LELY Tigo 35 S Classic User manual

Lely Tigo
S
L-H007-1104EN
Operator Manual

TRADEMARKS, COPYRIGHT AND
DISCLAIMER
Lely, Astronaut, Astri, Atlantis, Attis, AWS, C4C, Calm, Commodus,
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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.
Copyright © 2010 Lely Industries NV
All rights reserved
Lely Industries NV
Weverskade 110
3147 PA Maassluis
The Netherlands
Phone: [phone]
Fax: [phone]
Website: www.lely.com
PREFACE
Manual Contents
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
ii

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.
Warranty Conditions
For those parts that fail under normal operating conditions, the factory will
make replacement parts available, free of charge, for a period of 12 (twelve)
months from the date of purchase.
The warranty shall not apply if the instructions mentioned in this manual have
not been followed, or if they have not been followed completely or correctly.
Nor will the warranty apply if you or third parties modify the machine without
our foreknowledge and/or authorisation.
Registration
The 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

iv

Table of Contents
1. 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
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
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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
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8.2 Preventive Maintenance on the Tigo........................................................................................8-5
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 Preventive Maintenance on the Under Carriage....................................................................8-25
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
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viii Table of Contents
L-H007-1104EN

1. INTRODUCTION
1.1 Introduction
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 available. Therefore, parts of this manual may be not applicable
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
system and optionally to tilt the wagon
• 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:
• a superstructure to contain the fodder crop
• a floor conveyor to aid loading and unloading
• a tailgate to unload the carriage
• 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.
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.
Note:
Introduction 1-1
L-H007-1104EN

1. Superstructure - 2. Tailgate - 3. Carriage - 4. Cutting unit - 5. Pick-up unit - 6. Drawbar
Figure 1. Overview of a Tigo S Series Model
1-2 Introduction
L-H007-1104EN

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.
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
L-H007-1104EN

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
let the pick-up unit follow the terrain contour at the optimal elevation. The guide
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
1-4 Introduction
L-H007-1104EN

1.4 Cutting Unit
The rotor of the cutting unit has 3 or 5 cylindrical bars in bearings with tines
that thrust the fodder crop from the pick-up unit through an assembly of knives
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.
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
L-H007-1104EN

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)
1-6 Introduction
L-H007-1104EN

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
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
L-H007-1104EN

1. Semi-closed front wall - 2. Closed metal plate side wall - 3. Rear tarpaulin - 4. Top rigging
rope
Figure 8. Closed Superstructure
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
L-H007-1104EN

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
to shift the pile towards the (closed) tailgate to keep the conveyor channel open
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
or
• 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
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
L-H007-1104EN

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
1-12 Introduction
L-H007-1104EN