Page 1
Lely Splendimo
240 MCR
M-H025.1011EN
Operator Manual
Page 2
TRADEMARKS, COPYRIGHT AND
DISCLAIMER
Lely, Astronaut, Astri, Atlantis, Attis, AWS, C4C, Calm, Commodus,
Compedes,
Cosmix, Discovery, F4C, Fertiliner, Gravitor, Grazeway, Hibiscus,
Hubble, Juno, L4C, Lely Center, Lelywash, Lotus, Luna, Nautilus, Orbiter,
Qwes, SAE, Shuttle, Splendimo, T4C, Tigo, Viseo, Voyager, Walkway and
Welger are registered trademarks of the Lely Group. The right of exclusive use
belongs to the companies of the Lely Group. All rights reserved. The
information given in this publication is provided for information purposes only
and does not constitute an offer for sale. Certain products may not be available
in individual countries and products supplied may differ from those illustrated.
No part of this publication may be copied or published by means of printing,
photocopying, microfilm or any other process whatsoever without prior
permission in writing by Lely Holding S.à r.l. Although the contents of this
publication have been compiled with the greatest possible care, Lely cannot
accept liability for any damage that might arise from errors or omissions in this
publication.
The English language manual is the original manual. Translations into other
languages use the English language manual as the source document. Lely
accepts no liability for discrepancies between the original English language
manual and versions in other languages. If there is a conflict over the content
and accuracy of any translated manual, the English language manual is the
authority document.
Copyright © 2010 Lely Industries NV
All rights reserved
Lely Industries NV
Weverskade 110
3147 PA Maassluis
The Netherlands
Phone: Tel: +31 (0)10 59 96 333
Fax: Fax: +31 (0)10 59 96 444
Website: www.lely.com
PREFACE
Manual Contents
This manual contains the information necessary to operate the Lely
Splendimo. It also includes maintenance information that can be done by an
operator.
Study and understand this information thoroughly before you operate the Lely
Splendimo. Failure to do so could result in personal injury or damage to
equipment. Please consult your local Lely service provider if you do not
understand the information in this manual, or if you need additional information.
All information in this manual has been compiled with care. Lely shall not be
liable for errors or faults in this manual. The recommendations are meant to
ii
Page 3
serve as guidelines. All instructions, pictures and specifications in this manual
are
based on the latest information that was available at the time of publication.
Your Lely Splendimo may comprise improvements, features or options that are
not covered in this manual.
Warranty Conditions
For those parts that fail under normal operating conditions, the factory will
make replacement parts available, free of charge, for a period of 12 (twelve)
months from the date of purchase.
The warranty shall not apply if the instructions mentioned in this manual have
not been followed, or if they have not been followed completely or correctly.
Nor will the warranty apply if you or third parties modify the machine without
our foreknowledge and/or authorisation.
Registration
The Type and Serial Number Plate is on the front of the headstock.
Always include the type and serial numbers of your product when you contact
your local Lely service provider or order spare parts.
Type and Serial Number Plate
We
suggest you complete the table below with the type and serial numbers of
your product. This makes sure you can easily find the information.
Type number
Serial number
iii
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iv
Page 5
Table of Contents
1.
Introduction.........................................................................................................................................1-1
1.1 Cutter Bar.................................................................................................................................1-2
1.2 Roller Conditioner Unit.............................................................................................................1-3
1.3 Hydraulic System.....................................................................................................................1-3
1.4 Optional Extras Lely Splendimo 240 MCR...............................................................................1-4
1.4.1 Wear Plates.............................................................................................................................1-4
1.4.2 Topping Skids..........................................................................................................................1-4
1.4.3 Agitators...................................................................................................................................1-4
2. Safety...................................................................................................................................................2-1
2.1 Signal Words............................................................................................................................2-1
2.2 Safety Instructions....................................................................................................................2-1
2.3 Explanation of the Safety Decals on the Lely Splendimo 240 MCR........................................2-2
2.4 Position of the Safety Decals on the Lely Splendimo 240 MCR..............................................2-4
3. Operation.............................................................................................................................................3-1
3.1 Connect the Splendimo to the Tractor.....................................................................................3-1
3.2 Disconnect the Splendimo from the Tractor.............................................................................3-2
3.3 Move the Splendimo to the Transport Position........................................................................3-4
3.4 Move the Splendimo from the Transport Position to the Working Position..............................3-5
3.5 Move the Splendimo from the Working Position to the Headland Position..............................3-5
3.6 Start Mowing............................................................................................................................3-6
3.7 Stop Mowing............................................................................................................................3-7
4. Test and Adjustment..........................................................................................................................4-1
4.1 Adjust the Mowing Height........................................................................................................4-1
4.2 Adjust the Ground Pressure.....................................................................................................4-2
4.3 Adjust the Conditioning Intensity..............................................................................................4-3
4.4 Adjust the Swath Width............................................................................................................4-4
4.5 Adjust the V-belt Tension.........................................................................................................4-5
4.6 Adjust the Rotor Speed (If Extra V-belt Pulley is Available).....................................................4-7
4.7 Adjust the Clearance Between the Conditioner Rollers...........................................................4-9
5. Maintenance........................................................................................................................................5-1
5.1 Scheduled Maintenance...........................................................................................................5-1
5.1.1 Maintenance After Operation...................................................................................................5-1
5.1.2 Maintenance After the First 30 Working Hours........................................................................5-1
Table of Contents v
M-H025.1011EN
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5.1.3 Maintenance Every 50 Working Hours....................................................................................5-1
5.1.4
Maintenance Every 100 Working Hours..................................................................................5-1
5.1.5 Maintenance Every 250 Working Hours..................................................................................5-1
5.1.6 Maintenance Every 500 Working Hours or 1000 Hectare........................................................5-1
5.1.7 Maintenance Before Prolonged Storage..................................................................................5-1
5.1.8 Maintenance After Prolonged Storage.....................................................................................5-2
5.2 Preventive Maintenance...........................................................................................................5-3
5.2.1 Clean the Splendimo................................................................................................................5-3
5.2.2 Grease the Pivot Points...........................................................................................................5-3
5.2.3 Grease the PTO shaft..............................................................................................................5-4
5.2.4 Replace the Gearbox Oil..........................................................................................................5-4
5.2.5 Replace the Drive Element Oil.................................................................................................5-5
5.2.6 Grease a Mower Element........................................................................................................5-6
5.2.7 Grease the V-belt Tensioner....................................................................................................5-8
5.2.8 Grease the Bearings Block of the Conditioner Rollers.............................................................5-9
5.2.9 Grease the Bearing of the Transmission Suspension Arm....................................................5-10
5.3 Corrective Maintenance.........................................................................................................5-11
5.3.1 Remove and Install a Mower Knive.......................................................................................5-11
5.3.2 Remove and Install a Mower Disc.........................................................................................5-14
5.3.3 Remove and Install a Mower Disc on a Drive Element..........................................................5-15
5.3.4 Disassemble the Cutter Bar...................................................................................................5-18
5.3.5 Assemble the Cutter Bar........................................................................................................5-20
6. Diagrams and Tables.........................................................................................................................6-1
6.1 Lely Splendimo 240 MCR Diagrams and Schematics.............................................................6-1
6.2 Bolt and Nut Torque Table.......................................................................................................6-1
7. Troubleshooting.................................................................................................................................7-1
8. Specifications.....................................................................................................................................8-1
8.1 Splendimo 240 MCR Specifications.........................................................................................8-1
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M-H025.1011EN
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1. INTRODUCTION
The Lely Splendimo 240 MCR is a mower-to cut and condition fodder crops.
The
range of operation of the Lely Splendimo 240 MCR is between ± 20° from
the horizontal (relative to the tractor), and can be driven at speeds up to 20
km/h.Central suspension of the Splendimo enables the Lely Splendimo 240
MCR to follow ground contours accurately.
An anti-shock device protects the machine from damage if it hits obstacles
during mowing.
A headstock connects the mower to the tractor. The headstock contains
catergory II double linkage pins to adjust the position of the mower behind the
tractor.
The Lely Splendimo 240 MCR has:
• A cutter bar
• A roller conditioner unit
• A hydraulic control system
• An adjustable ground-pressure relief system.
Various optional extras are also available. Refer to Optional Extras Lely
Splendimo 240 MCR (page 1-4).
Introduction 1-1
M-H025.1011EN
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1. Headstock - 2. Operating cord - 3. Primary PTO-shaft - 4. Parking jack - 5. Secondary PTO-
shaft - 6. Hydraulic ram - 7. Mower element - 8. Cutter bar - 9. Roller conditioner unit - 10.
Swath width handle - 11. V-belt housing - 12. Tensioning device
Figure 1. Overview of the Lely Splendimo 240 MCR
1.1 Cutter Bar
The cutter bar contains the mower units. The modular design of the cutter bar
enables quick and easy replacement of mower units and drive shafts if they
are damaged. The mower units are connected to each other by a rod.
The first mower unit is driven from the top. A spring-steel shaft then transfers
the drive from the first mower unit to the other mower units. All mower units
are directly driven by this shaft.
The mower units turn in pairs, either clockwise or counterclockwise.
The mower knives are connected to the mower units by the Splendimo Clip
quick-release system. This enables easy replacement of mower knives.
1-2 Introduction
M-H025.1011EN
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1.2 Roller Conditioner Unit
The roller conditioner unit is used to condition leafy crops.
The
position of the rollers can be adjusted to give more clearance between the
rollers. This in combination with the tension between rollers determines the
intensity of the conditioning
The bottom roller is driven by a v-belt and drives the top roller by a gear
assembly. These gears are connected by movable arms to let the rollers move
separately from each other. This enables you to adjust to the crop flow or to
allow a larger crop volume to pass. The wide profile of the rollers give a firm
grip on the crop.
An optional drive pulley for the conditioner rollers changes the speed.
1.3 Hydraulic System
The hydraulic system raises and lowers the cutter bar.
When the hydraulic system is set to the floating position the cutter bar can
closely follow ground contours.
The ground-pressure relief system makes sure the cutter bar follows the
ground contours without damaging the crop and transfers some of the
Splendimo weight to the tractor.
It can be adjusted by regulating the pressure of the hydropneumatic spring
system.
Introduction 1-3
M-H025.1011EN
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1.4 Optional Extras Lely Splendimo 240 MCR
1.4.1 Wear Plates
Wear plates can be installed on the bottom of the skids to reduce wear of the
skids. The wear plates are available in thicknesses of 4 mm or 8 mm.
1. Wear plate - 2. Topping skid
Figure 2. Wear Plate and Topping Skid
1.4.2 Topping Skids
Topping skids can be installed on the bottom of the skids to raise the mowing
height approximately 3 cm. This is used for topping or when the mower is used
on rough ground, and reduces damage to the cutter bar by stones and other
debris.
If topping skids are installed, position 2 or 3 of the parking jack must be used
(fig. 6, page 3-3).
1.4.3 Agitators
Agitators can be installed on the mower discs to improve the crop flow across
the cutter bar in certain circumstances.
Figure 3. Agitator
1-4 Introduction
M-H025.1011EN
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2. SAFETY
This chapter contains safety instructions you must obey when you use or do
maintenance
on your Lely Splendimo. It also explains the safety decals on the
Lely Splendimo.
2.1 Signal Words
Note the use of the signal words DANGER, WARNING and CAUTION. The
signal word for each message uses the following guidelines:
Danger:
Indicates an imminently hazardous situation that, if
not avoided, will result in death or serious injury.
Warning: Indicates a potentially hazardous situation that, if not avoided,
could result in death, serious injury or product damage, and includes
hazards that are exposed when guards are removed.
Caution: Indicates a potentially hazardous situation that, if not avoided, may
result in minor or moderate injury or damage to the product or property.
Note: This shows extra information that may help the reader.
2.2 Safety Instructions
• Use the Splendimo only for the purpose for which it was designed.
• Follow all safety regulations, including those in this manual and instructions
or warnings indicated on the machine.
• Operate the Splendimo in a safe manner.
• The Splendimo must only be operated by authorised persons.
• Be alert and observe all safety precautions.
• Make sure all safety guards and protection devices are installed and
function correctly.
• Keep people and objects away from moving parts.
• Stop the tractor engine, the Power Take-Off (PTO) and all moving parts
before you do maintenance on the Splendimo.
• Make sure no people are in the danger zone when the Splendimo is in
operation. This is especially important when you work near or on areas that
are accessible to the public.
• Always use a tractor with a cab.
• Make sure there are no objects in the field that could be thrown up by the
Splendimo before you operate the Splendimo.
• Obey local legislation when you drive on a public road.
• Use flashing lights or other safety signs, when necessary.
• Do not stand on the Splendimo.
• Only use genuine LELY parts.
DANGER
WARNING
CAUTION
Note:
Safety 2-1
M-H025.1011EN
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• Depressurise the hydraulic system before you connect or disconnect
hydraulic hoses.
•
Use protective clothing, gloves, safety glasses and ear protectors, if
necessary.
• Clean or replace the safety decals regularly so that they can be read at all
times.
2.3 Explanation of the Safety Decals on the Lely Splendimo 240 MCR
Read the operator's manual carefully before you
operate the Splendimo
Keep a safe distance from the Splendimo when
the tractor engine is on.
Keep away from the folding area of the cutter bar.
Keep away from all moving parts unless they are
locked and cannot move.
Keep a safe distance from the Splendimo when
the tractor engine is on.
Read the operating instructions for the PTO
shaft. Always use the correct safety precautions
and protection when you operate the PTO shaft.
Only use the hoisting points indicated on the
Splendimo to lift the Splendimo.
Never operate the Splendimo at a PTO speed of
more than 540 rpm
2-2 Safety
M-H025.1011EN
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Never operate the Splendimo at a PTO speed of
more than 1000 rpm
Safety 2-3
M-H025.1011EN
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2.4 Position of the Safety Decals on the Lely Splendimo 240 MCR
Figure 4. Position of the Safety Decals on the Lely Splendimo 240 MCR
2-4 Safety
M-H025.1011EN
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3. OPERATION
3.1 Connect the Splendimo to the Tractor
1. Adjust the 3-point hitch on the tractor until the arms are at the same
height.
2.
Choose between connection position 1 or connection position 2 (fig. 5,
page 3-2). Connection position 1 is recommended.
A correct connection position is when the first mower disc is not in the
tyre track of the tractor.
3. Connect the two lower arms of the 3-point hitch to the linkage pins on
the headstock.
4. Connect the top link of the 3-point hitch to the headstock.
The maximum pressure of the tractor hydraulic system must not be more
than 21.0 MPa (210 bar).
5. Remove the dust caps from the two hydraulic hoses.
6. Connect the two hydraulic hoses to a double-acting hydraulic valve on
the tractor.
7. Use the tractor 3-point hitch to lift the headstock until the central pivot
pin of the support arm is 64 cm (25") above the ground.
8. Make sure the headstock is level.
9. If the headstock is not level, adjust the height of one of the two lower
arms.
10. Move the parking jack to the highest position.
11. If necessary, install stabilization chains (or rods) on the tractor lower
arms to prevent lateral movement.
12. Make sure no lateral movement is possible.
The first time you connect the Splendimo to each tractor, refer to the
instructions supplied with the PTO shaft and make sure the minimum and
maximum overlap of the two parts of the PTO shaft is correct.
13. Make sure the primary PTO shaft telescopes smoothly.
14. Connect the primary PTO-shaft to the tractor PTO.
Always connect the safety chain of the PTO shaft to a rigid part of the
tractor.
15. Put the end of the ram-lock operating cord in the tractor cab.
Note:
WARNING
CAUTION
WARNING
Operation 3-1
M-H025.1011EN
Page 16
1. Connection position 1 - 2. Connection position 2
Figure 5. Connection Points
3.2 Disconnect the Splendimo from the Tractor
Always position the tractor on solid ground before you disconnect the
Splendimo from the tractor.
Make
sure there are no persons near the Splendimo when you disconnect
it from the tractor.
1. Set the hydraulic valve in the tractor to the floating position.
2. Pull the operating cord to engage the locking hook on the hydraulic ram.
3. Lower the headstock until the locking hook of the hydraulic ram is
engaged in the parking position.
4. Move the parking jack to position 1 (fig. 6, page 3-3).
5. If topping skids are installed move the parking jack to position 2 or 3.
6. Use the tractor 3-point hitch to lower the headstock until the parking jack
is on the ground.
7. Switch off the tractor engine.
8. Disconnect the Splendimo primary PTO-shaft from the tractor PTO.
9. Attach the primary PTO-shaft to the PTO support.
10. Disconnect the two hydraulic hoses from the tractor hydraulic system.
11. Install the two dust caps on the two hydraulic hoses.
WARNING
WARNING
3-2 Operation
M-H025.1011EN
Page 17
12. Attach the two hydraulic hoses to the support on the headstock.
Always keep the ball valve on the hydraulic system closed. If the ball valve is
open, the hydraulic pressure is released and the Splendimo will be unstable.
13.
Disconnect the top link from the headstock.
14. Disconnect the two lower arms from the linkage pins on the headstock.
15. Remove the ram-lock operating cord from the tractor cab.
16. Remove the tractor from the area.
Figure 6. Parking Position
CAUTION
Operation 3-3
M-H025.1011EN
Page 18
3.3 Move the Splendimo to the Transport Position
Make sure there are no persons in the area when you move the Splendimo
to the transport position.
Make sure the front axle weight of the tractor is sufficient (use front weights if
necessary) and that you do not exceed the rear axle weight when the
Splendimo is in the transport position.
Use all lights and warning signals as defined by your local road traffic
regulations.
1.
Disengage the PTO shaft.
Wait for all moving parts of the Splendimo to stop.
2. Pull the operating cord to release the locking hook on the hydraulic ram.
3. Operate the tractor hydraulic system to retract the hydraulic rams until
the Splendimo is in the transport position.
4. Make sure the locking hook has engaged in the hydraulic ram.
Make sure the PTO shaft does not turn when the Splendimo is in the
transport position.
Figure 7. Transport Position
WARNING
CAUTION
CAUTION
WARNING
WARNING
3-4 Operation
M-H025.1011EN
Page 19
3.4 Move the Splendimo from the Transport Position to the Working
Position
Make sure there are no persons in the area when you move the Splendimo
to the headland position.
Make sure the PTO shaft does not turn when the Splendimo is in the
transport position.
1. Pull
the operating cord to release the locking hook on the hydraulic ram.
2. Operate the tractor hydraulic system to extend the hydraulic ram until
the Splendimo is in the working position.
Figure 8. Working Position
3.5 Move the Splendimo from the Working Position to the Headland
Position
1. Operate the tractor hydraulic system to lift the Splendimo to the
headland position.
Figure 9. Headland Position
WARNING
WARNING
Operation 3-5
M-H025.1011EN
Page 20
3.6 Start Mowing
Make sure no persons are near the Splendimo when you engage the PTO.
Make sure no persons are within a 100 meter radius of the Splendimo
during operation.
Do not exceed the maximum PTO speed as shown on the Splendimo.
Always switch off the tractor engine before you leave the tractor cab.
Do not operate the Splendimo without safety guards or covers, or if the
safety guards or covers are damaged.
Always operate the Splendimo with the safety guards or covers down
and engaged in the clamping blocks.
1.
Move the Splendimo to the headland position
2. Carefully engage the PTO at the lowest possible engine speed.
3. Slowly increase the speed of the PTO to the maximum PTO speed as
shown on the Splendimo.
4. Set the hydraulic valve in the tractor to the floating position to lower the
Splendimo to the ground.
The Splendimo is now in working position (fig. 8, page 3-5).
5. Drive the tractor at a minimum speed of 8 km/h and make sure:
• The hydraulic rams telescope smoothly
• The PTO speed stays at the speed shown on the Splendimo.
6. If necessary stop the tractor and:
• Adjust the mowing height (page 4-1)
• Adjust the ground pressure (page 4-2)
• Adjust the conditioning intensity (page 4-3)
7. If the Splendimo hits an obstacle and the anti-shock device engages:
1. Stop the tractor immediately.
2. Reverse a few meters until the anti-shock device resets.
Make sure the Splendimo is not damaged and is safe to use.
3. Move the Splendimo to the headland position.
4. Drive around the obstacle.
5. Lower the Splendimo to the ground.
6. Continue mowing.
WARNING
WARNING
CAUTION
WARNING
WARNING
WARNING
WARNING
3-6 Operation
M-H025.1011EN
Page 21
Figure 10. Engaged Safety Guard
3.7 Stop Mowing
Always switch off the tractor engine before you leave the tractor cab.
1.
Stop the tractor.
2. Lift the Splendimo to the headland position.
3. Disengage the PTO.
Wait for all moving parts of the Splendimo to stop.
4. Switch off the tractor engine.
WARNING
WARNING
Operation 3-7
M-H025.1011EN
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3-8 Operation
M-H025.1011EN
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4. TEST AND ADJUSTMENT
4.1 Adjust the Mowing Height
1. Operate the tractor's top link to adjust the mowing height.
Figure 11. Mowing Height
Test and Adjustment 4-1
M-H025.1011EN
Page 24
4.2 Adjust the Ground Pressure
1. Disengage the PTO.
Wait until all moving parts have stopped before you do adjustments to
the Splendimo.
2.
Turn the ball valve counterclockwise to release the pressure from the
hydraulic system (fig. 12, page 4-2).
3. Operate the hydraulic system until the pressure gauge shows the correct
pressure.
4. Turn the ball valve clockwise to close the hydraulic system.
5. Set the hydraulic valve in the tractor to the floating position.
On flat ground a pressure of 75 bar (7.5 MPa) is correct.
The ground pressure setting does not change when you lift the mower
to the headland or transport position.
The hydraulic pressure setting does not change if the ball valve stays
closed.
Figure 12. Hydraulic Pressure Gauge and Ball Valve
WARNING
Note:
Note:
Note:
4-2 Test and Adjustment
M-H025.1011EN
Page 25
4.3 Adjust the Conditioning Intensity
1. On both sides of the Splendimo:
1.
Loosen the counter nut.
2. Turn the adjustment bolt clockwise to increase the condition
intensity.
3. Turn the adjustment bolt counterclockwise to decrease the
condition intensity.
4. Tighten the counter nut.
Figure 13. Adjust the Condition Intensity
Test and Adjustment 4-3
M-H025.1011EN
Page 26
4.4 Adjust the Swath Width
1. On the left and right side of the Splendimo:
1.
Turn the swath width handle counterclockwise to unlock it.
2. Move the swath width handle sideways to adjust the swath width.
The outer position gives the biggest swath width. The inner position
gives the smallest swath width.
3. Turn the swath width handle clockwise to lock it.
Figure 14. Adjust the Swath Width
Note:
4-4 Test and Adjustment
M-H025.1011EN
Page 27
4.5 Adjust the V-belt Tension
1. Disconnect the secondary PTO-shaft.
2.
Remove the bolts of the inspection hole cover (1).
3. Remove the inspection hole cover (2).
4. Remove the nuts (3) and (4).
Nut (4) is accessible via the inspection hole.
5. Remove the bolts (5).
6. Remove the V-belt housing.
7. Turn the tensioning device clockwise to tighten the V-belt.
8. Adjust the V-belt tension until a force of 70 N (7 kg) applied to the V-belt
between the left and right pulleys moves the V-belt 10 mm.
9. Turn the pulleys several times and make sure the V-belt tension is
correct.
Figure 15. Remove the V-Belt Housing
Note:
Test and Adjustment 4-5
M-H025.1011EN
Page 28
Figure 16. Adjust V-Belt Tension
4-6 Test and Adjustment
M-H025.1011EN
Page 29
4.6 Adjust the Rotor Speed (If Extra V-belt Pulley is Available)
• Requirements:
•
Allen key
• Torque wrench
• Hammer
1. Remove the V-belt housing.
2. Turn the tensioning device counterclockwise to release the tension from
the V-belts.
3. Remove the V-belts.
4. Remove the two allen bolts from the right pulley.
5. Put one of the allen bolts in the center hole of the right pulley.
6. Tighten the bolt until the right pulley disconnects from the clamping
device.
7. Remove the clamping device and the pulley.
Do not use oil or grease when you install a new pulley.
8. Install the clamping device on the conditioner rotor shaft.
9. Install the new pulley on the clamping device.
10. Align the pulley with the top pulley and the left pulley.
11. Put the two allen bolts in the holes of the right pulley.
12. Torque-tighten the allen bolts to 50 Nm (5 kgm).
13. Tap the right pulley with a hammer, then torque-tighten the allen bolts
to 50 Nm (5 kgm) again.
14. Install the V-belts.
15. Turn the tensioning device clockwise to tighten the V-belt.
16. Adjust the V-belt tension until a force of 70 N (7 kg) applied to the V-belt
between the left and right pulleys moves the V-belt 10 mm.
17. Turn the pulleys several times and make sure the V-belt tension is
correct.
18. Install the V-belt housing.
CAUTION
Test and Adjustment 4-7
M-H025.1011EN
Page 30
Figure 17. Adjust the Rotor Speed
4-8 Test and Adjustment
M-H025.1011EN
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4.7 Adjust the Clearance Between the Conditioner Rollers
1. On both sides of the Splendimo:
1.
Loosen the counter nut.
2. Turn the adjustment bolt clockwise to decrease the clearance
between the conditioner rollers.
3. Turn the adjustment bolt counterclockwise to increase the
clearance between the conditioner rollers.
4. Tighten the counter nut.
Figure 18. Adjust the Clearance Between the Conditioner Rollers
Test and Adjustment 4-9
M-H025.1011EN
Page 32
4-10 Test and Adjustment
M-H025.1011EN
Page 33
5. MAINTENANCE
5.1 Scheduled Maintenance
5.1.1 Maintenance After Operation
• Clean the Splendimo (page 5-3).
•
Make sure the knife pins are tight.
• Make sure the mower discs are torque-tight.
• Grease the Splendimo with an anti-corrosion agent.
5.1.2 Maintenance After the First 30 Working Hours
After the Splendimo is used for the first time, or if a new gearbox or drive
element is installed:
•
Replace the gearbox oil (page 5-4).
• Replace the drive element oil (page 5-5).
5.1.3 Maintenance Every 50 Working Hours
• Grease the pivot points (page 5-3).
•
Grease the bearing of the transmission suspension arm (page 5-10).
5.1.4 Maintenance Every 100 Working Hours
• Make sure the PTO shafts telescope smoothly.
• Grease the PTO shaft (page 5-4).
• Grease the bearings block of the conditioner rollers (page 5-9).
• Grease the V-belt tensioner (page 5-8).
5.1.5 Maintenance Every 250 Working Hours
• Replace the gearbox oil (page 5-4).
• Replace the drive element oil (page 5-5).
• Make sure the hydraulic hoses are not damaged or worn. Replace if
necessary.
5.1.6 Maintenance Every 500 Working Hours or 1000 Hectare
• Grease the mower elements (page 5-6).
5.1.7 Maintenance Before Prolonged Storage
• Grease the Splendimo with an anti-corrosion agent.
• Grease the piston rod with an anti-corrosion agent.
• If necessary, grease the mower elements (page 5-6).
• Examine the wear plates, mower discs and knives for wear and damage.
Replace if necessary.
Maintenance 5-1
M-H025.1011EN
Page 34
• Make sure the knife pins are tight.
•
Make sure the mower discs are torque-tight.
• Examine the Splendimo for damage and defects. Repair or replace
damaged parts.
• Examine the hydraulic system for leaks and damaged parts. Repair or
replace damaged parts.
• Examine the gearboxes for leaks.
• Make sure all bolts and nuts are torque-tight (page 6-1).
• Make sure all safety decals are not damaged. Replace if necessary (page
2-4).
• Release the pressure from the V-belts. (page 4-5)
5.1.8 Maintenance After Prolonged Storage
• Remove anti-corrosion agent from piston rod.
•
Adjust the V-belt tension (page 4-5).
• Examine the wear plates, mower discs and knives for wear and damage.
Replace if necessary.
• Make sure the knife pins are tight.
• Examine the Splendimo for damage and defects. Repair or replace
damaged parts.
• Examine the hydraulic system for leaks and damaged parts. Repair or
replace damaged parts.
• Examine the gearboxes for leaks.
• Make sure all bolts and nuts are torque-tight (page 6-1).
• Make sure all safety decals are not damaged. Replace if necessary (page
2-4).
5-2 Maintenance
M-H025.1011EN
Page 35
5.2 Preventive Maintenance
5.2.1 Clean the Splendimo
1. Make sure the Splendimo is in the parking position.
2.
Lift the safety guard and lock it with the hook.
3. Use a water jet to thoroughly clean the Splendimo.
4. Carefully engage the PTO at the lowest possible engine speed for a
short time to remove any water from the cutter bar.
5.2.2 Grease the Pivot Points
• Requirements:
•
Grease pump
• Biodegradable grease (Total Biomultis SEP2 or equivalent)
1. Use the grease pump to grease the pivot points.
Figure 19. Pivot Points
Maintenance 5-3
M-H025.1011EN
Page 36
5.2.3 Grease the PTO shaft
• Requirements:
•
Grease pump
• Biodegradable grease (Total Biomultis SEP2 or equivalent)
1. Use the grease pump to grease the PTO shaft.
2. Grease the profiled tubes of the PTO shaft.
Figure 20. Grease Points PTO Shaft
5.2.4 Replace the Gearbox Oil
• Requirements:
•
Collection container (minimum capacity: 3 liters)
• GX85-W140 transmission oil or equivalent
An incorrect quantity of oil will cause overheating and permanent damage to
the gearbox.
1. Clean the area around the drain plug.
2. Put the collection container underneath gearbox A.
3. Remove the fill plug from gearbox A.
4. Remove the drain plug from gearbox A and allow the oil to flow into the
collection container.
5. When all the oil is out of the gearbox, install the drain plug in gearbox
A.
6. Fill gearbox A with 1.7 l of GX85-W140 transmission oil or equivalent.
7. Install the fill plug in gearbox A.
8. Put the collection container underneath gearbox B.
9. Remove the fill plug from gearbox B.
10. Remove the drain plug from gearbox B and allow the oil to flow into the
collection container.
11. When all the oil is out of the gearbox, install the drain plug in gearbox
B.
12. Fill gearbox B with 0.85 l of GX85-W140 transmission oil or equivalent.
CAUTION
5-4 Maintenance
M-H025.1011EN
Page 37
13. Install the fill plug in gearbox B.
14.
Remove the collection container from the area and dispose of the
drained oil as specified by local regulations.
Replace the oil after the first 30 working hours and every 250 working hours with GX85-W140
transmission oil or equivalent.
1. Drain plug - 2. Fill plug
A. Gearbox - B. Gearbox - C. Drive Element
Figure 21. Replace the Gearbox Oil and Drive Element Oil
5.2.5 Replace the Drive Element Oil
• Requirements:
•
Collection container (minimum capacity: 0.5 liter)
• GX85-W140 transmission oil or equivalent
An incorrect quantity of oil will cause overheating and permanent damage to
the drive element.
1. Move the Splendimo to the transport position (page 3-4).
2. Put a collection container under drive element C.
3. Clean the area around the drain plug.
4. Remove the drain plug from drive element C and allow the oil to flow
into the collection container.
5. Clean the drain plug.
6. Move the Splendimo to the working position.
7. Refill drive element C with 0.45 l of GX85-W140 transmission oil or
equivalent.
8. Install the drain plug.
CAUTION
Maintenance 5-5
M-H025.1011EN
Page 38
5.2.6 Grease a Mower Element
• Requirements:
•
Shell Alvania WR 0 or equivalent
• Loctite 243
• Torque wrench
Do not use solvent for removing grease from the mower element. Solvent can
cause damage to the seals and bearings.
An incorrect quantity of grease will cause overheating and damage to the
mower element.
Make sure the bearing housing is installed on the same mower element it was
removed from.
1. Remove the split pin (1) from the castellated nut (2) on top of the mower
disc (5).
2. Remove the castellated nut (2).
3. Remove the pressure piece (3).
4. Make sure the O-ring (4) stays inside the pressure piece.
5. Remove the mower disc (5).
6. Remove the four cilinder head bolts (6) from the bearing housing (7).
7. Remove the bearing housing.
8. Make sure shim (8) stays in the correct position.
9. Remove the old grease from the element.
10. Fill the mower element with 100 gr. of Shell Alvania WR 0 or equivalent.
11. Install the bearing housing on top of the mower element.
12. Make sure the hub of the bearing housing aligns with the hub of the
adjacent bearing housing.
13. Put Loctite 243 on the thread of the four cilinder head bolts.
14. Install the four cylinder head bolts in the holes of the bearing housing.
15. Torque-tighten the four cilinder head bolts to 39 Nm (3.9 kgm).
16. Turn the new mower disc 90° in relation to the adjacent mower disc.
17. Install the new mower disc on top of the bearing housing.
18. Examine the O-ring (4) for wear.
19. If the O-ring is worn, replace the O-ring.
20. Torque-tighten the castellated nut to 150-250 Nm (15-25 kgm).
21. Install the split pin in the castellated nut.
22. Make sure the split pin does not protrude above the pressure piece.
CAUTION
CAUTION
CAUTION
5-6 Maintenance
M-H025.1011EN
Page 39
1. Split pin - 2. Castellated nut - 3. Pressure piece - 4. O-ring - 5. Mower disc
6. Fillister bolt - 7. Bearing housing - 8. Shim
Figure 22. Grease a Mower Element
Maintenance 5-7
M-H025.1011EN
Page 40
5.2.7 Grease the V-belt Tensioner
• Requirements:
•
Biodegradable grease (Total Biomultis SEP2 or equivalent)
• Grease pump
1. Remove the inspection hole cover.
2. Use the grease pump to grease the bearing of the V-belt tensioner.
3. Install the inspection hole cover.
Figure 23. Grease the V-belt Tensioner
5-8 Maintenance
M-H025.1011EN
Page 41
5.2.8 Grease the Bearings Block of the Conditioner Rollers
• Requirements:
•
Biodegradable grease (Total Biomultis SEP2 or equivalent)
• Grease pump
1. On the left side of the Splendimo:
1. Remove the inspection hole cover of the V-belt housing.
2. Use the grease pump to grease the bearings of the top and bottom
conditioner roller.
3. Install the inspection hole cover.
2. On the right side of the Splendimo:
1. Remove the tarp from the transmission housing.
2. Remove the transmission housing.
3. Use the grease pump to grease the bearings of the top conditioner
roller.
4. Install the transmission housing.
5. Install the tarp on the transmission housing.
Figure 24. Grease the Bearing Blocks of the Conditioner Rollers
Maintenance 5-9
M-H025.1011EN
Page 42
5.2.9 Grease the Bearing of the Transmission Suspension Arm
• Requirements:
•
Biodegradable grease (Total Biomultis SEP2 or equivalent)
• Grease pump
1. On both sides of the conditioner unit, use the grease pump to grease
the bearing of the transmission suspension arm.
Do not grease the gears of the conditioner roller. These gears need to stay dry
to them clean.
Figure 25. Grease the Bearings of the Transmission Suspension Arm
CAUTION
5-10 Maintenance
M-H025.1011EN
Page 43
5.3 Corrective Maintenance
5.3.1 Remove and Install a Mower Knive
• Requirements:
•
Lely Knive Change Tool
• Splendimo clip
If a mower knife is not installed correctly it can cause injury
to people and damage to objects.
Always use a new Splendimo clip when you replace a mower knife.
Always replace, or reverse the two knives of a mower disc at the same time.
If only one knife is replaced or reversed the disc will not be balanced and may
cause vibration and damage to the mowing unit.
Mower knives have two cutting edges. When one edge is worn, the knife
can be reversed so that the second edge can be used.
1. Remove any dirt from the mower disc.
2. Turn the mower disc so the knife pin is above the hole in the skid.
3. Put the fork of the Lely Knive Change Tool behind the Splendimo clip
(1).
4. Pull the Lely Knive Change Tool downward to release the Splendimo
clip from the lock (1).
5. Remove the Splendimo clip (2).
The tip of the Lely knive change tool can be used to remove the knife pin
if it is stuck.
6. Remove the knife pin (2).
7. Examine the knife pin for wear.
8. If the knife pin is worn, replace the knife pin.
9. Remove the mower knife.
10. If you want to use the other side of the mower knife, reverse the mower
knife.
11. If you do not want to use the other side of the mower knife:
1. Discard the old mower knife.
2. Examine the rotation of the mower element.
3. Install a right hand mower knife for a right hand rotation mower
element.
4. Install a left hand mower knife for a left hand rotation mower
element.
12. Put the mower knife in front of the hole on the bottom of the mower disc
(3).
13. Put the knife pin trough the hole of the mower knife and the hole of the
mower disc (4).
14. Install the new Splendimo clip on the knife pin (4).
DANGER
WARNING
CAUTION
Note:
Note:
Maintenance 5-11
M-H025.1011EN
Page 44
15. Hammer the Splendimo clip into the groove of the knife pin until the
Splendimo clip is locked behind the locking cam (5).
Figure 26. Remove and Install a Mower Knife
5-12 Maintenance
M-H025.1011EN
Page 45
Figure 27. Lely Knive Change Tool
Maintenance 5-13
M-H025.1011EN
Page 46
5.3.2 Remove and Install a Mower Disc
1. Remove
the split pin (1) from the castellated nut (2) on top of the mower
disc (5).
2. Remove the castellated nut (2).
3. Remove the pressure piece (3).
4. Make sure the O-ring (4) stays inside the pressure piece.
5. Remove the mower disc (5).
6. Turn the new mower disc 90° in relation to the adjacent mower disc.
7. Install the new mower disc on top of the bearing housing.
8. Examine the O-ring (4) for wear.
9. If the O-ring is worn, replace the O-ring.
10. Torque-tighten the castellated nut to 150-250 Nm (15-25 kgm).
11. Install the split pin in the castellated nut.
12. Make sure the split pin does not protrude above the pressure piece.
1. Split pin - 2. Castellated nut - 3. Pressure piece - 4. O-ring - 5. Mower disc
6. Fillister bolt - 7. Bearing housing - 8. Shim
Figure 28. Remove and Install a Mower Disc
5-14 Maintenance
M-H025.1011EN
Page 47
5.3.3 Remove and Install a Mower Disc on a Drive Element
1. Remove the V-belt housing.
2. Turn
the tensioning device counterclockwise to release the tension from
the V-belts.
3. Remove the V-belts.
4. Remove the three bolts from the cover (1), then remove the cover
5. Remove the bolts that connect the gearbox (2) to the frame.
6. Remove the gearbox (2) from the yoke (4).
7. Remove the four bolts from the bottom of hat (5), then remove the hat.
8. Remove the bolts from the mower disc (6), then remove the mower disc.
9. Install the new mower disc on the bearing housing (7).
10. Install the hat (5) on the mower disc (6).
11. Install the gearbox (2) on the yoke (4).
12. Put Loctite 243 on the thread of the bolts that connect the gearbox to
the frame.
13. Torque-tighten the bolts that connect the gearbox to the frame to 80 Nm.
14. Install the cover (1).
15. Install the three bolts on the cover (1).
16. Install the V-belts.
17. Turn the tensioning device clockwise to tighten the V-belt.
18. Adjust the V-belt tension until a force of 70 N (7 kg) applied to the V-belt
between the left and right pulleys moves the V-belt 10 mm.
19. Turn the pulleys several times and make sure the V-belt tension is
correct.
20. Install the V-belt housing.
Maintenance 5-15
M-H025.1011EN
Page 48
Figure 29. Adjust V-Belt Tension
5-16 Maintenance
M-H025.1011EN
Page 49
1. Cover - 2. Gearbox - 3. Stub axle - 4. Yoke - 5. Hat - 6. Mower disc - 7. Bearing housing
Figure 30. Exploded view of the drive line
Maintenance 5-17
M-H025.1011EN
Page 50
5.3.4 Disassemble the Cutter Bar
• Requirements:
•
Socket spanner 46 mm
• Torque wrench
• 150 cm extension pipe
1. Clean the cutter bar.
2. Connect the Splendimo to the tractor (page 3-1).
3. Lower the Splendimo onto a level floor.
4. Remove the securing plate (13).
5. Extend the Torque wrench with the 150 cm extension pipe.
6. Use the torque wrench to loose the M30 nut (16). Do not remove the
nut.
7. On both sides of the cutter bar:
• Remove the five bolts (18) from the bottom of the support.
8. Remove the cutter bar.
9. Remove the M30 nut (16) and the ring (17).
10. Remove the end plate (19).
11. Remove the mower elements (10), and the intermediate spacers (9),
from the connecting rod (20).
5-18 Maintenance
M-H025.1011EN
Page 51
1.Mower knive - 2. Mower disc - 3. Pressure piece - 4. Castellated nut - 5.Hat - 6. Hat - 7.
Drive
shaft - 8. Centring ring - 9. Intermediate spacer - 10. Mower element - 11. Securing plug
- 12. Locking ring - 13. Securing plate - 14. Washer - 15. Bolt M10 x20 - 16. M30 nut - 17.
Ring - 18. Bolt - 19. End plate - 20. Connecting rod
Figure 31. Exploded View of the Cutter Bar
Maintenance 5-19
M-H025.1011EN
Page 52
5.3.5 Assemble the Cutter Bar
• Requirements:
•
Socket spanner 46 mm
• Torque wrench
• 150 cm extension pipe
• Castrol Tarp or equivalent
• Molykote BR2 Plus or equivalent
• Molykote P74 or equivalent
1. Clean:
• The centring rings (8)
• The contact areas of the mower elements (10) and the intermediate
spacers (9).
2. Make sure there is no dirt between all the contact areas.
3. Rub the contact areas of the mower elements and intermediate spacers
with Castrol Tarp or equivalent.
4. Grease the drive shaft (5) with Molykote BR2 Plus or equivalent.
5. Turn the mower disc (2) 90° in relation to the adjacent mower disc.
6. Install the mower elements and the intermediate spacers according to
the direction of rotation of the mower elements.
7. If a mower element cannot be installed on the drive shaft:
• Turn the mower disc several half turns until the element can be
installed.
8. Install the securing plug (11) and locking ring (12) in the outer mower
element.
9. Install the end plate (19).
10. Grease the M30 nut (16), the ring (17) and the treaded part of the
connecting rod (20) with Molykote P74 or equivalent.
11. Install the ring (17).
12. Tighten the M30 nut (16).
13. Put the cutter bar under the mower.
14. Put the yoke (4) in line with the stub axle (3) of the gearbox (2) (fig. 30,
page 5-17).
15. Carefully lower the Splendimo.
16. Make sure the stub axle of the gearbox moves in the yoke (fig. 30, page
5-17).
17. On both sides of the Splendimo:
1. Make sure the five holes of the end plate are in line with the five
holes at the bottom of the support.
2. Tighten the five bolts (18) fingertight.
3. Torque-tighten the five bolts (18) to 120 Nm (12 Kgm).
4. Install a second nut (locknut) on each of the five bolts (18).
18. Extend the Torque wrench with the 150 cm extension pipe.
19. Torque-tighten the M30 nut (16) to 950 Nm (95 Kgm).
5-20 Maintenance
M-H025.1011EN
Page 53
20. Tighten the M30 (16) nut until the securing plate (13) can be installed.
21.
Install the securing plate.
1.Mower knive - 2. Mower disc - 3. Pressure piece - 4. Castellated nut - 5.Hat - 6. Hat - 7.
Drive
shaft - 8. Centring ring - 9. Intermediate spacer - 10. Mower element - 11. Securing plug
- 12. Locking ring - 13. Securing plate - 14. Washer - 15. Bolt M10 x20 - 16. M30 nut - 17.
Ring - 18. Bolt - 19. End plate - 20. Connecting rod
Figure 32. Exploded View of the Cutter Bar
Figure 33. Direction of Rotation of Mower Elements
Figure 34. Torque load Nut M30
Maintenance 5-21
M-H025.1011EN
Page 54
5-22 Maintenance
M-H025.1011EN
Page 55
6. DIAGRAMS AND TABLES
6.1 Lely Splendimo 240 MCR Diagrams and Schematics
1. Accumulator
2. Pressure gauge
3. Connecting block
4. Ball valve
5. Throttle (1-way)
6. Combined ram
6a. Single-acting component (ground pressure relief)
6b. Double-acting component (lifting and lowering)
7. Throttle
Figure 35. Mechanically Controlled Hydraulic Schematic
6.2 Bolt and Nut Torque Table
The following table specifies the standard torque load for all quality 8.8 bolts
in combination with quality 8 nuts on the Splendimo.
Always
use a calibrated torque wrench when you torque-tighten bolts and nuts.
M6 M8 M10 M12 M14 M16 M20 M24
Nm 10 25 50 85 135 215 410 710
kgm 1.0 2.5 5.0 8.5 13.5 21.5 41.0 71.0
Diagrams and Tables 6-1
M-H025.1011EN
Page 56
6-2 Diagrams and Tables
M-H025.1011EN
Page 57
7. TROUBLESHOOTING
The crop flow through is irregular.
•
Do not drive too slowly, the effective working speed starts at 8 km/h.
• Adjust the condition intensity.
• Adjust the rotor speed.
• Install agitators.
The mower indents the ground.
• Decrease the ground pressure (page 4-2).
The mowed crop flow is irregular.
• See the crop flow-through is irregular.
The conditioner jams.
• Adjust the rotor speed.
An incorrect swath is produced.
• Adjust the swath width
• Install a spreading kit to narrow the swath.
• Increase your drive speed.
• If a spreading kit is installed:
• Adjust the spreading fins.
• Remove some spreading fins.
• Just use one big spreading fin.
The mower floats during operation.
• Increase the ground pressure. (page 4-2)
The crop is mowed at irregular heights.
• Increase the ground pressure (page 4-2).
• Replace the mower knives. (page 5-11)
The crop entangles around the cutter bar and mower discs.
• Maintain a PTO speed as shown on the Splendimo.
Troubleshooting 7-1
M-H025.1011EN
Page 58
7-2 Troubleshooting
M-H025.1011EN
Page 59
8. SPECIFICATIONS
8.1 Splendimo 240 MCR Specifications
Working width 2.40 m
Transport width 1.4 m
Transport height 3.40 m
Number of discs/knives 6/12
Mowing height ± 30 mm and higher
Infinitely adjustable via the top link
Approximate swath width 0.70 - 2.40 m
Range of operation ± 20º from the horizontal (relative to the
tractor)
PTO speed 540 rpm or 1000 rpm
Linkage Category II
Hydraulic connections 1 double-acting valve with floating position
Max. oil pressure 21.0 MPa (210 bar)
Rotor diameter 2 x 21 cm
Rotor width 180 cm
Rotor speed 890 rpm
Security 1200 Nm 4 plate slip clutch (K92/4)
Power requirement 51 kW (70 hp)
Approximate weight 1060 kg
All specifications may be changed without prior notice.
Note:
Specifications 8-1
M-H025.1011EN
Page 60
8-2 Specifications
M-H025.1011EN
Page 61
INTENTIONALLY BLANK
M-H025.1011EN
Page 62
LELY INDUSTRIES NV
Weverskade 110
NL-3147 PA Maassluis
Tel +31 (0)10 - 59 96 333
Fax +31 (0)10 - 59 96 444
www.lely.com
Live Life Lely
M-H025.1011EN
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