LELY Tigo 35 S Classic, Tigo 35 ST Classic, Tigo 40 S, Tigo 50 ST, Tigo 35 S Operator's Manual

...

Download

Lely Tigo

L-H007-1104EN

Operator Manual

TRADEMARKS, COPYRIGHT AND DISCLAIMER

Lely, Astronaut, Astri, Atlantis, Attis, AWS, C4C, Calm, Commodus, Compedes, Hubble, Juno, L4C, Lely Center, Lelywash, Lotus, Luna, Nautilus, Orbiter, Qwes, SAE, Shuttle, Splendimo, Storm, 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.

Cosmix, Discovery, F4C, Fertiliner, Gravitor, Grazeway, Hibiscus,

Manual Contents

Lely Industries NV Weverskade 110 3147 PA Maassluis The Netherlands Phone: +31 (0)10 59 96 333 Fax: +31 (0)10 59 96 444 Website: www.lely.com

PREFACE

This manual contains the information necessary to operate the Lely Tigo. It also includes maintenance information that can be done by an operator.

Study and understand this information thoroughly before you operate the Lely Tigo. 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 serve as guidelines. All instructions, pictures and specifications in this manual

Warranty Conditions

Registration

are based on the latest information that was available at the time of publication. Your Lely Tigo may comprise improvements, features or options that are not covered in this manual.

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.

warranty shall not apply if the instructions mentioned in this manual have

The 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.

The Serial Number Plate is on the right front of the main frame.The serial number is also stamped on the front of the main frame.

Always include the serial numbers of your product when you contact your local Lely service provider or order spare parts.

Serial Number Plate

We suggest you complete the table below with the model type, serial number and tyre size of your product. This makes sure you can easily find the information.

Model

Serial number

Tyre size

iii

Table of Contents

Introduction.........................................................................................................................................1-1

1.1 Introduction..............................................................................................................................1-1

1.2 Drawbar....................................................................................................................................1-3

1.3 Pick-up Unit..............................................................................................................................1-4

1.4 Cutting Unit..............................................................................................................................1-5

1.5 Carriage...................................................................................................................................1-7

1.5.1 Superstructure.........................................................................................................................1-7

1.5.2 Floor Conveyor...................................................................................................................... 1-10

1.5.3 Tailgate..................................................................................................................................1-12

1.5.4 Under-carriage.......................................................................................................................1-14

1.6 Hydraulic System...................................................................................................................1-16

1.7 Drive System..........................................................................................................................1-17

1.8 Control Panel......................................................................................................................... 1-19

1.8.1 Hydraulic Control Panel.........................................................................................................1-19

1.8.2 Comfort System.....................................................................................................................1-21

1.9 Optional Extras.......................................................................................................................1-23

1.9.1 Lely Grinder........................................................................................................................... 1-23

2. Safety...................................................................................................................................................2-1

L-H007-1104EN

2.1 Signal Words............................................................................................................................2-1

2.2 Safety Instructions....................................................................................................................2-1

2.3 Explanation of the Safety Decals.............................................................................................2-3

3. First Use..............................................................................................................................................3-1

3.1 Finish the Superstructure.........................................................................................................3-1

3.2 Adjust the Length of the PTO Shaft.........................................................................................3-2

3.3 Install the PTO Shaft with the Overload Protection..................................................................3-3

3.4 Adjust the Height of the Drawbar.............................................................................................3-4

3.4.1 Drawbar with Spindle...............................................................................................................3-5

3.4.2 Drawbar with Hydraulic Ram...................................................................................................3-6

3.5 Adapt the Electric Power Connection.......................................................................................3-7

3.6 Connect the Electric Cables.....................................................................................................3-8

3.7 Adjust the Load Sense Adjustment Screw...............................................................................3-9

3.8 Examine the Lever Setting of the ALB...................................................................................3-10

4. Before Operation................................................................................................................................4-1

4.1 At First......................................................................................................................................4-1

Table of Contents v

4.2 Connect the Cables and Hoses to the Tractor.........................................................................4-2

4.3

Connect the Tigo to the Tractor...............................................................................................4-4

4.4 Adjust the Working Depth of the Pick-up.................................................................................4-6

4.5 Adjust the Height of the Wind Guard........................................................................................4-7

4.6 Fold Up the Open Superstructure............................................................................................4-8

4.7 Select the Number of Knives..................................................................................................4-11

4.8 Drain the Air Container...........................................................................................................4-14

5. Operation.............................................................................................................................................5-1

5.1 Load the Fodder Crop..............................................................................................................5-1

5.2 Remove a Blockage by Moving the Knives Out and In............................................................5-2

5.3 Unload the Tigo........................................................................................................................5-5

6. After Operation...................................................................................................................................6-1

6.1 Disconnect the Tigo from the Tractor.......................................................................................6-1

7. Test and Adjustment..........................................................................................................................7-1

7.1 Remove and Install the Knife Assembly...................................................................................7-1

7.1.1 Remove the Knife Assembly....................................................................................................7-1

7.1.2 Install the Knife Assembly........................................................................................................7-2

7.2 Remove and Install a Single Knife...........................................................................................7-4

7.2.1 Remove a Single Knife............................................................................................................7-4

7.2.2 Install a Single Knife................................................................................................................7-4

7.3 Adjust the Clearance Between the Knives and the Rotor........................................................7-6

7.4 Disengage the Pneumatic Brake when the Tigo is not Connected..........................................7-8

7.5 Test the Overrun Brake............................................................................................................7-9

8. Maintenance........................................................................................................................................8-1

8.1 Scheduled Maintenance...........................................................................................................8-1

8.1.1 Maintenance Before Every Use...............................................................................................8-1

8.1.2 Maintenance After First Operation...........................................................................................8-1

8.1.3 Maintenance After the First 30 Working Hours........................................................................8-1

8.1.4 Maintenance Every 10 Working Hours....................................................................................8-1

8.1.5 Maintenance Every 25 Working Hours....................................................................................8-1

8.1.6 Maintenance Every 100 Working Hours..................................................................................8-2

8.1.7 Maintenance Every 200 Working Hours..................................................................................8-2

8.1.8 Maintenance Every 500 Working Hours..................................................................................8-2

8.1.9 Maintenance Every 3 Months..................................................................................................8-2

8.1.10 Maintenance Every 6 Months..................................................................................................8-2

8.1.11 Maintenance Every 12 Months................................................................................................8-2

8.1.12 Maintenance Every 6 Year.......................................................................................................8-2

8.1.13 Maintenance Before Prolonged Storage..................................................................................8-3

8.1.14 Maintenance After Prolonged Storage.....................................................................................8-3

L-H007-1104EN

vi Table of Contents

8.2 Preventive Maintenance on the Tigo........................................................................................8-

8.3 Preventive Maintenance on the Under Carriage....................................................................8-25

L-H007-1104EN

8.2.1 Clean the Tigo..........................................................................................................................8-5

8.2.2 Replace the Main Gearbox Oil.................................................................................................8-6

8.2.3 Replace the Floor Conveyor Gearbox Oil................................................................................8-7

8.2.4 Grease the PTO Shaft.............................................................................................................8-8

8.2.5 Grease the Pick-up Guide Wheels...........................................................................................8-9

8.2.6 Grease the Dog Clutch..........................................................................................................8-10

8.2.7 Grease the Bearing of the Lateral Shaft................................................................................8-11

8.2.8 Grease the Cutting Unit.........................................................................................................8-12

8.2.9 Grease the Bearing of the Pick-up Drive Sprocket................................................................8-14

8.2.10 Lubricate the Drive Chains of the Pick-up..............................................................................8-15

8.2.11 Grease the Freewheel Clutch of the Pick-up.........................................................................8-16

8.2.12 Lubricate the Running Wheels of the Floor Conveyor...........................................................8-17

8.2.13 Grease the Bearings of the Floor Conveyor Drive Shaft........................................................8-18

8.2.14 Clean the Filter of the Air Brake System................................................................................8-19

8.2.15 Replace the Hydraulic Filter...................................................................................................8-20

8.2.16 Tighten the Drive Chains.......................................................................................................8-21

8.2.17 Check the Critical Bolts for Tightness....................................................................................8-22

8.3.1 Grease the Pivot Points of the Leaf Spring Suspensions......................................................8-25

8.3.2 Grease the Bearings of the Wheel Brake Cam Shafts...........................................................8-26

8.3.3 Adjust the Taper Roller Bearing.............................................................................................8-27

8.3.4 Measure the Brake Linings....................................................................................................8-28

8.3.5 Adjust the Overrun Brake.......................................................................................................8-29

8.3.6 Adjust the Wheel Brake.........................................................................................................8-30

8.3.7 Torque Tighten the Axle Assembly........................................................................................8-31

8.3.8 Tighten the Floor Conveyor Chains.......................................................................................8-32

8.4 Corrective Maintenance.........................................................................................................8-33

8.4.1 Sharpen the Knives................................................................................................................8-33

9. Diagrams and Tables.........................................................................................................................9-1

9.1 Hydraulic Diagrams..................................................................................................................9-1

9.2 Electric Diagrams.....................................................................................................................9-3

9.3 Bolt and Nut Torque Table.......................................................................................................9-5

9.4 Wheel Nut Torque Table..........................................................................................................9-6

9.5 Tyre Pressure Table.................................................................................................................9-7

9.6 Summary of Grease and Lubrication Points............................................................................9-8

10. Troubleshooting...............................................................................................................................10-1

11. Specifications...................................................................................................................................11-1

Table of Contents vii

L-H007-1104EN

viii Table of Contents

1.1 Introduction

1. INTRODUCTION

Note:

L-H007-1104EN

This manual covers the Lely Tigo 35S(T) Classic, the Lely Tigo 35S(T), the Lely Tigo 40S(T) and the Lely Tigo 50S(T) in all variants and with all options to your specific model.

The Lely Tigo S is a loader wagon to pick up, cut and collect mown fodder crops from a swath. It has the following main components:

• a drawbar that can be adjusted in height to match the tractor coupling

• a pick-up unit that picks up the fodder crop and passes it to the cutting unit

• a cutting unit that chops the fodder crop and thrusts it into the carriage

• a carriage with:

• an under-carriage with a single axle or tandem axle

The pick-up unit and the cutting unit are driven by the Power Take-Off (PTO) of the tractor.

The floor conveyor and hydraulic rams are driven by the hydraulic power provided by the tractor. The hydraulic control valves are operated either manually or electrically via a control panel in the tractor cabin.

available. Therefore, parts of this manual may be not applicable

system and optionally to tilt the wagon

• a superstructure to contain the fodder crop

• a floor conveyor to aid loading and unloading

• a tailgate to unload the carriage

Electrical power for the lights and the (optional) electric control system and signals for braking lights and direction indicators are also provided by the tractor.

Introduction 1-1

1. Superstructure - 2. Tailgate - 3. Carriage - 4. Cutting unit - 5. Pick-up unit - 6. Drawbar

Figure 1. Overview of a Tigo S Series Model

L-H007-1104EN

1-2 Introduction

1.2 Drawbar

The drawbar can be either:

straight with a rigid coupling eye

•

• low with a coupling eye that can swivel

The drawbar can be adjusted in height either:

• manually by turning an adjustment spindle (height adjustment range approximately 30 cm to match the height of the tractor coupling system) or

• hydraulically (to tilt the wagon to facilitate unloading on a silage clamp. The maximum clearance between the ground and the pick-up is approximately 70 cm).

The overrun brake (if present) and the parking brake (safety brake) are integrated with the drawbar. In the case of an overrun brake, the wheels are provided with a mechanism to allow reverse driving. The parking brake lever has a nylon break-way rope that shall be attached to the tractor to engage the parking brake in the event that the coupling fails during riding.

Furthermore, there is a parking jack installed on the main frame. The height of the parking jack can be adjusted by a telescopic bottom part and turning a crank.

L-H007-1104EN

1. Hose holders - 2. Parking brake (position A = brake disengaged, position B = brake

engaged) - 3. Break-away rope - 4. Spindle to adjust drawbar height - 5. Optional hydraulic

ram for moving the drawbar - 6. Parking jack - 7. Coupling eye

Figure 2. Overview of the (Low) Drawbar

Introduction 1-3

1.3 Pick-up Unit

The pick-up unit picks up the fodder crop from the swath and conveys it to the cutting unit. The pick-up unit has 5 bars with tines at 54 mm clearance for optimal pick-up behaviour.

The guide wheels at the sides of the pick-up unit can be adjusted in height to

the pick-up unit follow the terrain contour at the optimal elevation. The guide

let wheels can be either:

• fixed or

• swiveled

The wind guard in front of the pick-up unit minimises fodder crop losses due to air turbulences. It can be adjusted in height to cope with the swath thickness and the properties of the fodder crop. Optionally, there is a wind guard available with a roller for short crops.

Two hydraulic rams (one at each side) allow to raise the pick-up unit when making turns or when travelling over the public road.

The pick-up unit has a built-in protective freewheel clutch that allows the rotor with the tines to rotate freely in the event that the tines touch the ground when driving reverse.

1. Wind guard - 2. Pick-up tines - 3. Guide wheel - 4. Hydraulic ram to move the pick-up unit

- 5. Optional swivelled guide wheel

Figure 3. Overview of the Pick-up Unit

L-H007-1104EN

1-4 Introduction

1.4 Cutting Unit

The rotor of the cutting unit has 3 or 5 cylindrical bars in bearings with tines

thrust the fodder crop from the pick-up unit through an assembly of knives

that into the carriage. There are 2 tines per knife (one at each side of the knife). Each tine bar has a lever with a roller. The roller follows a flattened circular track (cam track) so that the tines make a swinging movement upon each cycle of the rotor. As a result, the tines maintain a horizontal attitude from a point somewhere between the knives up to the point where they are withdrawn from the conveyor channel. This causes the cut fodder to be pushed upwards into the carriage.

The knife assembly can have two groups of knives. The upper group is always present and is divided into two sub-groups. It can have 17 knives at maximum. The lower group is optional and can have 16 knives at maximum. Using the Lely Tigo Tool, each group or one of both sub-groups can be moved in and out. This allows to have 5, 17, 21 or 33 knives in, thus different cut sizes down to 38 mm. Because small cut sizes are normally used for silage forage, the optional lower knife group is also called the 'silage knife group'.

With two optional hydraulic rams (one at each side), it is possible to move out all knives at once, for example to solve a blockage problem.

The knives are kept in place by buckle springs that let them deflect when foreign objects pass the cutting unit.This Trimatic™ release system prevents damage to the cutting unit.

L-H007-1104EN

The knife assembly can be easily detached and rolled out on (optional) transport wheels. Knives can be taken out by hand individually for sharpening or replacement.

1. Pick-up tine - 2. Cylindrical bar with tines - 3. Lever with roller- 4. Rotational path of the

swinging tine bars - 5. Cam track - 6. Conveyor channel - 7 Knife - 8. Buckle spring

Figure 4. Working Principle of the Pick-up Unit and Cutting Unit

Introduction 1-5

1. Rotor - 2. Lely Tigo Tool installed on the cam of the sub-group - 3. Upper knife group

Figure 5. Overview of the Cutting Unit

1. Sub-group that is in - 2. Sub-group that is out - 3. Lower knife group

Figure 6. Cutting Unit with Lower Knife Group (Sub-group of Upper Knife Group Moved Out)

L-H007-1104EN

1-6 Introduction

1.5 Carriage

1.5.1 Superstructure

Usually the carriage will be enlarged with a superstructure. This can be either:

an open superstructure consisting of 4 posts, a bow and lattice side walls,

• a semi-closed front wall, a rear tarpaulin, 14 rigging ropes at the top and 2 rigging ropes at the sides. Optionally there can be a front-top tarpaulin (recommended for loading short cut fodder crop). or

• a (relatively) closed superstructure with closed metal plate side walls, a semi-closed front wall, a rear tarpaulin and 14 rigging ropes at the top

The open superstructure can be folded down to park the wagon in a barn or hangar. Folding up and down can be done either:

• manually using a rocker lever or

• hydraulically

L-H007-1104EN

1. Optional front-top tarpaulin - 2. Rear tarpaulin - 3. Side rigging rope - 4. Top rigging rope -

5. Front wall - 6. Lattice side wall

Figure 7. Open Superstructure

Introduction 1-7

1. Semi-closed front wall - 2. Closed metal plate side wall - 3. Rear tarpaulin - 4. Top rigging

rope

Figure 8. Closed Superstructure

L-H007-1104EN

1-8 Introduction

L-H007-1104EN

Top: standard version with brace arm - Bottom: optional hydraulic version

Figure 9. Open Superstructure Folding Mechanism

Introduction 1-9

1.5.2 Floor Conveyor

Upon harvesting, a pile of fodder builds up above and behind the conveyor channel of the cutting unit. Periodically, the floor conveyor must be activated

shift the pile towards the (closed) tailgate to keep the conveyor channel open

to and to compress the fodder crop. The floor conveyor is also used to unload the carriage.

The floor conveyor consists of a wooden floor with two parallel metal gutters and equidistant metal slats. The slats are dragged over the floor by closed loop chains in the gutters. The chains are driven by an hydraulic motor that can be operated:

• from a control valve near the motor and

• from a second control valve that is either:

• part of the tractor hydraulic system

• electrically controlled from the operator panel in the tractor cabin

1. Wooden floor - 2. Gutter - 3. Closed loop chain - 4. Slat

Figure 10. Floor Conveyor

L-H007-1104EN

1-10 Introduction

L-H007-1104EN

1. Control valve - 2. Rod for control from the position next to the tailgate (position A = conveyor

off, position B = conveyor on) - 3. Hydraulic motor

Figure 11. Hydraulic Motor of the Floor Conveyor

Introduction 1-11

1.5.3 Tailgate

The tailgate hangs from the tailgate boom bar with 3 hinges and is locked at the bottom-left and bottom-right side. The locks can be unlocked with a lever at the rear left-bottom side of the carriage.

There are also latches at the top-left and top-right side of the tailgate. These are operated with a lever at the rear side of the tailgate. When locked, the tailgate can be lifted to a wide open position using the left and right hydraulic lifting arms. Lifting and lowering is done from the control panel in the tractor cabin.The locks at the bottom-left and bottom-right side of the tailgate open/ close automatically in this case.

Whether the tailgate must be just unlocked or wide open depends on the overhead space available at the unloading site. Use wide open whenever possible.

The button on the wire mesh on the inside of the carriage serves as a sensor to detect the carriage full status.

1. Hydraulic lifting arm - 2. Latch - 3. Latch lever (position A = latch locked to enable tailgate

lifting, position B = latch unlocked) - 4. Tailgate - 5. Rear lights and indicators - 6. Lock lever

(push in the direction of the arrow to unlock the tailgate) - 7. Lock - 8. Hydraulic ram for

automatic unlocking

Figure 12. Tailgate

L-H007-1104EN

1-12 Introduction

L-H007-1104EN

Figure 13. Tailgate Just Open (left) and Wide Open (right)

Introduction 1-13

1.5.4 Under-carriage

In case of a single wheel axle, the axle is fixed to the under-carriage without springs. For the tandem axle version, both wheel axles are suspended from packages of leaf springs. The wheels are fixed (i.e. not steered). Various tyre types are available.

All wheels are provided with a brake that can be activated:

mechanically by the parking brake

• and

• mechanically by an (optional) overrun mechanism that is activated when the tractor slows down or when riding downwards from a slope (however, a freewheel mechanism in the wheels allows reverse driving) or

• hydraulically by a hydraulic brake signal provided by the tractor or

• pneumatically by a pneumatic brake signal and pneumatic power (compressed air) provided by the tractor

In the case of a pneumatic brake ram, the brake force can be adapted to the load in the carriage. This can be done either:

• manually via a lever (4 settings) or

• automatically (Automatic Load-sensitive Brake system, ALB). For this system, the lever that controls the brake force valve is connected to the leaf spring package. The further the leaf springs deflect, thus the more load, the higher the brake force.

If there are two wheel axles and hydraulic or pneumatic brake rams, the parking brake is only connected to the front wheel brakes.

Optionally, mudguards can be mounted above the wheels.

1. Leaf spring suspension (only for tandem axle version) - 2. Brake ram - 3. Brake cam shaft

- 4. Parking brake connection

L-H007-1104EN

Figure 14. A Brake Configuration

1-14 Introduction

L-H007-1104EN

Left: version for manual setting (position A = air brake disabled, position B = carriage empty,

position C = carriage half full, position D = carriage full) - Right: ALB version

Figure 15. Pneumatic Break Force Valve

Introduction 1-15

1.6 Hydraulic System

The hydraulic system can be used in combination with three different types of tractor hydraulic systems:

conventional fixed displacement pump (the pump runs continuously and a

• valve recycles the over-pressure)

• load sensing system (the pump capacity is controlled to deliver pressure and flow on demand)

• closed centre system (the pump runs continuously but there is no recycle flow if no valve is operated)

Most of the control valves are either:

• in a control panel in the tractor cabin (manually controlled valves) or

• electrically controlled by an electric control panel in the tractor cabin (Comfort system). In this case, the control valves are mounted under a cover at the front-right side of the carriage.

1. Pin latch to hold the cover open - 2. Cover - 3. Label with valve assignments - 4. Hole in

cover (push a screwdriver through the hole to unlock the cover) - 5. Hydraulic hoses from/to

tractor - 6. Control panel connection - 7. Filter - 8. Valve block with control valves

Figure 16. Hydraulic Control Valves (Comfort System)

L-H007-1104EN

1-16 Introduction

1.7 Drive System

The pick-up unit and the cutting unit are driven by the PTO connection of the tractor. The transmission is as follows:

L-H007-1104EN

1. The

2. The PTO shaft drives the (angular) gear box via an overload protection.

3. The gear box is connected to the dog clutch that allows to engage/

4. The lateral shaft drives the rotor of the cutting unit via 3 gearwheels.

5. The middle gearwheel drives the pick-up unit via:

6. The pick-up unit shaft with the sprocket wheel drives the rotor with the

PTO of the tractor drives the telescopic PTO shaft of the Tigo. This

PTO shaft can be either:

• wide angle (max. 70°) at the tractor side and normal angle (max. 35°) at the Tigo side or

• wide angle at both sides (recommended in case of a movable hydraulic drawbar)

disengage the lateral shaft. The lever for manual operation of the clutch is at the front side of the Tigo. If the pick-up unit is lifted, an override mechanism disengages the clutch, independent of the clutch lever position.

• a sprocket wheel/chain transmission to a double sprocket wheel on a mount on the main frame

• a sprocket wheel/chain transmission from the double sprocket wheel to the sprocket wheel on the shaft of the pick-up unit

This configuration of two sprocket wheel/chain transmissions allows the pick-up unit to be lifted/lowered.

tines via a freewheel clutch.

The overload protection on the PTO shaft is dedicated to the Tigo and prevents damage to the cutting unit when it is jammed by a foreign object. If the shaft torque exceeds 1400 Nm, the overload protection cuts off the transmission. The overload protection can be reset by disengaging the dog clutch at low rotational PTO speed (remove the blockage before engaging the clutch again).

The freewheel clutch of the pick-up unit allows the tines to rotate freely and, therefore, protects the tines when the pick-up unit is not driven and the tines touch objects on the ground during reverse driving.

Note:

Introduction 1-17

For details of the PTO shaft, see the manual of the PTO shaft.

1. Safety cover of the overload protection - 2. Cover above the cutting unit (to open, release

the rubber hand grip at the front and use the strut in the lower right corner to hold the cover

open) - 3. Dog clutch lever (position A = clutch engaged, position B with lock = clutch

disengaged)

Figure 17. Dog Clutch Lever

1. End of lateral shaft (can be turned manually using the Lely Tigo Tool) - 2. Sprocket wheel

- 3. Chain - 4. Chain tensioner - 5. Lely Tigo Tool (stowed away) - 6. Mechanism to override

the dog clutch lever when the pick-up unit is lifted

L-H007-1104EN

Figure 18. External Parts of the Drive System

1-18 Introduction

1.8 Control Panel

Most functions can be operated from a control panel that can be installed in the tractor cabin. The control panel can be either hydraulic or electric.

1.8.1 Hydraulic Control Panel

The hydraulic control panel is connected to the tractor and the Tigo with hydraulic hoses and has a mount that allows to install/uninstall the panel by hand. The valves in the hydraulic control panel are to select a device, not to extend/retract the corresponding ram. This is done via a control valve of the tractor.

Lever 1: To lift and lower the pick-up unit

Set the lever to "Open" (the other levers should be set to "Closed").

2. Lift/lower the pick-up unit using the general control valve of the tractor.

3. Set the lever back to "Closed".

Note:

WARNING

CAUTION

L-H007-1104EN

Note:

Leave the lever in the position "Open" and the general control valve in the position for lowering during fodder crop loading.

Lever 2: To lift and lower the tailgate

Make sure that no persons are behind the tailgate.

Make sure that the tailgate latches are locked.

1. Set the lever to "Open" (the other levers should be set to "Closed").

2. Lift/lower the tailgate lifting arm using the general control valve of the tractor.

3. Set the lever back to "Closed".

The tailgate will be unlocked/locked automatically.

Lever 3: To lift and lower the drawbar (if a hydraulic drawbar is present)

1. Set the lever to "Open" (the other levers should be set to "Closed").

2. Lift/lower the drawbar using the general control valve of the tractor.

3. Set the lever back to "Closed".

Lever 4: To fold the open superstructure up and down (if an open superstructure with hydraulic ram is present)

1. Set the lever to "Open" (the other levers should be set to "Closed").

2. Fold up/down the open superstructure using the general control valve of the tractor.

3. Set the lever back to "Closed".

To move the floor conveyor:

Introduction 1-19

• The

hydraulic motor of the floor conveyor is directly connected to a second general control valve of the tractor, so there is no lever to select it. The control valve located near the hydraulic motor should be open to allow control from the tractor cabin. The speed varies with the speed of the tractor engine.

1. Select rams to lift/lower the pick-up unit - 2. Select rams to lift/lower the tailgate - 3. Select

ram to move the drawbar (optional) - 4. Select ram to fold the open superstructure (optional)

- 5. Panel mount - position A = closed, position B = open (select)

Figure 19. Hydraulic Control Panel

L-H007-1104EN

1-20 Introduction

1.8.2 Comfort System

The Comfort system provides an electric control panel that is connected to the Tigo with a cable and a connector and has a mount that allows to install/ uninstall the panel by hand.

S1: To lift and lower the pick-up unit

Hold in top position to lift the pick-up unit.

2. Set to bottom position to lower the pick-up unit and to keep it low during fodder loading.

3. Set to centre position to stop lifting/lowering, possibly leaving the pickup in an intermediate position.

S2: To lift and lower the drawbar (if a hydraulic drawbar is present)

1. Hold in top position to lift the drawbar.

2. Hold in bottom position to lower the drawbar.

3. Release to centre position to stop lifting/lowering the drawbar or when the drawbar is at the upper/lower position.

S3: To move the knife assembly in and out (if hydraulic rams are present)

1. Hold in top position to move the knives in (the number of knives that move in should be set in advance using the Lely Tigo Tool).

2. Hold in bottom position to move the knives out.

3. Release to centre position to stop moving out/in or when the knives are fully out or in.

L-H007-1104EN

Note:

WARNING

CAUTION

Note:

S4: To move the floor conveyor

1. Make sure that the control valve located at the hydraulic motor is open to allow control from the tractor cabin.

2. Set to bottom position to move the floor conveyor.

3. Set to centre position to stop the floor conveyor.

The top position has no function.

S5: To lift and lower the tailgate

Make sure that no persons are behind the tailgate.

Make sure that the tailgate latches are locked.

1. Hold in top position to lift the tailgate.

2. Hold in bottom position to lower the tailgate.

3. Release to centre position to stop lifting/lowering the tailgate or when the tailgate is at the wide open/closed position.

The tailgate will be unlocked/locked automatically.

S6: To fold the open superstructure up and down (if an open superstructure with hydraulic ram is present)

• Hold in top position to fold up the open superstructure.

Introduction 1-21

• Hold in bottom position to fold down the open superstructure (only if the

carriage is empty).

• Release

to centre position to stop folding the open superstructure up/down

or when the open superstructure is fully folded up/down.

H1: Buzzer (optional)

• Sounds when both the floor conveyor is activated and the carriage is full

(sensor on the tailgate activated). Releasing switch S4 will end the sound.

S1 Lift/lower the pick-up unit - S2 Lift/lower the drawbar (optional) - S3 Move the knives in/out

(optional) - S4 Move the floor conveyor - S5 Lift/lower the tailgate - S6 Fold the open

superstructure up/down (optional) - H1 Buzzer for carriage full alert (optional) - H Plug to

connect the control panel to the Tigo - Bottom: control panel in mount

Figure 20. Electric Control Panel (Comfort System)

L-H007-1104EN

1-22 Introduction

1.9 Optional Extras

1.9.1 Lely Grinder

The Lely grinder quickly and correctly sharpens the knives of the Lely Tigo. A blunt is moved at the correct angle across the blade of the knife.

knife is installed in a supporting frame. To sharpen the knife, the grinder

L-H007-1104EN

Figure 21. Lely Grinder

Introduction 1-23

L-H007-1104EN

1-24 Introduction

2.1 Signal Words

2. SAFETY

This chapter contains safety instructions you must obey when you use or do maintenance on your Lely Tigo. It also explains the safety decals on the Lely Tigo.

Note the use of the signal words DANGER, WARNING and CAUTION. The signal word for each message uses the following guidelines:

DANGER

WARNING

CAUTION

Note:

2.2 Safety Instructions

L-H007-1104EN

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.

General safety instructions:

• Read this manual completely before operating the Tigo. If anything is not

clear, please contact your local dealer.

• Use the Tigo 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.

• Always be alert on hazards and unusual signs (such as leakage and noise).

Observe all safety precautions.

• Let the Tigo be operated, driven and maintained by authorised persons

only.

• Use protective clothing, gloves, safety glasses and ear protectors, if

necessary.

• Keep people and objects away from moving parts.

• Always use a tractor with a cab.

• Clean the safety decals regularly so that they can be read at all times.

Replace the safety decals if necessary.

Safety instructions for preparing operation:

• Always connect the Tigo to the tractor as described in this manual. Only

connect the Tigo to a tractor trailer hitch that complies with your local regulations.

Safety 2-1

• Make sure the front axle weight of the tractor is sufficient and that you do

not exceed the rear axle weight.

• Never

connect the Tigo to the tractor when the tractor engine is still running.

• Depressurize the hydraulic system before you connect hydraulic hoses.

• If the Tigo has a hydraulic or pneumatic brake, connect the brake hose(s)

to the tractor.

• Make sure all safety guards and protection devices are installed and

function correctly.

• Always test the brakes before operation. Never drive the Tigo with damaged

brakes.

• Make sure all the lights on the Tigo operate correctly. Make sure the lights

are not covered by dirt.

• Before traveling:

• make sure the (hydraulic) drawbar is in the transport position

• make sure the parking jack is lifted and locked

• make sure the pick-up unit is lifted

• make sure the tailgate is closed and locked

• make sure that all other movable parts (such as the foldable superstructure and covers) are locked

Safety instructions for driving on public roads:

• Always obey your local road traffic regulations.

• Use flashing lights or other safety signs, when necessary.

• Be alert on the maximum height when approaching bridges, tunnels, electrical lines etc.

• Do not allow passengers unless there is an extra seat in the tractor. Persons shall never be transported in or on the Tigo.

• Do not operate the hydraulics when driving on the public road.

Safety instructions for operation:

• Operate the Tigo in a safe manner.

• Make sure no people are in the danger zone when the Tigo is in operation. This is especially important when you work near or on areas that are accessible to the public.

• Make sure there are no objects in the field that could be thrown up by the Tigo.

• Do not stand in or on the Tigo.

• Do not make sudden curves when driving uphill or downhill.

• Always reduce your driving speed when driving downhill.

• Do not disconnect the clutch or change gears on a slope.

• Do not exceed the maximum load or maximum axle loads.

Safety instructions for ending operation:

L-H007-1104EN

• Depressurize the hydraulic system before you disconnect hydraulic hoses.

• Always park the Tigo on a flat stable ground.

2-2 Safety

• Before disconnecting the Tigo from the tractor:

make sure the parking jack is on the ground

•

• make sure the parking brake is engaged

• make sure the wheel wedges are placed

Safety instructions for maintenance and troubleshooting:

• Stop the tractor engine, the Power Take-Off (PTO) and all moving parts before doing maintenance or troubleshooting. Never reach into moving parts or parts that may come life.

• Install the wheel wedges to prevent the Tigo from moving before doing maintenance.

• Make sure the covers are well locked if they are open.

• Obey the maintenance schema in this manual.

• Do not modify the Tigo.

• Only use genuine Lely parts.

2.3 Explanation of the Safety Decals

L-H007-1104EN

Read the manual and the safety instructions before operating the

machine.

Stay away from the tailgate as long as the tractor may drive

backwards or the tailgate may be operated.

Keep hands away from (external) machine parts as long as they

may come live.

Safety 2-3

Keep hands away from internal machine parts as long as the

machine is not completely stationary or may come live.

Do not step on the floor conveyor as long as its hydraulic motor is

moving or may come live.

Stop the tractor engine and remove the key from the tractor ignition

lock before doing troubleshooting or maintenance.

L-H007-1104EN

Release the pressure of the hydraulic and/or pneumatic system

before doing troubleshooting or maintenance.

Stay away from the pick-up unit as long as the PTO shaft is

connected and the tractor engine is running.

2-4 Safety

L-H007-1104EN

Regularly check the wheel nuts for tight

fit.

Do not exceed the maximum PTO speed of 540 rpm.

Do not exceed the maximum driving speed of 25 km/h.

Safety 2-5

L-H007-1104EN

2-6 Safety

3. FIRST USE

3.1 Finish the Superstructure

L-H007-1104EN

1. Hook

2. Fasten the rear tarpaulin between the bow and the tailgate boom using

3. Fasten the (optional) front-top tarpaulin to the front wall using the

the top rigging ropes between the hooks on the front wall and the hooks on the bow, thereby leading the ropes through the lugs on the middle crossbar (if applicable). In case of the open superstructure, also attach the side rigging ropes by looping them through the lugs on the bow corners and hooking the springs at the ends of the ropes to the lugs on the front wall corners.

the mounting rod at the bow side. Secure the mounting rod with a linch clip at both sides.

mounting rod. Secure the mounting rod with a linch clip at both sides. Tighten the other side of the tarpaulin to the lugs on the side walls using the expander ropes (one at each side).

1. Mounting rod - 2. Optional front-top tarpaulin - 3. Expander rope - 4. Bow - 5. Mounting rod

for rear tarpaulin - 6. Side rigging rope - 7. Top rigging rope - 8. Front wall

Figure 22. Finish the Open Superstructure

First Use 3-1

3.2 Adjust the Length of the PTO Shaft

CAUTION

The first time you connect the Tigo 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.

Disconnect the two halves of the telescopic PTO shaft.

2. Hold the two PTO shaft halves next to each other in the shortest operating position.

3. Mark the shortest operating position on the outer safety guard tube.

4. Substract 40 mm from the first mark and mark it with a second mark.

5. Remove the safety guard tubes from the PTO shaft halves.

6. Shorten the outer safety guard tube of the PTO shaft at the second mark.

7. Shorten the inner safety guard tube by the same distance.

8. Shorten the inner and outer PTO shaft halves by the same distance.

9. Deburr and clean the safety guard tubes and the PTO shaft halves.

10. Install the safety guard tubes on the PTO shaft halves.

11. Connect the two PTO shaft halves.

Figure 23. Shorten the Inner Safety Guard Tube and the PTO-shaft halves

Figure 24. Mark the Outer Safety Guard Tube of the PTO shaft

L-H007-1104EN

3-2 First Use

3.3 Install the PTO Shaft with the Overload Protection

1. Clean and grease the profile of the main drive shaft of the Tigo.

Loosen and turn out the clamping cone of the overload protection.

3. Open the maintenance hole in the guard cone. Slide the overload protection (with the connected PTO shaft) onto the drive shaft so that the location hole points towards the maintenance hole.

4. Position the location hole for the clamping cone above the ring groove of the shaft.

5. Turn the clamping cone into the location hole and tighten firmly (approximately 70 Nm) while moving the hub slightly to and fro in longitudinal direction.

6. Check if the seat of hub of the overload protection is tight and firm by compression and tensioning movements.

7. Close the maintenance hole in the guard cone.

L-H007-1104EN

1. Clamping cone - 2. Location hole - 3. Ring groove of the main drive shaft

Figure 25. Install the PTO Shaft with the Overload Protection

First Use 3-3

3.4 Adjust the Height of the Drawbar

The height of the drawbar should be adjusted so that, when the Tigo is connected to the tractor in travelling position, the upper edge of the front crossbeam is important for the optimal performance of the pick-up unit. The way to adjust the height depends on the type of drawbar. In both cases the tractor and the Tigo should be on a flat ground, with the Tigo connected to the tractor and the parking jack slightly above the ground.

of the main frame is approximately 118 cm above the ground. This

Figure 26. Optimal Drawbar Height

L-H007-1104EN

3-4 First Use

3.4.1 Drawbar with Spindle

Note:

Note that the threads at the left and the right side of the spindle are opposite.

Release both counter nuts of the spindle.

2. Adjust the spindle as necessary.

3. Tighten both counter nuts.

L-H007-1104EN

1. Spindle - 2. Counter nuts

Figure 27. Adjust the Height of a Drawbar with a Spindle

First Use 3-5

3.4.2 Drawbar with Hydraulic Ram

1. Release the pressure of the hydraulic ram.

Remove the split pin of the pin of the piston rod end eye. Do not yet

2. remove the pin.

3. Loosen the hexagon locking bolt of the piston rod.

4. Lower the parking jack until it rests on the ground.

5. Remove the pin of the eye of the piston rod end.

6. Screw the piston rod end in or out as necessary.

7. Re-insert the pin through the eye of the piston rod end.

8. Lift the parking jack slightly above the ground by turning its crank.

9. Verify if the drawbar height is correct. If this is not the case, repeat the steps 4 - 9.

10. Tighten the hexagon locking bolt of the piston rod.

11. Re-install the split pin to secure the pin of the piston rod end eye.

1. Hexagon locking bolt - 2. Piston rod end - 3. Split pin - 4. Pin

Figure 28. Adjust the Height of a Drawbar with Hydraulic Ram

L-H007-1104EN

3-6 First Use

3.5 Adapt the Electric Power Connection

In case of the Comfort system, the electric cable to be connected to the tractor does not only transfer the light signals, but also the electric power for the hydraulic control valve system. For this, the tractor shall provide continuous power on the 54g terminal (+) and the 31 terminal (-) of the 7-pole socket on the tractor side. It is best to have these terminals wired directly to the tractor

battery with 2.5 mm2 wire and a fuse of 16 A for the anode (+).

Figure 29. Direct Continuous Power Wire for the Comfort System

L-H007-1104EN

First Use 3-7

3.6 Connect the Electric Cables

1. Connect

the cable of the lighting system to the 7 pole socket at the right

front of the Tigo.

2. If the Tigo has a Comfort System, connect the cable of the control panel to the socket near the hydraulic valves under the cover at the front right side.

1. Socket for lighting system cable (including power for the Comfort system) - 2. Socket for

control panel (Comfort system)

Figure 30. Connect the Electric Cables

L-H007-1104EN

3-8 First Use

3.7 Adjust the Load Sense Adjustment Screw

In case of the Comfort system, there is a Load Sense adjustment screw that needs adjustment depending on the hydraulic system of the tractor.

CAUTION

L-H007-1104EN

Only make adjustments when there is no pressure on the hydraulic system (preferably switch off the tractor).

for a conventional fixed displacement pump system: screw out to the end

•

point

• for a load sensing system: screw in to the end point

• for a closed centre system: screw in to the end point

Figure 31. Adjust the Load Sense Adjustment Screw

First Use 3-9

3.8 Examine the Lever Setting of the ALB

If the Tigo has an Automatic Load-sensitive Brake system:

Make sure that the length of the lever of the automatic load responsive

•

regulating valve is the same as the length described on the Wabco or Haldex performance label.

Figure 32. Examine the Lever Setting of the ALB Valve

L-H007-1104EN

3-10 First Use

4.1 At First

4. BEFORE OPERATION

When the Tigo is not connected to the tractor, it shall rest on its parking jack, the parking brake shall be engaged and the wheel wedges shall be placed.

maintenance (greasing, replacement of lubricating oil, cleaning of filters

• All

etc.) should have been done according to the maintenance schema. The knives of the cutting unit should be sharp and well adjusted.

• Make sure that the tyres are at the right air pressure (page 9-7).

• Make sure that the wheel nuts are tight (page 9-6).

• Make sure that all safety covers are in a good condition and closed.

• Make sure that all hoses and cables are in good condition.

• Make sure that hinged assembly parts (tailgate, foldaway open

superstructure, covers etc.) are locked.

L-H007-1104EN

Before Operation 4-1

4.2 Connect the Cables and Hoses to the Tractor

WARNING

Make sure there are no persons near the Tigo when you connect it to the tractor.

When connecting hydraulic hoses, take care not to swap the pressure side and the return side by mistake.

Reverse the tractor to the drawbar and make sure the tractor and the

1. Tigo are aligned.

2. If the Tigo does not have a Comfort system:

• Connect the red-marked hydraulic hose of the hydraulic control panel

to a single acting control port of the tractor.

• Connect the red-marked hydraulic hose of the hydraulic motor of the

floor conveyor to another single acting control port of the tractor.

• Connect the blue-marked common return hydraulic hose to a

pressure-free return port of the tractor.

3. If the Tigo has a Comfort system:

• Connect the red-marked hydraulic hose to a single acting control port

of the tractor.

• Connect the blue-marked hydraulic hose to a pressure-free return

port of the tractor.

4. If the Tigo has a load sensing hose:

• Connect the red-marked hydraulic hose to a hydraulic power outlet

of the tractor.

• Connect the red-marked load sensing hose (hose with smallest

diameter) to the load sensing port of the tractor.

• Connect the blue-marked hydraulic hose to a pressure-free return

port of the tractor.

5. If the Tigo has a hydraulic brake system:

1. Connect the hydraulic brake hose to the tractor trailer brake

socket.

2. Make sure that the brakes operate correctly.

6. If the Tigo has a pneumatic brake system:

1. Make sure that the sealing rings in the brake coupling heads are

clean and in good condition.

2. Connect the red-marked air hose to a red marked air socket on

the tractor.

3. Connect the yellow-marked hose to a yellow marked air socket

on the tractor.

4. Make sure that the brakes operate correctly and that there is no

air leaking through the coupling head seals.

7. Connect the plug of the electric cable to the 7-pole socket of the tractor.

8. Make sure all the lights on the Tigo operate correctly.

L-H007-1104EN

4-2 Before Operation

9. Install

the control panel (either hydraulic or electric) on the mount in the

tractor cabin.

1. Red-marked hydraulic hose - 2. Blue-marked hydraulic hose - 3. Red-marked load sensing

hose - 4. Red-marked air hose - 5. Yellow-marked air hose - 6. Red-marked hydraulic brake

system hose

Figure 33. Hydraulic and Pneumatic Hoses

L-H007-1104EN

Before Operation 4-3

4.3 Connect the Tigo to the Tractor

WARNING

CAUTION

Make sure there are no persons near the Tigo when you connect it to the tractor.

Always switch off the tractor engine and remove the ignition key before you leave the tractor cab.

Do not move the Tigo with the parking jack in its lowest position.

Make sure that the tractor coupling system is aligned with the drawbar of the Tigo. Align the drawbar in height by turning the crank of the parking jack.

2. Connect the Tigo to the tractor:

1. Bring the drawbar coupling eye into the coupling fork of the

tractor.

2. Install the pin.

3. Secure the pin with the pin lock.

3. If the Tigo has a parking brake lever with a nylon break-away rope, attach the rope end to the tractor.

4. Retract the parking jack:

1. Turn the crank of the parking jack clockwise to release the parking

jack foot from the ground. Turn until the telescopic part of the stand is fully upwards (otherwise, the pin can not be inserted in step 4).

2. Remove the pin that locks the stand.

3. Lift the telescopic part of the stand by the hand grip on the foot

plate.

4. Re-install the pin.

5. Pull down the hinge locking pin and swivel the hinge towards the

front crossbar.

6. Release the hinge locking pin.

L-H007-1104EN

5. If the Tigo has a hydraulic drawbar, lower the drawbar to the transport position.

WARNING

4-4 Before Operation

Make sure the tractor PTO is disengaged before you connect the PTO shaft to the tractor PTO.

6. Connect the PTO shaft to the tractor PTO.

7. Secure the PTO guard against rotating by fixing its chain to a rigid part of the tractor.

8. Remove the wheel wedges and store them in the mounts under the carriage, behind the (rear) wheels.

9. Disengage the parking brake by pulling the lever a bit forward, then fully backward.

L-H007-1104EN

1. Crank - 2. Pin - 3. Hinge - 4. Hinge locking pin - 5. Stand - 6. Telescopic bottom part of the

stand with foot plate

Figure 34. Move the Parking Jack to the Top Position

Figure 35. Connect to the Tractor

Before Operation 4-5

4.4 Adjust the Working Depth of the Pick-up

The pick-up tines should be slightly above the ground during loading fodder crop. They should never scratch along the ground. Stony ground requires a higher setting. Adjust the working depth as follows:

Lift the pick-up unit.

2. On both sides of the pick-up:

1. Remove the linch clip from the slotted bar.

2. Adjust the guide wheel to the applicable position and re-install the

linch clip into the corresponding slot of the slotted bar.

3. Make sure that the position of the guide wheels is the same at both sides.

4. Lower the pick-up unit to the ground and make sure that the working depth is correct.

1. Linch clip - 2. Slotted bar

Figure 36. Adjust the Working Depth of the Pick-up Unit

L-H007-1104EN

4-6 Before Operation

4.5 Adjust the Height of the Wind Guard

The optimal height of the wind guard depends on the type of fodder crop. Fine fodder crop requires a somewhat lower setting than coarse fodder crop. As a starting Set the wind guard height as follows:

1. Remove the linch clip from the lug on the drawbar from which the wind

2. Suspend the wind guard chain from the lug at the appropriate link.

3. Re-install the linch clip.

point, adjust the height so that the wind guard just touches the swath.

guard chain is suspended.

L-H007-1104EN

1. Wind Guard - 2. Chain - 3. Lug with linch clip

Figure 37. Adjust the Height of the Wind Guard

Before Operation 4-7

4.6 Fold Up the Open Superstructure

In case of an open superstructure without a hydraulic ram:

Take the rocker lever that is stowed on the axle support cross beam.

2. Install the rocker lever by sticking its fork on the stud on the rung, then swiveling the rocker lever on the pin. Secure the rocker lever using the linch clip.

3. Remove the R-clip from the pin that holds the brace arm.

4. Release the brace arm by pulling its hand grip.

5. Pull the rocker lever downwards to fold up the superstructure.

6. Re-install the brace arm on the pin and secure it with the R-clip.

7. Remove the linch clip that secures the rocker lever and remove the rocker lever from the pin and the stud.

8. Stow the rocker lever on the axle support cross beam.

Folding down is done in the same way, but then pushing the rocker lever upwards in step 5.

In case of an open superstructure with a hydraulic ram, just operate the ram.

CAUTION

Always mind the available overhead space when driving through doors, tunnels etc.

L-H007-1104EN

4-8 Before Operation

L-H007-1104EN

1. Rocker lever - 2. Stud - 3. Pin for rocker lever - 4. Linch clip - 5. Brace arm - 6. Pin for brace

arm - 7. R-clip

Figure 38. Fold the Open Superstructure - Mount Rocker Lever, Release Brace Arm and Fold

Before Operation 4-9

Figure 39. Fold the Open Superstructure - Secure Brace Arm and Remove Rocker Lever

L-H007-1104EN

4-10 Before Operation

4.7 Select the Number of Knives

Using the Lely Tigo Tool, select the appropriate number of knives by moving

movable upper sub-group and/or the (optional) lower knife group in or out.

the

Note:

L-H007-1104EN

The (optional) lower knife group does not have a sub-group dat can be moved in or out. It is only possible to move the whole lower knife group in or out.

To move the (sub-)group out:

1. Place the Lely Tigo Tool on the cam of the (sub-)group (right side of the Tigo).

2. In case of the upper sub-group:

1. Pull the Lely Tigo Tool slightly counterclockwise and hold it to

release the tension from the safety link.

2. Release the safety link from the pin.

3. Pull the Lely Tigo Tool clockwise to move the (sub-)group out.

To move the (sub-)group in:

1. Place the Lely Tigo Tool on the cam of the (sub-)group (right side of the Tigo).

2. Pull the Lely Tigo Tool counterclockwise to move the (sub-)group in.

3. In case of the upper sub-group:

1. Hold the Lely Tigo Tool pulled counterclockwise.

2. Attach the safety link to the pin.

4. Remove the Lely Tigo Tool.

Before Operation 4-11

1. Cam - 2. Safety link - 3. Pin - 4. Knife - 5. Lely Tigo Tool - Upper figure: 17 knives in, lower

figure: 5 knives in

Figure 40. Select the Number of Knives of the Upper Knife Group

L-H007-1104EN

4-12 Before Operation

L-H007-1104EN

1. Cam - Position A = in, position B = out

Figure 41. Select the Knives of the (Optional) Lower Knife Group

Before Operation 4-13

4.8 Drain the Air Container

If the Tigo has a pneumatic brake:

Use a wire to pull the pin of the drain valve to drain the water from the air

•

container of the brake system (located under the carriage, behind the (rear) wheel). If the drainage valve is clogged, screw it out, clean it and screw it in again.

WARNING

Make sure the pressure of the pneumatic brake system is not less than 5 bar before you start driving (read the pressure gauge of the tractor pneumatic system).

Figure 42. Drain the Water From the Air Container of the Brake System

L-H007-1104EN

4-14 Before Operation

5. OPERATION

5.1 Load the Fodder Crop

WARNING

CAUTION

WARNING

L-H007-1104EN

Make sure no persons are near the Tigo when you engage the PTO.

Make sure no persons are within a 25 meter radius of the Tigo during operation.

Do not exceed the maximum PTO speed of 540 rpm.

Always switch off the tractor engine before you leave the tractor cab.

Do not operate the Tigo without safety guards or covers, or if the safety guards or covers are damaged.

Always operate the Tigo with the safety guards or covers down and engaged in the clamping blocks.

Always keep the tailgate closed when you drive on public roads.

Position the tractor at the beginning of the swath.

2. Carefully engage the PTO at the lowest possible engine speed.

3. Slowly increase the speed of the PTO to the maximum of 540 rpm.

4. Lower the pick-up unit to the ground.

5. Drive the tractor over the swath. The pick-up performance is best at higher speeds.

6. Before making a (sharp) turn:

• Lift the pick-up unit.

• Disengage the PTO.

7. Regularly activate the floor conveyor to move the collected fodder crop to the rear. When the (optional) buzzer sounds upon activating the floor conveyor, the Tigo is full. In that case stop loading:

1. Lift the pick-up to the top position.

2. Disengage the PTO.

3. Return to the unloading site.

Operation 5-1

5.2 Remove a Blockage by Moving the Knives Out and In

WARNING

Never reach into the pick-up unit, the cutting unit or the conveyor channel, when the tractor engine is still running.

Disengage the PTO.

2. Move the knives out:

• If the cutting unit has no hydraulic rams for moving the knives in and

out:

1. Place the Lely Tigo Tool on the cam of the turnbuckle.

2. Push the Lely Tigo Tool clockwise and remove the locking plate

that locks the turnbuckle fork.

3. Pull the Lely Tigo Tool counterclockwise.

• If the cutting unit has hydraulic rams for moving the knives in and out:

use the control panel.

3. Engage the PTO at the lowest possible speed.

4. If the overload protection is reset (so that the Tigo is driven again), move the knives in:

• If the cutting unit has no hydraulic rams for moving the knives in and

out:

1. Pull the Lely Tigo Tool on the cam of the turnbuckle clockwise.

2. Lock the turnbuckle fork with the locking plate.

3. Remove the Lely Tigo Tool from the cam.

• If the cutting unit has hydraulic rams for moving the knives in and out:

use the control panel.

L-H007-1104EN

WARNING

5. If the blockage has been resolved, the procedure ends here. Otherwise, proceed with the next steps.

6. Disengage the PTO.

7. Move the knives out (see step 2).

8. Stop the tractor engine.

9. Disengage the dog clutch.

10. Rotate the gear in reverse using the Lely Tigo Tool as a crank on the end of the lateral shaft.

11. Remove the blocking object(s).

Remove the Lely Tigo Tool from the lateral shaft before engaging the dog clutch.

12. Engage in the dog clutch.

13. Start the tractor engine.

14. Engage the PTO.

15. Move the knives in (see step 4).

5-2 Operation

L-H007-1104EN

Figure 43. Rotate the Gear Manually

Operation 5-3

1. Lely Tigo Tool (installed on the cam of the turnbuckle) - 2. Lip to be locked by the locking

plate - 3. Locking plate on turnbuckle fork

Figure 44. Move All Knives Out (Top) and In (Bottom)

L-H007-1104EN

5-4 Operation

5.3 Unload the Tigo

WARNING

Make sure that no persons are behind the tailgate.

Make sure no persons are in the carriage when the floor conveyor is activated.

Make sure no persons are near the Tigo when the hydraulic drawbar is raised or lowered.

Position the rear of the Tigo to the appropriate location.

2. If the overhead space allows lifting of the tailgate:

1. Make sure that the tailgate is locked in the tailgate latches.

2. Lift the tailgate.

3. If the overhead space does not allow lifting of the tailgate:

1. Unlock the tailgate latches.

2. Unlock the tailgate.

4. If the Tigo has a hydraulic drawbar and will be unloaded on a silage clamp:

• Tilt the Tigo by lowering the drawbar. The increased clearance

between the pick-up unit and the ground decreases the risk of damaging the pick-up unit.

L-H007-1104EN

5. Activate the floor conveyor (either from the tractor cabin or from the control valve next to the tailgate).

6. If the Tigo is empty, stop the floor conveyor.

7. If the Tigo was tilted, bring the drawbar back to the transport position.

8. If the tailgate was lifted, lower the lifting arms until the tailgate is locked.

9. If the tailgate was not lifted:

1. Drive the Tigo to a place where the overhead space allows lifting

of the tailgate.

2. Lift the tailgate.

3. Lower the lifting arms until the tailgate is locked.

Figure 45. Tilt the Tigo by Lowering the (Optional) Hydraulic Drawbar

Operation 5-5

L-H007-1104EN

5-6 Operation

6. AFTER OPERATION

6.1 Disconnect the Tigo from the Tractor

WARNING

L-H007-1104EN

Unload the Tigo before you disconnect it from the tractor.

Always position the tractor on solid ground before you disconnect the Tigo from the tractor.

Make sure there are no persons near the Tigo when you disconnect it from the tractor.

Always switch off the tractor engine before you leave the tractor cab.

Always engage the parking brake and install wheel wedges before you disconnect the Tigo from the tractor.

Lower the parking jack:

1. Pull down the hinge locking pin and swivel the parking jack

forward.

2. Remove the pin that locks the stand (hold the telescopic part of

the stand by the hand grip on the foot plate).

3. Lower the telescopic part of the stand.

4. Re-install the pin of the stand.

5. Turn the crank of the parking jack counterclockwise until the foot

plate rests on the ground.

WARNING

2. Turn the parking jack crank further until the coupling eye of the drawbar does not longer rest on the coupling fork of the tractor.

3. If the Tigo has a parking brake lever with a nylon break-away rope, loosen the rope from the tractor.

4. Engage the parking brake by pulling the lever forward beyond the slack point.

5. Place the wheel wedges (these are stowed under the carriage, behind the (rear) wheels).

6. If the Tigo is hydraulically or pneumatically braked from the tractor:

• Disconnect the brake hoses and put the hose ends in the hose

holders on the drawbar.

7. Disconnect the hydraulic hoses from the tractor and put the hose ends in the hose holders on the drawbar.

8. Unplug the electric cable from the tractor.

9. Unmount the (hydraulic or electric) control panel and remove it from the tractor cabin.

Make sure the tractor PTO is disengaged before you disconnect the PTO shaft from the tractor PTO.

10. Loosen the safety chain of the PTO guard at the tractor side.

After Operation 6-1

11. Disconnect

the PTO shaft from the tractor PTO. At the side of the Tigo, the PTO shaft may stay connected with the overload protection on the main drive shaft.

12. Disconnect the Tigo from the tractor:

1. Remove the pin lock.

2. Remove the pin.

3. Drive the tractor away from the Tigo.

13. Do the 10 hours maintenance.

L-H007-1104EN

6-2 After Operation

7. TEST AND ADJUSTMENT

7.1 Remove and Install the Knife Assembly

7.1.1 Remove the Knife Assembly

1. Move the knives out.

Loosen the turnbuckle forks at the left and the right side of the knife

2. assembly:

1. Remove the R-clip of the pin.

2. Remove the pin.

3. If the cutting unit has hydraulic rams:

1. Remove the washer and linch clip from the stud of the ram.

2. Remove the ram from the stud.

4. Install the (optional) transport wheels:

• Side wheels:

1. Insert the side wheel in the mount.

2. Screw the height adjustment screw out until the wheel touches

the ground.

3. Tighten the butterfly nut of the mount.

L-H007-1104EN

• Steerable centre wheel:

1. Stick the wheel mount onto the crossbar of the knife assembly (in

the middle of the crossbar).

2. Insert the locking plate.

5. At the left and the right side of the knife assembly, release the safety struts:

1. Remove the R-clip and the washer.

2. Release the strut from the pin.

3. If no transport wheels are installed: swivel the knife assembly to

the ground.

6. Remove the locking pins at the left and right side of the knife assembly:

1. Remove the linch clip from the locking pin.

2. Turn the flag of the locking pin downwards.

3. Remove the locking pin.

Test and Adjustment 7-1

1. Turnbuckle fork - 2. Pin - 3. R-clip - 4. Safety strut - 5. Washer and R-clip - 6. Linch clip -

7. Locking pin of knife assembly

Figure 46. Remove the Knife Assembly - Without the Optional Wheels

1. Locking plate - 2. Centre wheel mount - 3. Side wheel mount with butterfly nut - 4. Height

adjustment screw - 5. Side transport wheel

L-H007-1104EN

Figure 47. Remove the Knife Assembly - With the Optional Wheels

7.1.2 Install the Knife Assembly

1. Bring the knife assembly in place under the rotor.

Install the locking pins at the left and right side of the knife assembly:

1. Insert the locking pin.

2. Rotate the flag of the locking pin horizontal.

3. Secure the locking pin with the linch clip.

3. Install the safety struts at the left and right side of the knife assembly:

1. Install the strut on the pin.

2. Secure the strut with the washer and R-clip.

7-2 Test and Adjustment

4. Remove the (optional) transport wheels:

Loosen the butterly nuts of the side wheel mounts, screw in the

height adjustment screws and remove the side wheels.

2. Remove the locking plate of the steerable centre wheel mount

and remove the centre wheel assembly.

5. If the cutting unit has hydraulic rams:

1. Install the hydraulic ram on the stud.

2. Secure the hydraulic ram with the washer and the linch clip.

6. Install the turnbuckle forks at the left and the right side of the knife assembly:

1. Install the turnbuckle fork.

2. Insert the pin.

3. Secure the pin with the R-clip.

7. Move the knives in.

L-H007-1104EN

Test and Adjustment 7-3

7.2 Remove and Install a Single Knife

7.2.1 Remove a Single Knife

1. Move the knives out.

Loosen the turnbuckle forks at the left and the right side of the knife

2. assembly:

1. Remove the R-clip of the pin.

2. Remove the pin.

3. If the cutting unit has hydraulic rams:

1. Remove the washer and linch clip from the stud of the ram.

2. Remove the ram from the stud.

4. At the left and the right side of the knife assembly, release the safety struts:

1. Remove the R-clip and the washer.

2. Release the strut from the pin.

3. Swivel the knife assembly to the ground.

5. Remove the selected knives:

1. Push the locking bolt on the buckling spring (just push, do not

remove the locking bolt from the buckling spring).

2. Release the buckling spring from the knife.

3. Swivel the knife forward (towards the rotor).

4. Lift the knife from the knife shaft.

L-H007-1104EN

1. Buckle spring - 2. Knife - 3. Locking bolt

Figure 48. Remove a Single Knife

7.2.2 Install a Single Knife

1. Hold the knife with an inclined attitude above the knife shaft and lower it onto the shaft.

Swivel the knife backwards so that it locks on the knife shaft.

3. Push the locking bolt on the buckling spring and slide it into the slot of the knife.

4. Release the locking bolt and make sure that it is locked.

7-4 Test and Adjustment

5. Repeat the steps 1 - 4 for the other knifes (if applicable).

Swivel the knife assembly upwards.

7. Install the safety struts at the left and right side of the knife assembly:

1. Install the strut on the pin.

2. Secure the strut with the washer and R-clip.

8. If the cutting unit has hydraulic rams:

1. Install the hydraulic ram on the stud.

2. Secure the hydraulic ram with the washer and the linch clip.

9. Install the turnbuckle forks at the left and the right side of the knife assembly:

1. Install the turnbuckle fork.

2. Insert the pin.

3. Secure the pin with the R-clip.

10. Move the knives in.

L-H007-1104EN

Test and Adjustment 7-5

7.3 Adjust the Clearance Between the Knives and the Rotor

Upper knife group:

Open the cover above the cutting unit.

2. Observe the clearance of all knives by looking from above. The clearance is the distance between knife tip and the tine bar when the rotor is in such position that the tine bar is closest to the knife tip. In principle all knives should have the same clearance. However, due to wear there may be differences. In that case the knife with the smallest clearance is critical. The clearance should be approximately 3 mm (estimated by eye). Proceed this procedure if the clearance must be adjusted. At both sides of the knife assembly:

3. Loosen the counter nut on the axle of the turnbuckle fork.

4. Release the turnbuckle fork from the upper hinge point:

1. Remove the R-clip of the pin.

2. Remove the pin.

3. Release the turnbuckle fork axle from the hinge.

5. Adjust the turnbuckle fork axle length:

• Screw the axle in to decrease the clearance.

• Screw the axle out to increase the clearance.

6. Re-install the turnbuckle fork axle on its hinge point. Only insert the pin, not the R-clip.

7. Observe the clearance again. Repeat the steps 4 - 5 until the clearance is approximately 3 mm at both sides of the cutting unit.

8. If the clearance is good, secure the pin of the upper hinge point with the R-clip.

9. Fasten the counter nut on the axle of the turnbuckle fork.

Lower knife group (if present):

1. Move out the upper knife group to have sight on the lower knife group.

2. Observe the clearance of all knives by looking from above. The clearance is the distance between knife tip and the curved metal strip that forms the wall of the conveyor channel. The clearance should be approximately 0 - 3 mm (estimated by eye). Proceed this procedure if the clearance must be adjusted. At both sides of the knife assembly:

3. Loosen the counter nut on the axle of the adjustable link.

4. Release the adjustable link from its upper hinge point.

5. Adjust the link axle length:

• Screw the axle in to decrease the clearance.

• Screw the axle out to increase the clearance.

L-H007-1104EN

6. Re-install the adjustable link. Do not yet install the R-clip.

7. Observe the clearance again. Repeat the steps 4 - 6 until the clearance is approximately 3 mm at both sides of the cutting unit.

8. If the clearance is good, install the R-clip of the adjustable link hinge.

7-6 Test and Adjustment

9. Fasten the counter nut on the link axle.

1. Upper hinge point of turnbuckle fork - 2. Axle and counter nut of turnbuckle fork - 3. Upper

hinge point of adjustable link - 4. Axle and counter nut of adjustable link

Figure 49. Adjust the Clearance between the Knives and the Rotor

L-H007-1104EN

Test and Adjustment 7-7

7.4 Disengage the Pneumatic Brake when the Tigo is not Connected

If the Tigo has a pneumatic brake ram, the brakes will remain engaged when the brake hose is disconnected and the air container is still pressurised. To move the Tigo under these circumstances, the air pressure on the brake ram can be released manually:

case of a pneumatic brake system without ALB: set the break force valve

• In

(located at the left side under the carriage in front of the (fore) wheel) to the release position.

• In case of a pneumatic brake system with ALB: press the button on the

manual air release valve (located at the left side under the carriage in front of the (fore) wheel). As long as there is sufficient pressure in the air container, the brake can be engaged again by pulling the button out.

Left: Release position of break force valve (no ALB) - Right: Air release button (ALB)

Figure 50. Disengage the Pneumatic Brake by Hand

L-H007-1104EN

7-8 Test and Adjustment

7.5 Test the Overrun Brake

If the Tigo has an overrun brake, it can be tested as follows:

Pull the coupling end of the drawbar.

2. Engage the handbrake.

3. Push the coupling end of the drawbar. Check if the handbrake cable is automatically tensioned with the help of the gas spring.

4. Check if a slight retraction occurs when pulling the drawbar again.

1. Coupling end - 2. Gas spring - 3. Hand brake

Figure 51. Test the Overrun Brake

L-H007-1104EN

Test and Adjustment 7-9

L-H007-1104EN

7-10 Test and Adjustment

8. MAINTENANCE

8.1 Scheduled Maintenance

8.1.1 Maintenance Before Every Use

• Grease the PTO shaft (page 8-8) and verify if it functions well.

8.1.2 Maintenance After First Operation

• Check all critical bolts and nuts for tightness (page 8-22) and tighten if

necessary.

Check the wheel nuts for tightness (page 9-6) and torque-tighten if

•

necessary.

• Check the play of the taper roller bearings of the wheels (page 8-27) and

adjust if necessary.

• Adjust the overrun brake (page 8-29) (if present).

• Torque-tighten the axle assembly (page 8-31) (in case of a tandem axle).

8.1.3 Maintenance After the First 30 Working Hours

• Replace the oil of the gearbox of the main drive (page 8-6).

•

Replace the oil of the gearbox of the hydraulic motor of the floor conveyor (page 8-7).

L-H007-1104EN

Note:

The gearbox oil should also be replaced after 30 working hours after the replacement of a gearbox.

8.1.4 Maintenance Every 10 Working Hours

• Make sure that the PTO shaft telescopes smoothly.

•

Grease the bearings of the floor conveyor drive shaft (page 8-18).

• Grease the cutting unit (page 8-12):

• the bearings of the rotor shaft

• the bearings of the swinging tine bars

• the rollers on the tine bar levers

• the gear wheel

• Grease the bearing of the double sprocket wheel (page 8-14) on the main

frame mount.

• Grease the bearing of the lateral shaft (page 8-11).

8.1.5 Maintenance Every 25 Working Hours

• Grease the pivot points of the leaf spring suspensions (page 8-25) (in

case of a tandem axle).

• Grease the hinge points of the pick-up guide wheels (page 8-9).

• Grease the dog clutch (page 8-10).

Maintenance 8-1

• Grease the freewheel clutch of the pick-up unit (page 8-16).

Lubricate the drive chains of the pick-up unit (page 8-15).

•

• Lubricate the running wheels in the chain tensioners of the floor conveyor

(page 8-17).

8.1.6 Maintenance Every 100 Working Hours

• Check the play of the taper roller bearings of the wheels (page 8-27) and

adjust if necessary.

Check the wheel brake (page 8-30) and adjust if necessary.

•

• Grease the bearings of the wheel brake cam shafts (page 8-26), next to

the levers on the cam shafts.

8.1.7 Maintenance Every 200 Working Hours

• Check the brake linings (page 8-28). Let them be replaced by the local

dealer if they are worn.

8.1.8 Maintenance Every 500 Working Hours

• Examine the axle suspension.

• Torque-tighten the axle assembly (page 8-31) (in case of a tandem axle).

• Torque-tighten the wheel nuts (page 9-6).

8.1.9 Maintenance Every 3 Months

• Clean the filters of the pneumatic brake system (page 8-19) (if present).

8.1.10 Maintenance Every 6 Months

• Torque-tighten the axle assembly (page 8-31) (in case of a tandem axle).

•

Examine the axle suspension.

8.1.11 Maintenance Every 12 Months

• Clean the Tigo (page 8-5).

• Replace the oil of the main drive gearbox (page 8-6).

• Replace the oil of the floor conveyor gearbox (page 8-7).

• Replace the hydraulic filter (page 8-20).

• Grease the freewheel clutch of the pick-up unit (page 8-16).

• Check all critical bolts and nuts for tightness (page 8-22) and tighten if

necessary.

• Let the wheel bearings be checked and re-greased by the local dealer.

8.1.12 Maintenance Every 6 Year

• Replace all hydraulic hoses six years after their production date. Refer to

the text on the hoses for their production date.

L-H007-1104EN

8-2 Maintenance

8.1.13 Maintenance Before Prolonged Storage

• Clean the Tigo (page 8-5).

Apply anti-corrosion agent to the rods of the hydraulic rams.

•

• Grease the PTO (page 8-8) shaft and make sure that it telescopes

smoothly.

• Grease the hinge points of the pick-up guide wheels (page 8-9).

• Grease the bearings of the floor conveyor drive shaft (page 8-18).

• Lubricate the running wheels in the chain tensioners of the floor conveyor

(page 8-17).

• Grease the cutting unit (page 8-12):

• the bearings of the rotor shaft

• the bearings of the swinging tine bars

• the rollers on the tine bar levers

• the gear wheel

• Grease the bearing of the double sprocket wheel (page 8-14) on the main

frame mount.

• Lubricate the drive chains of the pick-up unit (page 8-15).

• Grease the freewheel clutch of the pick-up unit (page 8-16).

• Grease the bearing of the lateral shaft (page 8-11).

• Grease the dog clutch (page 8-10).

• Check the play of the taper roller bearings of the wheels (page 8-27) and

re-adjust if necessary.

• Check the brake linings (page 8-28). Let them be replaced by the local

L-H007-1104EN

dealer if they are worn.

• Examine the axle suspension.

• Torque-tighten the axle assembly (page 8-31) (in case of a tandem axle).

• Torque-tighten the wheel nuts (page 9-6).

• Grease the pivot point of the leaf spring suspension (page 8-25) (in case

of a tandem axle).

• Grease the bearings of the wheel brake cam shafts (page 8-26), next to

the levers on the cam shafts.

• Replace the hydraulic filter (page 8-20).

• Clean the filters of the pneumatic brake system (page 8-19) (if present).

• Make sure all the safety decals are not damaged. Replace if necessary.

• Make sure the Tigo operates correctly.

8.1.14 Maintenance After Prolonged Storage

• Clean the Tigo (page 8-5) if necessary.

• Remove the anti-corrosion agent from piston rods.

• Grease the PTO shaft (page 8-8) and make sure that it telescopes

smoothly.

• Grease the hinge points of the pick-up guide wheels (page 8-9).

• Grease the bearings of the floor conveyor drive shaft (page 8-17).

Maintenance 8-3

• Lubricate the running wheels in the chain tensioners of the floor conveyor

(page 8-

17).

• Grease the cutting unit (page 8-12):

• the bearings of the rotor shaft

• the bearings of the swinging tine bars

• the rollers on the tine bar levers

• the gear wheel

• Grease the bearing of the double sprocket wheel (page 8-14) on the main

frame mount.

• Lubricate the drive chains of the pick-up unit (page 8-15).

• Grease the freewheel clutch of the pick-up unit (page 8-16).

• Grease the bearing of the lateral shaft (page 8-11).

• Grease the dog clutch (page 8-10).

• Grease the pivot point of the leaf spring suspension (page 8-25) (in case

of a tandem axle).

• Grease the bearings of the wheel brake cam shafts (page 8-26), next to

the levers on the cam shafts.

• Make sure all the safety decals are not damaged. Replace if necessary.

• Make sure the Tigo operates correctly.

L-H007-1104EN

8-4 Maintenance

8.2 Preventive Maintenance on the Tigo

8.2.1 Clean the Tigo

• Requirements:

High-pressure steam cleaner

•

CAUTION

L-H007-1104EN

Do not use a high pressure steam cleaner to clean the Tigo during the first three months of operation.

Do not use cleaning agents.

Do not use water with a temperature of more than 50º C.

Do not use a steam pressure of more than 100 bar.

Keep the nozzle of the high pressure steam cleaner at least 20 cm from the surface of the Tigo. A smaller distance can cause damage to the painted surfaces of the Tigo.

Do not spray water directly onto the hydraulic system, electric system or bearings. This causes damage to the hydraulic system, electric system and bearings.

1. Use a high pressure steam cleaner to clean the Tigo.

2. Grease all bearings to remove any water from the bearings.

Maintenance 8-5

8.2.2 Replace the Main Gearbox Oil

• Requirements:

Collection container (minimum capacity: 1.5 litres)

•

• GX85-W140 transmission oil or equivalent

CAUTION

An incorrect quantity of oil will cause overheating and permanent damage to the gearbox.

1. Clean the area around the drain and fill plugs.

2. Put the collection container underneath the gearbox.

3. Remove the fill plug from the gearbox.

4. Remove the drain plug from the gearbox 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 the gearbox.

6. Fill the gearbox with approximately 1.0 l of GX85-W140 transmission oil or equivalent.

7. Install the fill plug on the gearbox.

8. Remove the collection container from the area and dispose of the drained oil as specified by local regulations.

L-H007-1104EN

1. Fill plug - 2. Drain plug

Figure 52. Replace the Main Gearbox Oil

8-6 Maintenance

8.2.3 Replace the Floor Conveyor Gearbox Oil

• Requirements:

Collection container (minimum capacity: 1.5 litres)

•

• GX85-W140 transmission oil or equivalent

CAUTION

L-H007-1104EN

An incorrect quantity of oil will cause overheating and permanent damage to the gearbox.

1. Clean the area around the drain and fill plugs.

2. Put the collection container underneath the gearbox of the floor conveyor motor.

3. Remove the fill plug from the gearbox.

4. Remove the drain plug from the gearbox and allow the oil to flow into the collection container.

5. When all the oil is out of the gearbox, install the drain plug.

6. Fill the gearbox of the floor conveyor motor with 1.0 l of GX85-W140 transmission oil or equivalent.

7. Install the fill plug.

8. Remove the collection container from the area and dispose of the drained oil as specified by local regulations.

1. Fill plug - 2. Drain plug

Figure 53. Replace the Floor Conveyor Gearbox Oil

Maintenance 8-7

8.2.4 Grease the PTO Shaft

• Requirements:

•

• 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 54. Grease Points of a Wide-angle/Normal-angle PTO Shaft (Single Wide-angle)

Grease pump

Figure 55. Grease Points of a Wide-angle/Wide-angle PTO Shaft (Double Wide-angle)

L-H007-1104EN

8-8 Maintenance

8.2.5 Grease the Pick-up Guide Wheels

• Requirements:

Grease pump

•

• Biodegradable grease (Total Biomultis SEP2 or equivalent)

1. Use the grease pump to grease the bearings of the pick-up guide wheels.

Left: standard pick-up guide wheels - Right: swivelled pick-up guide wheels

Figure 56. Grease the Pick-up Guide Wheels

L-H007-1104EN

Maintenance 8-9

8.2.6 Grease the Dog Clutch

• Requirements:

•

• Biodegradable grease (Total Biomultis SEP2 or equivalent)

1. Swivel away the cover of the grease point/inspection hole.

2. Use the grease pump to grease the dog clutch.

3. Swivel the cover back.

Grease pump

Figure 57. Grease the Dog Clutch

L-H007-1104EN

8-10 Maintenance

8.2.7 Grease the Bearing of the Lateral Shaft

• Requirements:

Grease pump

•

• Biodegradable grease (Total Biomultis SEP2 or equivalent)

1. Open the cover of the external drive parts.

2. Use the grease pump to grease the bearing of the lateral shaft.

L-H007-1104EN

Figure 58. Grease the Bearing of the Lateral Shaft

Maintenance 8-11

8.2.8 Grease the Cutting Unit

• Requirements:

Grease pump

•

• Biodegradable grease (Total Biomultis SEP2 or equivalent)

1. Open the cover of the cutting unit and the cover of the drive.

2. Use the grease pump to grease:

• the bearings of the rotor shaft

• the bearings of the swinging tine bars (optionally these grease points

• the rollers on the tine bar levers

• the gear wheel

are brought together by two grease nipple blocks on one of the tine bars)

Left: internal greasing point - Right: external greasing point

Figure 59. Grease the Bearings of the Rotor Shaft

L-H007-1104EN

8-12 Maintenance

L-H007-1104EN

Figure 60. Grease the Bearings and Rollers of the Tine Bars

Figure 61. Grease the Gear Wheel of the Cutting Unit

Maintenance 8-13

8.2.9 Grease the Bearing of the Pick-up Drive Sprocket

• Requirements:

Grease pump

•

• Biodegradable grease (Total Biomultis SEP2 or equivalent)

1. Use the grease pump to grease the bearing of the pick-up drive sprocket.

Figure 62. Grease the Bearing of the Pick-up Drive Sprocket

L-H007-1104EN

8-14 Maintenance

8.2.10 Lubricate the Drive Chains of the Pick-up

• Requirements:

Oil can

•

• Lubricating oil

1. Use the oil can to lubricate the drive chain of the pick-up.

2. Make sure the drive chains runs smoothly.

L-H007-1104EN

Figure 63. Lubricate the Drive Chains of the Pick-up Unit

Maintenance 8-15

8.2.11 Grease the Freewheel Clutch of the Pick-up

• Requirements:

Grease pump

•

• Biodegradable grease (Total Biomultis SEP2 or equivalent)

1. Lift the pick-up to the transport position.

2. Remove the plastic cover from the inspection hole.

3. Manually turn the pick-up until you can access the grease nipple through the inspection hole.

4. Use the grease pump to grease the freewheel clutch.

5. Install the plastic cover on the inspection hole.

Figure 64. Grease the Freewheel Clutch of the Pick-up

L-H007-1104EN

8-16 Maintenance

8.2.12 Lubricate the Running Wheels of the Floor Conveyor

• Requirements:

Oil can

•

• Lubricating oil

1. Use the oil can to lubricate the running wheels of the floor conveyor.

2. Make sure the running wheels run smoothly.

L-H007-1104EN

Figure 65. Lubricate the Running Wheels of the Floor Conveyor

Maintenance 8-17

8.2.13 Grease the Bearings of the Floor Conveyor Drive Shaft

• Requirements:

Grease pump

•

• Biodegradable grease (Total Biomultis SEP2 or equivalent)

1. Use the grease pump to grease the bearings of the floor conveyor drive.

Figure 66. Grease the Bearings of the Floor Conveyor Drive Shaft

L-H007-1104EN

8-18 Maintenance

8.2.14 Clean the Filter of the Air Brake System

If air brake system is available.

Requirements:

•

• Nitro cleaning agent

1. Push the locking tappet on both brackets and remove the slider.

2. Remove the locking tappet, O-ring, spring and filter cardridge.

3. If necessary, replace the damaged filter.

4. Use a Nitro cleaning agent to clean the filter.

5. Use compressed air to blow the filter clean.

6. Install the filter cardridge, spring, O-ring, slider and locking tappet.

7. Make sure the O-ring does not jam the slots of the slider.

L-H007-1104EN

Figure 67. Clean the Filters of the Air Break System

Maintenance 8-19

8.2.15 Replace the Hydraulic Filter

• Requirements:

Collection container (minimum capacity: 3 litres)

•

• Hydraulic filter

1. Put the collection container underneath the hydraulic control block.

2. Remove the filter housing and clean the inside of the filter housing.

3. Replace the hydraulic filter.

4. Install the filter housing.

5. Remove the collection container from the area and dispose of the drained oil as specified by local regulations.

Figure 68. Replace the Hydraulic Filter

L-H007-1104EN

8-20 Maintenance

LELY Tigo 35 S Classic, Tigo 35 ST Classic, Tigo 40 S, Tigo 50 ST, Tigo 35 S Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 Introduction

1. INTRODUCTION

1.2 Drawbar

1.3 Pick-up Unit

1.4 Cutting Unit

1.5 Carriage

1.5.1 Superstructure

1.5.2 Floor Conveyor

1.5.3 Tailgate

1.5.4 Under-carriage

1.6 Hydraulic System

1.7 Drive System

1.8 Control Panel

1.8.1 Hydraulic Control Panel

1.8.2 Comfort System

1.9 Optional Extras

1.9.1 Lely Grinder

2.1 Signal Words

2. SAFETY

2.2 Safety Instructions

2.3 Explanation of the Safety Decals

3. FIRST USE

3.1 Finish the Superstructure

3.2 Adjust the Length of the PTO Shaft

3.3 Install the PTO Shaft with the Overload Protection

3.4 Adjust the Height of the Drawbar

3.4.1 Drawbar with Spindle

3.4.2 Drawbar with Hydraulic Ram

3.5 Adapt the Electric Power Connection

3.6 Connect the Electric Cables

3.7 Adjust the Load Sense Adjustment Screw

3.8 Examine the Lever Setting of the ALB

4.1 At First

4. BEFORE OPERATION

4.2 Connect the Cables and Hoses to the Tractor

4.3 Connect the Tigo to the Tractor

4.4 Adjust the Working Depth of the Pick-up

4.5 Adjust the Height of the Wind Guard

4.6 Fold Up the Open Superstructure

4.7 Select the Number of Knives

4.8 Drain the Air Container

5. OPERATION

5.1 Load the Fodder Crop

5.2 Remove a Blockage by Moving the Knives Out and In

5.3 Unload the Tigo

6. AFTER OPERATION

6.1 Disconnect the Tigo from the Tractor

7. TEST AND ADJUSTMENT

7.1 Remove and Install the Knife Assembly

7.1.1 Remove the Knife Assembly

7.1.2 Install the Knife Assembly

7.2 Remove and Install a Single Knife

7.2.1 Remove a Single Knife

7.2.2 Install a Single Knife

7.3 Adjust the Clearance Between the Knives and the Rotor

7.4 Disengage the Pneumatic Brake when the Tigo is not Connected

7.5 Test the Overrun Brake

8. MAINTENANCE

8.1 Scheduled Maintenance

8.1.1 Maintenance Before Every Use

8.1.2 Maintenance After First Operation

8.1.3 Maintenance After the First 30 Working Hours

8.1.4 Maintenance Every 10 Working Hours

8.1.5 Maintenance Every 25 Working Hours

8.1.6 Maintenance Every 100 Working Hours

8.1.7 Maintenance Every 200 Working Hours

8.1.8 Maintenance Every 500 Working Hours

8.1.9 Maintenance Every 3 Months

8.1.10 Maintenance Every 6 Months

8.1.11 Maintenance Every 12 Months

8.1.12 Maintenance Every 6 Year

8.1.13 Maintenance Before Prolonged Storage

8.1.14 Maintenance After Prolonged Storage

8.2 Preventive Maintenance on the Tigo

8.2.1 Clean the Tigo

8.2.2 Replace the Main Gearbox Oil