals consist of two components: – Part 1 shows the risk of injury in a warning triangle.

– Part 2 shows how injury and accidents can be prevented by appropriate actions.

The pictures on the safety decals consist of generally understandable pictograms. As far as possible, the safety decals must be located in close proximity to the hazardous area.

The original CLAAS safety decals are equipped with the CLAAS part number and the date of manufacture.

The positioning and meanings of the safety decals is explained below: – When ordering, please use the 10-digit CLAAS part number given ahead of every safety decal, – The safety decal number given in ( ) shows the correct position of the safety decals in the associated picture, – followed by an explanation of the safety decal graphics in text form.

Danger!

Danger zones on the machine Death or serious injury.

– Damaged and illegible warning symbols / safety decals are to be replaced immediately.

– If components with warning symbols / safety decals are replaced always ensure that the new components are equipped with the warning symbols / safety decals.

12

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2 Safety precautions 2.3 Safety decals 40786 65541

2.3.2 Adapter 00 0514 038 2 (1) 1

1 22238

Use the marked points only to lift the machine. Never stand in the hazardous area below the suspended machine.

2

00 0514 839 0 (5)

5

3 22238

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Wait until all machine components have completely stopped before touching them.

4

13

2 Safety precautions 2.3 Safety decals 40786

00 0516 028 0 (11)

11

5 22869

Do not open or remove safety shields while engine is running.

14

6

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3 Package list 3.1 Adapter for LEXION front attachments 40787

3 Package list 3.1 Adapter for LEXION front attachments 65850

3.1.1 Supplementary kit

1

22333

Retrofit kit 00 0143 272 0 (JAGUAR type 494) Retrofit kit 00 0143 271 0 (JAGUAR type 493) Retrofit kit 00 0143 270 0 (JAGUAR type 492) Pos. no.

Designation

1

Adapter

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Dimensions

ISO/DIN standard

Quantity 1

15

3 Package list 3.1 Adapter for LEXION front attachments 40787

2

6

3 4 5

22363

2

Retrofit kit 00 0143 271 0 (JAGUAR type 493) Retrofit kit 00 0143 270 0 (JAGUAR type 492) Pos. no.

Designation

Dimensions

ISO/DIN standard

Quantity

2

Hex. bolt

M8x110 **

4

Hex. bolt

M8x90 **

4

Hex. nut

M8

4

3

Rubber bearing

15/15

4

4

Reducing adapter

10 to 8

2

5

Centre cross

2

6

Hydraulic hose pre-assembled

1

* Component is not shown. ** Is required as a function of machine involved.

16

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3 Package list 3.1 Adapter for LEXION front attachments 40787

10

11

12

13

14

17 16

15

19

15 18

20

3

22364

Retrofit kit 00 0143 272 0 (JAGUAR type 494) Retrofit kit 00 0143 271 0 (JAGUAR type 493) Retrofit kit 00 0143 270 0 (JAGUAR type 492) Pos. no.

Designation

10

Rocker switch, hydraulic fore and aft reel adjustment

1

11

Rocker switch, reel peripheral speed

1

12

Rocker switch, fold front attachment

1

13

Green pushbutton, fold front attachment to open position

1

14

Red pushbutton, fold front attachment to closed position

1

15

Relays

2

16

Self-locking strap

6

17

Cable clamp

1

18

Hex. bolt

M8x20

1

Contact washer

A8

1

Hex. bolt

M8x20

1

Contact washer

A8

1

19

Dimensions

ISO/DIN standard

Quantity

* Component is not shown.

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

17

3 Package list 3.1 Adapter for LEXION front attachments 40787

Retrofit kit 00 0143 272 0 (JAGUAR type 494) Retrofit kit 00 0143 271 0 (JAGUAR type 493) Retrofit kit 00 0143 270 0 (JAGUAR type 492) Pos. no.

Designation

Dimensions

Hex. nut

M8

20

Cable entry (only type 494)

21

Fuse (only type 494) *

ISO/DIN standard

Quantity 1 1

15A

2

* Component is not shown.

18

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

3 Package list 3.1 Adapter for LEXION front attachments 40787

26

25

31

28

27

34

30

29

4

22337

Retrofit kit 00 0143 272 0 (JAGUAR type 494) Retrofit kit 00 0143 271 0 (JAGUAR type 493) Retrofit kit 00 0143 270 0 (JAGUAR type 492) Pos. no.

Designation

25

Protective guard (only type 493/494)

1

26

Bracket (only type 493/494)

1

27

Double joint (only type 492)

1

28

Double joint (only type 493/494)

1

29

Wiring loom (type 493 only)

1

30

Wiring loom

1

31

Wiring loom (only type 494)

32

Hex. bolt *

M8x20

5

Hex. nut *

M8

5

Contact washer *

A8

5

Panhead screw *

M8x20

1

Hex. nut *

M8

1

Contact washer *

A8

1

33

34

Bracket (only type 494)

Dimensions

ISO/DIN standard

Quantity

1

* Component is not shown.

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

19

3 Package list 3.1 Adapter for LEXION front attachments 40787

41

40

35

38 36

37

39

22389

5

Retrofit kit 00 0143 272 0 (JAGUAR type 494) Retrofit kit 00 0143 271 0 (JAGUAR type 493) Retrofit kit 00 0143 270 0 (JAGUAR type 492) Pos. no.

Designation

35

Multicoupler

1

36

Union

2

37

Screw fitting

2

38

Dust cap

2

39

Threaded fitting

2

40

Hex. bolt

M8x20

1

Hex. nut

M8

1

Contact washer

B8

1

41

20

Pipe clamp

Dimensions

ISO/DIN standard

Quantity

1

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

3 Package list 3.1 Adapter for LEXION front attachments 40787

45

46

49

50

48

47

51

6

22392

Retrofit kit 00 0143 271 0 (JAGUAR type 493) Retrofit kit 00 0143 270 0 (JAGUAR type 492) Pos. no.

Designation

45

Cable conduit

46

Hex. bolt

M10x35

1

Hex. nut

M10

1

Contact washer

B10

1

Hex. bolt

M8x25

2

Hex. nut

M8

2

Contact washer

B8

2

47

Dimensions

ISO/DIN standard

Quantity 1

48

Bracket

2

49

Pipe end

2

50

Pipe clamp

51

Wiring loom

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

RSGU 30

2 1

21

4 Mounting 4.1 Preparing the installation 40788

4 Mounting 4.1 Preparing the installation 34840

4.1.1 Putting the machine out of action Danger!

Before starting to work on the machine, always stop the engine.

Moving machine parts and / or unexpected machine movements.

Death or serious injury.

– – – –

Diesel engine OFF. Apply the parking brake.

Remove the ignition key.

Remove the key of the battery isolating switch.

– Wait for all moving machine parts to come to a complete halt.

– Secure machine using wheel chocks.

– Ensure that the machine cannot be put into operation by third parties.

54745

4.1.2 Check shipping package Note!

Installation without checking the shipping package.

Uneconomic installation procedure.

– Check shipping package before starting installation.

22

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

4 Mounting 4.1 Preparing the installation 40788 4.2 Fitting the machine components

66283

4.2.1 Installing the hydraulic system (only JAGUAR type 492/493) Danger!

Jacking up the machine.

Death or serious injuries!

– Use a jack / support frame with sufficient load bearing capacity.

– Use a jack / support frame that is functioning correctly.

– Use the jack / support frame on solid and flat ground.

– Position the jack / support frame in a suitable position on the machine.

– Jack up the machine at the front left and remove the left drive wheel.

– Remove the guards (S).

S

1 22481

S

2 22482

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

23

4 Mounting 4.1 Preparing the installation 40788

– Remove panels (B).

B

B

B

3 22483

– Mark hoses of screw fittings (A) and (B) for identification.

– Unscrew hoses from screw fittings (A) and (B).

– Unscrew screw fittings (A) and (B) from the valve.

A

B

4 22484

4 A

4

– Pre-assemble centre crosses (5) with screw fittings (4).

– Screw pre-assembled centre crosses (5) to the valve, using the screw fitting (4).

– Screw hoses (A) and (B) to the corresponding centre cross (5) as marked previously.

B 5

5

5 22485

24

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

4 Mounting 4.1 Preparing the installation 40788

Designation A

B

C

D

E

F

6 22486

A A

A

Fitting

B

Washer red/blue

C

Contact washer

D

Hex. nut

E

Screw fitting

F

Reducing screw fitting

– Place washers (B) on fittings (A).

– Insert fittings (A) with red washer (B) into the upper bore beneath the operator's platform.

– Screw on fitting (A) with washer (C) and nut (D).

– Screw on the second fitting (A) with the blue washer (B) in the bottom bore.

– Screw hoses (6) to fittings (A), using the screw fittings (E) and (F).

7 22487

– Lay hoses (6) as shown and screw down using the rubber bearings (3) and bolts (2).

6

3

8 22488

– Lay hoses (6) as shown and screw down using the rubber bearings (3) and bolts (2).

3 6

3

9 22489

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

25

4 Mounting 4.1 Preparing the installation 40788

– Lay hoses (6) as shown and screw down using the rubber bearings (3) and bolts (2).

3

10 22490 66282

4.2.2 Installing the electric system (only JAGUAR type 492/493) – Open the pre-punched hole at (A).

– Deburr the hole edges.

– Bolt down socket of wiring loom (30), using bolts (32) at (A).

– Guide wiring loom (30) through opening (B).

B

A

11 22491

– Pull brackets (H) slightly forward.

– Lay wiring loom (30) along the brackets (H).

– Guide branch line of wiring loom (30) with the small connectors into opening (A).

– Lay the branch line of wiring loom (30) with the large connectors up to the central terminal compartment at (B).

A

B

H

12 22492

– Unscrew bracket (H).

– Remove the existing sleeve at (A).

– Guide wiring loom (30) through the opening at (A) upwards to the central terminal compartment.

– Insert sleeve of wiring loom (30) at (A).

– Screw on bracket (H).

– Bolt down (30) with clamp (17) and bolt (18).

A H

30 17 13 22493

26

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

4 Mounting 4.1 Preparing the installation 40788

– Slacken off knurled nut (A) beneath the monitor.

– Remove tray area (B).

– Fold up the switch console.

A

B

14 22494

– Remove cover (C).

– Slacken off nut (D).

D

C

15 22495

– Fold up the PCB (P).

– Disconnect connectors (FA), (H3) and (H4) from the board.

The sockets are marked on the board.

P

FA

H4

H3

16 22496

JAGUAR type 492 only: H3

FA

– Get the wiring loom (30) ready.

H4

30 17

JAGUAR type 492

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

22497

27

4 Mounting 4.1 Preparing the installation 40788

JAGUAR type 493 only: FL2

30

– Connect wiring loom (29) to wiring loom (30).

29

H3 H4

18

JAGUAR type 493

22498

– Insert connectors of wiring loom (29/30) into the marked sockets of the board.

– Connect the previously disconnected cables with the corresponding connectors of wiring loom (29/30).

Observe the markings!

FL2

FA

H3

H4 19 22499

– Fold down the board.

– If necessary, plug the relays (15) on the sockets of the board at (K21) and (K22).

The sockets are marked on the board.

15

20 22500

– Close and lock the central terminal compartment.

– Refit the tray area.

28

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

4 Mounting 4.1 Preparing the installation 40788

– Remove panels at (A), (B) and (C).

– Remove connectors from panels (A), (B) and (C).

– Connect connector with switches (10), (11) and (12).

Switch (10) at (A), Hydraulic fore and aft reel adjustment.

Switch (11) at (B), Reel peripheral speed Switch (12) at (C), Fold front attachment.

– Insert switches (10), (11) and (12) into the openings (A), (B) and (C).

A C

B 21 22519

11

22 22520

– Fasten wiring loom (30) with cable bands (16).

30 16 23 22521

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

29

4 Mounting 4.1 Preparing the installation 40788

A

30 K

B F

C 24 22522

– Open the pre-punched holes at (A).

– Deburr the edges of holes.

– Connect wiring loom (30) with the existing wiring loom (K).

Plug (F) remains unconnected.

– Insert switches (13) and (14) into the holes at (A).

The green switch (13) is at the top.

The red switch (14) is at the bottom.

– Connect the connector (B) with the short cable to the green switch (13).

Cable = green/white/brown – Connect connector (C) with the long cable to the green switch (14).

Cable = green/blue/brown

13 14 25 22523

– Refit all guards.

– Refit panels.

30

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

4 Mounting 4.1 Preparing the installation 40788 85826

4.2.3 Installing the electric system (only JAGUAR type 494) – Screw socket of wiring loom (31) down to bracket (34) with screws (32).

Observe the installation position!

31

26 29445

A

32

34

27 29454

– Screw on the bracket (34) on the left side of the operator's platform.

34 28 29455

– Lay the wiring loom (31) to the right side of the machine beneath the operator's platform.

– Fasten wiring loom (31) with clamp (17).

31

17 29 29443

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

31

4 Mounting 4.1 Preparing the installation 40788

– – – –

Unscrew plate (A).

Remove plug at (B).

Guide wiring loom (31) through the opening at (A).

Clip the cable entry (20) around the wiring loom (31) and insert it into the opening at (B).

– Bolt down plate (A).

B 20

A

30 29456

– Fold up the switch console.

– Remove cover (A).

A 31 15456

– Ensure that the relays of positions (K32 and K33) are provided on the PCB and plug in relays (15) if necessary.

– Ensure that the fuses of positions (F79 and F80) are plugged on the PCB and plug in fuses (21) if necessary.

– Disconnect connector (H3) from the socket.

– Plug connector (H3) of wiring loom (31) into the socket and connect it with the connector (H3) previously removed.

H3 21

15 32

Note!

Malfunction of machine when the adapter is not used.

28884

H3

Uneconomic use due to troubleshooting.

– When the adapter for LEXION front attachments is not required, ensure that connector (H3) of wiring loom (31) is disconnected from socket (H3) and the initial connector (H3) is connected again.

31

33 29445

32

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

4 Mounting 4.1 Preparing the installation 40788

– Fold up the PCB (P).

P

34 28886

– Disconnect connectors of positions (FL1 and FR1) from the PCB. – Plug the connectors (FL1, FR1, RSA and RSB) of wiring loom (31) into the sockets and connect them with the connectors (FL1 and FR1) previously disconnected.

– Connect terminal (+30) with the PCB.

+30 FL1

RSA

FR1

RSB

35 29445

16

1 19

18

16 10

21 3

P2

E1

MX

18 12

3

1

LS1 1

19

KA

15

ATP 3

FL2 3 21

16

18

MR FR1

3

E3 19

1

19

E5

21

3

1

3

1

3

SV

1

3

1

9

MU 1

3

15

13

15

3

1

MW

E2

MG 7

15

7

3

13

9

7

KB

RS2 9

18

1 3

1 1

3

13

P1

12

10

21

1

3

1

3

1 3

1

15

16

3

19

MV 3

13

H2 3 9

1 7

18

9

1

MS

16 1

9

7

15

ZS

15

13

1

3 7 3

1

H1 3

RSB 1

3

1

3 15

RSA

21

LS2 13

1

1 13

13

1 12

3 15

3

10

10

9

1 13

FL1

3

1

3

1

7

KC

12

3

-31 +30

+30D

36 29451

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

33

4 Mounting 4.1 Preparing the installation 40788

– Lay the wiring loom branch (A) upwards into the switch console.

A

37 29445

38 29458

– Remove panels at (A), (B) and (C).

A

B

C 39 13456

34

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

4 Mounting 4.1 Preparing the installation 40788

– Connect connector with switches (10), (11) and (12).

– Insert switches (10), (11) and (12) into the openings of the switch console.

S24

S19

S21

40 29445

S19 12 10

S21

11 S24

41 29448

– Unscrew bolts (S).

– Remove cover (B).

B S

42 29448

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

35

4 Mounting 4.1 Preparing the installation 40788

– Disconnect connector (S) from the lighting of display (A).

– Plug connector (E35) of wiring loom (31) on the display (A) and connect it with the connector (S) previously removed.

E35

43 29445

S

E35

E35

A

44 29452

– Fasten wiring loom (31) with cable bands (16).

31

45 29443

– Refit panels.

36

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

4 Mounting 4.1 Preparing the installation 40788 66281

4.2.4 Cutting the adapter PTO shaft (only JAGUAR type 493/494) When the adapter is to be built on a JAGUAR type 493/494 machine, the PTO shaft (1) of the adapter must be cut off.

Note!

Shorter PTO shaft.

The adapter cannot be used for a JAGUAR type 492 any more.

1

46

– Before using the adapter on a JAGUAR type 492 again, a new PTO shaft must be installed.

22292

Danger!

Cutting of PTO shaft with unsuitable tool.

Death or serious injury.

X

– Use suitable tools.

– Wear suitable protective clothing.

– Cut off dimension (X) from PTO shaft (1).

Dimension (X) = 30 mm – Deburr PTO shaft.

1

47 22480 66301

4.2.5 Pre-assembling the multicoupler – Bolt screw fittings (36) and (37) to the multicoupler (35).

– Place the caps (38) on the fitting (39) and screw it to the screw fitting (37).

35 36

37

39 38 48 22530

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

37

4 Mounting 4.1 Preparing the installation 40788

– Relocate the bracket of the multicoupler from position (A) to (B).

If required, drill a hole at (B) beneath the frame.

– Fit the multicoupler (35) on the bracket of adapter (1).

– Screw the hose of multicoupler (35) to adapter (1), using clamp (41) and screw (40).

Ensure that a sufficient length of hose is available for connecting to the operator's platform of the machine.

35 41

A

49 22531

B

50 29572 67144

4.2.6 Installing the reel peripheral speed wiring loom (only cutterbar, only type 492/493) This wiring loom is necessary only when the adapter for fitting a cutterbar with electric reel adjustment is used.

– Bolt bracket (48) down to the frame with bolt (46).

– Unscrew bolt (S).

– Bolt bracket (48) down to the bearing plate with bolt (S).

48

48 46 S

51 22890

38

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

4 Mounting 4.1 Preparing the installation 40788

– Cut off tube (45) according to the cutterbar width.

Deburr the cutting point.

– Bolt tube (45) to brackets (48), using clamps (50) and bolts (47).

50

45

50

52 22891

– Plug the connector of wiring loom (51) into the socket on the operator's platform.

51

53 22892

– Lay the wiring loom (51) from the operator's platform to the engine (M) through the tube.

– Fit the end piece (49) around the cable on both sides and plug it into the tube ends.

M 49 51

54 22893

– Ensure that wiring loom (51) is laid in tube (45) without stress.

51

55 22894

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

39

4 Mounting 4.1 Preparing the installation 40788

– Disconnect connector (S) from the engine at (A).

– Connect connector of wiring loom (51) to the engine at (A).

– Fasten wiring loom (51) to the front attachment, using cable bands.

A 51

S

56 22895 67124

4.2.7 Prepare and carry out a test run – Fit front attachment.

– If necessary, carry out the following work prior to the test run: - Retighten threaded joints of all newly fitted parts.

- Fit any safety features previously removed.

- Put the tools used back into place.

– Check the settings on the machine.

– Carry out a test run.

40

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

5 Specifications 5.1 JAGUAR - LEXION front attachments adapter - Types 492 / 493 / 494 40789

5 Specifications 5.1 JAGUAR - LEXION front attachments adapter - Types 492 / 493 / 494 65774

5.1.1 Dimensions

L1 L3

H1

L2

22273

Size

Dimension

L1 Overall width

2182 mm

L2 Distance between fitting points

1700 mm

L3 Installation depth

approx. 350 mm

H1 Overall height

1160 mm

1

65776

5.1.2 Weights Adapter

Weight

for LEXION front attachment

488 kg

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

41

5 Specifications 5.1 JAGUAR - LEXION front attachments adapter - Types 492 / 493 / 494 40789 66827

5.1.3 Permissible front attachments The adapter is allowed for fitting the front attachments listed below. Depending on the front attachment and the machine, additional weights may be required at the rear of the machine.

Front attachment

Type

Cutterbar (folding) C540-C450

706

CONSPEED 8-75FC / 6-75FC

911 up to serial no.: 91101393 912 up to serial no.: 91201185

42

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

6 Prior to initial operation 6.1 General Information 40790

6 Prior to initial operation 6.1 General Information 85902

6.1.1 General warnings prior to putting the machine into operation for the first time In the following sections of this chapter, the general warnings below are referred to by means of instructions.

Danger!

Before starting to work on the machine, always stop the engine.

Moving machine parts and / or unexpected machine movements.

Death or serious injury.

– – – –

Diesel engine OFF. Apply the parking brake.

Remove the ignition key.

Remove the key of the battery isolating switch.

– Wait for all moving machine parts to come to a complete halt.

– Secure machine using wheel chocks.

– Ensure that the machine cannot be put into operation by third parties.

Danger!

The front attachment, reel and feeder unit may drop uncontrolled.

Death or serious injury.

– Apply safety locks.

– Keep a safe distance from the hazard area.

66285

6.1.2 Initial operation check list This chapter only describes the actions required before the first use of the front attachment. It does not replace the actions that must be performed before every subsequent use.

– Observe the general warnings at the beginning of the Prior to initial operation chapter.

Before operating the unit for the first time, the following activities must be carried out.

– Complete all necessary steps according to the maintenance chart.

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

43

7 Prior to each operation 7.1 General Information 40791

7 Prior to each operation 7.1 General Information 85903

7.1.1 General warnings Prior to operation In the following sections of this chapter, the general warnings below are referred to by means of instructions.

Danger!

Before starting to work on the machine, always stop the engine.

Moving machine parts and / or unexpected machine movements.

Death or serious injury.

– – – –

Diesel engine OFF. Apply the parking brake.

Remove the ignition key.

Remove the key of the battery isolating switch.

– Wait for all moving machine parts to come to a complete halt.

– Secure machine using wheel chocks.

– Ensure that the machine cannot be put into operation by third parties.

Danger!

The front attachment, reel and feeder unit may drop uncontrolled.

Death or serious injury.

– Apply safety locks.

– Keep a safe distance from the hazard area.

66286

7.1.2 Checklist for putting the machine into operation – Observe the general warnings at the beginning of the Prior to operation chapter.

Every time before operating the unit, the following activities must be carried out.

– Complete all necessary steps according to the maintenance chart.

– If required, fit additional weights according to the front attachment to the machine.

– Check tyre pressure of machine according to the front attachment, and adjust if necessary.

44

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

8 Mounting/removing front attachment 8.1 General Information 40792

8 Mounting/removing front attachment 8.1 General Information 85906

8.1.1 General warnings Installing / removing the front attachment In the following sections of this chapter, the general warnings below are referred to by means of instructions.

Danger!

Before starting to work on the machine, always stop the engine.

Moving machine parts and / or unexpected machine movements.

Death or serious injury.

– – – –

Diesel engine OFF. Apply the parking brake.

Remove the ignition key.

Remove the key of the battery isolating switch.

– Wait for all moving machine parts to come to a complete halt.

– Secure machine using wheel chocks.

– Ensure that the machine cannot be put into operation by third parties.

Danger!

The front attachment, reel and feeder unit may drop uncontrolled.

Death or serious injury.

– Apply safety locks.

– Keep a safe distance from the hazard area.

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

45

8 Mounting/removing front attachment 8.2 Mounting the adapter 40792

8.2 Mounting the adapter 85880

8.2.1 Connecting the wiring loom (only JAGUAR type 494) – Disconnect connector (H3) from the socket.

– Plug connector (H3) of wiring loom (31) into the socket and connect it with the connector (H3) previously removed.

Note!

H3

Malfunction of machine when the adapter is not used.

Uneconomic use due to troubleshooting.

1 28884

H3

– When the adapter for LEXION front attachments is not required, ensure that connector (H3) of wiring loom (31) is disconnected from socket (H3) and the initial connector (H3) is connected again.

31

2 29445 66295

8.2.2 Removing the quick-release coupler (only JAGUAR type 493/494) – Observe the general warnings at the beginning of the Installing/removing the front attachment chapter.

– Remove lid (1).

1

3 12516

46

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

8 Mounting/removing front attachment 8.2 Mounting the adapter 40792

– Turn out screw (1).

1

4 13418

– Unscrew bracket (1).

– Pull out quick-release coupler (2).

1 2

5 12439 66311

8.2.3 Mounting the adapter – Observe the general warnings at the beginning of the Installing/removing the front attachment chapter.

The adapter requires different universal drive shafts for the machines of type JAGUAR 492 and 493/494.

(A) = JAGUAR type 493/494 A

(B) = JAGUAR type 492

B

6 22576

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

47

8 Mounting/removing front attachment 8.2 Mounting the adapter 40792

JAGUAR type 493/494 only: 3

1

– Insert stub of coupling (1) into gearbox (2).

– Bolt down stub of coupling (2) with the previously unscrewed bolt (3).

2 7 22577

JAGUAR type 493/494 only: – Bolt bracket (1) down with bolt (2) previously removed.

2

1

8 22689

2

Danger!

Unexpected machine movements.

1

Death or serious injury.

– Ensure that there are no persons between the adapter and the machine.

– Approach the machine slowly to the adapter until the coupling pins (1) are positioned beneath the coupling pockets (2).

9 22578

JAGUAR type 492 only: Warning!

Pinch points during assembly work.

2

3

Limbs may be bruised.

– Keep your limbs away from the hazard area.

4

1 10 22579

48

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

8 Mounting/removing front attachment 8.2 Mounting the adapter 40792

– Unlock coupling (1) at (2) and slide it on the gearbox stub.

– Align the coupling (1) towards the stub (3) and have the feeder unit of the machine carefully raised by another person.

By raising the feeder unit, the adapter slowly moves towards the feeder unit.

– During this process, fit coupling (1) carefully on stub (3).

– Close safety device (4).

JAGUAR type 493/494 only: Warning!

Pinch points during assembly work.

2

Limbs may be bruised.

– Keep your limbs away from the hazard area.

1 11

– Align the coupling (1) towards the stub (2) and have the feeder unit of the machine carefully raised by another person.

By raising the feeder unit, the adapter slowly moves towards the feeder unit.

22580

– During this process, fit coupling (1) carefully on stub (2).

JAGUAR type 493/494 only: 3

1

– Bolt down safety device (1) with the previously removed bolts (2).

– Bolt down safety device (1) with bolt (3).

The panhead of bolt (3) must be on the inside!

Bolt (3) is enclosed in the shipping package.

Bolt (3) = Panhead bolt M8x20

2

12 22896

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

49

8 Mounting/removing front attachment 8.2 Mounting the adapter 40792

– Raise feeder unit so that the face ends of the feeder unit and of the adapter make contact on top of one another.

– Apply the parking brake of the machine and stop the engine.

– Swing lever (1) to the inside.

– Secure lever (1) with spring clip (2).

– Ensure that lever (3) has engaged at rod (4).

2 1 13 22581

4

3

14 22582

– Remove lock (1).

– Push up support (2) and arrest it in the topmost position with lock (1).

1

2

15 22583

– Remove lock (1).

– Push up support (2) and arrest it in the topmost position with lock (1).

1 2

16 22584

50

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

8 Mounting/removing front attachment 8.2 Mounting the adapter 40792

– Connect connector (1) at the operator's platform.

– Connect red connector (2) with the red socket on the operator's platform.

– Connect blue connector (3) with the blue socket on the operator's platform.

2 1

3

17 JAGUAR type 492/493

22585

2 1

3

18 JAGUAR Type 494

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

29455

51

8 Mounting/removing front attachment 8.3 Fitting the front attachment 40792

8.3 Fitting the front attachment 66390

8.3.1 Mounting CONSPEED – Observe the general warnings at the beginning of the Installing/removing the front attachment chapter.

– Open lid (1).

– Remove universal drive shaft (2).

- Push in pin (3) and pull off universal drive shaft from the front attachment stub.

- Push universal drive shaft (2) together.

- Remove universal drive shaft (2) through the opening in lid (1).

– Repeat this process on the other side of the front attachment.

1

3 2

1 19 22616

Danger!

Unexpected machine movements.

Death or serious injury.

2

– Ensure that there are no persons between the front attachment and the machine.

1

20 22619

– Approach the machine slowly to the front attachment until the coupling pins (1) are positioned beneath the coupling pockets (2).

– Raise feeder unit so that the face ends of the front attachment and of the adapter make contact on top of one another.

– Apply the parking brake of the machine and stop the engine.

Danger!

The front attachment is not sufficiently safeguarded.

Death or serious injury.

– Strictly comply with instructions.

– Make sure the mechanical lock of the front attachment is secure.

52

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8 Mounting/removing front attachment 8.3 Fitting the front attachment 40792

– Pull out lock (1) on the left side and slide down lever (2).

– Engage lock (1) in lever (2).

2

The locking pins (3) engage in the pockets (4).

1

– Repeat this process on the other side of the front attachment.

4

3 21 22620

Danger!

1

Rotating universal drive shafts.

3

3

Death or serious injury.

2

1 22 22616

– Check for secure latching of the locks or locking pins.

– Never operate universal drive shaft without protective guard.

– Replace defective protective guards on the universal drive shaft immediately.

– Observe the recommendations of the drive shaft manufacturer.

– Fit universal drive shaft.

- Push universal drive shaft (2) together.

- Guide universal drive shaft (2) through the opening in lid (1).

- Push in pins (3) and fit universal drive shaft on the stubs of the adapter and of the front attachment.

- Ensure that the pins (3) engage safely.

- Close lid (1).

– Repeat this process on the other side of the front attachment.

Caution!

2

Dirt will enter hydraulic components.

Damage to hydraulic system.

– Make sure the multi-coupler is seated and sealed properly.

– Never place multi-coupler on the ground.

1

23 22621

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

– Remove safety device from front attachment at (1).

– Unscrew multicoupler from adapter at (2).

– Fit safety device on the adapter at (2).

– Screw multicoupler on the front attachment at (1).

53

8 Mounting/removing front attachment 8.3 Fitting the front attachment 40792 66760

8.3.2 Fitting the cutterbar (folding) – Observe the general warnings at the beginning of the Installing/removing the front attachment chapter.

– Approach the machine slowly to the front attachment until the coupling pins (1) are positioned beneath the coupling pockets (2).

– Raise the front attachment, using the feed rake conveyor.

– Apply the parking brake of the machine and stop the engine.

2 1

24 22710

– Adjust the cutting angle position.

Refer to front attachment's operator's manual.

– Lock coupling pins (1).

- Pull out pins (2).

- Turn lock (3) into the coupling pin (1).

- Refit pin (2) back into the bore.

1 3 2

The lock (3) is safeguarded against twisting.

– Repeat this process on the other side of the front attachment.

25 22711

Danger!

The front attachment is not sufficiently safeguarded.

3

4

Death or serious injury.

– Strictly comply with instructions.

– Make sure the mechanical lock of the front attachment is secure.

1 2

26 22714

– Pull spring clip (1) out of pin (3).

– Push lever (2) to the inside.

– Fit spring clip (1) into pin (3).

The pin (3) engages in the pockets (4) of the feed rake conveyor.

– Repeat this process on the other side of the front attachment.

54

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8 Mounting/removing front attachment 8.3 Fitting the front attachment 40792

Caution!

Dirt will enter hydraulic components.

2

Damage to hydraulic system.

– Make sure the multi-coupler is seated and sealed properly.

– Never place multi-coupler on the ground.

1

27 22715

– Remove safety device from front attachment at (1).

– Unscrew multicoupler from adapter at (2).

– Fit safety device on the adapter at (2).

– Screw multicoupler on the front attachment at (1).

Danger!

Rotating universal drive shafts.

1

2

Death or serious injury.

28 22716

– Check for secure latching of the locks or locking pins.

– Never operate universal drive shaft without protective guard.

– Replace defective protective guards on the universal drive shaft immediately.

– Observe the recommendations of the drive shaft manufacturer.

– Push in locking pin (1).

Slide universal drive shaft on the stub (2).

– Ensure that the locking pin (1) engages safely.

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

55

8 Mounting/removing front attachment 8.4 Removing the adapter 40792

8.4 Removing the adapter 85876

8.4.1 Disconnecting the wiring loom (only JAGUAR type 494) – Disconnect adapter cable (H3) from the socket and from the connector.

– Plug the connector of the wiring loom into the socket.

The adapter cable (H3) has no function.

H3

29 28884

H3

30 29445 67035

8.4.2 Removing the adapter – Observe the general warnings at the beginning of the Installing/removing the front attachment chapter.

– Remove front attachment.

– Disconnect connector (1) from the operator's platform.

– Fit cover (2) on socket and connector.

2 1 1

1 2

31 22585

56

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8 Mounting/removing front attachment 8.4 Removing the adapter 40792

– Remove lock (1).

– Pull out support (2) and arrest it in its bottommost position, using lock (1).

1 2

32 22584

– Remove lock (1).

– Pull out support (2) and arrest it in its bottommost position, using lock (1).

1

2

33 22583

– Pull out spring clip (2).

– Swing lever (1) to the outside.

2 1 34 22581

– Ensure that lever (3) is moved back far enough so that lock rod (4) will not collide with lever (3) when the feeder unit will soon be lowered.

4

3

35 22582

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

57

8 Mounting/removing front attachment 8.4 Removing the adapter 40792

JAGUAR type 493/494 only: 2

– Remove guard (1).

1

2

36 22897

– Slowly lower the feeder.

By lowering the feeder unit, the adapter slowly moves away from the feeder unit. The universal drive shaft (1) comes off of the stub.

1 37 22579

2

Danger!

Unexpected machine movements.

1

Death or serious injury.

– Ensure that there are no persons between the adapter and the machine.

– Ensure that the feeder unit is fully lowered.

– Slowly back up the machine from the adapter.

38 22578

JAGUAR type 493/494 only: – Unscrew bracket (1).

1 39 22689

58

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

8 Mounting/removing front attachment 8.4 Removing the adapter 40792

JAGUAR type 493/494 only: 2

1

– Unscrew the stub of universal drive shaft (1) at (2).

– Pull universal drive shaft (1) out of gearbox (3).

3 40 22577 66298

8.4.3 Installing the quick-release coupler (only JAGUAR Type 493/494)

13070 41 – Observe the general warnings at the beginning of the Installing/removing the front attachment chapter.

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

59

8 Mounting/removing front attachment 8.4 Removing the adapter 40792

– Apply high-temperature assembly paste to the external spline (1).

E.g.: Anti Seize, part no. 00 0136 571 0 – Introduce the external spline of the quick-release coupler (2) into the gearbox.

1 2 42 13071

– Insert hex. bolt (1) with liquid locking compound.

E.g.: DELO-ML-5328, part no. 00 0178 779 1 Tightening torque = 215 Nm 1

43 13072

– Bolt down the bracket (1) hand-tight.

1

44 12439

– Align bracket (1) to the dimension (X) relative to the housing (2).

Adjusting dimension (X) = 301 ± 1 mm To be measured on all faces!

– Bolt down bracket (1).

X

2

1 45 12515

60

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8 Mounting/removing front attachment 8.4 Removing the adapter 40792

– Insert lid (1).

1

46 12516

– Fit front attachment.

– Slacken off the bevel gear (1) of the front attachment and align it to dimension (Y) towards bracket (2).

Set dimension (Y) = 23.5 mm – Bolt down bevel gear (1) handtight.

Y

1

2

47 13073

– Align bevel gear (1) towards the bracket (2) to dimension (Z).

Set dimension (Z) = 30 mm – Bolt down the bevel gear (1).

1 2 Z

48 13074

– Testing the function: - When fitting the front attachment, the clutch half (1) of the front attachment must slightly push back the clutch half (2) of the machine against the spring (3).

- The clutch halves (1) and (2) must engage completely with one another and make even contact.

- The universal drive shaft must not touch the bracket (4).

2

1

3 4

49 13075

– Perform a function check.

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

61

9 Fieldwork 9.1 General Information 40793

9 Fieldwork 9.1 General Information 85907

9.1.1 General warnings Fieldwork In the following sections of this chapter, the general warnings below are referred to by means of instructions.

Danger!

Before starting to work on the machine, always stop the engine.

Moving machine parts and / or unexpected machine movements.

Death or serious injury.

– – – –

Diesel engine OFF. Apply the parking brake.

Remove the ignition key.

Remove the key of the battery isolating switch.

– Wait for all moving machine parts to come to a complete halt.

– Secure machine using wheel chocks.

– Ensure that the machine cannot be put into operation by third parties.

Danger!

The front attachment, reel and feeder unit may drop uncontrolled.

Death or serious injury.

– Apply safety locks.

– Keep a safe distance from the hazard area.

62

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9 Fieldwork 9.2 Cab / Operator's platform 40793

9.2 Cab / Operator's platform 67136

9.2.1 Controls – Observe the general warnings at the beginning of the "Fieldwork" chapter.

– Observe the operating instructions provided in the Operator's manual of the front attachment and of the machine.

Designation 1 2

1

Reel horizontal adjustment switch

2

Reel peripheral speed switch

3

Switch Fold front attachment in/out (only CONSPEED) Raise/lower reel (only folding cutterbar)

3

1

JAGUAR type 492/493

22882

3

1

2 2

JAGUAR type 494

29448

Designation 4

Front attachment fold in switch (with folding cutterbar only)

5

Front attachment fold out switch (with folding cutterbar only)

4

5

3 22883

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

63

10 Faults and remedies 10.1 General Information 40794

10 Faults and remedies 10.1 General Information 85909

10.1.1 General warnings Faults and remedy In the following sections of this chapter, the general warnings below are referred to by means of instructions.

Danger!

Before starting to work on the machine, always stop the engine.

Moving machine parts and / or unexpected machine movements.

Death or serious injury.

– – – –

Diesel engine OFF. Apply the parking brake.

Remove the ignition key.

Remove the key of the battery isolating switch.

– Wait for all moving machine parts to come to a complete halt.

– Secure machine using wheel chocks.

– Ensure that the machine cannot be put into operation by third parties.

Danger!

The front attachment, reel and feeder unit may drop uncontrolled.

Death or serious injury.

– Apply safety locks.

– Keep a safe distance from the hazard area.

64

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10 Faults and remedies 10.2 Various components / Machine body 40794

10.2 Various components / Machine body 66690

10.2.1 Adjusting the lock Adjusting the lock becomes necessary when the hooks (1) do not fully fit around the axle (2) any more.

2

1

1 22582

– Fit adapter to the machine and lock it using lever (1).

1

2 22581

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

65

10 Faults and remedies 10.2 Various components / Machine body 40794

– – – – – –

Slacken off nut (1) by a few turns.

Pull out cotter pin of pin (2).

Pull pin (2) out of the yoke.

Adjust lock by turning the yoke.

Ensure that hook (3) fully fits around axle (4).

Connect the lock rod and the yoke, using the pin (2).

– Secure pin (2) with cotter pin.

– Jam nut (1) against the yoke.

1 2 3 22697

4

3

4 22582

66

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11 Maintenance 11.1 General Information 40795

11 Maintenance 11.1 General Information 85912

11.1.1 General warnings Maintenance In the following sections of this chapter, the general warnings below are referred to by means of instructions.

Danger!

Before starting to work on the machine, always stop the engine.

Moving machine parts and / or unexpected machine movements.

Death or serious injury.

– – – –

Diesel engine OFF. Apply the parking brake.

Remove the ignition key.

Remove the key of the battery isolating switch.

– Wait for all moving machine parts to come to a complete halt.

– Secure machine using wheel chocks.

– Ensure that the machine cannot be put into operation by third parties.

Danger!

The front attachment, reel and feeder unit may drop uncontrolled.

Death or serious injury.

– Apply safety locks.

– Keep a safe distance from the hazard area.

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

67

11 Maintenance 11.2 General maintenance notes 40795

11.2 General maintenance notes 1298

11.2.1 Fixing material – Replace worn or damaged fixing material immediately.

– Remove any rust and corrosion from the fixing material before harvesting use.

– Clean fixing material only with a non-corrosive cleaning agent.

66767

11.2.2 Maintenance operations after the harvest Note!

Thorough care and repair of worn or damaged parts saves time and money when putting the machine back into operation.

Caution!

Cleaning of product with water.

Material damage due to corrosion.

– Avoid cleaning with water.

– After cleaning with water, grease all grease points.

Now let the product run for some minutes.

– Do not clean hollow spaces and cable leadthroughs with water.

– Clean product with compressed air.

– Remove dirt and grease from the outside of all the bearing assemblies.

– Preserve all grease points by pressing in grease.

After this, start all units of the product briefly in order to achieve even grease distribution.

– Grease all unpainted parts.

– Remove product from the machine.

68

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

11 Maintenance 11.2 General maintenance notes 40795 1299

11.2.3 Tightening torques for metric standard threads – The tightening torque values indicated below are only applicable if: - in conjunction with thread lubricant a friction coefficient of µ tot = 0.14 is achieved.

For this purpose a surface protection agent such as A3C+L, Dacromet or Termosil is recommended.

– no other tightening torque is indicated in the descriptive text.

– no additional screw locking devices such as Nyloc nuts or liquid thread adhesives are used.

Bolts and nuts Strength class

Tightening torque in Nm for a coefficient of friction of µ total = 0.14 8.8

10.9

12.9

M4

2.9

4.3

5

M5

5.8

8.5

10

M6

10

14.5

17

M8

24.5

36

42

Hex. bolts

M 10

48.5

71

83.5

ISO 4014 to

M 12

83.5

123

144

ISO 4018

M 14

133

196

229

M 16

207

304

355

Cheese-head screws

M 18

296

422

494

ISO 4762

M 20

417

594

695

M 22

570

813

951

Hex. nuts

M 24

718

1022

1196

ISO 4032

M 27

1058

1506

1763

M 30

1437

2046

2395

M 33

1944

2770

3240

M 36

2500

3561

4167

M 39

3237

4610

5394

Dimensions

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

69

11 Maintenance 11.2 General maintenance notes 40795 1300

11.2.4 Tightening torques for metric fine threads – The tightening torque values indicated below are only applicable if: - in conjunction with thread lubricant a friction coefficient of µ tot = 0.14 is achieved.

For this purpose a surface protection agent such as A3C+L, Dacromet or Termosil is recommended.

– no other tightening torque is indicated in the descriptive text.

– no additional screw locking devices such as Nyloc nuts or liquid thread adhesives are used.

Bolts and nuts Strength class

Tightening torque in Nm for a coefficient of friction of µ total = 0.14 8.8

10.9

12.9

M8x1

26

38.5

45

M 10 x 1

54

79

92.5

M 10 x 1.25

51

74.5

88

M 12 x 1.25

90.5

134

156

M 12 x 1.5

87

128

150

M 14 x 1.5

143

210

246

Hex. bolts

M 16 x 1.5

219

323

378

ISO 8765

M 18 x 1.5

331

470

551

ISO 8876

M 18 x 2

313

446

522

M 20 x 1.5

459

655

766

Hex. nuts

M 22 x 1.5

622

886

1037

ISO 4032

M 24 x 1.5

809

1152

1348

M 24 x 2

778

1108

1297

M 27 x 1.5

1173

1672

1956

M 27 x 2

1135

1617

1892

M 30 x 2

1580

2251

2634

M 33 x 2

2116

3015

3528

M 36 x 2

2773

3951

4623

M 39 x 2

3557

5067

5930

Dimensions

70

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

11 Maintenance 11.2 General maintenance notes 40795 1301

11.2.5 Tightening torques for hydraulic screw fittings with ferrule according to DIN 3861 Tube outside diameter in mm

Nominal diameter in mm

Width across flats in mm

Tightening torque in Nm

8

6

17

25

10

7

19

35

12

9

22

50

15

11

27

80

18

14

32

100

22

18

36

185 1302

11.2.6 Tightening torques for hydraulic screw fittings and air conditioner fittings with a sealing cone and O-ring DIN 3865 Tube outside diameter in mm

Nominal diameter in mm

Width across flats in mm

Tightening torque in Nm

8

6

17

25

10

7

19

30

12

9

22

40

15

11

27

60

18

14

32

80

22

18

36

110

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

71

11 Maintenance 11.3 Maintenance schedule 40795

11.3 Maintenance schedule 66776

11.3.1 Service intervals – You can find detailed information on maintenance work below in this chapter.

Maintenance Operations

50

100

250

After the harvest

100

As required

Every day

Before the harvest

40

Every

Once a year or every 500

Service intervals in working hours After the first

General maintenance Complete all steps according to the lubrication intervals.

•

Gearbox / clutch •

Check the drive gear oil level and top up if necessary.

Changing the drive gearbox oil.

•

Checking the output gearbox oil level and top up if necessary.

Changing the output gearbox oil.

72

• •

•

•

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

11 Maintenance 11.4 Lubricants chart 40795

11.4 Lubricants chart 66780

11.4.1 Lubricants Component

Capacity

Type of lubricant / Specification

Viscosity class / SAE class

Drive gearbox

2 litres

AGRISHIFT MT 80W-90

80W-90

Remarks

(total driveline) API GL4, GL5 MIL: 2105 D Output gearbox

2 litres each

AGRISHIFT MT 80W-90

80W-90

(total driveline) API GL4, GL5 MIL: 2105 D

Grease nipples

AGRIGREASE EP 2 EP 2 Grease

Lubrication points see lubrication chart

DIN 51502: KP2K-25NLGI2 Chains

CLAAS special chain oil

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

Lubrication points see lubrication chart

73

11 Maintenance 11.5 Gearbox / Clutch 40795

11.5 Gearbox / Clutch 66785

11.5.1 Checking the drive gearbox oil level – Place the adapter on level ground or raise it to a horizontal position.

– Observe the general warnings at the beginning of the "Maintenance" chapter.

– Turn out screw (1).

The oil level must be at the level of the bore at bolt (1).

– Top up oil if necessary.

– Turn in screw (1).

1

1 22780 66790

11.5.2 Topping up drive gearbox oil – Place the adapter on level ground or raise it to a horizontal position.

– Observe the general warnings at the beginning of the "Maintenance" chapter.

Environment!

Lubricants and fuels end up in the environment.

Environmental pollution.

– Lubricants and fuels must be collected and stored in suitable containers and disposed of in a way that is harmless to the environment and in accordance with existing anti-pollution regulations.

Warning!

Use of unauthorised spare parts.

Machine damage.

– Spare parts must at least comply with the technical standards required by the manufacturer of the implement!

– We recommend using genuine CLAAS spare parts.

74

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11 Maintenance 11.5 Gearbox / Clutch 40795

– – – – –

1

Remove screw (1).

Fill in new oil.

Check oil level and top up if necessary.

Clean screw (1).

Turn in screw (1).

2 22781 66795

11.5.3 Draining drive gearbox oil – Place the adapter on level ground or raise it to a horizontal position.

– Observe the general warnings at the beginning of the "Maintenance" chapter.

Warning!

Contact with hot liquids or machine parts.

Danger of burns – Wear suitable protective clothing.

– Let liquids or machine parts cool down.

– Comply with instructions.

Environment!

Lubricants and fuels end up in the environment.

Environmental pollution.

– Lubricants and fuels must be collected and stored in suitable containers and disposed of in a way that is harmless to the environment and in accordance with existing anti-pollution regulations.

– Remove screw (1).

– Collect the used oil in a sufficiently large container.

– Turn in screw (1).

1

3 22782

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

75

11 Maintenance 11.5 Gearbox / Clutch 40795 66800

11.5.4 Checking the output gearbox oil level – Place the adapter on level ground or raise it to a horizontal position.

– Observe the general warnings at the beginning of the "Maintenance" chapter.

– Turn out screw (1).

The oil level must be at the level of the bore at bolt (1).

– Top up oil if necessary.

– Turn in screw (1).

– Repeat this procedure on the other side of the machine.

1

4 22784 66802

11.5.5 Topping up output gearbox oil – Place the adapter on level ground or raise it to a horizontal position.

– Observe the general warnings at the beginning of the "Maintenance" chapter.

Environment!

Lubricants and fuels end up in the environment.

Environmental pollution.

– Lubricants and fuels must be collected and stored in suitable containers and disposed of in a way that is harmless to the environment and in accordance with existing anti-pollution regulations.

Warning!

Use of unauthorised spare parts.

Machine damage.

– Spare parts must at least comply with the technical standards required by the manufacturer of the implement!

– We recommend using genuine CLAAS spare parts.

76

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11 Maintenance 11.5 Gearbox / Clutch 40795

– – – – – – 1

Remove screw (1).

Fill in new oil.

Check oil level and top up if necessary.

Clean screw (1).

Turn in screw (1).

Repeat this procedure on the other side of the machine.

5 22784 66805

11.5.6 Draining output gearbox oil – Place the adapter on level ground or raise it to a horizontal position.

– Observe the general warnings at the beginning of the "Maintenance" chapter.

Warning!

Contact with hot liquids or machine parts.

Danger of burns – Wear suitable protective clothing.

– Let liquids or machine parts cool down.

– Comply with instructions.

Environment!

Lubricants and fuels end up in the environment.

Environmental pollution.

– Lubricants and fuels must be collected and stored in suitable containers and disposed of in a way that is harmless to the environment and in accordance with existing anti-pollution regulations.

– Remove screw (1).

– Collect the used oil in a sufficiently large container.

– Turn in screw (1).

– Repeat this procedure on the other side of the machine.

1 6 22784

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

77

12 Lubrication chart 12.1 General Information 40796

12 Lubrication chart 12.1 General Information 85794

12.1.1 General warnings Lubrication chart The following general warnings are addressed in the sections below of this chapter by means of instructions.

Danger!

Before starting to work on the machine, always stop the engine.

Moving machine parts and / or unexpected machine movements.

Death or serious injury.

– – – –

Diesel engine OFF. Apply the parking brake.

Remove the ignition key.

Remove the key of the battery isolating switch.

– Wait for all moving machine parts to come to a complete halt.

– Secure machine using wheel chocks.

– Ensure that the machine cannot be put into operation by third parties.

Danger!

The front attachment, reel and feeder unit may drop uncontrolled.

Death or serious injury.

– Apply safety locks.

– Keep a safe distance from the hazard area.

78

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12 Lubrication chart 12.2 Lubrication points 40796

12.2 Lubrication points 66812

12.2.1 Greasing cycles – Observe the general warnings at the beginning of the Lubrication chart chapter.

Grease point number

Working hours 10

50

100

1

•

2

•

3

•

4

•

5

•

6

•

7

•

250

Remarks 500

Grease point on both sides of adapter

Lubricant symbols in figures The following symbols are used in figures: Grease the grease point.

Grease the grease point.

For grease see Lubricants Chart.

For chain oil see Lubricants Chart.

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12 Lubrication chart 12.2 Lubrication points 40796 66861

12.2.2 Lubrication points - 100 h

22273

80

22579

1

22791

3

22792

5

22790

2

22581

4

22898

6

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22273

22791

7

00 0295 776 1 - ABA/BA ADPR VSG - 10/08

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Index

I

A

Identification plate ..................................................... 9 Initial operation Check list ............................................................ 43

Accessories ............................................................... 7 Adapter Remove .............................................................. 56 After the harvest Maintenance operations ..................................... 68

B Before putting the machine in operation Checklist ............................................................. 44

C Check list Initial operation ................................................... 43 Checking the oil level Drive gearbox ..................................................... 74 Output gearbox .................................................. 76 Controls ................................................................... 63 Cutterbar Fitting the cutterbar (folding) .............................. 54

L Lock Adjustment ......................................................... 65 Lubriation points Symbols .............................................................. 79 Lubricants ................................................................ 73 Lubrication Lubrication points - 100 h ................................... 80 Lubrication points .................................................... 79

M Machine Putting out of action ............................................ 22 Machine serial number .............................................. 8 Mounting the adapter .............................................. 47 Multicoupler Pre-assembly ..................................................... 37

D

O

Draining oil Drive gearbox ..................................................... 75 Output gearbox .................................................. 77 Drive gearbox Checking the oil level ......................................... 74 Draining oil ......................................................... 75 Topping up oil ..................................................... 74

Optional equipment ................................................... 7 Output gearbox Checking the oil level ......................................... 76 Draining oil ......................................................... 77 Topping up oil ..................................................... 76

E Electric system Installation .................................................... 26, 31

F Fixing material ......................................................... 68 Formatierung von Texten ........................................................... 6 Front attachment Permissible ......................................................... 42

P PTO shaft Cutting the adapter PTO shaft ............................ 37

Q Quick-release coupler Installation .......................................................... 59 Removal ............................................................. 46

R Reel peripheral speed Installation of wiring loom ................................... 38

G

S

General warnings Faults and remedy ............................................. 64 Fieldwork ............................................................ 62 Installing / removing the front attachment .......... 45 Lubrication chart ................................................. 78 Maintenance ....................................................... 67 Prior to operation ................................................ 44 Prior to putting the machine into operation for the first time .................................. 43 Greasing cycles ....................................................... 79

Safety Intended use ....................................................... 10 Warning signs ..................................................... 11 Safety decals ........................................................... 12 Safety rules ............................................................. 11 Service intervals ...................................................... 72 Shipping package check .................................................................. 22 Spare parts ................................................................ 9 Specifications ............................................................ 8 Symbol Legend ................................................................. 6

H How to use this manual ............................................. 6 Hydraulic system Installation .......................................................... 23

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T Technical questions ...................................................9 Test run preparation and execution ..................................40 Tightening torques Air conditioner fittings with a sealing cone and O-ring DIN 3865 ...................71 Hydraulic screw fittings with a sealing cone and O-ring DIN 3865 ...................71 Hydraulic screw fittings with ferrule according to DIN 3861 .............................71 Metric fine threads ..............................................70 Metric standard threads ......................................69 Topping up oil Drive gearbox ......................................................74 Output gearbox ...................................................76

V Validity of instructions ................................................8

W Warning signs General instructions ............................................12 Identification ........................................................11 Wiring loom Connecting ..........................................................46 Disconnecting .....................................................56 Installing the reel peripheral speed wiring loom ...............................................38

83

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84

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

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

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

CLAAS KGaA mbH 33426 HARSEWINKEL Germany

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

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

00 0295 776 1 ABA/BA ADPR VSG EN - 10/08 Printed in Germany