Claas LEXION 580 - 510 Folding cutterbar 5.40 M 4.50 M Fitting and Operator's Manual - PDF DOWNLOAD

LEXION 580 - 510

Fitting and Operating Instructions Folding cutterbar 5.40 m / 4.50 m

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

We

CLAAS Hungaria KFT.

(Name of supplier)

Postaflók 106 H - 5200 Törökszentmiklós (full address of the manufacturer - authorized representative established in the Community must also give the business name and address of the manufacturer)

declare under our sole responsibility, that the product

Cutterbar - Type No.: (Make, model)

to which this declaration relates corresponds to the relevant basic safety and health requirements of the Directive 98/37/EC Appendix I, (if applicable)

and to the requirements of the other relevant Directives

89/336/EEC in the version 92/31/EEC. (Title and/or number and date of issue of the other Directives)

(if applicable)

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

EN 632 - August 1995

0187 555.4 - EN - 09.04

(Title and/or number and date of issue of standard(s) and/or technical specification(s))

by order of the Technical Management of CLAAS Selbstfahrende Erntemaschinen GmbH (J. H. Mohr)

Product management (B. Hoffmann)

(Name, function and signature of the authorized person)

Törökszentmiklós, (Place and date of issue)

1 Introduction

Introduction

Introduction INTRODUCTION

These instructions describe how to assemble and operate the folding cutterbar, and how to mount the necessary accessories on the machine.

The accessory parts for the switching equipment and the additional driving lights are listed in Group 7.1.

You should explain the function, operation and maintenance to the customer on the basis of these instructions.

Please hand over these instructions to the customer subsequently.

These instructions are only valid when used in conjunction with the combine harvester operating instructions.

CLAAS Service Department

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

1.1.1

Introduction

1.1.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

2 Table of contents

Table of contents

Table of contents TABLE OF CONTENTS 1. Introduction Introduction ............................................................................ 1.1.1

2. Table of contents Table of contents ................................................................... 2.1.1

3. General Information Vehicle type approval ............................................................. 3.1.1 Important information ............................................................. 3.2.1 Identification plate / Serial number ......................................... 3.3.1

4. Safety rules Safety rules ............................................................................

Safety locks .....................................................................

Feed rake safety locks .....................................................

Reel safety lock ...............................................................

Safety decals with pictorials ...................................................

4.1.1 4.1.3 4.1.3 4.1.3 4.2.1

5. Specifications Weights / Dimensions / Safety devices .................................. 5.1.1 Additional weights ............................................................ 5.1.1

6. Prior to operation Carry out prior to initial operation ........................................... 6.1.1 Driving lights / Cutterbar cylinder ........................................... 6.2.1 Driving lights for road use ................................................ 6.2.1 Changing the driving lights (up to serial no. ...) ......................................... 6.2.1 Changing the driving lights (from serial no. ...) .......................................... 6.2.1 Safety lighting rail on the cutterbar .................................. 6.2.2 Removing the transport fixtures ....................................... 6.2.2 Third cutterbar cylinder .................................................... 6.2.2 Adjusting the cutterbar floatation springs ........................ 6.2.2

7. Accessory equipment Additional headlights ..............................................................

Fitting the switches and the additional headlights ...........

Installing the push buttons for switching ..........................

Mounting the additional headlights on both sides ............

Adjusting the additional headlights ..................................

7.1.1 7.1.2 7.1.2 7.1.2 7.1.6

8. Operation Cutterbar skids ....................................................................... 8.1.1 Adjusting the cutterbar skids ........................................... 8.1.1 Cutting angle adjustment ....................................................... 8.2.1 Adjusting the cutting angle .............................................. 8.2.1 Mounting the spacer bar .................................................. 8.2.1 Mounting the coupling brackets ....................................... 8.2.2 Locking the coupling lug after fitting the cutterbar ........... 8.2.2 Unlocking the coupling lug before removing the cutterbar .................................................................... 8.2.3 Mounting the shaft extension ................................................. 8.3.1 Mounting the extension to the intermediate drive shaft (LEXION 530 – 510) ...................................... 8.3.1

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

Fitting the cutterbar ............................................................... 8.4.1 Tilting the cutterbar from the transport position ............... 8.4.1 Installing and removing the cutterbar .............................. 8.4.2 Installing the cutterbar when folded in (cutterbar in the transport position) ................ 8.4.2 Locking the cutterbar at top and bottom on both sides ... 8.4.3 Connecting the universal coupling .................................. 8.4.4 Changing the cutterbar from transport position to working position ..................................................................... 8.5.1 Fitting the universal drive shafts LEXION MONTANA (from serial no. 71300231) ............................. 8.5.6 Removing standard universal drive shafts ...................... 8.5.7 Installing the universal drive shaft for LEXION MONTANA ........................................................ 8.5.7 Changing the cutterbar from working position to transport position ................................................................... 8.6.1 Aligning the cutterbar / removing the cutterbar ..................... 8.7.1 Aligning the cutterbar (machines without Auto-Contour) .................. 8.7.1 Removing the cutterbar ................................................... 8.7.2 Adjustments on the cutterbar ................................................ 8.8.1 Crop dividers ................................................................... 8.8.1 Outer deflector ................................................................ 8.8.2 Adjusting the dividers ...................................................... 8.8.3 Crop lifters ....................................................................... 8.8.3 Knife ................................................................................ 8.8.4 Removing the knife ......................................................... 8.8.4 Installing the knife ........................................................... 8.8.4 Adjusting the knife height ................................................ 8.8.5 Aligning the knife clips ..................................................... 8.8.5 Spare knife ...................................................................... 8.8.5 Reel ................................................................................. 8.8.6 Adjusting the reel height .................................................. 8.8.6 Fine height adjustment of the reel ................................... 8.8.6 Reel drive ........................................................................ 8.8.7 Reel fore and aft adjustment ........................................... 8.8.7 Feed auger ...................................................................... 8.8.8 Adjusting the clearance to the cutterbar bottom plate ..... 8.8.8 Height adjustment of the feed auger ............................... 8.8.9 Adjusting the intake finger position ............................... 8.8.10 Safety feature ................................................................ 8.8.11 Cutterbar skids .............................................................. 8.8.11 Malfunction, possible cause and/or remedy .......................... 8.9.1

9. Maintenance Maintenance schedules and lubricants charts ......................

Maintenance schedule ....................................................

Lubricants chart ...............................................................

Transmissions .......................................................................

Knife drive transmission ..................................................

Spring-loaded cylinders / Drive chains / Inductive sensors ...

Adjusting the spring-loaded cylinders for knife drives .....

Tensioning the drive chains ............................................

Tensioning the reel drive chain .......................................

Cleaning the guide rails of the locking cylinder ...............

9.1.1 9.1.1 9.1.2 9.2.1 9.2.1 9.3.1 9.3.1 9.3.1 9.3.2 9.3.2

2.1.1

Table of contents General .................................................................................. 9.4.1 Aligning the double fingers .............................................. 9.4.1 Adjusting the reel limit switch ........................................... 9.4.1 Adjusting the locking pawl at the centre reel guide .......... 9.4.1 Cleaning the spaces of the supporting arm bearings ...... 9.4.2 Cleaning the coupling lug areas ...................................... 9.4.3 Suggestions for winter storage .............................................. 9.5.1

10. Lubrication chart Lubricants and notes ............................................................ 10.1.1

11. Index Index .................................................................................... 11.1.1

2.1.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

3 General Information

General Information

General Information VEHICLE TYPE APPROVAL

Installing the foldable 5.40 m or 4.50 m cutterbar will invalidate the Vehicle Type Approval of your combine harvester.

Therefore, it will be necessary to obtain a new Type Approval for the combine harvester from the relevant authorities by presenting a certificate confirming the combine harvester's technical condition (§ 19, Section 2 of German Regulations authorizing the Use of Vehicles for Road Traffic).

The new certificate can be issued e.g. by your local Technical Inspection Association.

On request, and to simplify the certification procedure, CLAAS can provide a sample certificate specifying the harvester type, the machine number, and the year of manufacture or will carry out the acceptance together with TÜV Hannover e.V. Specific care must be taken regarding the necessary counterweights on the steering axle to prevent lifting while braking. If no counterweights are fitted, the certificate might not be issued.

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

3.1.1

General Information

3.1.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

General Information

General Information IMPORTANT INFORMATION

To prevent accidents, the instructions contained in this manual should be carefully read and observed by all persons involved with the operation, maintenance and inspection of this machine. In particular, you should read the sections "Safety rules" and "Prior to operation".

The use of spare parts, accessories, and ancillary equipment that was not originally manufactured, checked and released by CLAAS can have a negative effect on specific design features or functions of the CLAAS machine, with possible adverse effects on the machine's active and/or passive driving safety, and on its working safety (accident prevention).

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

Technical specifications, dimensions, and weights are understood with the usual tolerances. CLAAS reserves the right to make changes subsequently as technical developments continue. Liability for errors or omissions not accepted.

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

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

3.2.1

General Information

3.2.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

General Information

General Information IDENTIFICATION PLATE / SERIAL NUMBER The identification plate with the cutterbar serial number is located at the back on the left-hand side of the cutterbar crossbeam.

(Fig.1)

1 When placing orders for spare parts or making technical inquiries please quote the cutterbar serial number.

This is necessary in order to ensure correct delivery of spare parts.

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

3.3.1

General Information

3.3.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

4 Safety rules

Safety rules

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

The warning and instruction signs attached to the cutterbar provide important information for safe operation. These instructions involve your safety – observe them at all times.

Identification of warning and danger signs

Intended use

All parts of this manual having to do with your safety or the safe operation of the machine are marked with the following signs. Please pass on all safety instructions to other users too.

The folding cutterbar is designed exclusively for customary agricultural operations (intended use).

Danger!

Use for any other purpose is considered as improper use; the manufacturer accepts no liability for any damage or injury resulting from such misuse; the risks are borne solely by the user.

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

Compliance and strict adherence to the conditions of operation, service and repair as specified by the manufacturer also constitute essential elements of the intended use.

☞ Preventive measures.

The folding cutterbar can only be operated, maintained and repaired by personnel who are familiar with these tasks and the associated dangers.

Attention!

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

☞ Measures to prevent damage to the machine.

Caution!

Sign to indicate instructions to be followed during disassembly / assembly.

Note!

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

Environment!

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

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

The relevant accident prevention regulations, and all other generally accepted regulations on working safety, occupational health, and road traffic regulations must be observed at all times.

Fitting and retrofitting of ancillary equipment which is not originally manufactured by CLAAS, and, in addition, also modifications and changes may only be carried out with the consent of CLAAS, as any such actions may have considerable adverse effects on the safety and operational function of the machine.

Any arbitrary modifications carried out on the cutterbar will relieve the manufacturer of all liability for any resulting damage or injury.

General safety and accident prevention regulations 1. In addition to these operating instructions, please observe the general safety and accident prevention regulations.

2. Always comply with local traffic regulations when driving on public roads.

3. Before starting work, familiarise yourself with all the controls and instruments and their functions. During work or road travel it is too late.

4. Before starting work, check the cutterbar for loose parts.

5. When working on or around the cutterbar, stop the engine and remove the ignition key.

Hydraulic hoses must be depressurised.

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

4.1.1

Safety rules 6. Only work under the cutterbar and the reel if they are securely supported.

7. On public roads and lanes, the cutterbar must always be folded.

The dividers must be folded.

Switch the driving lights from the lower to the upper headlights.

19. Nobody must be allowed between the combine harvester and cutterbar unless the parking brake is applied and/or the wheels are chocked so that the vehicle cannot start to move on its own!

Observe all further safety precautions contained in the Combine Operator’s Manual.

Attach safety rail with warning plates and sidelights on the front of the cutterbar, and connect the lighting.

8. When folding the cutterbar, the machine should be secured from rolling away (parking brake, wheel chocks).

9. When actuating the push button for the cutterbar folding mechanism, nobody should be standing between the drive wheels and the cutterbar.

10. When folding the cutterbar nobody should be standing within the swing area.

11. Removing and fitting knives involves a great risk of personal injury, particularly if the cutterbar is misaligned and/or very dirty.

12. Due to their function, knives, cutterbar, intake auger and reel etc. cannot be completely shielded by constructional measures. For this reason, an adequate safety distance must be maintained to these moving elements during operation.

13. Never operate universal drive shafts with damaged or missing guards.

14. When carrying a cutterbar during travel on public roads and lanes, the finger bar and/or the crop lifters must be covered.

15. Under no circumstances attempt to service, lubricate or clean the machine or to remedy any operational problems unless the drive is disengaged and the engine stopped. Remove the ignition key.

16. When working on the electrical equipment always switch off the battery master switch!

17. Always replace safety guards and shields after carrying out maintenance work!

18. There are injury hazards when attaching the cutterbar to the combine.

4.1.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Safety rules

Safety rules Safety locks Danger!

Any work underneath the raised cutterbar or reel may only be done with the cutterbar securely supported.

Feed rake safety locks – Raise the feed rake to the highest position.

– Release latch (R) of the safety lock (S), and fold it onto the hydraulic ram.

R

(Fig. 1, 2)

S

1 – Before operating the combine, the safety lock must be secured with latch (R).

(Fig. 2)

R

2 Reel safety lock For all work underneath the cutterbar, the raised reel must also be secured by means of the safety lock (S) on the right-hand side.

– Raise the reel completely, and position the safety lock.

S

(Fig. 3)

3

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

4.1.3

Safety rules – Before operating the combine, the safety lock must be folded up and secured in holder (H).

(Fig. 4)

H

4

4.1.4

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Safety rules

Safety rules SAFETY DECALS WITH PICTORIALS

Danger areas that cannot be shielded adequately by constructional or protective measures, are marked with safety decals. These safety decals alert persons to hazards which can cause personal injury.

The warning decals consist of 2 parts. The 1st part shows the nature of the possible danger. The 2nd part shows how accidents and injuries can be avoided by correct behaviour.

To ensure that the warnings are not language-dependent, the possible dangers are represented by means of icons. As far as possible, the safety decals are located in the immediate vicinity of the danger area.

Explanations of the safety decals, together with details of their correct location on the machine are given in the section "Safety rules" of this manual.

Original CLAAS safety decals are identified by a CLAAS order no. and their date of issue.

Danger!

Danger area on the machine Danger to life and limb!

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

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

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

4.2.1

Safety rules

Safety rules

22

31

1

3 514 824.1 (31) 31

22

2

Do not go near feed mechanisms of front-mounted harvesting units before the drive has been disengaged, the engine shut off, the ignition key removed and battery disconneting switch is off. Wait for all mechanisms to stop and only then attempt to correct any problems.

(Fig. 1, 2, 3)

4 516 039.0 (22) Do not attempt to open or remove guard while the engine is running.

(Fig. 1, 2, 4)

4.2.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

5 Specifications

Specifications

Specifications WEIGHTS / DIMENSIONS / SAFETY DEVICES Weights / Dimensions Cutterbar type

Weight

Working width

Transport width

Cutterbar 5.40 m (18’)

2100 kg

5970 mm

3000 mm

Cutterbar 4.50 m (15’)

1980 kg

5060 mm

3000 mm

Safety feature Slip clutch settings Cutterbar type

Intake auger

Upper shaft of feed rake

Cutterbar 5.40 m (18’)

700 ± 40 Nm

840 ± 40 Nm

Cutterbar 4.50 m (15’)

700 ± 40 Nm

840 ± 40 Nm

Additional weights For details, see the operator’s manual of the combine harvester

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

5.1.1

Specifications

5.1.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

6 Prior to operation

Prior to operation

Prior to operation CARRY OUT PRIOR TO INITIAL OPERATION 1. Take off all wired-on parts and / or extra parts packages and unpack.

2. Remove the transport brackets from the reel carrier arms.

3. Check all oil levels in the gearboxes and refill if necessary.

4. Check all safety guards and correctly position them, if required.

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

6.1.1

Prior to operation

6.1.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Prior to operation

Prior to operation DRIVING LIGHTS / CUTTERBAR CYLINDER Driving lights for road use The normal front driving lights of the combine harvester are covered by the cutterbar when it is folded into transport position.

A

A

When driving on public roads, the lighting must therefore be switched to the upper headlights (A).

(Fig. 1)

1 Changing the driving lights (up to serial no. ...)

U

– Switch on the driving lights as usual.

O

– Turn rotary switch (D) to position (O).

The upper driving lights are now switched on, and the lower lights are off.

O = upper headlights on U = lower headlights on

D

(Fig. 2) 2 Changing the driving lights (from serial no. ...)

At the left below the driving cab, there is a connector plug (S) for switching over the driving lights.

S

Connector position "Cable upwards" = lower headlights.

Connector position "Cable downwards" = upper headlights.

Also see adhesive label.

3

– Switch on the driving lights as usual.

(Fig. 3)

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

6.2.1

Prior to operation Safety lighting rail on the cutterbar The safety lighting rail (L) is mounted in front of the cutterbar and fixed by means of turn lock bolts (B).

– Insert the plug for the lighting at (S).

(Fig. 4)

S

L 4 Removing the transport fixtures Before using the cutterbar for the first time, the struts (T) and the hexagon-head bolts (S) must be removed on both sides.

S S

(Fig. 5)

TT

5 Third cutterbar cylinder Machines with a folding 5.40 m cutterbar must always be fitted with 3 cutterbar cylinders.

Adjusting the cutterbar floatation springs Note: The cutterbar flotation springs are set ex works.

Check the settings. Readjust, if necessary! Please refer to "Adjusting the cutterbar flotation springs" in the combine harvester's operator’s manual.

6.2.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

7 Accessory equipment

Accessory equipment

9 6

7

13 2

7

12

1

3

3

10 8 4 14

11

5

1

ADDITIONAL HEADLIGHTS Description of parts

Quantity

1 Push button green................................................1 2 Push button red....................................................1 3 Light bracket, left..................................................1 Light bracket, right................................................1 4 Hexagon head bolt M 8 x 55 ISO 4014-8.8......... 2 Contact washer A 8............................................. 2 Hexagonal nut M 8 .............................................. 2 5 Hexagonal caps ...................................................4 6 Headlight .............................................................2 7 Cable set ..............................................................2 8 Rubber grommet ..................................................2 9 Cable tie ..............................................................8 10 Rotary switch (selector switch) ............................1 11 Knob.....................................................................1 12 Inlay for knob........................................................1 13 Rocker switch .......................................................1 14 Adhesive label......................................................1 (Fig. 1)

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

7.1.1

Accessory equipment Fitting the switches and the additional headlights Installing the push buttons for switching Remove the two blind plugs (B) on the left side.

(Fig. 2)

B

2 Screw in the green push button (1) in the upper hole, and the red push button (2) in the lower hole.

Note the direction of the arrows on the push buttons: The arrow of the green button must point to the rear, and the arrow of the red button must point to the front.

1

(Fig. 1, 3)

2

3 Mounting the additional headlights on both sides

G

Drill a 8.5 mm Ø hole into the rail (G) on both sides.

Dimensions: Distance (X) from top edge of operator's platform (perforated plate) to hole in rail (G) is 670 mm.

X

(Fig. 4)

4 Mount the light brackets (3) on the rails (G) on both sides using hexagon head bolts (4).

Fit the hexagon caps (5) on the hexagon head bolts (4) and nuts on both sides.

(Fig. 1, 5) 5

3 G

5

7.1.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Accessory equipment Open the headlight housing (6).

Pull the cable sets (7) through the housings and the rubber grommets (8). If necessary, use circlip pliers to expand the grommets.

Fit the connectors to the terminals of the light bulbs.

3

Insert the rubber grommets (8) into the housing openings.

G

Close the housing.

6

Run the cable sets (7) along the rail on both sides down to below the operator's platform, and secure them by means of the cable ties (9).

(Fig. 1, 6)

Connect the cable sets (7) to the existing cables.

(Fig. 7, 8) 7

7

7

8

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

7.1.3

Accessory equipment Release the fixing screws of the shield (B), and pull the shield slightly forwards.

S

Remove the blind plugs (S).

(Fig. 9) B

9 Insert the rotary switch (10) and screw it tight. Connect the existing cables to the rotary switch (10).

(Fig. 10)

10

10 Replace the shield (B).

Mount the knob (11), and insert the inlay (12).

(Fig. 1, 11)

12

B

11

11 Remove the blind cover (D) on the switch console.

D

(Fig. 12)

12

7.1.4

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Accessory equipment Disconnect the existing cables from the blind cover, and connect them to the rocker switch (13). Mount the rocker switch (13) in the switch console.

(Fig. 1, 13, 14)

13

13

13

14 Attach the adhesive label (14) on the left side of the operator's platform.

(Fig. 15)

14

15

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

7.1.5

Accessory equipment

.

Adjusting the additional headlights

16

1. Check the tyres for correct inflation pressure.

2. Position the machine at right angles to a vertical wall at a distance (X = 15 metres).

3. Adjust the headlights so that the top edge of the light/dark sections on the wall is at half the height of the headlights.

S1 S2 L W

= ½ headlight height = headlight height = light beam = wall

(Fig. 16)

7.1.6

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

8 Operation

Operation

Operation CUTTERBAR SKIDS Adjusting the cutterbar skids Before mounting the cutterbar, the skids (K) must be changed from the transport position to the working position, and adjusted.

B

– Remove the hexagon head bolts at (A and B), whilst holding the skids.

– Remove the washers at (A).

A

A

– Raise the skids, and remount them at (B) using the hexagon head bolts and the washers. Hereby, place the washers on the inner side of the skids.

K 1

(Fig. 1, 2)

A

2 – Mount the skids at (A) and the adjusting levers (D) using hexagon head bolts (C).

The skids are adjustable in five positions at (C): D

C

– Positions 1 – 4 using the adjusting levers (D)

1

– Position 5 without the adjusting levers 2

Always adjust the skids as far out as possible.

3

Position 4 with adjusting lever (D) = biggest setting

4

Position 4 without adjusting lever (D) = smallest setting 3

Note!

For position 4 without adjusting levers (D), the levers are placed on the inner side of the skids and fixed together with the skid using hexagon bolts (A).

(Fig. 1, 2, 3)

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

8.1.1

Operation

8.1.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation

Operation CUTTING ANGLE ADJUSTMENT Adjusting the cutting angle A Note!

The cutting angle can only be adjusted with the cutterbar removed from the machine.

The cutting angle depends on the size of the tyres.

A = Lower the front of the cutterbar with smaller tyres and possibly on wet ground.

B = Raise the front of the cutterbar with larger tyres.

B

(Fig. 1)

1 Mounting the spacer bar S

The front and rear surfaces of the spacer bar (D) are conical to each other.

The narrow side of the spacer bar is identified by the bevelled edge (S).

D

Machines with small tyres: (front of the cutterbar lowered) – Mount the spacer bar (D) at the bottom of the cutterbar so that the narrow side (S) faces downwards.

2

– Secure spacer bar at points (K) using linch pins.

Machines with large tyres: (front of the cutterbar raised) – Mount the spacer bar (D) at the bottom of the cutterbar so that the narrow side (S) faces upwards.

– Secure spacer bar at points (K) using linch pins.

(Fig. 1, 2, 3)

K

D

K

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

3

8.2.1

Operation Mounting the coupling brackets H

T

– Position the coupling bracket (F).

M

F

Machines with small tyres: (front of the cutterbar lowered) – Position the coupling brackets (F) in the supports (M) on the cutterbar.

L

– Insert the pins (L) in the holes at (T), and secure with linch pins (N).

4

Machines with large tyres: (front of the cutterbar raised) – Position the coupling brackets (F) in the supports (M) on the cutterbar.

– Insert the pins (L) in the holes at (H), and secure with linch pins (N).

(Fig. 4, 5)

N

5 Locking the coupling lug after fitting the cutterbar – Remove the linch pins from pin (E), and pull them out completely.

C

– Rotate stops (R) manually towards the coupling lugs and push pins (E) back in.

R

F

– Secure the pins (E) with the spring clips (C).

F = coupling bracket E

Note!

6

The stops (R) can only be rotated when the cutterbar has only light contact with the ground or is slightly raised.

If necessary, use a tool (screwdriver or round bar) that can be inserted into the holes of stops (R).

(Fig. 6)

8.2.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation Unlocking the coupling lug before removing the cutterbar

C

– Remove the spring clips from pin (E), and pull them out completely.

R

F

– Rotate stops (R) manually to the front, and push pins (E) back in.

– Secure the pins (E) with the spring clips (C).

F = coupling bracket (Fig. 7)

E 7

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

8.2.3

Operation

8.2.4

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation

Operation MOUNTING THE SHAFT EXTENSION Mounting the extension to the intermediate drive shaft (LEXION 530 – 510) Danger!

Stop the engine and switch off the battery isolating switch!

– Remove the universal coupling (K) and put it aside.

K

– Remove protective covers (A, B, and C).

(Fig. 1)

B

A

C 1 – Push the extension (W) onto the shaft until the hole in shaft extension is aligned with the notch on the shaft.

W

– Screw in a hexagon bolt and tighten it at 80 Nm. (Fig. 2)

2 – Loosely mount flange (F) to the guard plate.

– Mark the positions of the two missing holes at (E) and (T) respectively.

E

– Remove the flange, and drill two 9 mm Ø holes.

– Mount the flange using four M 8 x 16 hex. bolts, A 8 contact washers, and M 8 nuts.

T

(Fig. 3)

F 3

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

8.3.1

Operation – Reinstall the protective cover (A) and the universal coupling (K).

K

– Reinstall the protective covers (B) and (C) on flange (F) using the existing screws.

(Fig. 4) B

A

C

F 4 up to serial no. ...: – Remove protective covers (T) and (S).

– Cut off the stud (Z), if present.

(Fig. 5)

S

T

Z 5 – Push the extension (V) onto the shaft until the hole in shaft extension is aligned with the notch on the shaft.

V

– Screw in a hexagon bolt and tighten it at 80 Nm. (Fig. 6)

6 – Mount protective device (E) to cover (T) using M 6 x 12 hex. bolts.

– On machines up to serial no. ..., align the protective device (E), and drill the holes.

(Fig. 7) T

E

7

8.3.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation – Replace the cover (T).

– Reinstall the protective cover (S) using the existing screws.

S T

(Fig. 8)

E

8 from serial no. ...

– Remove protective cover (S).

(Fig. 9)

S

9 – Push the extension (V) onto the shaft until the hole in shaft extension is aligned with the notch on the shaft.

v

– Screw in a hexagon bolt and tighten it at 80 Nm. (Fig. 10)

10 – Remove cover (K).

– Cut cover (K) at the notch (in direction of arrows).

– Smooth the cut edge.

(Fig. 11, 12) K

11

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

8.3.3

Operation

K

12 – Mount cover (K) and holder (H) to protective cover (S) using the existing screws.

(Fig. 13)

S

K

H 13 – Mount cover (T) using M 8 x 20 hexagon bolts and Vm 8 self-locking nut.

T

(Fig. 14)

14 – Reinstall protective cover (S).

(Fig. 15)

S

15

8.3.4

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation

Operation FITTING THE CUTTERBAR Tilting the cutterbar from the transport position Danger!

When fitting front attachments, there is a risk of injury!

No persons are permitted in the danger area!

1

Before operating the cutterbar for the first time, it should be tilted from the vertical to the horizontal position (if necessary).

– Lift the cutterbar by means of the transport support using a suitable lifting device.

At the same time, hold the cutterbar in place on the opposite side with a suitable lifting device (fork-lift truck or similar).

Protect the forks with a pallet or similar to ensure that the cutterbar is not damaged.

If there is no suitable lifting device available on site, large tyres can be used instead.

(Fig. 1, 2)

2

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

8.4.1

Operation Installing and removing the cutterbar The cutterbar can be installed / removed in both the transport position (cutterbar folded) and in the working position (cutterbar unfolded).

We will show you both versions.

Installing the cutterbar when folded in (cutterbar in the transport position) Danger!

When installing front attachments on the combine harvester (cutterbar etc.) there is danger of injury!

Danger!

When installing the cutterbar, there is danger of injury. Nobody must stand between combine harvester and cutterbar.

– Before installing the cutterbar, make sure that the upper and lower couplings are open.

– Remove the locking pins (V) on both sides.

(Fig. 3)

V 3 – Drive the combine harvester up to the cutterbar until the coupling lugs (F) of the hydraulic cylinders on the feeder housing are located under the locating holes of the upper cutterbar beam.

– Raise the cutterbar by actuating the hydraulic control unit.

– Stop the engine and switch off the battery isolating switch!

F

(Fig. 4) 4

8.4.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation Locking the cutterbar at top and bottom on both sides Upper locks: – see page 8.2.2, Locking the coupling lug after fitting the cutterbar Lower locks: – Push the locking pins (V) inwards, and secure them with linch pins.

(Fig. 5)

V 5

– Drive the combine harvester up to the cutterbar until the coupling lugs on the feeder housing are located under the coupling brackets of the upper cutterbar beam.

– Slightly raise the cutterbar by actuating the hydraulic control unit.

Danger!

Stop the engine and switch off the battery isolating switch!

– Pull out the pins (E), and rotate the locks to the rear.

– Reinstall the pins (E), and secure them.

– see Cutting angle adjustment on page 8.2.1.

– Lock the cutterbar at the bottom on both sides.

Push the locking pins (V) inwards, and secure them with linch pins.

(Fig. 5, 6, 7) E

6

7

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

8.4.3

Operation Connecting the universal coupling – Remove the dust cover (T) from the cutterbar.

– Remove the universal coupling (K) from the feeder housing, and mount it on the cutterbar.

– Replace the dust cover (T) on the feeder housing.

K

– Tighten the universal coupling (K) securely by means of the handwheel (M).

T

(Fig. 8, 9) 8

M 9

Caution!

H

Do not hook chain (A) over lever (H).

This is only necessary on Vario and standard cutterbars.

A

(Fig. 10)

10

8.4.4

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation

Operation CHANGING THE CUTTERBAR FROM TRANSPORT POSITION TO WORKING POSITION – Start the engine, and actuate the safety switch.

Danger!

Put drive into neutral!

– Briefly actuate switch "Reel reverse" (horizontal reel adjustment) and switch "Lower reel". This must be done after road travel in transport position.

B

S

L 1

– Remove crop lifter guard and knife guard.

– Remove the safety lighting bar (L). To do this, remove the connector (S), and loosen both turn lock bolts (B).

– Unfold the cutterbar to the working position.

Attention!

Avoid jerkily raising and lowering with the cutterbar halfway folded.

2

2

Danger!

When unfolding the cutterbar nobody should be within the danger area. Secure the machine against rolling away (parking brake, wheel chocks).

– Press the push button (2) until the cutterbar has been fully unfolded.

Attention!

The machine may only be moved if the cutterbar has been fully folded out and locked.

(Fig. 1, 2)

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

8.5.1

Operation – Install the right-hand universal drive shaft.

Caution!

(Fitting the universal drive shaft for LEXION MONTANA machines will be shown later on)

Danger!

Never operate universal drive shafts with damaged or missing guards.

Folding cutterbar 4.50 m: LEXION 530 – 510 – Open guard (D) on the feeder housing.

– Open universal drive shaft retainer (G) and take out universal drive shaft.

G

– Push in the locking pin (1) of the universal drive shaft.

3

– Push the drive shaft onto the transmission shaft, and make sure that the locking pin engages securely.

– Close the guard (D).

(Fig. 3, 4)

1

D

4

8.5.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation – Folding cutterbar 5.40 m: – Open guard (D) on the feeder housing.

1

– Fold up the guard (D).

D

– Open universal drive shaft retainer (G) and take out universal drive shaft.

– Push in the locking pin (1) of the universal drive shaft.

5

– Push the drive shaft onto the transmission shaft, and make sure that the locking pin engages securely.

– Close the guard (D).

(Fig. 3, 5, 6)

D

6 – Fold out right-hand crop divider.

To do this, retract the lock (R) and swing out the crop divider to the end positions.

Caution!

In the end position, the lock must be engaged securely.

R (Fig. 7) 7 – Fold out left-hand crop divider.

To do this, retract the lock (R) and swing out the crop divider to the end positions.

Caution!

In the end position, the lock must be engaged securely.

R (Fig. 8) 8 4. Install left-hand universal drive shaft.

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

8.5.3

Operation

Caution!

(Fitting the universal drive shaft for LEXION MONTANA machines will be shown later on)

Danger!

Never operate universal drive shafts with damaged or missing guards!

Folding cutterbar 4.50 m: LEXION 530 – 510

G

– Open guard (D) on the feeder housing.

– Open universal drive shaft retainer (G) and take out universal drive shaft.

– Push in the locking pin (1) of the universal drive shaft.

9

– Push the drive shaft onto the transmission shaft, and make sure that the locking pin engages securely.

– Close guard (B).

(Fig. 9, 10)

B

1

10

8.5.4

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation Folding cutterbar 5.40 m: – Open guard (B) on the feeder housing.

– Open universal drive shaft retainer (G) and take out universal drive shaft.

B

1

– Push in the locking pin (1) of the universal drive shaft.

– Push the drive shaft onto the transmission shaft, and make sure that the locking pin engages securely.

11

– Close guard (B).

(Fig. 9, 11, 12)

B

12 – Move the reel forward from the driver's seat.

The cutterbar is now ready for operation.

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

8.5.5

Operation Fitting the universal drive shafts LEXION MONTANA (from serial no. 71300231) When putting the cutterbar into operation for the first time, convert the universal drive shafts from standard to Montana version.

A

Fit the universal drive shaft retainers on both sides of the cutterbar as follows:

C

D

– Drill holes according to the specified dimensions.

– Drill the front 9 mm Ø hole at the bolt height (D).

B

– Drill the holes (F and G) after mounting the retainers (H and I).

13

– Mount the retainer (H) using M 8 x 25 hexagon bolts, A 8 contact washers, and M 8 nuts.

– Mount the retainer (I) using M 8 x 16 mushroom head screws, A 8 contact washers, and M 8 hexagon nuts.

G

Dimensions:

I

A = 40 mm from the centre of bolt to centre of hole B = 940 mm C = 80 mm

F H

(Fig. 13, 14)

14 – Before transport, push the universal drive shaft halves onto retainers (H) and place them in retainers (I).

(Fig. 15) I H

15

8.5.6

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation Removing standard universal drive shafts – Remove cover (K).

(Fig. 16)

K

16 – Remove locking screw (S).

Rotate guard tube (R) through 60° against the conical guard.

S

– Remove guard tube (R) from the universal drive shaft.

(Fig. 17) R

17 – Use a slightly bent length of round steel (Ø 8 x 280 mm, self-made) to drive the expansion pins out of the drive shafts (W).

– Remove drive shaft halves.

Note: To make assembly easier, the covers (D) on the inside of the cutterbar may be removed.

D

(Fig. 18)

W 18 Installing the universal drive shaft for LEXION MONTANA – Release drive shaft guard, rotate it, and remove it from the drive shaft.

(Fig. 19)

19

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

8.5.7

Operation – Push drive shaft (E) onto the transmission shaft, and secure it with an expansion pin.

(Fig. 20)

E

20 – Mount and secure the drive shaft guard tube.

(Fig. 21)

21 – Place drive shaft into the retainer (L), and secure.

– Mount cover (K), and hang in chain at (A).

A

(Fig. 22)

L K

22

8.5.8

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation Connecting the universal drive shafts: – Remove universal drive shaft half (H) from the retainer, and push it onto the universal drive shaft of the cutterbar.

(Fig. 23, 24) H

23

H

24 – Open guard (B) on the feeder housing.

– Push in the locking pin (1) of the universal drive shaft.

B

– Push the drive shaft onto the transmission shaft, and make sure that the locking pin engages securely.

1

– Close guard (B).

(Fig. 25, 26)

25 – Repeat the procedure on the other side.

(Fig. 26) B

26

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

8.5.9

Operation

8.5.10

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation

Operation CHANGING THE CUTTERBAR FROM WORKING POSITION TO TRANSPORT POSITION – Start the engine, and actuate the safety switch.

– From the driver's seat, raise the reel, retract it fully, and lower it onto the support.

– With the reel in the rearmost position, lower it briefly one more time.

– On cutterbar with Auto-Contour, raise cutterbar so that the sensing bands no longer touch the ground.

K

Danger!

1 Cutterbar 4.50 m standard

Put drive into neutral, and secure the machine against rolling away!

B – Remove left universal drive shaft from the transmission shaft in the feeder housing.

– To do this, push in the locking pin (1), and pull off the drive shaft.

– Place the universal drive shaft in the retainer (G), and secure it.

1

(Fig. 1, 2, 3, 4, 5) 2 Cutterbar 5.40 m standard

1

3

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

8.6.1

Operation Cutterbar 5.40 m / 4.50 m LEXION MONTANA

1

4 Cutterbar 5.40 m / 4.50 m standard

5 – With LEXION Montana, remove the outer drive shaft half (H), and place it on the cutterbar.

(Fig. 6, 7)

H

6

7

8.6.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation – Place the universal drive shaft on the cutterbar side into the retainer (K) and secure it.

(Fig. 8)

K

8 – Fold in the left-hand crop divider.

For this, pull out the locking pin (R), and let it engage again when the crop divider is in the folded end position.

(Fig. 9)

R 9 – Remove the outer deflector (A) on the right side, and stow it inside the cutterbar.

– Fold in the right-hand crop divider.

For this, pull out the locking pin (R), and let it engage again when the crop divider is in the folded end position.

(Fig. 10, 11) A

10

R

11

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

8.6.3

Operation Cutterbar 4.50 m

– Remove right universal drive shaft from the transmission shaft in the feeder housing.

To do this, push in the locking pin (1), and pull off the drive shaft.

1

Place the universal drive shaft in the retainer (G), and secure it.

(Fig. 12, 13, 14)

12 Cutterbar 5.40 m

1

13

G

14 – With LEXION MONTANA, push in the locking pin (1), and pull off the universal drive shaft.

– Stow the drive shaft in the same way as on the left-hand side.

(Fig. 15)

1

15

8.6.4

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation 5. Fold the cutterbar to the transport position.

Press the push button (1) until the cutterbar has been fully folded into the transport position.

Caution!

1

Raise the cutterbar until the Auto-Contour sensing bands are sufficiently free of the ground. If the cutterbar is raised too high, the folding procedure will be hampered.

16

(Fig. 16)

– Mount the guards on crop lifter and knife.

– Mount the safety lighting bar (L), and secure by means of turn lock bolts (B).

– Plug in the connector (S).

– The cutterbar is now ready for transport.

(Fig. 17)

B

S

L 17

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

8.6.5

Operation

8.6.6

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation

Operation ALIGNING THE CUTTERBAR / REMOVING THE CUTTERBAR Aligning the cutterbar

F

(machines without Auto-Contour)

R

Before using the combine harvester for the first time, check horizontal alignment of the cutterbar.

If necessary, the cutterbar position can be modified by relocating the washers (E) beneath the coupling lugs.

E

Ex-works, two washers (43 x 53 x 3) are provided for each side.

– Drive the combine harvester and cutterbar onto a flat, level surface.

24021

1

– Lower the cutterbar to the ground.

– First, remove the washers beneath the coupling lug (F) on the higher side. To do this, unscrew the hexagon bolt (R), and slightly raise the coupling lug.

– After removing the washers, retighten the coupling lug and install the cutterbar.

Should this prove to be insufficient, the removed washers can be added on the opposite side.

(Fig. 1)

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

8.7.1

Operation Removing the cutterbar Note: The cutterbar can be removed in the transport position and in the working position. The procedure is the same in both cases.

Removing the cutterbar: Danger!

Stop the engine and switch off the battery isolating switch.

– Remove the right-hand universal drive shaft from the intermediate drive shaft in the feeder housing, and place it in the retainer on the cutterbar.

– Open the lower lock on the right-hand side.

– Open the lock for the cutting angle adjustment at the top right-hand side. To do this, lower the cutterbar until it just touches the ground.

– Fold in both crop dividers (if necessary).

– Unscrew quick-release coupling from the cutterbar, and attach it to feeder housing. Fit dust guard on the cutterbar coupling.

– Remove the left-hand universal drive shaft from the transmission shaft in the feeder housing, and place it in the retainer on the cutterbar.

– Open the lock for the cutting angle adjustment at the top left-hand side.

– Open the lower lock on the left-hand side.

– Start the engine, and fully lower the cutterbar.

– Reverse the machine.

While reversing, ensure that the coupling lugs do not catch in the coupling holes or in the coupling brackets.

8.7.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation

Operation ADJUSTMENTS ON THE CUTTERBAR Danger!

Due to their function, knives, cutterbar, intake auger and reel etc. cannot be completely shielded by constructional measures.

For this reason, an adequate safety distance must be maintained to these moving elements during operation!

For all work underneath the raised cutterbar, the raised reel or the feeder housing, the safety locks on the reel cylinders and the cutterbar cylinders must be in place.

Crop dividers The crop dividers consist of divider plates (A) and inner deflectors (B). Additionally, an outer deflector plate (C) may be fitted.

A

– If required, mount the crop dividers on stud (P) using hexagon bolts (S), contact washer (C) and three Belleville spring washers (T).

The crop divider is foldable, and can remain mounted also in the transport position.

B

(Fig. 1, 2, 3) 1 S C D T O P

S

P

= = = = = =

Hexagon bolt M 12 x 35 ISO 4017-8.8 Contact washer B 12 Spacer Spring washers (3 per side) Divider support tube Stud

(Fig. 2) C D O

T 2

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

8.8.1

Operation Outer deflector Mounting the outer deflector: A B

– Push the adjusting pins (A) of the adjusting tubes into the holes of the cutterbar uprights (see arrow) up to the stop.

C

– Mount the outer deflector (C), and adjust.

(Fig. 3, 4) 5

6

3 Adjusting the outer deflector: – Adjust the height of outer deflector (C) after releasing the toggle bolt (5) and the turn lock (6) so that the stalks are pushed into the standing crop.

A

(Fig. 3)

4 – To remove the adjusting tube, retract the clip (K), and pull out the connecting pins (A).

(Fig. 5)

A K

5

8.8.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation Adjusting the dividers – Push the divider plates (A) as close as possible to the reel, after releasing the bolts (2).

Caution: Make sure that the reel does not collide.

– Position left-hand divider plate (A) in the middle of the slot.

3

– Push the right-hand divider plate (A) completely to the right-hand side.

1

L = Left-hand crop divider 6

R = Right-hand crop divider – Adjust the inner deflectors (B) so that the reel shafts do not wind, and the reel does not collide.

R

L

– Adjust the height of the crop divider with the adjusting slider (1) after releasing the screws (3) so that the points of the crop divider do not continuously scrape on the ground, and do not dig into uneven ground.

(Fig. 3, 6, 7)

2

2

37341

7

Crop lifters The number of crop lifters to be fitted depends on the condition of the crop.

For down crops and weed growth, attach a crop lifter to every fourth to sixth finger, and closer together for short, upright crops with ears hanging downwards.

(Fig. 8)

8 Fitting the crop lifter: – Loosen nut (M).

– Push the crop lifter between the washer and the top nut, and at the same time place pocket (T) on the finger tip.

T

– Tighten the nut.

Do not fit a lifter on the first three fingers from either end of the cutterbar.

M

(Fig. 9) 9

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

8.8.3

Operation Knife Danger!

Always wear gloves to avoid injuries when removing and installing the knife.

Use particular care when pulling out the knife, if the finger bar is bent or very dirty.

Removing the knife – Move the knife to the outside dead centre.

– Remove the hexagon bolts (N), and pull out the knife.

N

(Fig. 10, 11)

M 10

11 Installing the knife – Push the knife into the finger bar, and secure with hexagon bolts (N).

Make sure that the recess (M) has been cleaned and that the drive key is fully engaged.

(Fig. 10)

8.8.4

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation Adjusting the knife height – After loosening the clamping bolt (K), adjust the lever (G) so that a clearance of 0.5 to 1.0 mm is provided between the first knife blades and the double finger supports.

– Retighten the clamping bolt after adjustment.

G

(Fig. 12) K

12 Aligning the knife clips – By adding or removing equalizing washers, align the knife clips (D) so that the cutting knife runs smoothly.

D

There should be about 1.5 mm clearance between the knife blade and the knife clips.

(Fig. 13)

13 Spare knife A spare knife can be stowed in the holders (H) on each side of the cutterbar.

– Secure the knives on both sides with the latches (R).

(Fig. 14)

R H 14

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

8.8.5

Operation Reel Adjusting the reel height The reel height can be adjusted by means of a solenoid valve actuated by the pushbuttons (2a and 2b) on the multifunction handle.

2a

Lower the reel for down crops, and use a higher setting when harvesting standing crop.

2b

2a = lowering the reel 2b = raising the reel (Fig. 15)

15 Fine height adjustment of the reel If the reel tines come into contact with the knife when the reel is in the lowest position, the distance to the knife can be increased by unscrewing the eye bolts (B).

B K

– To adjust, loosen lock nut (K) and rotate the hydraulic piston accordingly.

– After adjustment, retighten the lock nut.

When adjusting the eyebolts, the internal lock nuts (D) must also be adjusted accordingly.

16

(Fig. 16, 17)

D

17

8.8.6

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation Reel tines: B

A vertical setting of reel teeth, or slightly forward is best in normal harvesting conditions.

In heavy down grain or with very short-stalked crops, the reel tines should be set backward to grip position by relocating lever (B) in the perforated segment (C).

C

Note!

Adjusting the tines of the reel too much to the rear causes the reel to wrap.

18 (Fig. 18)

Reel drive The reel is driven by hydraulic motor (M), roller chain (R) and sprockets.

M

The reel speed is infinitely adjustable. Also refer to the operating manual of the combine harvester.

R

(Fig. 19)

19 Reel fore and aft adjustment By actuating the pushbuttons (2c and 2d) on the multifunction handle, the reel can be adjusted forward and backward by means of the horizontal, double-acting hydraulic cylinders (H).

H

2c = horizontal reel adjustment, backwards 2d = horizontal reel adjustment, forwards (Fig. 20, 21)

20

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

8.8.7

Operation

2d

2c

21

Feed auger S

Adjusting the clearance to the cutterbar bottom plate

S

The basic auger setting has a gap of approx. 15 mm between auger flights (S) and bottom of cutterbar trough.

F

Raise the feed auger setting when taking in very heavy swaths or bulky or brittle crops.

Also refer to the "threshing table" in the combine harvester's operating manual.

22

The crops conveyed to the centre by the auger spirals are pulled under the feed auger to the feed rake by the controlled fingers (F).

Damaged fingers should be replaced immediately.

(Fig. 22)

8.8.8

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation Height adjustment of the feed auger C

After loosening the clamping bolts (4), the feed auger adjustment can be changed with the setscrew (C) on each side and the centre of the cutterbar.

4

Adjust both sides and the centre by equal amounts.

After adjusting, retighten all bolts.

4

(Fig. 23, 24)

23

C

4

24

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

8.8.9

Operation

25 Adjusting the intake finger position The position of the intake fingers (F) can be adjusted by rotating the plate (T) after removing the screws (3).

T

T

3

A = right-hand feed auger B = left-hand feed auger G = direction of travel With identical intake finger settings, the locations of the stamped identification letters (L and R) are opposite between the two feed augers.

3

26

M = middle position Caution!

Do not use the position (L) on the right-hand feed auger (A) and do not use the position (R) on the left-hand intake auger (B)! #

27

8.8.10

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation

Danger!

Risk of injury when rotating the plate (T).

Steady the plate (T) with a spanner.

Replace and retighten the screws after adjustment.

Adjustment can only be done with the cutterbar in the transport position.

(Fig. 25, 26, 27)

Safety feature The feed augers are protected from overload by slip clutches (R).

Attention!

Do not adjust the slip clutches so tightly that they block and fail to provide a safety function.

R

28

See Specifications for the slip clutch torque settings.

(Fig. 28)

Cutterbar skids Cutterbar skids (K) are height-adjustable.

S

Proper adjustment of skids depends on the tyre size.

F

Extend the skids as far out as possible.

L

Working in grass: If necessary, the skids can be retracted completely, for example on lodged grass.

K

To do this, proceed as follows: 29

– Unbolt the flat bars (F).

– Fully raise the skids.

– Place flat bars (F) into the skids.

– Reattach skids in holes (L) using bolts (S) and flat bars (F).

Extend the skids again as soon as possible.

(Fig. 29)

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

8.8.11

Operation

8.8.12

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Operation

Operation MALFUNCTION, POSSIBLE CAUSE AND/OR REMEDY Malfunction Cutterbar cannot be folded

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

Possible cause and/or remedy 1. Limit switch (interlock) faulty.

Replace switch.

2. Reel not fully retracted.

Retract reel completely.

The limit switch must be actuated.

3. Limit switch (rear reel position) faulty.

Replace limit switch.

4. Reel not fully lowered.

Lower the reel completely.

5. Limit switch (bottom reel position) faulty.

Replace limit switch.

6. Limit switch not adjusted correctly.

Adjust limit switch.

7. Pushbutton on machine faulty.

Replace the pushbutton.

8. Reel is askew. Limit switch on left side is not actuated. Raise reel to its end position. This restores the reel to the horizontal position.

If this does not help, check for internal leaks of reel cylinders, and remedy. Also refer to "Adjusting the reel limit switch", page 9.4.1.

8.9.1

Operation

8.9.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

9 Maintenance

Maintenance

Maintenance MAINTENANCE SCHEDULES AND LUBRICANTS CHARTS Maintenance schedule

100

Working hours

Every 50

100 Working hours

250

After the harvest

40

As required

Every day

After the first

Annually = every 500 working hrs.

Service intervals Before the harvest

Maintenance operations

HYDRAULIC SYSTEM – Bleed reel cylinders GEARBOXES Knife drive gears – Check oil level – Change oil Bottom angle drive (driven via universal drive shaft) DRIVES Check and adjust the belts with spring-loaded belt tensioners – Knife drive Check chain drives and adjust if necessary – Intake auger drive – Reel drive

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

9.1.1

Maintenance Lubricants chart Component

Type of lubricant

Capacity

Viscosity

Multi-purpose gear oil to (MIL-L-2105 B) API-GL-5-90

0.85 litres each

Change intervals

Check

Gearboxes Knife drive gears

9.1.2

See maintenance schedule

See maintenance schedule

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Maintenance

Maintenance TRANSMISSIONS Knife drive transmission Oil filling quantity – see page 9.1.2, Lubricants chart E

Oil type – see page 9.1.2, Lubricants chart Change oil – see page 9.1.1, Maintenance schedule Environment!

Dispose of used oil properly!

1

E = oil filler cap A = oil drain plug Check the oil level: – Bring the knife drive transmissions to a horizontal position by raising the cutterbar.

– Remove the oil filler cap (E) for checking the oil level.

– The oil level can be checked with a wire.

Details of the wire:

A

Overall length approx. 300 mm Insertion depth approx. 210 mm 2

– Make a slight bend in the wire at approx. 220 mm.

– Insert the wire at an angle to perform the check.

Correct level = 80 mm above the end of the wire.

– Replace the oil filler cap after checking the oil level.

(Fig. 1, 2)

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

9.2.1

Maintenance

9.2.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Maintenance

Maintenance SPRING-LOADED CYLINDERS / DRIVE CHAINS / INDUCTIVE SENSORS Adjusting the spring-loaded cylinders for knife drives – Loosen the lock nut (K), and adjust the spring guide tube so that the end of the gauge rod (D) is flush with the washer (S).

D K

– Retighten the lock nut (K).

(Fig. 1) S

1

Tensioning the drive chains The drive chain can be tensioned by means of the chain tensioner (T).

T

– For tensioning, loosen the clamping bolt of the sprocket.

M

– Adjust the chain tensioner (T) with the nuts (M).

– Retighten the clamping bolt after adjustment.

(Fig. 2) 2

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

9.3.1

Maintenance Tensioning the reel drive chain – Unscrew cover (D).

– Slightly loosen the bolts (E).

D

– Tension the chain moderately at the tensioning bolt (F).

– Retighten the screws (E), and replace the cover (D).

(Fig. 3, 4) 3 E F

4

Cleaning the guide rails of the locking cylinder If possible, clean the guide rails with compressed air every day.

The guide rails of the rear cylinder at (M) are accessible in the working position.

The guide rails of the front cylinder at (V) are accessible in the transport position.

M

(Fig. 5, 6) 5

V 6

9.3.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Maintenance

Maintenance GENERAL Aligning the double fingers 15

S

16

1

2

18

17

3

4

5

19

20

21

To ensure a perfect overlap of the double fingers (18 and 19), the double fingers (16 – 18) can be adjusted in height using the spacer washers (S, 11 x 21 x 0.5).

Numbers 1 – 6 = Number of spacers

6

When mounting the double fingers (18 and 19), please note: – Push the double finger (18) all the way back.

M 1

– Push the double finger (19) and the mulch finger (M) all the way forward.

(Fig. 1)

Adjusting the reel limit switch Caution!

To fold the cutterbar, the limit switch (E) must be actuated by the reel. Otherwise the cutterbar cannot be folded. Also refer to "Malfunction, possible cause and/or remedy", page 8.9.1.

E

(Fig. 2) 2

Adjusting the locking pawl at the centre reel guide X

The basic dimension (X) from flange surface (F) to behind the bolt head (S) is 38 mm.

The hexagon bolt (S) can also be adjusted while the cutterbar is in the working position.

S F

3

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

9.4.1

Maintenance Check with the cutterbar in working position: Y

K

The clearance (Y) between the locking pawl (K) and the locking block (T) should be approx. 3 mm.

– Adjust accordingly, if necessary.

T

(Fig. 3, 4)

S

4

Cleaning the spaces of the supporting arm bearings Perform cleaning work with the cutterbar in the working position.

Remove dirt and straw from the free spaces on both sides of the supporting arm bearings, as necessary (see arrows).

(Fig. 5, 6)

5

6

9.4.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Maintenance Cleaning the coupling lug areas Perform cleaning work with the cutterbar in the transport position.

Clean the supports in the area of the coupling lugs, as necessary (see arrows).

(Fig. 7, 8)

7

8

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

9.4.3

Maintenance

9.4.4

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Maintenance

Maintenance SUGGESTIONS FOR WINTER STORAGE The cutterbar must be prepared for winter after the harvest so that the machine lasts for as long as possible. With consistent and conscientious care, as well as the preventive maintenance of worn and possibly damaged parts at the same time, both time and money is saved when using the machine again.

1. Clean the exterior of all bearings of dust and grease.

2. Thoroughly clean the cutterbar.

3. Preserve the cutterbar by inserting brand name lubricant in the lubrication points to be maintained, once a year after the harvest. To ensure the even distribution of the grease, briefly run the machine until a small circle of grease has formed on the outside of the bearings.

Seal off peripheries of slip clutches with paint to keep moisture out and to keep friction faces from rusting.

4. Grease all polished parts such as finger bars and crop lifters.

5. Change the transmission oil.

6. Lower the cutterbar to the ground or remove it in order to relieve the hydraulic system.

Attention!

If the cutterbar is washed (to be avoided if possible), all lubrication points must be greased after washing. Afterwards, allow the machine to run for a few minutes.

Cavities, such as cable inlets, should not be washed with water. In some cases the water can no longer be removed from the hollow spaces and can lead to rusting.

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

9.5.1

Maintenance

9.5.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

10 Lubrication chart

Lubrication chart

Lubrication chart

LUBRICANTS AND NOTES

Grease brand name

Remove humped cover plate

Examples: Manufacturer Description FINA ARAL FUCHS SHELL DEA AVIA FAG SKF

See the lubrication intervals recommended by the PTO shaft supplier

"Marson EPL 2" "Aralub HLP 2" "Renolit EP 2" "Retinax EP 2" or "Alvania G3" "Glisando EP2" "Avilup Special grease EP" "Arcanol L 135 V" "LGEP2"

Every 100 working hours

Every 250 working hours

Once per year (500 operating hours)

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

10.1.1

Lubrication chart

1

2

1

3

2

3

10.1.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Lubrication chart

4

4

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

10.1.3

Lubrication chart

5

5

10.1.4

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Lubrication chart

1

2

3

Standard

4

Montana

1 Standard

2 Montana

3

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

4

10.1.5

Lubrication chart

2

3

7

6

5

1

10.1.6

4

1

2

3

4

6

7

5

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

11 Index

Index

Index INDEX Additional headlights .............................................................. 7.1.1 Additional weights .................................................................. 5.1.1 Adjusting the additional headlights ........................................ 7.1.6 Adjusting the clearance to the cutterbar bottom plate ............ 8.8.8 Adjusting the cutterbar floatation springs ............................... 6.2.2 Adjusting the cutterbar skids .................................................. 8.1.1 Adjusting the cutting angle ..................................................... 8.2.1 Adjusting the dividers ............................................................. 8.8.3 Adjusting the intake finger position ...................................... 8.8.10 Adjusting the knife height ....................................................... 8.8.5 Adjusting the locking pawl at the centre reel guide ................ 9.4.1 Adjusting the reel height ........................................................ 8.8.6 Adjusting the reel limit switch ................................................. 9.4.1 Adjusting the spring-loaded cylinders for knife drives ............ 9.3.1 Adjustments on the cutterbar ................................................. 8.8.1 Aligning the cutterbar / removing the cutterbar ...................... 8.7.1 Aligning the cutterbar (machines without Auto-Contour) ....................... 8.7.1 Aligning the double fingers ..................................................... 9.4.1 Aligning the knife clips ........................................................... 8.8.5 Carry out prior to initial operation ........................................... 6.1.1 Changing the cutterbar from transport position to working position ..................................................................... 8.5.1 Changing the cutterbar from working position to transport position ................................................................... 8.6.1 Changing the driving lights (from serial no. ...) ............................................... 6.2.1 Changing the driving lights (up to serial no. ...) .............................................. 6.2.1 Cleaning the coupling lug areas ............................................. 9.4.3 Cleaning the guide rails of the locking cylinder ...................... 9.3.2 Cleaning the spaces of the supporting arm bearings ............. 9.4.2 Connecting the universal coupling ......................................... 8.4.4 Crop dividers .......................................................................... 8.8.1 Crop lifters .............................................................................. 8.8.3 Cutterbar skids ....................................................................... 8.1.1 Cutterbar skids ..................................................................... 8.8.11 Cutting angle adjustment ....................................................... 8.2.1 Driving lights / Cutterbar cylinder ........................................... 6.2.1 Driving lights for road use ...................................................... 6.2.1 Feed auger ............................................................................ 8.8.8 Feed rake safety locks ........................................................... 4.1.3 Fine height adjustment of the reel .......................................... 8.8.6 Fitting the cutterbar ................................................................ 8.4.1 Fitting the switches and the additional headlights .................. 7.1.2 Fitting the universal drive shafts LEXION MONTANA (from serial no. 71300231) .................................. 8.5.6 General .................................................................................. 9.4.1 Height adjustment of the feed auger ...................................... 8.8.9 Identification plate / Serial number ......................................... 3.3.1 Important information ............................................................. 3.2.1 Installing and removing the cutterbar ..................................... 8.4.2 Installing the cutterbar when folded in (cutterbar in the transport position) ..................... 8.4.2 Installing the knife .................................................................. 8.8.4 Installing the push buttons for switching ................................ 7.1.2 Installing the universal drive shaft for LEXION MONTANA ... 8.5.7

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION

Introduction ............................................................................ 1.1.1 Knife ...................................................................................... 8.8.4 Knife drive transmission ........................................................ 9.2.1 Locking the coupling lug after fitting the cutterbar ................. 8.2.2 Locking the cutterbar at top and bottom on both sides ......... 8.4.3 Lubricants and notes ........................................................... 10.1.1 Lubricants chart ..................................................................... 9.1.2 Maintenance schedule .......................................................... 9.1.1 Maintenance schedules and lubricants charts ...................... 9.1.1 Malfunction, possible cause and/or remedy .......................... 8.9.1 Mounting the additional headlights on both sides ................. 7.1.2 Mounting the coupling brackets ............................................. 8.2.2 Mounting the extension to the intermediate drive shaft (LEXION 530 – 510) ............................................ 8.3.1 Mounting the shaft extension ................................................ 8.3.1 Mounting the spacer bar ........................................................ 8.2.1 Outer deflector ....................................................................... 8.8.2 Reel ....................................................................................... 8.8.6 Reel drive .............................................................................. 8.8.7 Reel fore and aft adjustment ................................................. 8.8.7 Reel safety lock ..................................................................... 4.1.3 Removing standard universal drive shafts ............................ 8.5.7 Removing the cutterbar ......................................................... 8.7.2 Removing the knife ................................................................ 8.8.4 Removing the transport fixtures ............................................ 6.2.2 Safety decals with pictorials .................................................. 4.2.1 Safety feature ...................................................................... 8.8.11 Safety lighting rail on the cutterbar ........................................ 6.2.2 Safety locks ........................................................................... 4.1.3 Safety rules ........................................................................... 4.1.1 Spare knife ............................................................................ 8.8.5 Spring-loaded cylinders / Drive chains / Inductive sensors ... 9.3.1 Suggestions for winter storage .............................................. 9.5.1 Tensioning the drive chains ................................................... 9.3.1 Tensioning the reel drive chain ............................................. 9.3.2 Third cutterbar cylinder .......................................................... 6.2.2 Tilting the cutterbar from the transport position ..................... 8.4.1 Transmissions ....................................................................... 9.2.1 Unlocking the coupling lug before removing the cutterbar .... 8.2.3 Vehicle type approval ............................................................ 3.1.1 Weights / Dimensions / Safety devices ................................. 5.1.1

11.1.1

Index

11.1.2

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

At CLAAS KGaA mbH we are constantly improving our products to reflect the latest technological developments. For this reason, we may from time to time need to make changes to diagrams and descriptions in this documentation which do not reflect products that have already been delivered and which will not be implemented on these machines.

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 CLAAS KGaA mbH. All rights under the provision of the Copyright Act are reserved.

CLAAS KGaA mbH 33426 HARSEWINKEL Germany

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

000 299 846 1 ABA / BA klappb. SW 5.40 m / 4.50 m LEXION EN - 06/05 Printed in Germany