CLAAS SWATHERS TEDDERS Repair and Adjustment Instructions Manual - PDF DOWNLOAD

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Repair and Adjustment Instructions

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Introduction

Introduction

1 Introduction

INTRODUCTION This manual contains general instructions on the repair of CLAAS forage harvesting equipment. It also contains information on the repair of: – LINER reduction gear – CLAAS rotary gear – DISCO mower head – CORTO direct-cut drive Please read this manual thoroughly before starting work! Pay particular attention to the “General Information” section.

The required spare parts can be found in the parts list of your forage harvesting equipment.

Your CLAAS Service Department

299 605.1 - RHB Futtererntemaschinen

1.1

Contents

Contents

2 Contents 1. Introduction Introduction ............................................................................... 1.1

2. Contents 3. General Information Of special importance ............................................................... 3.1 Identification of warnings and dangers ............................... 3.2 Designated use ................................................................... 3.2 Explanation of symbols ............................................................. 3.3 Tightening torques .................................................................... 3.4 General repair instructions ........................................................ 3.6 General ............................................................................... 3.6 Test run ............................................................................... 3.6 Screw connections .................................................................... 3.6 General ............................................................................... 3.6 Special shaft nuts ............................................................... 3.6 Self-locking screws (with micro-encapsulated glue) ........................................... 3.6 Liquid screw lock ................................................................ 3.7 Correct use ......................................................................... 3.7 Gaskets ..................................................................................... 3.7 Liquid gaskets ..................................................................... 3.7 Flat gaskets ........................................................................ 3.7 Finished gaskets ................................................................. 3.7 Radial shaft seals ............................................................... 3.8 Bearings .................................................................................... 3.8 Assembly of clamping ring bearings ................................... 3.8 Assembly of adapter sleeve bearings ................................. 3.8 Loosening ........................................................................... 3.8 Tightening ........................................................................... 3.8 Assembly of roller bearings ................................................ 3.9 General ............................................................................... 3.9 Adjustment of roller bearings .............................................. 3.9 Shaft-hub connections ........................................................ 3.9 DRIVE SYSTEMS ..................................................................... 3.9 General ............................................................................... 3.9 Gears ................................................................................ 3.10 Spur gears ........................................................................ 3.10 Bevel gears ....................................................................... 3.10 Adjustment of spur gears .................................................. 3.10 Adjustment of cyclopalloid gears ...................................... 3.10 Tensioning steel roller chains ........................................... 3.12 Tapered ring connections ................................................. 3.13 Disassembly ..................................................................... 3.13 Assembly .......................................................................... 3.13 Hydraulic system ..................................................................... 3.13 Ferrule retaining screws on hydraulic system hoses ........ 3.13 Assembly .......................................................................... 3.13 Final assembly .................................................................. 3.13 Repeat assembly .............................................................. 3.13 Leaking ferrule connection ................................................ 3.13 Progressive ring retaining screws on hydraulic system hoses .................................................... 3.13 Assembly .......................................................................... 3.13 Final assembly .................................................................. 3.14

2.1

Repeat assembly ..............................................................

Leaky profile ring connection ............................................

Conical nipple retaining screws on hydraulic system hoses ...................................................................

Assembly ..........................................................................

Welding ...................................................................................

Fuel and lubricants ................................................................

Fill amounts ......................................................................

3.14 3.14 3.14 3.14 3.14 3.15 3.15

4. Drive systems LINER reduction gear ............................................................... 4.1 General assembly and maintenance instructions ............... 4.1 Bearings ............................................................................. 4.1 Screw connections ............................................................. 4.1 Radial shaft seals ............................................................... 4.1 Gearbox in oil bath ............................................................. 4.1 Reduction gear “LINER 680 / 680 L / 680 Profil / 650 Twin / 350 S / 350 T” – version “9.792.100.40” and “9.792.101.40” ..................... 4.2 List of parts ......................................................................... 4.2 Dimensions ......................................................................... 4.3 Disassembly ....................................................................... 4.4 Assembly ............................................................................ 4.7 Reduction gear “LINER 680 / 680 L / 680 Profil / 650 Twin / 350 S / 350 T” – version “9.792.116.20” .................................................. 4.12 List of parts ....................................................................... 4.12 Dimensions ....................................................................... 4.13 Disassembly ..................................................................... 4.14 Assembly .......................................................................... 4.17 Reduction gear “LINER 680 / 680 L / 680 Profil / 650 Twin / 350 S / 350 T” – general assembly instructions ....................................... 4.22 Contact pattern ................................................................. 4.22 Backlash ........................................................................... 4.22 Lubricants ......................................................................... 4.22 “CLAAS” reduction gear – General assembly instructions ...................................... 4.23 Installation of curved track ................................................ 4.23 Lubricants ......................................................................... 4.23 “CLAAS” rotary gearbox ......................................................... 4.24 General assembly instructions ......................................... 4.24 Assembly of the angle drive ............................................. 4.24 Lubricants ......................................................................... 4.24 DISCO cutter bar .................................................................... 4.25 Cutter bar with 6 cutting discs “COMER FR-566A” .......... 4.25 Parts list “cutter bar with 6 cutting discs” .......................... 4.25 Cutter bar with 7 cutting discs “COMER FR-567A” .......... 4.25 Parts list “cutter bar with 7 cutting discs” .......................... 4.26 Parts description ............................................................... 4.26 Dimensions “cutter bar with 6 cutting discs” ..................... 4.27 Dimensions “cutter bar with 7 cutting discs” ..................... 4.28 Disassembly ..................................................................... 4.29 Assembly .......................................................................... 4.31 Assembling rotors ............................................................. 4.32 Assembling inlet rotor ....................................................... 4.33

RHB Futtererntemaschinen - 299 605.1

Contents Replacing intermediate gear wheel – bearing .................. 4.34 Assembling cutter bars ..................................................... 4.36 Installing rotor ................................................................... 4.37 Leak test ........................................................................... 4.38 Installing slide ................................................................... 4.38 Installing cutting disc and drum ........................................ 4.39 Drum – inlet side ............................................................... 4.39 “COMER” cutter bar – General assembly instructions ...................................... 4.40 Lubricants ......................................................................... 4.40 “CORTO” direct-cut attachments ............................................ 4.41 Installing direct-cut attachment ......................................... 4.41 Lubricants ......................................................................... 4.41

299 605.1 - RHB Futtererntemaschinen

2.2

General Information

General Information

3 General Information

OF SPECIAL IMPORTANCE Persons who operate, service, repair or check this machine/attachment must read and observe the information in this manual so they can work safely. Pay particular attention to the “General Information” section in the operator's manual and observe the accident prevention regulations in force in your jurisdiction.

Before starting work make sure that you have all the required tools and equipment.

See the parts list for the relevant machine or the parts overview for the specifications of parts, e.g. screws and bolts.

Parts are identified with numbers (item numbers) for better orientation in the assembly descriptions. The numbers correspond to the item numbers in the parts overview.

Text and pictures are kept as neutral as possible. Text notes call attention to differences in the specific types.

Technical specifications, dimensions and weights are understood with the usual tolerances.

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

3.1

RHB Futtererntemaschinen - 299 605.1

General Information Identification of warnings and dangers

Designated 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 supply all safety instructions to any other user.

The use of spare parts, accessories and additional equipment which is not originally manufactured, and not checked and released by CLAAS can have its negative effect on specific design features of the CLAAS machine or on its operability, thereby impair active and/or passive operating safety, as well as safety at work (accident prevention).

Danger!

Failure to observe the instructions identified by this symbol results in danger for life and limb of the user or other persons.

– Measures for avoiding danger.

CLAAS will in no way be liable for damage or personal injury caused by the use of other than original CLAAS parts, accessories and additional equipment.

Caution!

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

– Measures for avoiding danger to the machine.

Note!

This symbol identifies instructions that make it easier to use the machine effectively and economically.

Important!

This symbol identifies information that must be observed during disassembly and assembly.

Environment!

Failure to observe the instructions identified by this symbol results in damage to the environment.

The environment is in danger if environmentally hazardous material (e.g. waste oil) is not subject to correct use and/or disposal.

The warning and instruction signs placed on the combine provide recommendations for safe operation. These instructions involve your safety – observe them at all times!

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3.2

General Information

General Information EXPLANATION OF SYMBOLS This CLAAS REPAIR MANUAL uses certain symbols from the “Symbols–Overview DIN 30600” published by the German Institute for Standardisation.

Disassembly

Grease

Prevention of material damage

Dismantle

Oil

Use of special tools

Assembly

Set-up

Drain drainage hole

Removal

Install Attach

Visual, monitor inspect

Filling Filler opening

Mark

Unlock, lock

Overflow

Balance

Hold fluid, glue seal

Bleeding

Re-usable to a limited extent

3.3

The user will quickly learn the meanings of these symbols. They are intended to assist in quick recognition of frequently repeated procedures and illustrated instructions.

Support Prop

Dispose of parts correctly

Catch

Replace on every

Observe installation

assembly

direction

Retain parts for re-use

RHB Futtererntemaschinen - 299 605.1

General Information TIGHTENING TORQUES Tightening torques (in Nm) for hexagon head bolts, cheese-head screws and hexagonal nuts Nuts and bolts Strength class

carbonised, phosphatised or galvanised 8.8

Dimensions

Hexagon head bolts DIN 931 DIN 933 Cheese-head screws DIN 912 hexagonal nuts DIN 934

Hexagonal nuts DIN 934

CAUTION!

12.9

Metric coarse-pitch thread

M4

2.7

3.8

4.6

M5

5.5

8.0

9.5

M6

10.0

14.0

16.0

M8

23.0

33.0

40.0

M 10

45.0

63.0

75.0

M 12

78.0

110.0

130.0

M 14

122.0

175.0

210.0

M 16

195.0

270.0

325.0

M 18

260.0

370.0

440.0

M 20

370.0

525.0

630.0

M 22

510.0

720.0

870.0

M 24

640.0

900.0

1080.0

M 27

980.0

1400.0

1650.0

M 30

1260.0

1800.0

2160.0

Dimensions

Hexagon head bolts DIN 960 DIN 961

10.9

Metric fine-pitch thread

M8x1

25

35

42

M 10 x 1.25

48

67

80

M 12 x 1.25

88

125

150

M 12 x 1.5

82

113

140

M 14 x 1.5

135

190

225

M 16 x 1.5

210

290

345

M 18 x 1.5

300

415

505

M 20 x 1.5

415

585

700

M 22 x 1.5

560

785

945

M 24 x 2

720

1000

1200

M 27 x 2

1050

1500

1800

M 30 x 2

1450

2050

2500

Cadmium-plated or copper-plated nuts and bolts must be tightened with torques 25% lower than the specified values.

299 605.1 - RHB Futtererntemaschinen

3.4

General Information

Tightening torques for hydraulic system retainers with o-rings in accordance with ISO 6149 Dimensions

Tightening torque in accordance with ISO 6149

M8x1

7+2 Nm

M 10 x 1

11+4 Nm

M 12 x 1.5

16+5 Nm

M 14 x 1.5

23+8 Nm

M 16 x 1.5

29+10 Nm

M 18 x 1.5

38+13 Nm

M 20 x 1.5

46+15 Nm

M 22 x 1.5

67+22 Nm

M 24 x 1.5

86+29 Nm

M 26 x 1.5

103+34 Nm

M 27 x 2

103+34 Nm

M 30 x 2

170+57 Nm

M 33 x 2

200+67 Nm

M 36 x 2

245+82 Nm

M 38 x 2

245+82 Nm

M 39 x 2

310+103 Nm

M 42 x 2

380+127 Nm

M 45 x 2

440+147 Nm

Tightening torques for screw plugs

3.5

Dimensions

Tightening torque

M 16 x 1.5 conical

30 Nm

M 18 x 1.5 conical

50 Nm

M 16 x 1.5 cylindrical

30 Nm

M 18 x 1.5 cylindrical

50 Nm

RHB Futtererntemaschinen - 299 605.1

General Information GENERAL REPAIR INSTRUCTIONS

SCREW CONNECTIONS

General

General

1. Find cause of damage, limit damage and secure machine.

2. Use original CLAAS parts and appropriate CLAAS special tools.

3. Repairs can be carried out quickly and correctly when the following are observed: • Mark machine parts before removing them to ensure that they are correctly re-installed and correctly balanced after replacement.

• Expansion pins must always be positioned with the slot to the loaded side. If they are displaced by 90°, they will loosen, fall out or shear.

• Replace split pins, wire locks, metal-plate locks, lock washers and spring washers during repairs.

• Grease lubricated ball bearings and roller bearings with good-quality grease.

• Align sprockets and v-belt pulleys with each other.

• Observe cleanliness when working on hydraulic systems.

• Do not mix different oil types.

• Rotate or operate machine or machine assemblies slowly after repair.

4. Inform the machine owner of the cause, type and scope of repairs!

Test run 5. Always prepare and conduct a test run after repairs.

• Correctly screw in and tighten all screws!

• Clear up all tools used!

• Touch up paint at points where welding, drilling and grinding work was carried out.

• Replace all safety features so they operate correctly!

• Check electrical connections!

• Check settings on the machine!

• Lubricate all required grease points!

• Check all oil levels!

• Conduct test run!

299 605.1 - RHB Futtererntemaschinen

All nuts and bolts must be checked against the parts list for strength class, length and correct standard before assembly.

When tightening the screws and bolts ensure that they are tightened crosswise starting in the centre, unless otherwise specified. Then all threaded connections must be tightened again.

The threaded connections are tightened and retightened with a torque spanner.

Nuts must be no more than one strength class below the bolts used.

All screws and bolts must be tightened as specified in the Tightening torques on page 3.4 table, unless otherwise specified.

Special shaft nuts Special shaft nuts are generally specially manufactured and have a turned collar. Unlike the standardised shaft nuts tab washers are not required. They are locked by the turned collar being locked or tapped into a groove or a profile gap, unless otherwise specified.

The turned collar must not be deformed by locking or tapping to the extent that they are cracked through.

If the external diameter of the shaft nut is used as a seal, the thread of the shaft nut and the shaft is locked with locking fluid, unless otherwise specified – see Liquid screw lock, page 3.7.

Self-locking screws (with micro-encapsulated glue) Replace self-locking screws, e.g. Verbus Plus / Imbus–Plus etc., at every assembly. They can be re-used up to three times in exceptional cases. Always tighten at the specified torque.

Always tighten self-locking screws with micro-encapsulated glue quickly to the specified torque. Unscrew these screws quickly to remove them completely. The self-locking screws must not come into contact with sealing compound (e.g. “Epple 33” etc.).

Instead of self-locking screws, screws locked with liquid locking material must only be used where the screw connections can be heated up to about 200°C to loosen them. Note also the specified quality class of the screws (8.8/10.9 etc.).

Self-locking screws with micro-encapsulated glue can only be used where the operating temperature does not exceed max. +90 °C.

3.6

General Information Screws of this type reach their full load capacity after 24 hours at +20 °C. The hardening period can be reduced by heating (e.g. at +70 °C for 15 minutes).

GASKETS Liquid gaskets Liquid gaskets are used to seal:

Liquid screw lock

– Housing sections

(e.g. Delo–ML 187 / Loctite 242 etc.)

– Flanges

Only use liquid screw lock when recommended by the manufacturer.

– Covers – Threads

Correct use Metallic connections that are to be locked with liquid thread-lock must be absolutely free from grease.

Clean them with the “activator” included in the workshop pack.

The metal surfaces must be completely free of activator before applying the liquid thread lock. In particular, blind holes must not have any activator residue (use cleaner).

With threaded connections apply the liquid thread lock to the internal thread (nut) in as small a quantity (drop by drop) as possible. Apply approximately 1d (d = rated –∅ of the bolt) to the base of the thread only in blind holes. Proceed in the same way with all overlength screw-in threads.

Note!

If the liquid thread lock is applied to the thread of the bolt or at the start of the inserted end, the liquid will be distributed over the entire length of the thread when screwing it in and the breaking torque will be too high when attempting to unscrew the bolt later and the bolt may break.

Screw connections that are locked with liquid thread lock can be loosened easily by heating them to about 200°C.

The sealed parts must smooth and undamaged and also free from oil and grease on the gasket contact surfaces. The sealing compound must be spread evenly on the surfaces without breaks and in the amount required to seal the special part. Ensure that drilled holes and threads are covered with sealing compound on the sides that require sealing.

The sealing compound must be ventilated to ensure a proper seal in accordance with the manufacturer's specifications for joining the parts. Threads on bolts are sealed by applying the sealing compound to the outer thread in the specified quantity.

Flat gaskets Flat gaskets are used to seal covers, screw heads, screw plugs, ventilation components etc.

These gaskets can be paper, rubber, cork, copper or special materials. The gaskets must be undamaged, otherwise the effectiveness of the seal may be affected.

The sealing surfaces of the sealed parts must be undamaged.

Observe the special regulations for special requirements.

Finished gaskets Finished gaskets are used for static and dynamic seals. This includes o-rings, quad-rings and seals.

The sealed components must be undamaged and free from roughness and cavities on the seal surfaces.

Visually inspect the seal components before assembly.

The gaskets must be used with oil, grease or a special lubricant. Use special tools as specified.

During assembly it is particularly important to prevent crushing or any other damage to the sealing elements.

3.7

RHB Futtererntemaschinen - 299 605.1

General Information Radial shaft seals

Assembly of adapter sleeve bearings

Radial shaft seals must be installed as specified by the drawings. Pay particular attention to installation direction, squareness and installation parity.

Adapter sleeve bearings do not require a specially machined bearing seat. They can be installed on any drawn or turned shaft. This has the advantage that the shaft can be slid axially as desired and so can be easily aligned.

The seal parts (shaft and bore) must be inspected for damage and repaired if necessary.

Visually inspect the radial shaft seals before assembly.

The lip of the seal must also be covered with oil.

During assembly of radial shaft seals protective bushes must be slid over the shafts to protect them from damage by the sharp edges of safety grooves, keyways etc. If possible, use drive bushes with attached protective bushes. If protective bushes are not available, at least cover the sharp edges, threads etc. with adhesive tape.

When using radial shaft seals with a metal sheath, the sheath region and the corresponding bore section must be degreased and covered with the specified sealing compound for sealing.

If the assembly procedure for two-section cases requires the radial shaft seals to be installed before the two halves of the case are joined, ensure that the case halves are positioned centrally to each other to prevent crushing in the area of the case separation at the mantle of the radial shaft seals.

Always install adapter sleeve bearings to match the conical inner race. Clean the expansion pin and shaft before installation and check that the expansion pin nut moves easily to prevent the expansion pin from rotating on the shaft during tightening.

Loosening First loosen the released expansion pin nut by a few revolutions only (thread must still grip fully). Loosen expansion pin with a stroke pipe and a firm tap.

Tightening First tighten expansion pin nut until the expansion pin is free of play and has a light tension. Now tighten the nut approximately 90° and then continue to turn until the next groove has passed the locking tab. Lock the expansion pin nut with the locking tab.

BEARINGS Assembly of clamping ring bearings Clamping ring bearings are fixed on the shaft by rotation of the eccentric ring over the bearing inner race.

Before positioning them grease the inner race and the shaft with semi-fluid lubricant (e.g. Shell Retinax G or similar) to make it easier to remove the bearing during a subsequent disassembly.

Always gently tap the eccentric ring in the direction of rotation of the shaft and fix it with a setscrew. To loosen the bearing tap the eccentric ring against the direction of rotation of the shaft.

299 605.1 - RHB Futtererntemaschinen

3.8

General Information

Assembly on shaft

Assembly in drilled hole

Assembly on shaft and assembly in drilled hole

71195 1

Assembly of roller bearings

Shaft-hub connections

General

When assembling wheels and flanges it is very important that the workpieces are only heated to the required joining temperature.

When assembling roller bearings on shafts ensure that the temperature is raised only as far as required for easy assembly. Make sure that the bearing installation surfaces are absolutely free from burs to provide a clean surface for the roller bearing.

Bearings must be installed on shafts or in drilled holes with the specified installation bushes only so only the outer or inner races or both are loaded (Fig. 1).

Never press on the rollers, balls or cages during assembly.

When using keys or profiles ensure that no burs are formed while joining.

Any burs found must be removed before final assembly.

DRIVE SYSTEMS General

Adjustment of roller bearings Roller bearings must always be adjusted. Set the specified bearing play or the required pretension as specified. If there are no specifications for adjusting the roller bearings, they are adjusted free of play.

Dispose of oil and grease according to regulations!

They are adjusted with the adjusting nuts, by adding shims or by calibration of the bearing covers or flanges.

When disassembling gearboxes first drain the oil and then disassemble the gearbox. Separate internally connected parts with a soft metal or plastic hammer.

3.9

Environment!

RHB Futtererntemaschinen - 299 605.1

General Information

Initial adjustment

required correction

Correct adjustment

1

2

71249 2

Gears

Adjustment of spur gears

Spur gears

The position of the contact patterns and the required correction for spur gears are shown in figure 2.

Spur gears must be assembled axially as specified in the drawing and adjusted as required. To ensure that spur gears run correctly, the tooth flanks must not be damaged. They must also have the required backlash.

Check that tooth flanks connect correctly by rotating the spur gears.

Example 1 – contact pattern nearer the tooth tip Required correction:

• Adjust pinion further away from crown wheel and • crown wheel nearer to pinion.

Bevel gears

Example 2 – contact pattern nearer to foot of tooth

Bevel gears must be adjusted to achieve optimum contact pattern of the tooth flanks. The required backlash must be retained.

Required correction:

The position of the contact patterns and of the tooth flank play is adjusted by changing the installation dimensions of the pinion shaft and/or crown wheel.

They are adjusted with the adjusting nuts, by adding shims or by calibration of the bearing covers or flanges.

299 605.1 - RHB Futtererntemaschinen

• Adjust pinion nearer crown wheel and • crown wheel away from pinion.

Adjustment of cyclopalloid gears The position of the contact patterns and the required correction for cyclopalloid gears are shown in figures 3 and 4.

3.10

General Information

Initial adjustment

required correction

Correct adjustment

3

4

71250 Height adjustment of the contact pattern

3

Example 3 – contact pattern centred but too near the tooth tip Required correction:

• Adjust pinion further away from crown wheel and • crown wheel nearer to pinion.

Example 4 – contact pattern centred but too near to foot of tooth Required correction:

• Adjust pinion nearer crown wheel and • crown wheel away from pinion.

(Fig. 3)

3.11

RHB Futtererntemaschinen - 299 605.1

General Information

Initial adjustment

required correction

Correct adjustment

5

6

71251 4

Longitudinal adjustment of the contact pattern Example 5 – contact pattern too far left or right but in the centre of the tooth flanks Required correction:

• Adjust pinion further away from crown wheel and • crown wheel nearer to pinion.

Example 6 – contact pattern too far right or left but in the centre of the tooth flanks 5

Required correction:

• Adjust pinion nearer crown wheel and • crown wheel away from pinion.

(Fig. 4)

Tensioning steel roller chains Steel roller chains are correctly tensioned when the slack side can be pressed approximately 2% from the axle distance in the centre between the sprockets with low load on the tight span. Check the tension more frequently with new chains.

Example: Axle distance 500 mm = pressure distance at slack side ca. 10 mm.

299 605.1 - RHB Futtererntemaschinen

3.12

General Information Tapered ring connections Tapered ring connections are a secure connection for transfer of high forces from the drive element to the shaft and reverse when correctly preloaded.

Disassembly After loosening the axial clamp release the tapered ring connections with a stroke pipe and a firm tap with a hammer.

Important!

The internal diameter of the stroke pipe must be sufficient to grip over the tapered ring.

Assembly For assembly it is important to clean the shaft, hub, key and tapered rings thoroughly, grease them with semi-fluid lubricant (e.g. Shell Retinax G or similar) and tighten them with the specified torque in the correct assembly sequence.

Important!

Do not assemble parts with viscous grease.

HYDRAULIC SYSTEM Ferrule retaining screws on hydraulic system hoses All assemblies and factory-assembled ferrule retaining screws are installed in the matching, well-oiled retaining supports with half a turn of the union nut past the point where the force required significantly increases.

Assembly Saw off the pipe at a right angle.

Note!

Do not use a pipe cutter! It will cut the pipe wall at an angle and will leave burs inside and outside.

Lightly debur the end of the pipe inside and outside (do not grind!) and clean it.

With elbows the distance from the straight end of the pipe to the beginning of the curve must be at least twice the height of the union nut.

Slide union nut and ferrule onto the pipe.

3.13

Press the pipe against the stop in the connectors and tighten the union nut until the ferrule grips the pipe (pipe must no turn). This point can be detected by the increase in force required.

Tighten union nut half a turn past the pressure point.

Check the indent in the edge: a visible collar must occupy the space before the ferrule face. The ferrule can be rotated but must not be movable axially.

Final assembly Position the assembled pipe in the well lubricated retainer support, tighten the union nut until the force increases and then half a turn further.

Repeat assembly Whenever the ferrule retaining screw is loosened, the union nut must be retightened without increased force.

Leaking ferrule connection If a connection leaks, the union nut must first be loosened until oil comes out and then tightened as specified.

Progressive ring retaining screws on hydraulic system hoses All assemblies and factory-assembled profile ring retaining screws are installed in the matching, well-lubricated retaining supports with half a turn of the union nut past the point where the force required significantly increases.

Assembly Saw off the pipe at a right angle.

Note!

Do not use a pipe cutter! It will cut the pipe wall at an angle and will leave burs inside and outside.

Lightly debur the end of the pipe inside and outside (do not grind!) and clean it.

With elbows the distance from the straight end of the pipe to the beginning of the curve must be at least twice the height of the union nut.

Slide union nut and profile ring onto the pipe.

Press the pipe against the stop in the connectors and tighten the union nut until the profile ring grips the pipe (pipe must not turn). This point can be detected by the increase in force required.

Tighten union nut half a turn past the pressure point.

RHB Futtererntemaschinen - 299 605.1

General Information Check the indent in the edge: a visible collar must occupy the space before the profile ring face. The profile ring can be rotated but must not be movable axially.

Conical nipple retaining screws on hydraulic system hoses

Final assembly

Oil o-ring on the conical nipple. Tighten the union nut one third of a turn past the point of significantly increased force.

Position the assembled pipe in the well lubricated retainer support, tighten the union nut until the force increases and then half a turn further.

Important!

Hold the retaining supports in place with a spanner!

Assembly

Important!

Hold the retaining supports in place with a spanner!

Note!

Repeat assembly Every time the profile ring retaining screw is loosened the union nut must be tightened until the force increases and then half a turn more.

Important!

Hold the retaining supports in place with a spanner!

Leaky profile ring connection If a connection leaks, the union nut must first be loosened until oil comes out and then tightened as specified.

Note!

Deviating inlet paths reduce the rated pressure and the life of the retaining screw. This will result in leakage and displacement of the pipe.

299 605.1 - RHB Futtererntemaschinen

Deviating inlet paths reduce the rated pressure and the life of the retaining screw. This will result in leakage and displacement of the retaining screws.

WELDING Important!

Proceed as follows for all electrical welding on the machine: • Switch off the battery master switch!

• Disconnect snap-on connection to monitor.

• Remove the electrical plug-in-type module in the central electrics.

• Disconnect the electrical snap-on connections between the engine and main wiring harness.

• Always clamp the welder earth as close as possible to the welded section.

3.14

General Information FUEL AND LUBRICANTS Unit/ application

Specifications/ SAE class

Fuel Gear oil

Gearbox

Season/ temperature

MIL-L-2105 API-GL-4 SAE 90

Semi-fluid grease

DIN 51502 - G 00 F Retinax G

Grease nipple

Multipurpose grease

DIN 51825 - K2K Retinax EP2

Battery clamps

Anti-acid grease

All-year

All-year All-year

Important!

Observe the lubrication instructions in the machine operator's manuals!

Fill amounts See the operator's manual for the fill amounts. The specified fill amounts are approximate values; always check the oil level for the exact amount required.

3.15

RHB Futtererntemaschinen - 299 605.1

Drive systems

Drive systems

4 Drive systems LINER REDUCTION GEAR General assembly and maintenance instructions Bearings Never press on the rollers, balls or cages during assembly.

Screw connections Screw connections must be tightened with torque wrenches.

Tighten screws and bolts with tightening torques, – see Tightening torques, page 3.4.

Radial shaft seals When installing radial shaft seals the contact surfaces between the seal and shaft must be lubricated beforehand.

Do not allow the seals of radial shaft seals to contact sharp objects (edges, etc.) during assembly, otherwise they may be damaged.

Gearbox in oil bath First oil change after the first 50 hours of operation and/or at least once a year.

299 605.1 - RHB Futtererntemaschinen

4.1

Drive systems

Drive systems

1

2

3

4

5

6

7

8

9

8

10 12 18 13 14 16 15 16 14 13 17

15 10 36 7

22

21

23

37

19 11

20

25 24 25 24

26 35 34 38 32 31 36

5

12 30 29

8

28 27 33 26 20

71187

Reduction gear “LINER 680 / 680 L / 680 Profil / 650 Twin / 350 S / 350 T” – version “9.792.100.40” and “9.792.101.40” COMER

K-792B

Comer no.:

9.792.100.40; 9.792.101.40

CLAAS no.:

110 236.2; 110 237.2

List of parts Item Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

4.2

Ring gear Cover Internal hex bolt Roller bearing Internal snap ring Identification plate Key Flat washer External snap ring Flat washer Grease Cover Bearing seal ring Roller bearing Grease nipple

Remarks Z82 M3.75 M10x22 8.8 6310 Z 110UNI7437 B 10X8X50 70.3 50 UNI7436 50.3x2.5

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

Internal snap ring Nut Pinion Flat washer Flat washer Oil plug Oil plug Oil plug Lever Radial shaft seal Spacer washer Radial shaft seal Spacer washer Shaft Radial shaft seal Roller bearing Oil drain plug Cam Hexagon head bolt Cover O-ring Housing Seal

80 UNI7437 M40X1.5

1

79.9 35.2x43.8x1 3/8“ GAS 1/2“ GAS 1/2“ GAS 35X45X7 55X72X10 50X72X8 6310 3/8“ GAS M10x30 8.8 101.27X2.62 17X22X1.5

(Fig. 1) 30208 AV 30208 45G.M10X1

RHB Futtererntemaschinen - 299 605.1

Drive systems Dimensions

70

238.5 162

59 18

35

Ø26E8

P

119

1" 3/8 Z6

Oil drain plug ABLASSCHRAUBE

341.5

534.5

193

Oil plugs

OELEINFUELLSTOPFEN

137

3˚

15

14

N.3xM12

208

222.5

Oil level plug OELSTANDSCHRAUBE

Ø23 50x2x24 h9 DIN 5480

P 160 120

N.4xØ16.5 Direction of travel FAHRTRICHTUNG

120

80 = =

= =

SCHMIERFETT Grease

131

NL GI2

Inlet EINGANG

145

540 U/min.

290

N.2Ø13H12 71188

Ø35h8

57

75 22

80

370

131

M10x28

2

299 605.1 - RHB Futtererntemaschinen

4.3

Drive systems

Drive systems Disassembly Remove snap ring (9) and shims (10) and (8).

(Fig. 3)

3 Remove cover (2) with a pulling tool.

Environment!

Dispose of old grease correctly!

Clean grease from cover (2).

Remove key (7) and shim (8).

(Fig. 4) 4 Unscrew bolts (3).

Clean grease from ring gear (1).

Disassemble ring gear (1) with a pulling tool.

(Fig. 5)

5 Drain oil from the gearbox as follows: Environment!

Dispose of drained oil correctly!

Place oil container under the gearbox and remove plug (32), seal (38) and plug (21).

(Fig. 6) 6

4.4

RHB Futtererntemaschinen - 299 605.1

Drive systems Remove grease nipple (15).

Note!

The flange nut (17) is caulked with the pinion shaft.

Loosen caulking and remove the flange nut (17) from the pinion (18).

(Fig. 7) 7 Tap pinion (18) off with light taps of the hammer in the direction of the inside of the cover.

Use a pulling tool to remove the shim (18), the bearing seal ring (13) and the bearing inner race (14) from the pinion (18).

Note!

The inside bearing seal ring (13) may need to be replaced.

8

(Fig. 8) Remove the outside bearing seal ring (13) and outside bearing inner race (14).

Remove the outside outer race (14) from the cover (2) with a pulling tool.

Remove snap ring (16).

Clean grease from cover (11).

Remove shim (19).

Remove the inside outer race (14) from the cover (2) with a pulling tool.

9

(Fig. 9) Remove snap ring (5) and bolts (34).

Remove cover (35).

Remove shim (8) and spacer (28).

(Fig. 10)

10

299 605.1 - RHB Futtererntemaschinen

4.5

Drive systems Remove shaft (29) with bearing (4), shim (10) and cover (12) with o-ring (36) upwards.

Remove bearing (4), shim (10) and cover (12) with o-ring (36) from the shaft (29).

Remove radial shaft seal (27) from the cover (12).

Remove key (7) from the shaft (29).

(Fig. 11)

11 Remove cam plate (33) from the housing (37).

(Fig. 12)

12 Remove lever (24) from the housing (37).

Remove shims (20) and spacers (26) from the levers (24).

Remove radial shaft seals (25) from the housing (37).

(Fig. 13)

13 Remove snap ring (5) from the cover (35).

Remove cover (12) and bearing (31).

Remove o-ring (36) and radial shaft seal (30) from cover (12).

Remove plug (22) and (23).

(Fig. 14)

14

4.6

RHB Futtererntemaschinen - 299 605.1

Drive systems Assembly Note!

Always use new o-rings and radial shaft seals!

Assemble lever (24) with spacer (26) and shim (20).

Install the assembled levers in the housing (37).

Caution!

15

The seal of the radial shaft seal (25) may be damaged during assembly!

– Cover the holes in the levers (24) with adhesive tape before assembly of the radial shaft seal.

Install radial shaft seals (25).

Remove tape.

(Fig. 15) Position key (7) in the shaft (29) and install cam plate (33) on the shaft (29).

Install assembled shaft (29) in the housing (37) and insert the levers (24) in the cam plate (33) at the same time.

(Fig. 16)

16 Apply silicone strips on the centring of the cover (35).

Assemble cover (35) and housing (37) with the bolts (34).

Remove excess silicone.

(Fig. 17)

17

299 605.1 - RHB Futtererntemaschinen

4.7

Drive systems Assemble cover (12) with o-ring (36) and radial shaft seal (27).

Caution!

Do not damage the seal of the radial shaft seal (27)!

– Before assembly of the cover (12) and the bearing (4), fasten shaft (29) from the opposite side.

18

Install assembled cover (12) in the housing.

Grease shaft and bearing seat in housing.

Slide key (10) on the shaft (29).

Fill bearing (4) with grease.

Install bearing (4), snap ring (5) and shim (8).

(Fig. 18)

Assemble cover (12) with o-ring (36) and radial shaft seal (30).

Slide spacer (28) and shim (8) on the shaft (29).

Install bearing (31) and assembled cover (12) in the cover (35).

Install snap ring (5).

(Fig. 19)

19 Install oil drain plug (32) with seal (38).

Install plug (21) with Loctite 270.

(Fig. 20)

20

4.8

RHB Futtererntemaschinen - 299 605.1

Drive systems Install ring gear (1) with bolts (3).

Position key (7).

Grease ring gear (1).

(Fig. 21)

21 Assemble pinion (18) with shim, bearing seal ring (13) and bearing inner race (14).

(Fig. 22)

22 Install inside outer ring (14), shim (19) and inside snap ring (16).

Install outside snap ring (16) and outside outer ring (14).

Caution!

The bearing seal ring (13) may be damaged during assembly of the pinion!

– Install pinion carefully.

23

Insert assembled pinion (18) in cover (2) from the inside.

(Fig. 23)

299 605.1 - RHB Futtererntemaschinen

4.9

Drive systems Install outside bearing inner race (14) and outside bearing seal ring (13).

Tighten flange nut (17) with a torque of 79 ÷ 108 Nm. (Fig. 24)

24 Attach assembled cover (2) to housing (37).

(Fig. 25)

25 Slide keys (8) and (10) on the shaft.

Install snap ring (9).

Important!

Ensure that there is no axial play between the shaft (29) and the cover (2).

(Fig. 26) 26

Check contact pattern and tooth flank play, adjust if required with shim (8) (Fig. 18) and (19) (Fig. 23) – see Reduction gear “LINER 680 / 680 L / 680 Profil / 650 Twin / 350 S / 350 T” – general assembly instructions, page 4.22 and Adjustment of spur gears, page 3.10.

Remove flange nut (17) and reinstall with Loctite 270.

Tighten flange nut (17) with a torque of 79 ÷ 108 Nm. Caulk flange nut (17) with pinion.

(Fig. 24)

4.10

RHB Futtererntemaschinen - 299 605.1

Drive systems Install grease nipple (15) and fill gearbox with grease (11).

(Fig. 27)

27 Fill gearbox with oil and install plug (22) and (23) with Loctite 243.

(Fig. 28)

28

299 605.1 - RHB Futtererntemaschinen

4.11

Drive systems

Drive systems

1

2

3

4

5

6

42 9

8

12 18 13 14 16 15 16 14 13 17

15 43 36 7

22

21

23

37

19 11

20

25 24 25 24

26 35 34 38 32 31 36

5

41 30 40

29 39 10 8 28 43 33 27 26 20

71190

Reduction gear “LINER 680 / 680 L / 680 Profil / 650 Twin / 350 S / 350 T” – version “9.792.116.20” COMER:

K-792B

Comer no.:

9.792.116.20

CLAAS no.:

110 538.0

List of parts Item Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

4.12

Ring gear Cover Internal hex bolt Roller bearing Internal snap ring Identification plate Key Flat washer Slotted nut Flat washer Grease Cover Bearing seal ring Roller bearing Grease nipple Internal snap ring

Remarks Z82 M3.75 M10x22 8.8 6310 Z 110UNI7437 B 10X8X40 70.3 M45X1.5 50.3x2.5 30208 AV 30208 45G.M10X1 80 UNI7437

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

Nut Pinion Flat washer Flat washer Oil plug Oil plug Oil plug Lever Radial shaft seal Spacer washer Radial shaft seal Spacer washer Shaft Radial shaft seal Roller bearing Oil drain plug Cam Hexagon head bolt Cover O-ring Housing Seal O-ring Bush Cover Flat washer Spacer washer

M40X1.5

29

79.9 35.2x43.8x1 3/8“ GAS 1/2“ GAS 1/2“ GAS 35X45X7 55X72X10 65X80X7/8 6310 3/8“ GAS M10x30 8.8 101.27X2.62 17X22X1.5 2-135 45.3x1.0

(Fig. 29)

RHB Futtererntemaschinen - 299 605.1

Drive systems Dimensions

70

238.5 +0.08 +0.03

162 14

N.3xM12

Ø26

59 18

35

119

1" 3/8 Z6

Oil drain plug ABLASSCHRAUBE

227

425

198

Oil plugs

OELEINFUELLSTOPFEN

Oil level plug OELSTANDSCHRAUBE

100

108

137

3˚

15

P

+0.08

23 2.15

14

Ø26 +0.03 50x2x24 g9

P

DIN 5480

120

0 -0.3

160 N.4xØ16.5 120

80 = =

6.6

= =

Ø47h12

Direction of travel FAHRTRICHTUNG

Grease SCHMIERFETT

131

NL GI2

Inlet EINGANG

145

540 U/min.

290

N.2Ø13H12 Ø35h8

57

75 22

80

370

131

M10x28

71189

30

299 605.1 - RHB Futtererntemaschinen

4.13

Drive systems

Drive systems Disassembly Note!

The flange nut (9) is caulked on the shaft (29).

Loosen caulking and remove the flange nut (9) from the shaft (29).

Remove shim (42).

(Fig. 31) 31 Remove cover (2) with a pulling tool.

Environment!

Dispose of old grease correctly!

Clean grease from cover (2).

Remove snap ring (5) and shim (8).

(Fig. 32) 32 Unscrew bolts (3).

Clean grease from ring gear (1).

Disassemble ring gear (1) with a pulling tool.

(Fig. 33)

33 Drain oil from the gearbox as follows: Environment!

Dispose of drained oil correctly!

Place oil container under the gearbox and remove plug (32), seal (38) and plug (21).

(Fig. 34) 34

4.14

RHB Futtererntemaschinen - 299 605.1

Drive systems Remove grease nipple (15).

Note!

The flange nut (17) is caulked with the pinion shaft.

Loosen caulking and remove the flange nut (17) from the pinion (18).

(Fig. 35) 35 Tap pinion (18) off with light taps of the hammer in the direction of the inside of the cover.

Use a pulling tool to remove the shim (18), the bearing seal ring (13) and the bearing inner race (14).

Note!

The inside bearing seal ring (13) may need to be replaced.

36

(Fig. 36) Remove the outside bearing seal ring (13) and outside bearing inner race (14).

Remove the outside outer race (14) from the cover (2) with a pulling tool.

Remove snap ring (16).

Clean grease from cover (11).

Remove shim (19).

Remove the inside outer race (14) from the cover (2) with a pulling tool.

37

(Fig. 37) Remove bush (40) with o-ring (39) with a pulling tool.

Unscrew bolts (34) and remove cover (35).

Remove shim (8) and spacer (28).

(Fig. 38)

38

299 605.1 - RHB Futtererntemaschinen

4.15

Drive systems Remove shaft (29) with bearing (4), spacer (43) and cover (12) with o-ring (36) upwards.

Remove radial shaft seal (27) from the cover (27).

Remove spacer (43) and key (7) from the shaft (29).

(Fig. 39)

39 Remove cam plate (33) from the housing (37).

(Fig. 40)

40 Remove lever (24) from the cover (37).

Remove shims (20) and spacers (26) from the levers (24).

Remove radial shaft seals (25) from the housing (37).

(Fig. 41)

41 Remove snap ring (5) from the cover (35).

Remove cover (41), shim (10) and bearing (31).

Remove o-ring (36) and radial shaft seal (30) from cover (41).

Remove plug (22) and (23).

(Fig. 42)

42

4.16

RHB Futtererntemaschinen - 299 605.1

Drive systems Assembly Note!

Always use new o-rings and radial shaft seals!

Assemble lever (24) with spacer (26) and shim (20).

Install the assembled levers in the housing (37).

Caution!

43

The seal of the radial shaft seal (25) may be damaged during assembly!

– Cover the holes in the levers (24) with adhesive tape before assembly of the radial shaft seal.

Install radial shaft seals (25).

Remove tape.

(Fig. 43) Install spacer (43), key (7) and cam plate (33) on the shaft (29).

Install assembled shaft (29) in the housing (37) and insert the levers (24) in the cam plate (33) at the same time.

(Fig. 44)

44 Apply silicone strips on the centring of the cover (35).

Assemble cover (35) and housing (37) with the bolts (34).

Remove excess silicone.

(Fig. 45)

45

299 605.1 - RHB Futtererntemaschinen

4.17

Drive systems Assemble cover (12) with o-ring (36) and radial shaft seal (27).

Caution!

Do not damage the seal of the radial shaft seal (27)!

– Before assembly of the cover (12) and the bearing (4), fasten shaft (29) from the opposite side.

46

Lightly grease sliding surface.

Install assembled cover (12) in the housing (37).

Fill bearing (4) with grease.

Slide spacer (43) on the shaft (29).

Install bearing (4), snap ring (5) and shim (8).

(Fig. 46)

Assemble cover (41) with o-ring (36) and radial shaft seal (30).

Slide spacer (28) and shim (8) on the shaft (29).

Install bearing (31), shim (10) and assembled cover (41) in the cover (35).

Install snap ring (5).

Caution!

The o-ring (39) may be damaged during assembly!

47

– Cover shaft transition with adhesive tape before assembling the o-ring.

Install o-ring (39) on the shaft (29).

Remove tape.

Install bush (40) on the shaft (29).

(Fig. 47)

4.18

RHB Futtererntemaschinen - 299 605.1

Drive systems Install oil drain plug (32) with seal (38).

Install plug (21) with Loctite 270.

(Fig. 48)

48 Install ring gear (1) with bolts (3).

Grease ring gear (1).

(Fig. 49)

49 Assemble pinion (18) with shim, bearing seal ring (13) and bearing inner race (14).

(Fig. 50)

50

299 605.1 - RHB Futtererntemaschinen

4.19

Drive systems Install inside outer ring (14), shim (19) and inside snap ring (16).

Install outside snap ring (16) and outside outer ring (14).

Caution!

The bearing seal ring (13) may be damaged during assembly of the pinion!

– Install pinion carefully.

51

Insert assembled pinion (18) in cover (2) from the inside.

(Fig. 51) Install outside bearing inner race (14) and outside bearing seal ring (13).

Tighten flange nut (17) with a torque of 79 ÷ 108 Nm. (Fig. 52)

52 Attach assembled cover (2) to housing (37).

Important!

The serrated tooth on the shaft (29) must match the indent on the cover (2).

(Fig. 53)

53

4.20

RHB Futtererntemaschinen - 299 605.1

Drive systems Install shim (42) and flange nut (9). Tighten flange nut with a torque of 196 ÷ 245 Nm. Check contact pattern and backlash, adjust if required with shim (8) (Fig. 46) and (19) (Fig. 51) – see Reduction gear “LINER 680 / 680 L / 680 Profil / 650 Twin / 350 S / 350 T” – general assembly instructions, page 4.22 and Adjustment of spur gears, page 3.10.

Caulk flange nut (9) with shaft.

(Fig. 54) 54

Remove flange nut (17) and reinstall with Loctite 270.

Tighten flange nut (17) with a torque of 79 ÷ 108 Nm. Caulk flange nut (17) with pinion.

(Fig. 52) Install grease nipple (15) and fill gearbox with grease (11).

(Fig. 55)

55 Fill gearbox with oil and install plug (22) and (23) with Loctite 243.

(Fig. 56)

56

299 605.1 - RHB Futtererntemaschinen

4.21

Drive systems

Drive systems Reduction gear “LINER 680 / 680 L / 680 Profil / 650 Twin / 350 S / 350 T” – general assembly instructions Contact pattern Tooth contact between ring gear and pinion must follow as shown in Figure 57.

(Pressure point without load on ring gear and pinion.)

Use shims to adjust the correct contact pattern for the tooth contact – see Adjustment of spur gears, page 3.10.

57

Backlash The backlash must comply with the following guidelines: (0.03 ÷ 0.08) x m (module) E. g.: module m = 3.75 Backlash = 0.11 ÷ 0.30 mm (Fig. 57) Lubricants Gearbox is lubricated with oil and grease.

Recommended oil type: SAE 90 EP (ISO VG 320) Amount: 6.2 litres.

Recommended grease type: NLGI 00 EP Oil change : First oil change after the first 50 hours of operation, then every 500 hours and/or at least once a year.

4.22

RHB Futtererntemaschinen - 299 605.1

Drive systems

Drive systems “CLAAS” reduction gear – General assembly instructions Installation of curved track When installing the curved track the installation position must be correct to ensure the formation of clean windrows in use.

2 1 2 1

The curved track has marks that must be noted.

B

A

The straight arrow (1) shows the direction of travel.

The curved arrow (2) shows the direction of rotation.

58

The curved track is correctly installed when the straight arrow (1) points in the direction of travel with reference to the direction of rotation with the reduction gear installed.

Mark “A” = anticlockwise rotating Mark “B” = clockwise rotating Machine model

Direction of rotation of rotors

LINER 3000

clockwise and anticlockwise rotating

LINER 1550 TWIN Profil anticlockwise rotating only LINER 1550 Profil

anticlockwise rotating only

LINER 880 Profil

clockwise and anticlockwise rotating

LINER 780 Profil

clockwise and anticlockwise rotating

LINER 470 S / 470 T

anticlockwise rotating only

LINER 430 S

anticlockwise rotating only

LINER 390 S

anticlockwise rotating only

(Fig. 58) Lubricants Gearbox is lubricated with grease.

Amount: see operator's manual Recommended grease type: see operator's manual

299 605.1 - RHB Futtererntemaschinen

4.23

Drive systems

Drive systems “CLAAS” ROTARY GEARBOX

A

General assembly instructions Machine model:

3

VOLTO 870 H / 870 T VOLTO 770 H / 770 T

A

VOLTO 670 H

1

2

Assembly of the angle drive 1 Section A-A

When installing the angle drive the installation position of the two gears must be noted. This is necessary to prevent the rotors from contacting each other during operation and for a clean scatter pattern.

For this purpose the drive gear (1) has a red mark (2) (countersunk).

3

To install the driven gear (1) rotate the drive gear (3) so the corner (4) of the internal hex (gap) is pointed perpendicularly down. Install the driven gear (1) so the opposite tooth of the tapped hole contacts the mark (2) in the gap (4) (Fig. 2).

4 1

(Fig. 1, 2) 2

2

Lubricants Gearbox is lubricated with grease.

Amount: see operator's manual Recommended grease type: see operator's manual

4.24

RHB Futtererntemaschinen - 299 605.1

Drive systems

Drive systems A

1

43 49 39 40 12 41 8

A

B

D

3

2

B

1

C

B

C

B

B

17

5

4

B

B

C

B

B

C

C 22

44 45

6

B

B

D 43 18 19 47 21 8 44

44

43

47

4

4

45

32

13

5

5

42

31

23

18

6

2

30

34

29

3 6

28

3

15

11

14

3

7

26 19 25 21

31 20

20

27 10

46 13 16 15 14 13 11 10

33 8

71191

9

2

24

32

48 38 37 36 35 A-A

2 45

B-B 10 9 8 7

DISCO CUTTER BAR

C-C

9 8 7 20

D-D

8

1

Cutter bar with 6 cutting discs “COMER FR-566A” Comer no.:

9.566.610.10

Parts list “cutter bar with 6 cutting discs” – see page 4.26, Parts description

Cutter bar with 7 cutting discs “COMER FR-567A” Comer no.:

9.567.610.10

(Fig. 1)

299 605.1 - RHB Futtererntemaschinen

4.25

Drive systems

B

A

2

1

B

43 10 49 39 40 12 41 8

A

B

C

3

B

B

D

C

4

C

B

5

B

B

B

B

C

6

B

45

32

42

31 30

2

B

B

D 44 45

22 43

C

C

1 17

44

B

7

18 19 47 21 8 44

45

47 13

4

5

5

23

18

6

34 3 6

28

3

15

11

14

3

24

32 20

71193

B-B

Parts list “cutter bar with 7 cutting discs” (Fig. 2) Parts description Item Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

4.26

Expansion pin Skid Bolt Roller bearing Pinion O-ring Schnorr spring washer Hex. nut Spacer bushing Countersunk bolt Radial shaft seal Spacer washer Hexagon head bolt Disc spring Self-locking nut Drum Internal hex bolt Bush Bush Self-locking nut Bearing sleeve Cutting disc Reinforcement rear

Remarks 10X12 D1481 M10X30 DCRT320 6306 2Z/C3 KBC Z18 M3.5 OR-3112 10.2X22X1.6 M10 DCRT320 DCRT320 10.9 40X60X6 M10x20 0.4X40X2.25 20X1,5 H17,3 M10x22 -12.9 DCRT320 M10 DIN980

7 20 46 13 16 15 14 13 11 10

33 8 10 9 8 7

9

2

26 19 25 21 27 10

31

A-A

2

4

29

48 38 37 36 35

10 43

C-C

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49

9 8 7 20

D-D

8

2 Hexagonal nut Snap ring 85 Roller bearing 6209 N/C3 Intermediate gear wheelZ58 M3.5 Internal hex bolt M20x30 12.9 DCRT320 Pin Spacer washer Oil plug 3/8 GAS Spring washer 17.16X22X1 CU Bolt M10X19 DCRT320 Beam housing and cover Bearing sleeve Roller bearing BAH-0013 Internal snap ring 72 UNI7437 Drum Self-locking nut M24 H21 Disc spring 50X25.4X3 Flange Pinion Z18 M3.5 Countersunk bolt DCRT320 10.9 Reinforcement front Hexagon head bolt M10X40 DCRT320 Cover Roller bearing 6306 DDUC3EEST3H6 NSK Hexagon head bolt M10x30 Double universal joint

(Fig. 1, 2)

RHB Futtererntemaschinen - 299 605.1

Drive systems Dimensions “cutter bar with 6 cutting discs”

162.8

320 100

100

67.5

76.5

4

425.8

6

60

5

50

N.6xØ11

402.2

6

52.5

Oil plugs Oil level plug

27.5

162

50

1

76.5

N.6xØ11

402.2

2

60

1

425.8

3

402.2

2383

27.5

Inlet

52.5 Oil drain plug

100

100

67.5

320

71192 3

299 605.1 - RHB Futtererntemaschinen

4.27

Drive systems Dimensions “cutter bar with 7 cutting discs”

162.8

320 100

100

67.5

76.5 27.5

425.8

4

2797

402.2

5

7

60

50

N.6xØ11

425.8

6

402.2

7

52.5

27.5

76.5

162

1

414

N.6xØ11

50

2

60

1

402.2

3

Oil plugs Oil level plug

52.5 Inlet

Oil drain plug

100

100

67.5

320

71194 4

4.28

RHB Futtererntemaschinen - 299 605.1

Drive systems

Drive systems Disassembly Drain oil as follows: Environment!

Dispose of drained oil correctly! position suitable container under the cutter bar, open plug (31) and remove seal (32).

(Fig. 5) 5 Unscrew bolts (17) and remove cover (23).

(Fig. 6)

6 Unscrew bolts (13) and remove metal cover (46).

Unscrew bolts (48) and remove double universal joint (49) and spacer (12).

Remove drum (38).

(Fig. 7)

7 Remove bolts (13).

Remove drum (16) and cutting discs (22).

Unscrew nuts (8) and remove rotors (35) with a pulling tool.

Turn over cutter bar.

(Fig. 8)

8

299 605.1 - RHB Futtererntemaschinen

4.29

Drive systems Remove nuts (20) and washers (7).

Remove slide.

Remove perforated strip (44) and bolt (45).

Unscrew all nuts (8) near the edge of the trough and remove spacer (9).

Note!

The bolts near the bar cover are pressed in!

9

Remove all bolts near the bar cover with a press tool.

Turn over cutter bar.

(Fig. 9) Remove hexagonal head bolts (28) while holding the nut (24) in place.

Turn over cutter bar.

Remove nuts (24) and pins (29) with a pull tool.

Open cutter bar by removing the cover from the trough.

Remove intermediate gear wheels (27).

Remove spacers (30).

10

Note!

The roller bearings of the intermediate gear wheels (27) cannot be disassembled (Fig. 10)

Note!

The bolts (3) and (45) are pressed in!

Use a press tool: To remove bolts (3) from the trough.

To remove bolts (45) from the perforated bar (44).

(Fig. 11)

11

4.30

RHB Futtererntemaschinen - 299 605.1

Drive systems Unscrew nut (15) from the mowing disc flange (19).

Remove washer (14).

Use a pull tool: – Remove mowing disc flange from the pinion (5), – pinion (5) from the bearing flange (21), – roller bearing (47) and (4) from the bearing flange.

Remove o-ring (6), bush (18) and radial shaft seal (11).

12

(Fig. 12) Unscrew nut (39) from the mowing disc flange/input rotor (41).

Remove washer (40).

Remove pinion (42) from mowing disc flange (41) with a pull tool.

Remove circlip (37).

Use a pull tool: – Remove pinion (42) from the bearing flange (35), – roller bearing (36) from pinion (42).

13

(Fig. 13)

Assembly Caution!

Do not damage radial shaft seal and o-rings during assembly!

– Follow general assembly instructions from page 3.6.

Note!

Always use new o-rings and radial shaft seals!

299 605.1 - RHB Futtererntemaschinen

4.31

Drive systems Assembling rotors Install roller bearings (4) in bearing flange (21).

Install assembled bearing flange (21) on pinion (5).

Install o-ring (6) on pinion (5); ensure that the o-ring is not damaged.

Grease o-ring (6).

Install bush (18).

Caution!

Do not damage radial shaft seal during assembly.

14

– Use suitable tools.

When installing the radial shaft seal make sure that there is space between the radial shaft seal (11) and bearings (47) and (4)!

– Install radial shaft seal (11) about 0.5 mm lower than the bearing base (47).

Install radial shaft seal (11).

Install roller bearings (47) with the outside race fixed with LOCTITE 603.

Wipe off excess LOCTITE. Important!

During installation of the mowing disc flange note mark/notches on the parts!

Install mowing disc flange on pinion (5).

Install washer (14) and position nut (15) with LOCTITE 270.

Tighten nut (15) with a torque of 343 Nm. Wipe off excess LOCTITE. (Fig. 14)

4.32

RHB Futtererntemaschinen - 299 605.1

Drive systems Assembling inlet rotor Install roller bearings (36) in bearing flange (35).

Assemble bearing flange (35) with pinion shaft (42).

Install circlip (37).

Install mowing disc flange (41) on pinion shaft (42) in correct position (see notch on parts).

Install washer (40).

Position nut (39) with LOCTITE 270.

Tighten nut (39) with a torque of 393 Nm. 15

Wipe off excess LOCTITE. Check resistance torque (rolling resistance) of the pinion/mowing disc flange.

Note!

The resistance torque must not exceed 59 Ncm. (Fig. 15)

299 605.1 - RHB Futtererntemaschinen

4.33

Drive systems Replacing intermediate gear wheel – bearing Removing bearing

≈ 700 kN S

Danger!

27

The bearing cannot be removed without destroying it! The external ring of the bearing is destroyed with the press-out tool. This requires a press force (P) of approximately 700 kN (70 t).

16

73556

25

– Wear protective clothing, eye protection, hearing protection and safety gloves.

K

26

Risk of injury from flying, sharp-edged chips and sharp broken edges!

– Use a stable support for the intermediate gear wheel!

P

– Do not touch the intermediate gear wheel while it is being pressed out.

– Place a guard (S) around the intermediate gear wheel (27) during the press-out process.

27

A 73557

17

– Follow safety instructions for the press-out procedure.

The bearing (26) is fixed with the snap ring (25) in the intermediate gear wheel (27).

The position of the groove is marked by the circular slot (K) on the ring gear.

The bearing (26) is destroyed by being pressed out.

Caution!

If the press tool is incorrectly positioned the intermediate gear wheel (27) will be damaged.

– Position press tool on the same side of the bearing as the slot (K) of the intermediate gear wheel (Fig. 17).

Proceed as follows to press the bearing out: – Place a stable support under the hub of the intermediate gear wheel. The best support is a steel ring (A) with clean contact surfaces.

– Make sure there is sufficient space!

– The slot (K) must point to the press tool!

– Position press tool on the outer ring of the bearing.

– Position guard (S) around the intermediate gear wheel.

4.34

RHB Futtererntemaschinen - 299 605.1

Drive systems – Start press tool cautiously.

Required pressing force (P): approx. 700 kN (70 t) Dimensions of steel ring (A): approx. ø120x87x25 mm (Fig. 16, 17)

25

Installing bearing

T

Important!

26

Note installation position of bearing!

When the bearing is installed flush the groove in the bearing must be aligned with the groove in the intermediate gear wheel.

Incorrectly installed bearings cannot be removed with damaging the hub of the gear.

18

73558

T

– Install the bearing (26) as far as the groove in the intermediate gear wheel.

– Position snap ring (25) SP85 DIN 5417 in the groove.

– Fix the snap ring (25) in the groove with a circlip (T) ø85x3 DIN 472 (order no.: 235 189.0).

25

– Install he bearing (26) flush with the hub; the circlip (T) is pushed to the outside during this process.

– Make sure that the snap ring is clicked into place in the groove in the bearing.

19

299 605.1 - RHB Futtererntemaschinen

(Fig. 18, 19)

4.35

Drive systems Assembling cutter bars Place a continuous silicone cord underneath the bolt heads (3).

Press in rotor mounting bolts (3) in the cutter bar cover (34) (except for bolts near edge).

Wipe off excess silicone.

Place a continuous silicone strip in the slot of the nuts (24).

Place nuts (24) at one level and place the cutter bar trough (34) on the nuts; align the nuts so they are centred on the matching drilled holes.

20

Position intermediate gear wheels (27) in the trough while ensuring that the identification slot are up and the intermediate gear wheels are centred to the matching drilled holes.

(Fig. 20) Position spacers (30) on the intermediate gear wheels.

Apply a continuous, unbroken silicone strip to the outside edge of the trough.

Important!

Apply the silicone strip carefully, because this gasket must be absolutely leak-free!

21

Position cutter bar cover on the trough and fix with the expansion pins (1).

Apply a continuous silicone strip on the two conical parts of the pin (29) (seal on cover and trough).

Install pins (29) in sequence; this centres the spacers (30) and the gears (27).

Fix bolts (28) with LOCTITE 270.

Tighten bolts (28) with a torque of 618 ÷ 638 Nm while holding the nuts stationary.

Check that the intermediate gear wheels run without problems.

Turn over cutter bar.

(Fig. 21)

4.36

RHB Futtererntemaschinen - 299 605.1

Drive systems Position all bolts with nuts (8) and if applicable with spacers (9) on the cutter bar contour.

Important!

Ensure that the correct type of bolt is used (countersunk or cheese-head screw) and that the length is correct.

Tighten all bolts or nuts (8) with a torque of 84 ÷ 98 Nm. 22

Install plug (31) with seal (32).

Tighten plug (31) with a torque of 30 ÷ 35 Nm. Turn over cutter bar.

(Fig. 22) Installing rotor Apply a continuous silicone strip to the contact area of the rotors.

Install assembled inlet rotor (42) at the corresponding position in the cutter bar.

Important!

The drilled holes in the reinforcements are conical. The bolts are inserted from the narrower side of the conical drilled hole.

23 Position front perforated bar (44) with bolts (45).

Position rear nuts (8) on the inlet rotor with LOCTITE 243.

Note!

When the seal has been tested the bolts (45) must be removed again to install the slide.

Tighten nuts (8) with a torque of 84 ÷ 98 Nm. Install remaining rotors in the same way as the inlet rotor in their correct relative positions – see page 4.27, Dimensions “cutter bar with 6 cutting discs” and Dimensions “cutter bar with 7 cutting discs” on page 4.28.

(Fig. 23)

299 605.1 - RHB Futtererntemaschinen

4.37

Drive systems Check cutter bar for free running rotors by turning rotors by hand.

Leak test Conduct a leak test as follows Blow compressed air at 0.35 bar through the plug (31) into the cutter bar and immerse cutter bar in a water bath. No bubbles must come out of the bar or Connect a pressure gauge with a maximum reading of 0.6 bar to the drilled hole (31) and fill cutter bar with compressed air at 0.6 bar.

24

Cut off air feed There must be no loss of pressure over 10 minutes.

Dry cutter bar if required.

Turn bar.

(Fig. 24) Installing slide Remove bolts (45) (rotor fastening) and perforated bar (44) (Fig. 23).

Install slide (2) with toothed washers (7) and nuts (20).

Tighten slide nuts (20) with a torque of 64 ÷ 74 Nm. Install bolts (45) and perforated bar (44) (Fig. 23).

Position nuts (8) on the inlet rotor with LOCTITE 243.

Tighten nuts (8) on inlet rotor with a torque of 84 ÷ 98 Nm.

25

Turn bar.

(Fig. 23, 25)

4.38

RHB Futtererntemaschinen - 299 605.1

Drive systems Installing cutting disc and drum Place cutting discs (22) and drum (16) (opposite inlet side) on the mowing disc flange.

Position flange bolts (13) and LOCTITE 243; note number of flange bolts: Cutting discs (22) =

4 units

Drum (16)

6 units

=

Tighten flange screws (13) with a torque of 69 ÷ 79 Nm. 26

(Fig. 26) Place cover (23) on cutting discs.

Apply LOCTITE 243 to bolts (17).

Tighten bolts (17) with a torque of 69 ÷ 79 Nm. (Fig. 27) Install cover (46) with bolts (13) on the other drum.

Tighten bolts (13) with a torque of 69 ÷ 79 Nm. (Fig. 28)

27 Drum – inlet side Assemble drum, spacer and double universal joint with bolts (48).

Tighten bolts (48) with a torque of 79 ÷ 89 Nm. (Fig. 28)

28 Fill cutter bar with the specified amount of oil.

299 605.1 - RHB Futtererntemaschinen

4.39

Drive systems “COMER” cutter bar – General assembly instructions The rotors must be installed together at the specified position; Offset: 90° Tolerance: L-angle error within 5° for counter-rotating rotors and within 3° for synchronous rotors.

Lubricants Gearbox is lubricated with oil and grease.

Recommended oil type: SAE 90 EP (ISO VG 320) Oil amount: DISCO 260:

3.5 litres

DISCO 300:

4.0 litres

Recommended grease type: NLGI 2 Oil change : First oil change after the first 50 hours of operation, then every 500 hours and/or at least once a year.

4.40

RHB Futtererntemaschinen - 299 605.1

Drive systems

Drive systems “CORTO” DIRECT-CUT ATTACHMENTS

1 2

Machine model:

3

CORTO

Installing direct-cut attachment

4

73560

1

When installing the direct-cut attachments the drive shaft (4) must not be struck. The drive shaft (4) must be installed manually. After tightening the securing bolts (1) the drive shaft must still slide easily. This is required to ensure that the mower unit runs more quietly.

Proceed as follows to install the direct-cut attachments: – Coat sealing surfaces with Atmosit. Observe the general instructions Liquid screw lock on page 3.7.

– Insert direct-cut attachments into the frame, while paying attention to the direction of rotation.

– Position securing bolts (1) with bush (3) and washer (2).

– Tighten securing bolts (1) lightly only.

– Slide in drive shaft (4) manually.

– Align direct-cut attachments.

– Tighten securing bolts (1) to the specified torque.

Torque: 70 Nm

– Check that the drive shaft (4) can still be moved easily, if necessary adjust alignment of the direct-cut attachments.

Important!

The max. sliding force must not exceed 150 N. (Fig. 1) Lubricants Amount: see operator's manual Recommended gear oil: see operator's manual

299 605.1 - RHB Futtererntemaschinen

4.41

Drive systems

4.42

RHB Futtererntemaschinen - 299 605.1

Following the policy of CLAAS KGaA mbH of continuous product improvement to keep abreast of technical development, we reserve the right to make modifications which must not necessarily correspond to the text and illustrations contained in this operator's manual, and this without assuming the obligation to modify any machines previously delivered.

Technical specifications, dimensions and weights are understood with the usual tolerances.

Reproduction or translation, in whole or part, only with written authorization by CLAAS KGaA mbH. All rights under the provision of the Copyright act are reserved.

CLAAS KGaA mbH 33426 Harsewinkel Germany

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

299 605.1 RHB Futtererntemaschinen EN - 10.04 Printed in Germany