CLAAS JAGUAR 900 – 830 Adapter for LEXION front attachments Fitting And Maintenance Instruction Manu

FITTING AND MAINTENANCE INSTRUCTIONS

Adapter for LEXION front attachments

JAGUAR 900 – 830

Introduction

Introduction INTRODUCTION

This manual shows you how to mount the wiring loom and the hydraulic connections as well as the adapter for LEXION front attachments to JAGUAR 900 – 830 forage harvesters.

In addition, the maintenance of the adapter is also explained.

The various components for the wiring loom and the hydraulic connections are shown on pages 2.2 and 2.3.

The various components for the adapter are shown on pages 3.2 and 3.3.

CLAAS Service Department

298 421.1 - ABA Adapter

1.1

Introduction

Introduction CONTENTS

Introduction ............................................................................... 1.1 Contents ................................................................................... 1.2

Installing the wiring loom Shipping package ............................................................... 2.3 Mounting the hydraulic connections ................................... 2.4 Installing the wiring loom .................................................... 2.7 Cable connections ............................................................ 2.12

Mounting the adapter Shipping package ............................................................... 3.3 Mounting the adapter ......................................................... 3.4 Mounting the «Conspeed» maize picker ............................ 3.6 Connecting the universal drive shafts ................................ 3.6 Mounting the universal drive shaft on the left-hand side ........................................................... 3.7 Mounting the universal drive shaft on the right-hand side ......................................................... 3.7 Mounting the cutterbar ....................................................... 3.8 Connecting the universal drive shafts ................................ 3.9 Mounting the wiring loom for reel speed adjustment .......... 3.9 Mounting the folding cutterbar .......................................... 3.11 Locking the cutterbar on both sides ................................. 3.11 Connecting the universal drive shafts .............................. 3.12

Maintenance Maintenance .............................................................................

Angle drive .........................................................................

Oil change ..........................................................................

Oil level check ....................................................................

Spur gear ............................................................................

Oil change ..........................................................................

Oil level check ....................................................................

Lubrication chart .................................................................

1.2

4.3 4.3 4.3 4.3 4.4 4.4 4.4 4.5

ABA Adapter - 298 421.1

Installing the wiring loom

Installing the wiring loom

Installing the wiring loom

12

3

11 2

5 1 10 7 4

8

9

6

1

13 18

19

22

20

23

15 17 16

21

14

2

2.2

ABA Adapter - 298 421.1

Installing the wiring loom

Installing the wiring loom Shipping package Item Designation 1 2 3 4 5 6 7 8 9 10 11 12

13 14

15 16 17 18 19 20

21 22 23

Number

Centre cross.........................................................2 Reducing adapter 10 to 8.....................................2 Hydraulic hose .....................................................2 Threaded plug......................................................2 Identification washer, red .....................................1 Contact washer B 14............................................2 Hexagon nut.........................................................2 Identification washer, blue....................................1 Straight connector................................................2 Reducing adapter.................................................2 Rubber bearing 15/15 ..........................................4 Fastening clamp...................................................4 Hexagon bolt M 8 x 110 DIN 931-8.8* .................4 Hexagon bolt M 8 x 90 DIN 931-8.8* ...................4 Lock nut VM 8 ......................................................4 Wiring loom..........................................................1 Hexagon bolt M 8 x 20 DIN 933-8.8.....................2 Hexagon nut M 8..................................................2 Contact washer A 8..............................................2 Cable clamp .........................................................1 Hexagon bolt M 8 x 20 DIN 933-8.8.....................1 Contact washer A 8..............................................1 Relay....................................................................2 Return rocker switch, horizontal reel adjustment....................................1 Return rocker switch, reel speed ............................................................1 Return rocker switch, fold front attachments for MEDION and DOMINATOR front attachments .................................................1 Cable band...........................................................6 Push-button, green ..............................................1 Push-button, red ..................................................1

* Use depends on machine equipment

298 421.1 - ABA Adapter

2.3

Installing the wiring loom

Installing the wiring loom Mounting the hydraulic connections DANGER! Turn off the battery isolating switch!

Support the machine safely at the front lefthand side. Use a suitable support with a load-carrying capacity of approx. 10 t.

Unscrew guards (S and T) on the left-hand side.

(Fig. 3, 4)

S

3

T

4 Unscrew the panels (A, B and C).

(Fig. 5)

A

B

C

5

2.4

ABA Adapter - 298 421.1

Installing the wiring loom Unscrew the hydraulic hoses from both L-type unions (L).

NOTE! Marking the hydraulic hoses is recommended in order to avoid confusion.

L

ENVIRONMENT! 6

Collect any dripping oil and dispose of in a way that is harmless to the environment and in accordance with existing environmental regulations.

(Fig. 6)

Screw centre crosses (1) to reducing adapters (2).

First screw one centre cross with reducing adapter (2) to the inside of the solenoid valve. Refit the hydraulic hoses previously removed at the same location.

Screw hydraulic hose (3) to centre cross (1).

1

Tighten all hose connections.

(Fig. 1, 7)

7 Screw the second centre cross (1) to the outside of the solenoid valve and refit the hydraulic hoses previously removed at the same location.

Screw hydraulic hose (3) to centre cross (1).

Tighten all hose connections.

(Fig. 1, 8)

8

298 421.1 - ABA Adapter

2.5

Installing the wiring loom Screw threaded plug (4), identification washer (5 – red) with contact washer (6) and hexagon nut (7) into the top bore.

Screw threaded plug (4), identification washer (8 – blue) with contact washer (6) and hexagon nut (7) into the bottom bore.

(Fig. 1, 9, 10) 4

9 Screw threaded plug (4) and hydraulic hoses (3) together with straight connector (9) and reducing adapter (10).

5

4

Fasten the hydraulic hoses with rubber bearings (11) and long hexagon bolts (12).

7 10

6

9

(Fig. 1, 10, 11, 12, 13)

3

4 8

6

9 7

10

3 10

3 4 11

11

11 11

12

2.6

ABA Adapter - 298 421.1

Installing the wiring loom

11

13

Installing the wiring loom Punch out the pre-punched spot on the left-hand side (see arrow). Deburr the edges.

Bolt on the socket of wiring loom (13) with hexagon bolts (14).

Guide wiring loom through the top opening and lay to the right-hand side. To do this, slightly pull the cable holders (H) forward and press back on after inserting the cable.

14

Guide the junction line with the small connectors from the wiring loom through the opening on the right-hand side.

Lay the junction line with the big connectors beneath the operator's platform to the central terminal compartment (see arrows).

(Fig. 2, 14, 15, 16)

H

15

16

298 421.1 - ABA Adapter

2.7

Installing the wiring loom Fold up the switch console. To do this, remove tray area (A) and unscrew the knurled nut at the front below the switch console.

(Fig. 17) A

17 Unscrew the knurled nut (R) and fold up the central terminal compartment.

R

(Fig. 18)

18 – Unscrew the mounting plate (H) beneath the operator's platform.

– Remove rubber sleeve at the duct.

– Lay wiring loom (13) upwards to the central terminal compartment.

H

– Insert rubber sleeve of wiring loom at the duct.

– Re-fit mounting plate (H).

13

– Fasten wiring loom (13) with cable clamp (15) and hexagon bolt (16).

15 19

2.8

(Fig. 2, 19)

ABA Adapter - 298 421.1

Installing the wiring loom Disconnect the plugs (FA, H3 and H4) beneath the central terminal compartment.

Connect plugs (FA, H3 and H4) of wiring loom (13) at the same locations.

Connect the previously disconnected plugs with those of wiring loom (13), paying attention to matching colours.

(Fig. 20, 21, 22) FA

H4

H3

20

FA

H3

H4 21

22

298 421.1 - ABA Adapter

2.9

Installing the wiring loom Install relay (17) at location (K21 and K22) (if not provided).

(Fig. 23)

17

23 Close central terminal compartment and secure with knurled nut.

Refit tray area.

Remove blind covers (see arrows) using a knife.

(Fig. 24)

24 Remove plugs from blind covers and connect to switches (18, 19 and 20). Now install the switches in the corresponding openings.

Switch 18 Switch 19 Switch 20

= = =

Horizontal reel adjustment Reel speed adjustment Folding the front attachments for MEDION and DOMINATOR front attachments

(Fig. 25, 26)

25

18

20 19

26

2.10

ABA Adapter - 298 421.1

Installing the wiring loom Fasten wiring loom (13) with cable bands (20).

(Fig. 27)

13 27 Punch out the pre-punched spot on the right-hand side (see arrow). Deburr the edges.

Connect wiring loom (13) with the existing cable (V).

Cable (F) remains unconnected.

(Fig. 28) V

13 F K L

28 Install push-buttons (22 and 23) into the open bores.

Green push-button (22) at the top Red push-button (23) at the bottom Connect short cable (K) to push-button (22).

Connect long cable (L) to push-button (23).

(Fig. 28, 29)

22 23

29

298 421.1 - ABA Adapter

2.11

Installing the wiring loom Cable connections Green push-button (22): Short cable (K) = green / white and brown Red push-button (23): Long cable (L) = green / blue and brown (Fig. 2, 28, 29)

Re-install all panels and guards.

Re-install left-hand drive wheel.

For tightening torque of wheel nuts see Operating manual of forage harvester.

Carry out a trial run.

Check tightness of hydraulic system.

2.12

ABA Adapter - 298 421.1

Mounting the adapter

Mounting the adapter

Mounting the adapter

1

1

7

8 2

5

3

4

3

4

6

6

5

2

3.2

ABA Adapter - 298 421.1

Mounting the adapter

Mounting the adapter

11

10 9

15

12

13

14

3

Shipping package Item Designation 1 2 3 4 5 6 7 8

9 10

11 12 13

14 15

Number

Adapter ................................................................1 Universal coupling................................................1 Union ...................................................................2 Straight connector................................................2 Dust caps .............................................................2 Threaded fittings ..................................................2 Pipe clamp ...........................................................2 Hexagon bolt M 8 x 20 .........................................1 Hexagon nut M 8..................................................1 Contact washer B 8..............................................1 Angle plate ...........................................................2 Hexagon bolt M 10 x 35 DIN 931-8.8...................1 Hexagon nut M 10................................................1 Contact washer B 10............................................2 Cable conduit .......................................................1 Pipe clamp RSGU 30...........................................2 Hexagon bolt M 8 x 25 .........................................2 Hexagon nut M 8..................................................2 Contact washer B 8..............................................2 Wiring loom..........................................................1 Pipe end pieces ...................................................2

(Fig. 1, 2, 3)

298 421.1 - ABA Adapter

3.3

Mounting the adapter

Mounting the adapter Mounting the adapter Move the machine close enough to the adapter (1) so that the coupling pins (F) at the feed mechanism are located below the coupling holes of the adapter.

F

Raise the adapter using the machine's hydraulic system.

1

(Fig. 4)

4 Raise the adapter using the machine's hydraulic system.

Release the rear supports (S), push them upwards and secure with pins (T).

S T

(Fig. 5)

5 Lock the claws (K) on the shaft (W) using the lever (H).

Ensure that the claws (K) make contact flawlessly at the shaft (W). Make corresponding adjustments at the linkage if necessary.

Now put lever (H) on pin (B) and secure with spring clip (F).

H

(Fig. 6, 7) F B 6

W

K

7

3.4

ABA Adapter - 298 421.1

Mounting the adapter Slide universal drive shaft (G) first on the shaft on the adapter transmission and then on the manual transmission and reverser gear. Keep the respective locking pin (E) pressed during this process.

E

Ensure that the locking pins (E) engage safely.

Close protective device (U).

(Fig. 8) G U 8 Screw the hydraulic hoses of universal coupling (2), the union (3), straight connector (4), dust caps (5) and threaded fittings (6) together.

5 3

4

3

4

(Fig. 9)

6

2 6 5 9 Connect the threaded fittings (6) of the pre-assembled hydraulic hoses on the left-hand machine side, paying attention to matching colours.

6

Connect plugs of wiring loom (K).

K

(Fig. 10)

10 Suspend wiring loom (2) in wire clamp (D).

Bolt down wiring loom (2) to the adapter with pipe clamp (7) and hexagon bolt (8).

D

Bolt down universal coupling (U) to the bracket provided for this purpose.

7 U

(Fig. 11)

11

298 421.1 - ABA Adapter

3.5

Mounting the adapter Release the front supports (S), push them upwards and secure with pins (T).

(Fig. 12)

T

S

12

Mounting the «Conspeed» maize picker Move machine close enough to the maize picker that the coupling pins (F) on the adapter are located below the coupling holes (G) of the maize picker.

G F

Raise the maize picker using the machine's hydraulic system.

(Fig. 13)

13 Lock the maize picker.

To do this, pull out safety pin (S) and push lever (H) downward.

Ensure that lever (H) is securely stopped after locking.

S

Carry out locking on both sides.

(Fig. 14)

H

14 Connecting the universal drive shafts DANGER! Never operate universal drive shafts without or with a damaged guard!

3.6

ABA Adapter - 298 421.1

Mounting the adapter Mounting the universal drive shaft on the left-hand side:

D

Open covers (D) of guards.

1 1

First join the universal drive shaft.

Guide universal drive shaft through the openings.

While doing so, push in the respective locking pin (1).

Now check if both locking pins are securely engaged.

(Fig. 15) D 15 Close both covers (D).

(Fig. 16)

D

D

16 Mounting the universal drive shaft on the right-hand side: D

Open covers (D) of guards.

First join the universal drive shaft.

1

Guide universal drive shaft through the openings.

While doing so, push in the respective locking pin (1).

1

Now check if both locking pins are securely engaged.

D

(Fig. 17) 17 Close both covers (D).

(Fig. 18)

D

D

18

298 421.1 - ABA Adapter

3.7

Mounting the adapter Connecting the universal coupling: – Remove dust cap (T) from the maize picker.

– Unscrew universal coupling (U) from adapter and screw it on maize picker.

– Screw dust cap (T) to adapter.

(Fig. 19)

T

U

19

Mounting the cutterbar

G

Move the machine close enough to the cutterbar that the coupling pins (F) on the adapter are located beneath the coupling holes (G) of the top cutterbar cross beam.

F

(Fig. 20)

20 Lock maize picker to the adapter with lever (H).

Pull out safety lever (S) before actuating lever (H).

Ensure that after locking, lever (H) is secured by safety lever (S).

H S

Carry out locking on both sides.

(Fig. 21)

21 Connecting the universal coupling: – Remove dust cap (T) from the cutterbar.

– Unscrew universal coupling (U) from adapter and screw it on cutterbar.

T

– Screw dust cap (T) to adapter.

(Fig. 22)

U

22

3.8

ABA Adapter - 298 421.1

Mounting the adapter Connecting the universal drive shafts DANGER!

E

Never operate universal drive shafts without or with a damaged guard!

Push in locking pin (E) and slide it on the intermediate drive shaft. Ensure that the locking pin is safely engaged.

23

Connect universal drive shaft on the right-hand side (if provided).

(Fig. 23, 24)

E

24 Mounting the wiring loom for reel speed adjustment – Bolt down angle plate (9) to bearing plate (L) with existing hexagon bolt.

L F

– Remove hexagon bolt from flange bolting at (F).

– Bolt down angle plate (9) with hexagon bolt (10).

10

(Fig. 25) 9

9

25 – Cut off cable conduit (11) according to cutterbar width.

12

– Deburr edge of conduit.

F

– Bolt down cable conduit (11) to angle plate (9) at (L) and (F) with pipe clamps (12) and hexagon bolts (13).

11

(Fig. 26)

12

L 26

298 421.1 - ABA Adapter

3.9

Mounting the adapter Left-hand pipe fastening, at (L) (Fig. 27)

L

12

27 Right-hand pipe fastening, at (F) (Fig. 28) F

12

28 – Connect wiring loom (14) to the socket provided for it on the right-hand machine side.

(Fig. 29)

14

29 – Pull wiring loom (14) through the cable conduit (11).

– Align length of wiring loom (14) with the machine.

15

– Plug in end pieces (15) at both pipe ends.

(Fig. 30)

14 30

3.10

ABA Adapter - 298 421.1

Mounting the adapter – Disconnect existing wiring loom (K) from electric motor (E).

– Connect wiring loom (14) to electric motor (E) and fasten it with cable bands.

E

(Fig. 31, 32) K

31

32

Mounting the folding cutterbar Move machine close enough to the cutterbar that the coupling pins on the adapter are located beneath the holes of the cutterbar cross beam.

Raise the cutterbar using the machine's hydraulic system.

(Fig. 33)

33 Locking the cutterbar on both sides Top locks: (cutterbar with cutting angle adjustment) E

Adjust the desired cutting angle position prior to mounting the cutterbar. See chapter «Cutting angle adjustment» in the Operator's Manual.

Pull out the pins (E) and turn the locks to the rear.

Re-insert the pins (E) and secure them.

(Fig. 34) 34

298 421.1 - ABA Adapter

3.11

Mounting the adapter Bottom locks: Push the lock pins (V) to the inside and secure them with the linch pins (K).

(Fig. 35)

K V 35 Connecting the universal coupling: – Remove dust cap (T) from the adapter.

– Unscrew universal coupling (U) from adapter and screw it on cutterbar.

T

– Screw dust cap (T) to adapter.

(Fig. 36) U

36 Connecting the universal drive shafts E

DANGER! Never operate universal drive shafts without or with a damaged guard!

Push in locking pins (E) and slide on the intermediate drive shaft. Ensure that the locking pins are safely engaged.

37

3.12

(Fig. 37)

ABA Adapter - 298 421.1

Maintenance

Maintenance

Maintenance MAINTENANCE NOTE: When checking the oil level, set the adapter so that the transmissions are in a horizontal position.

ENVIRONMENT! Dispose of the old oil in a way that is harmless to the environment and in accordance with existing environmental regulations.

Angle drive Oil change A = Oil drain plug E = Oil filler plug

E

Oil capacity: The oil capacity is 2 litres Oil grade: SAE 85 - 90 API-GL-5 (Fig. 1, 2) 1

A 2 Oil level check K = Oil level check plug (Fig. 3)

K

3

298 421.1 - ABA Adapter

4.3

Maintenance left-hand side

Spur gear Oil change A = Oil drain plug E = Oil filler plug Oil capacity:

E

The oil capacity is 2 litres per transmission Oil grade: SAE 85 - 90 API-GL-5 A 4

Oil level check E = Oil level check plug

right-hand side

(Fig. 4, 5)

E

A 5

4.4

ABA Adapter - 298 421.1

Maintenance Lubrication chart NOTE: All lubrication points must be lubricated every 100 operating hours.

Main drive universal drive shaft (Fig. 6)

6 Bearing – feed roller (Fig. 7)

7 Bearing – feed roller (Fig. 8)

8

298 421.1 - ABA Adapter

4.5

Maintenance Bearing – feed roller (Fig. 9)

9 Bearing – feed roller (Fig. 10)

10 Transmission – drive shaft (Fig. 11)

11 Transmission – drive shaft (Fig. 12)

12

4.6

ABA Adapter - 298 421.1

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

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

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

CLAAS KGaA mbH 33426 HARSEWINKEL Germany

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

CLAAS KGaA mbH 33426 HARSEWINKEL Germany

298 421.1 ABA Adapter GB - 08.02 - 25 - BEV Printed in Germany