Overview

This document is a detailed parts book and assembly guide for the Köckerling Rebell Classic agricultural machinery series, covering models 300, 410, and 520 up to January 2015. It includes comprehensive listings of spare parts, assembly components, torque specifications, and installation instructions for frames, fasteners, lighting, hydraulic systems, and other subassemblies.

1. Parts Identification and Specifications

The parts are organized by position and article numbers with multilingual descriptions (German, English, French). Key components include:

• Lockpin Components: Nuts, washers, spring bushes with diameters Ø25, Ø28, Ø36, Ø45.
• Frames: Main frames (300, 410, 520), side frames (left and right), folding arms, and center frames with variations based on manufacturing dates.
• Fasteners: Hex bolts (M8 to M22), nuts, washers (including lock and star washers), lynch pins, with strength classes 8.8, 10.9, 10.0, and 12.9, mostly zinc-plated.
• Specialized Parts: Toothed discs, SKF-Agrihub bearings, seedbed tines, lighting kits, cables, and hydraulic components.

2. Frame Variants and Assembly Details

• Rebell Classic 300 Frame: Separate parts lists for frames manufactured before May 2014 and from June 2014, reflecting updated bolt sizes and quantities.
• Rebell Classic 410 / 520 Frames: Detailed components for center and side frames, including plates, bolts, bearings, spacers, and folding parts.
• Folding and Height Adjustment Arms: Pins and lynch pins specified for secure assembly.

3. Fastening and Torque Specifications

• Torque values are critical and specified as 130 Nm, 230 Nm, and 500 Nm depending on bolt size and application.
• Copper paste application (approx. 1g) on certain bolt threads is recommended to ensure proper torque retention and prevent corrosion.
• Use of lock washers and star-disks is emphasized to maintain secure fastening.

4. Lighting Kit Components

• LED position lights with cables and protective casings, including part numbers for various LED models.
• Warning plates and decals, laser-cut for rear and side visibility compliance.
• Mounting hardware such as washers, nuts, bolts, flange nuts, U-bolts, and rubber grommets for secure installation.
• Pre-assembled lighting cable sets with specified wire gauges and lengths for right and left sides.
• Electrical connectors including 7-pole plugs and wire end ferrules.

5. Hydraulic Components

• Hydraulic cylinders with detailed dimensions and thread specifications.
• Valve assemblies including double holding valves, angle screws, and load holding valves with pre-assembled configurations.
• Sealing elements such as soft sealing cutting rings, lock nuts, throttle washers, and clamping bushes to ensure leak-proof connections.
• Hydraulic hoses (DN6-2SC) with protective grips and 90° fittings.
• Coupling markers (plus and minus blue) to ensure correct hydraulic connections.

6. Materials and Dimensions

Material specifications include rectangular tubes (e.g., 120x80x8 mm), flat plates (e.g., 120x80x40 mm), hardened washers, star-disks, and toothed discs with precise dimensions (e.g., 510x5 mm).

7. Model and Version Differentiation

• Parts lists are segmented by machine model and manufacturing date to ensure compatibility.
• Roller bearings and bolts differ based on production year (pre/post 2016).
• Lighting systems include traditional and LED versions, with LED introduced from 2017.

8. Recommendations and Best Practices

• Apply copper paste on specified bolt threads to prevent seizing and maintain torque.
• Adhere strictly to torque specifications for safety and structural integrity.
• Use designated safety pins and lynch pins to secure moving parts during operation.
• Match parts to the correct model and production year to ensure proper fit and function.
• Follow manufacturer instructions for hydraulic assembly to avoid leaks and maintain system performance.

9. Document Structure and Navigation

The parts book includes a content index referencing frame types, subassemblies, and hydraulic plans, facilitating easy identification and ordering of spare parts for maintenance and repair.

Summary

This document is an essential technical reference for maintenance personnel, spare parts suppliers, and assembly technicians working with the Köckerling Rebell Classic agricultural machinery series. It provides detailed multilingual parts descriptions, precise quantities, torque and assembly instructions, and critical safety recommendations to ensure correct installation, optimal performance, and safe operation of the machinery.