Claas Direct Disc 610 Direct Disc 520 Comfort Jaguar Operator's Manual - PDF DOWNLOAD

DIRECT DISC 610 DIRECT DISC 520 Comfort JAGUAR Typ 494 / 493

Operator's Manual

Or ig i na lo pe ra to r's

ma

nu

al

1

EC Declaration of Conformity We

This declaration of conformity is the original declaration of conformity according to Directive 2006/42/EG CLAAS Saulgau GmbH Zeppelinstraße 2, D - 88348 Bad Saulgau

declare under our sole responsibility that the product Direct disc (type - serial number - trade name) 904 - from 90401001 - DIRECT DISC 610 426 - from 42601001 - DIRECT DISC 520 Comfort

to which this declaration relates corresponds to the relevant basic safety and health requirements of Directive 2006/42/EC Appendix I. For the relevant implementation of the safety and health requirements mentioned in the Directives, the following standard(s) and/or technical specification(s) has (have) been respected: EN ISO 4254-1, EN 745.

The person responsible for documentation in the European Community is: J. Prenzler, CLAAS Saulgau GmbH, Zeppelinstraße 2, D - 88348 Bad Saulgau

Technical Management

Quality Management

(J. Prenzler)

(J. Switalski)

Supply Chain Management / Production (A. Fetscher) Bad Saulgau, 28.01.10

Introduction

Introduction

1 Introduction INTRODUCTION This operator's manual is the original operator's manual. In the following texts, it will be referred to simply as the operator's manual.

This operator's manual contains information on the use, adjustment and operation of the CLAAS harvester.

Please note that in the following chapters, the CLAAS harvester is also referred to as a front attachment. The forage harvester is referred to as the machine.

Follow the advice on correct maintenance and servicing in order to ensure maximum performance and a long service life of your front attachment.

Also, have assembly of your front attachment and regular inspections carried out by your specialist workshop. Failure to carry out maintenance work or incorrect operation will result in poor machine efficiency and loss of valuable time.

By ensuring correct operation and carrying out maintenance and service work with care, you will be able to make full use of state-of-the-art technology and of the experience with which your front attachment has been designed.

Your CLAAS Service Department

Validity This operator's manual applies to all cutterbars: DIRECT DISC 610 Type 904 From serial no. 90401001.

DIRECT DISC 520 Comfort Type 426 From serial no. 42601347.

1.1

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Contents

Contents

2 Contents 1. Introduction

7. Prior to operation

Introduction ............................................................................... 1.1 Validity ................................................................................ 1.1

Check and observe the following before putting into operation ..................................................... 7.1 Fitting front attachment ............................................................. 7.2 Opening the lock ................................................................ 7.3 Greasing the coupling flange ............................................. 7.3 Hitching up the front attachment ........................................ 7.3 Closing the lock .................................................................. 7.4 Connecting hydraulics ........................................................ 7.5 Connecting electric system ................................................ 7.5 Checking the setting of the coupling flange to the quick-fit coupling ...................................................... 7.7 Setting the paddle roller ..................................................... 7.8 Hydraulic adjustment of the paddle roller (additional equipment) ......................................................................... 7.9 Adjusting cutterbar skids .................................................. 7.10 Setting mower head inclination ........................................ 7.10 Required parts .................................................................. 7.11 Setting the mower head to a steeper angle ..................... 7.11 Setting inclination of mower head to a smaller angle ....... 7.12 Setting the safety bars ..................................................... 7.13 Working and transport position ............................................... 7.14 Transport position ............................................................ 7.14 Working position ............................................................... 7.14 Removing and storing the front attachment ........................... 7.15

2. Contents ......................................................... 2.1 3. Preface Of special importance ............................................................... 3.1 Identification plate ..................................................................... 3.2 Transport on public roads ......................................................... 3.3 Safety device for driving on public roads ............................ 3.3

4. Safety rules IIntended use ............................................................................

Reasonable foreseeable misuse ...............................................

Identification of warnings and hazard signs ..............................

General safety and accident prevention regulations ...............................................................

Decommissioning and disposal ................................................

Safety decals with pictorials ......................................................

Safety support ...........................................................................

4.1 4.1 4.2 4.2 4.4 4.5 4.9

5. Specifications DIRECT DISC 610 .................................................................... 5.1 DIRECT DISC 520 Comfort ...................................................... 5.1

6. Assembly Loading and unloading the front attachment ............................. 6.1 Fitting the front attachment for the first time ............................. 6.2 Front attachment ....................................................................... 6.3 Installing cutterbar skids ..................................................... 6.3 Attaching / removing prop stands ....................................... 6.4 Using the front attachment ........................................................ 6.5 Adjusting the front attachment .................................................. 6.5 Operating the front attachment on the JAGUAR Type 494 ............................................................. 6.5 Operation of the front attachment on the JAGUAR Type 493 ............................................................. 6.5 Adjustments on forage harvester .............................................. 6.6 Additional weights ............................................................... 6.6 JAGUAR Type 493 ............................................................. 6.6 Boosted drive feeder unit .................................................... 6.6 Shipping package installation kit JAGUAR Type 493 (D03/0090) .......................................................................... 6.6 Installing the 3-groove belt drive ......................................... 6.7 Additional damping ............................................................. 6.8 Setting the drop rate (JAGUAR Type 493 only) .................. 6.8 JAGUAR Type 494 ........................................................... 6.10 Boosted drive feeder unit .................................................. 6.10 Shipping package installation kit JAGUAR Type 494 (D03/0090) ........................................................................ 6.10 CEBIS settings ................................................................. 6.11 Front attachment menu .................................................... 6.11

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8. Operation Operation .................................................................................. 8.1 Precondition ....................................................................... 8.1 Multifunction handle ........................................................... 8.2 Raising and lowering the front attachment ......................... 8.3 Operating front attachment ................................................ 8.4 Instructions for mowing ...................................................... 8.7 Difficult application conditions ............................................ 8.8 Adjusting cutting height ...................................................... 8.8 Locking / unlocking the pendulum frame ............................ 8.9 Adjusting length of cut ...................................................... 8.10 Length and height of cut range ........................................ 8.10 Additional equipment .............................................................. 8.11 Hydraulic adjustment of the paddle rollers (R03/0100) .... 8.11 Laser pilot (R03/0090, DIRECT DISC 520 Comfort only) .................. 8.12 Feed hats (D03/0080) ...................................................... 8.13 Additional damping (R05/0060, JAGUAR Type 493 only) ............................... 8.13 3-groove belt drive (D03/0090) ........................................ 8.13 Speed sensor ................................................................... 8.14

9. Maintenance Important maintenance instructions .........................................

Hydraulic system ................................................................

Bolts ...................................................................................

Lubrication ..........................................................................

Safety devices ....................................................................

Drive systems ...........................................................................

Gearbox .............................................................................

9.1 9.1 9.1 9.1 9.1 9.2 9.2

2.1

Contents Intake auger gearbox (A) .................................................... 9.3 Angle drive – mower drive / feeder unit drive (B) ............................................................ 9.4 Angle drive - mower drive (C) ............................................. 9.4 Angle drive - mower drive (D) ............................................. 9.5 Breather valve ..................................................................... 9.5 Mower head .............................................................................. 9.6 Oil level check ..................................................................... 9.7 Oil change ......................................................................... 9.10 Clutches .................................................................................. 9.11 Clutches (E, G) ................................................................. 9.11 Torque setting ................................................................... 9.12 Friction clutch (E) mower drive ......................................... 9.12 Overload clutch (G) feeder units ....................................... 9.12 Free wheel (F) mower drive .............................................. 9.13 Venting the friction clutch .................................................. 9.13 Chains ..................................................................................... 9.14 Lubricating the drive chain ................................................ 9.14 Tensioning steel roller chains ........................................... 9.14 Tensioning drive chain ...................................................... 9.14 Tensioning drive chain with clamping bracket .................. 9.14 Tensioning drive chain with chain tensioner ..................... 9.18 V-belts ..................................................................................... 9.19 Tensioning V-belts ............................................................ 9.19 Checking V-belts ............................................................... 9.20 Spring adjustment ................................................................... 9.21 Spring tension of intake auger .......................................... 9.21 Pendulum frame - adjusting the float springs ................... 9.22 Universal drive shafts .............................................................. 9.23 Servicing the universal drive shaft .................................... 9.23 General information on universal drive shafts .................. 9.24 Dismantling / fitting universal drive shaft guards ...................................................................... 9.24 Guard cup, initial gearbox ................................................. 9.26 Guard, universal drive shaft mower drive / initial gearbox ............................................. 9.26 Universal drive shafts with clamping screws .................... 9.28 Mounting lever ........................................................................ 9.28 Locking the cutting discs ................................................... 9.28 Mower blades .......................................................................... 9.30 Mower blade box .............................................................. 9.31 Checking the mower blades ............................................. 9.32 Quick-change system for mower blades ........................... 9.33 Checking the mower blade bracket (mower blade quick-change system) ................................ 9.36 Replacing screwed mower blades .................................... 9.38 Mower blade fixing (bolted version) .................................. 9.40 Cutting discs ........................................................................... 9.41 Checking the cutting discs ................................................ 9.41 Replacing cutting discs ..................................................... 9.42 Feed drums ............................................................................. 9.42 Checking the feed drums .................................................. 9.43 Replacing feed drums ....................................................... 9.43 Feed drum cap .................................................................. 9.44 Removing / fitting wear bars ............................................. 9.45 Electric system ........................................................................ 9.46 Setting the speed sensor .................................................. 9.46 Aligning the toothed lock washer ...................................... 9.46

2.2

Adjusting spacing speed sensor - toothed lock washer (DIRECT DISC 520 Comfort only) ....................................

Hydraulic system ....................................................................

Anti-wrap guard ......................................................................

Setting the anti-wrap guard ..............................................

Panelling .................................................................................

Hood .................................................................................

Side panelling ...................................................................

Top side panelling ............................................................

Lock ........................................................................................

Adjusting the lock .............................................................

Adjusting interlocking bars ...............................................

Screw connections .................................................................

Fasteners ................................................................................

Cleaning and care ..................................................................

Winter storage ........................................................................

Lubricants chart ......................................................................

DIRECT DISC 520 Comfort ..............................................

DIRECT DISC 610 ..........................................................

Lubrication points .............................................................

Malfunctions ...........................................................................

9.46 9.47 9.48 9.48 9.49 9.50 9.50 9.51 9.51 9.51 9.52 9.52 9.52 9.53 9.54 9.55 9.55 9.55 9.56 9.56

10. Lubrication Chart Safety rules ............................................................................. 10.1 Lubricants ............................................................................... 10.1 Lubrication .............................................................................. 10.1

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Preface

Preface

3 Preface OF SPECIAL IMPORTANCE Note that in the following chapters the CLAAS “DIRECT DISC” cutterbar is also referred to as the front attachment.

The instructions in this operator's manual must be read carefully and followed by all persons concerned with the operation, maintenance, repair or inspection of this front attachment in order to prevent accidents.

Some safety devices and covers have been removed for illustration in this manual. All safety devices and covers must be attached before the front attachment is put into operation.

In particular, read the sections “Safety rules” and “Prior to operation” in the forage harvester operator's manual.

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

CLAAS will in no way be liable for damage or personal injury caused by the use of parts, accessories and ancillary equipment that are not original CLAAS. Technical specifications, dimensions and weights are understood with appropriate tolerances.

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

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3.1

Preface IDENTIFICATION PLATE The machine number (Fz-Ident-Nr.) (2), the model and the serial number are required with all orders for spare parts and technical inquiries. This is necessary in order to ensure correct delivery of spare parts.

The identification plate (1) with the serial number (Fz-Ident-Nr.) (2) is affixed on the back panel on the right side.

(Fig. 1, 2) 1

1 11

2 Bezeichnung/Désignation

Typ/Type:

Direktschneidwerk/ Coupe directe

426

Fz-Ident.-Nr.:

42601001

381

UTyp/Variante ASF

Baujahr/Annee

GRP

Reception à la DRIRE

Zul. Ges. Gewicht

CLAAS SAULGAU GMBH 88348 Bad Saulgau Made in Germany

Zul. Stütz381 0 1001 last Masse max. admissible attelage

PTAC

kg

kg

Zul.Achslast

2

charge max. admissible

kg

2

3.2

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Preface

Preface TRANSPORT ON PUBLIC ROADS DANGER! The front attachment must not be transported on public roads when attached. The front attachment must be removed for transport on public roads and carried on a vehicle of suitable size.

– Remove front attachment and load it on the vehicle and secure it.

2

– Attach safety device to feeder housing.

Before leaving the forage harvester: – Lower front attachment completely!

– Switch off engine!

– Remove the ignition key!

– Switch off the battery isolating switch!

ATTENTION! Do not exceed permissible axle load of towing vehicle!

Safety device for driving on public roads The following requirements must be fulfilled for transport on public roads: 1. Front attachment removed and loaded and secured on a suitable vehicle – see Transport position, page 7.14.

2. Safety device attached to feeder housing and secured – see forage harvester operator's manual.

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3.3

Safety rules

Safety rules

4 Safety rules Before putting the machine into operation, read the operator's manual and follow the safety instructions.

IINTENDED USE The CLAAS front attachment (direct mower) is designed exclusively for professional use in line with the recognised regulations of agricultural practices in agricultural harvesting of grain.

The front attachment is an agricultural working machine intended for being fitted to a forage harvester approved by the manufacturer and which is suited and intended for mowing forage plants on fields while travelling. Forage plants include crop such as grass, lucerne, barley and rye.

This front attachment cuts standing or slightly inclined forage plants up to a stalk height of around 1.50 m from the field with a cutter. The front attachment transfers the forage plants to the forage harvester, using a conveying unit. The application is restricted to fields with a level surface and without stones causing damage to the basic machine.

When travelling on public roads, the front attachment may be transported on a transport trailer approved by the manufacturer, depending on the provisions of the road traffic regulations in force.

REASONABLE FORESEEABLE MISUSE Use outside of intended use constitutes use not intended by the manufacturer of the machine and therefore amounts to misuse for the purposes of the machinery directive. The manufacturer accepts no liability for damage resulting from this. All liability is borne by the user.

Misuse of the CLAAS front attachment (direct mower) includes: Performance of adjustment work, cleaning work and maintenance work against the specifications in the operator's manual.

Performance of fault elimination and servicing work with drives and/or the diesel engine running.

Nonobservance of warning signs on the machine and in the operator's manual.

Performance of servicing and repair work by untrained personnel.

Unauthorised modifications to the machine.

Attachment of non-approved additional equipment.

Use of non-original CLAAS spare parts.

Use in a stationary position.

Use to mow / cut goods that are not considered forage crops, such as hedges, bushes, maize stubble or woody shrubs.

The machine may only be used, maintained and serviced by persons who are familiar with the machine and briefed on the hazards that may arise as a result of the machine's functions.

Use to mow roadsides / waysides / stony areas.

Compliance with the conditions of operation, maintenance and servicing as specified in the operator's manual and by the manufacturer also constitute essential elements for the intended use.

People transport.

Use for levelling uneven ground.

Use in subsurface work (mowing / cutting).

Goods transport.

The relevant accident prevention regulations, all other generally recognised regulations on safety and occupational medicine and the road traffic regulations must be observed by users and owners at all times.

Any use other than this is considered "unintended", and the manufacturer is not liable for any resulting damage. All liability in this case is borne by the user.

4.1

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Safety rules IDENTIFICATION OF WARNINGS AND HAZARD SIGNS

GENERAL SAFETY AND ACCIDENT PREVENTION REGULATIONS

All parts of this operator's manual having to do with your safety or the safe operation of the front attachment are marked with the following signs. Please pass all safety instructions on to other users, too.

Before putting the front attachment and the machine into operation, always check that they meet the requirements for operational safety and safety on the roads!

DANGER! Sign to indicate the instructions which must be observed. Failure to do so could cause danger to the life and limb of the operator and to the people around him.

– Preventive measures.

ATTENTION! Sign to indicate instructions which must be observed. Failure to do so could result in damage to the front attachment.

– Measures to prevent danger to the front attachment.

NOTE! Sign to indicate instructions for more effective and economic use of the front attachment.

1. In addition to the information set forth in this operator's manual, also follow the general instructions for safety and accident prevention.

2. The fitted warning and instruction signs provide important recommendations for safe operation.

These instructions ensure your safety – observe them at all times!

3. Follow the regulations in force when using public roads!

4. On public roads the front attachment must always be loaded and secured on a suitable transport vehicle.

5. Before starting work, familiarise yourself with all operating elements and their function, as it will be too late once you have commenced field work.

6. Before starting, check the front attachment for any loose parts on the machine.

7. Always stop the engine, remove the ignition key and switch off the battery isolating switch before working in or on the front attachment. All control levers must be in their neutral position and the hydraulic lines must not be under pressure.

8. Before performing work under the raised front attachment, support it safely.

ENVIRONMENT!

9. Wear close-fitting clothing when working on the front attachment. Do not wear loose clothing!

Sign to indicate instructions which must be observed in order to avoid damage to the environment.

10. Keep the machine clean to prevent fire!

Danger to the environment is caused by irregular handling and incorrect disposal of toxic material ( e. g. used oil).

11. Before starting and before putting it into operation, check the area around the machine (children!).

Ensure that your field of vision is unobstructed!

The warning and instruction decals placed on the front attachment provide important recommendations for safe operation. These instructions ensure your safety – observe them at all times!

12. Riding on the front attachment while it is working or during transport is prohibited!

13. Safe operation of the cutterbar can only be guaranteed with correctly installed mower blades.

14. There is an increased risk of injury when installing and removing the mower blades - wear gloves!

15. Check cutterbar for damaged, missing and worn mower blades before every use and replace mower blades if necessary – see Checking the mower blades, page 9.32!

16. Replace missing and damaged mower blades in sets only as specified by the manufacturer to prevent danger resulting from unbalance – see Checking the mower blades, page 9.32!

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4.2

Safety rules 17. When replacing mower blades, check the securing bolts on every blade as specified by the manufacturer and replace if necessary!

18. It is very important to check the wear of the mower blade retaining bolts caused by the mower blade at the internal radius. At the latest when the wear limit has been reached, – see Checking the mower blades, page 9.32 the mower blade bracket must be replaced by a new blade with an unused mower blade retaining bolt.

19. The riveted joints of the mower blade bolt in the mower blade bracket and the wear of the mower blade bracket at the outer edge must also be checked. If necessary, all mower blade brackets of the cutting discs must be replaced with new mower blade brackets.

20. Some safety devices and covers have been removed for illustration in this manual. All safety devices and covers must be attached before the front attachment is put into operation.

30. Always switch off the drive and the engine before troubleshooting, and before repair, maintenance and cleaning work.

– Remove the ignition key!

– Switch off the battery isolating switch!

31. Always switch off the battery isolating switch before starting work on the electrical system!

32. Reinstall safety devices after maintenance operation!

33. |There is a danger of injury when fitting the front attachment to the machine!

34. Keep out of the area between the machine and the front attachment unless the machine has been secured against rolling off by applying the parking brake and/or wheel chocks!

Observe all further safety instructions in the machine operator's manual.

21. The safety guards must be checked regularly and worn or damaged safety guards must be replaced!

22. The safety devices on the front attachment, e.g. canvas and hoods, provide protection against stones etc. which are thrown upward and against persons reaching into dangerous areas on the equipment. For this reason they must be placed in safety position before starting work!

23. Intake augers, cutting discs etc. cannot be fully secured by design measures without impairing their function. Therefore, keep an adequate safety distance from these moving parts during operation.

24. Before putting into operation and while working, the glide discs must be in contact with the ground!

25. Even when operating the front attachment as prescribed, there is a danger of stones etc. being hurled away from the equipment. Therefore, no-one should be in the danger zone. Special care is required when working near roads and buildings!

26. After switching off the drive, the working tools on the front attachment and the machine may run on.

Do not approach them until they have stopped.

27. After striking an obstacle, switch the front attachment / machine off immediately and check them for damage!

28. Never start universal drive shafts turning without the appropriate guard.

29. Secure the power take-off shaft guard against rotating, e.g. by attaching the chains.

4.3

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Safety rules DECOMMISSIONING AND DISPOSAL When the machine (or its components) reaches the end of its useful life and is surrendered as scrap, the components must be disposed of in the correct manner. The regulations of the local authorities responsible must be observed.

The operating materials in the machine require special disposal and must not be released into the environment. More information on disposal can be obtained from the local authorities responsible, your CLAAS dealer or the CLAAS service department.

– Operating materials, such as oils, hydraulic fluids, brake fluids or fuels, must be treated as hazardous waste and disposed of correctly.

– Have refrigerants disposed of only by specialist companies with experienced personnel and the necessary technical equipment. Refrigerants must never be released into the atmosphere. Have refrigerants disposed of by your CLAAS dealer.

Observe country-specific regulations.

– Follow the regulations of the local authorities responsible.

– Do not dispose of products marked with the symbol (1) in your domestic waste at the end of their service life.

1

1 – Recycle used materials marked with the symbol (2) in accordance with their labelling.

2

2 – Recycle packaging material, do not dispose of it in domestic waste.

– Recycle plastics that are labelled with material information, e.g. PP TV 20, do not dispose of them in domestic waste.

– Used batteries contain hazardous substances and must be taken back by the distributor, disposed of correctly or delivered to a collection point. Do not dispose of used batteries in domestic waste.

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

4.4

Safety rules

Safety rules SAFETY DECALS WITH PICTORIALS Safety decals are attached to the danger zones of the machine. These safety decals help to alert persons to hazards which can cause personal injury. The pictorials on these decals provide instructions on how to avoid the hazard.

These pictorials, their placement on the machine and a brief explanatory text are shown on the following pages.

The CLAAS part number of every decal is stated ahead of the text.

The figures in ( ) refer to the adjacent picture and indicate the correct location of the decal on the machine.

Safety decals that are damaged or illegible must be replaced immediately by new ones.

When parts that have safety decals are replaced, always make sure to install the relevant new decals with each new part.

4.5

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Safety rules

2 1

2 Safety decal 00 0514 946 1 (1) Before putting the machine into operation, read the operator's manual and follow the safety instructions.

(Fig. 1, 2)

2 3

4 Safety decal 00 0514 895 1 (2) Before carrying out maintenance and repair work, switch off engine and remove ignition key.

(Fig. 3, 4)

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

4.6

Safety rules

B

A

C

3 5

7 Safety decal 00 0480 462 0 (3) Decal (A) Keep a sufficient distance from the cutting units while the engine is running.

Decal (B) Do not touch any moving machine parts. Wait for all parts to come to a complete standstill.

3

Decal (C) 6

Keep a safe distance while the engine is running.

(Fig. 5, 6, 7)

4

8

10 Safety decal 00 0514 042 0 (4) Keep out of the danger area between front attachment and machine.

(Fig. 8, 9, 10) 4

4.7

9

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Safety rules

7

6

11

13 6

Safety decal 00 0514 877 1 (6)

7

Maintain a safe distance from the knife when the drive is switched on and the engine is running.

(Fig. 11, 12, 13) 12

STOP 14 Safety decal 00 0514 878 0 (7) Do not touch machine components before they have stopped completely.

(Fig. 11, 12, 14)

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4.8

Safety rules

Safety rules SAFETY SUPPORT DANGER! There is a danger of injury when working on or under the raised front attachment.

– Never work under the raised front attachment without safe support.

– Provide secure support / propping for the front attachment.

– Use suitable supporting elements.

4.9

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Specifications

Specifications

5 Specifications NOTE! Technical specifications, dimensions and weights are understood with appropriate tolerances.

DIRECT DISC 610

DIRECT DISC 520 Comfort

Width:

mm

6080

5175

Length:

mm

2400

2400

Height:

mm

1650

1650

Weight

kg

2800

2600

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5.1

Assembly

Assembly

6 Assembly LOADING AND UNLOADING THE FRONT ATTACHMENT DANGER! Incorrect loading and transport of the front attachment involves risk of accidents!

1

– When loading / unloading the front attachment, attach it only at the application points (1) on the left, right and in the centre!

1 1

– Make sure the slings are sufficiently dimensioned!

Weight of the front attachment – see Specifications, page 5.1.

The application points are marked with the symbol (2).

2

(Fig. 1, 2)

2

6.1

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Assembly FITTING THE FRONT ATTACHMENT FOR THE FIRST TIME 1. Check the shipping package against the delivery note.

2. To adjust the front attachment – see Adjusting the front attachment, from page 6.5.

3. To adjust the forage harvester – see Adjustments on forage harvester, from page 6.6.

4. Opening the lock, see page 7.3.

5. Hitching up the front attachment, see page 7.3.

6. Closing the lock, see page 7.4.

7. Hoist the front attachment from the transport cradle using the forage harvester hydraulics.

8. Installing cutterbar skids, see page 6.3.

9. If required, insert the prop stands – see Attaching / removing prop stands, page 6.4.

If the front attachment is to be removed from the forage harvester again after removing it from the transport cradle, the prop stands must be fitted.

Otherwise there could be problems when refitting the front attachment.

10. Lower front attachment.

11. Connect the hydraulic lines if necessary – see Connecting hydraulics, page 7.5.

12. Connect power supply – see Connecting electric system, page 7.5.

13. Check the coupling flange and align if necessary – see Checking the setting of the coupling flange to the quick-fit coupling, page 7.7.

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6.2

Assembly FRONT ATTACHMENT Installing cutterbar skids DANGER! Never work under or on the raised front attachment unless it is safely supported.

1

– Provide secure support / propping for the front attachment.

– Use suitable supporting elements.

3

2 3

ATTENTION! Adjust cutterbar skids to the same height on each side – if a cutterbar skid is set higher it will be subject to increased wear!

Proceed as follows to attach the cutterbar skids (2):

3

1 2 3 4

• • • •

Raise front attachment completely.

Switch off the engine and remove the ignition key.

Switch off the battery isolating switch!

Provide secure support / propping for the front attachment. Use suitable supporting elements.

• Loosen bolts (3).

• Turn straps (1) down.

• Set the minimum cutting height – see Adjusting cutterbar skids, page 7.10.

• Replace bolts (3).

• Tighten all bolts.

(Fig. 3, 4)

6.3

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Assembly Attaching / removing prop stands 4

5

4 DANGER! Never work under or on the raised front attachment unless it is safely supported.

– Provide secure support / propping for the front attachment.

– Use suitable supporting elements.

5

ATTENTION! 6

Under difficult conditions (e.g. max. cutting height), the front attachment can only be refitted with great difficulty.

7

– Attach prop stands to the mower head before unhitching / lowering.

8

Proceed as follows to attach the prop stands: – Raise front attachment completely.

5

– Switch off the engine and remove the ignition key.

6

– Switch off the battery isolating switch!

– Provide secure support / propping for the front attachment.

Use suitable supporting elements.

– Detach the S-hook (4).

– Remove prop stands (5) from the brackets by pulling prop stands backwards and removing them in an upward direction.

10 9

NOTE! 5 7

The prop stands (5) are held in place only with the aid of two magnets (6).

– Insert prop stands (5) left and right on the outside of the mower head by inserting the nose (8) in the recess (9) on the mower head. Push the prop stand upwards while inserting the side straps (7) into the recesses (10).

– Make sure that the magnets hold firmly; clean contact surfaces it necessary.

Remove prop stands and attach them to the brackets before every use.

(Fig. 5, 6, 7)

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

6.4

Assembly USING THE FRONT ATTACHMENT The DIRECT DISC 520 Comfort Type 426 front attachment is designed for machines from serial number 42601861 for operation on the JAGUAR Type 494.

The DIRECT DISC 520 Comfort Type 426 front attachment is designed for machines up to serial number 42601860 for operation on the JAGUAR Type 493.

The DIRECT DISC 610 Type 904 front attachment is designed for operation on the JAGUAR Type 494.

ADJUSTING THE FRONT ATTACHMENT

Operating the front attachment on the JAGUAR Type 494 To use the DIRECT DISC 520 Comfort on machines up to serial number 426 0 1860 on the JAGUAR Type 494, it is necessary to replace the speed sensor.

6 5

– Remove the speed sensor (4) and wiring loom which are fitted.

– Install new speed sensor (5).

– Set speed sensor – see Setting the speed sensor, page 9.46.

4

– Route wiring loom (6) on the left side and attach it.

8

77390

Order No.: Add-on kit

00 1312 127 0

(Fig. 8)

Operation of the front attachment on the JAGUAR Type 493 To use the DIRECT DISC 520 Comfort on machines from serial number 42601861 and DIRECT DISC 610 on the JAGUAR Type 493, it is necessary to replace the speed sensor.

2

– Remove the speed sensor (1) and wiring loom which are fitted.

1

– Install new speed sensor (3).

– Set speed sensor – see Setting the speed sensor, page 9.46.

3

77389

9

– Route wiring loom (2) on the right side and attach it.

Order No.: Add-on kit

00 1312 128 0

(Fig. 9)

6.5

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Assembly ADJUSTMENTS ON FORAGE HARVESTER Before fitting the front attachment, make the following adjustments to the forage harvester.

Additional weights The load on the rear wheels of the forage harvester must be sufficient when operating the front attachment. This is necessary to prevent the back of the machine lifting during braking or when driving on slopes.

The load on the steering axle wheels should be 20% of the machine weight with the front attachment fitted.

Observe permissible axle loads!

Attaching the additional weights – see operator's manual for forage harvester.

NOTE! The required ballasting on the rear axle can also be achieved by other means, e.g. by filling the tyres with water.

JAGUAR Type 493 Boosted drive feeder unit On forage harvesters with 2-groove belt drive on the feeder unit, we recommend changeover to a 3-groove belt drive for operation of the front attachment. This considerably reduces the wear on the multiple belt.

Shipping package installation kit JAGUAR Type 493 (D03/0090)

JAGUAR Type 493

2

1

Installation kit complete Pos. Order no.

3

00 0495 820 2

Designation

1 00 0495 008 0 Multiple belt (1x) 2 00 0495 822 0 Drive pulley 3-groove (1x) 3 00 0495 824 1 Rocker arm, complete (1x)

75084

4

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

4 00 0495 821 3 V-belt pulley 3-groove (1x) 10

(Fig. 10)

6.6

Assembly Installing the 3-groove belt drive

JAGUAR Type 493

DANGER! Never work under the raised forage harvester unless it is safely supported.

T

– Use suitable aids to support the forage harvester!

11 JAGUAR Type 493

S

A

• • • •

Remove guard (T).

Release and remove guide bracket (F).

Remove v-belt (R).

Detach v-belt pulley (K), jockey pulley (S) and drive pulley (A).

K

R

F

12

• Fit 3-groove drive pulley (2), rocker arm (3) and

JAGUAR Type 493

3-groove V-belt pulley (4).

2

• Put multiple belt (1) in position.

• Refit and secure guide bracket (F).

• Refit guard (T).

1

3

75084

6.7

4

(Fig. 11, 12, 13)

13

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Assembly Additional damping When operating the front attachment, we recommend fitting the forage harvester with the “additional damping” for medium duty front attachments (DIRECT DISC). This ensures that the contour system works properly and that the front attachment presses down on the ground with the preset ground pressure.

JAGUAR Type 493

If the front attachment is operated only with the “pre-set cutting height control”, this additional equipment is not required.

Order no.: Additional damping 14

(R05/0060) 00 0495 510 0

(Fig. 14) Setting the drop rate (JAGUAR Type 493 only)

ATTENTION! Conversion of the drop rate to “heavy front attachment” must be carried out before the front attachment is fitted, otherwise the shifting linkage may be damaged.

If the front attachment has already been fitted: – Lower the front attachment to the ground and depressurise the hydraulic cylinder.

As the weights of the various permissible front attachments differ, the drop rates of the feeder units are also different.

ATTENTION! Incorrectly set drop rate.

Machine damage.

– The drop rate must be reset each time the front attachment is changed.

– Lower feeder unit until its hydraulic cylinders are depressurised.

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

6.8

Assembly – Open side cover (1).

JAGUAR Type 493

(Fig. 15) 1

15

Adjustment for medium-duty front attachments

JAGUAR Type 493

DIRECT DISC Note: Lift the star wheel to change – do not rotate.

– Lift star wheel (2) and engage in position (A).

2

Additional damping (additional equipment): ATTENTION! The switchover valve (4) can only be operated before the front attachment is fitted.

B

A

16 Jaguar Type 493

– Lower the front attachment to the ground and depressurise the hydraulic cylinder.

C

4

If the front attachment has already been fitted:

– Move lever (3) to position (C).

B

(Fig. 16, 17)

3

17

6.9

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Assembly – Set bolt (4) to the desired position with warm hydraulic oil.

JAGUAT Type 493

Faster drop rate: – Turn bolt (4) in.

Slower drop rate: – Back off bolt (4).

The drop rate is correctly set when the front attachment drops to the ground from fully raised position in approx. 5 to 6 seconds.

4 18

Further information – see forage harvester operator's manual, under “Medium heavy to heavy front attachments”.

(Fig. 18)

JAGUAR Type 494 Boosted drive feeder unit On forage harvesters with 2-groove belt drive on the feeder unit, we recommend changeover to a 3-groove belt drive for operation of the front attachment. This considerably reduces the wear on the multiple belt.

Shipping package installation kit JAGUAR Type 494 (D03/0090)

JAGUAR Type 494

2

1

Installation kit complete Pos. Order no.

00 1312 373 0

Designation

1 000 495 008 0 Multiple belt (1x) 2 000 495 822 0 Drive pulley 3-groove (1x) 3 000 644 467 0 Assembled jockey pulley, (1x) 3

77391

4

4 000 495 821 3 V-belt pulley 3-groove (1x) (Fig. 19) 19

Installation analogue to that for JAGUAR Type 493.

– see Installing the 3-groove belt drive, page 6.7.

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

6.10

Assembly CEBIS settings – Setting the front attachment in CEBIS. – Follow the CEBIS instructions.

Front attachment menu Front attachment menu Menu

Submenu

Description Set the cutting height.

The cutting height can also be set via the multifunction handle.

Setting the front attachment parameters.

Set front attachment type.

Set width of front attachment fitted.

Set number of active partial widths.

This value refers to the partial widths of the front attachment which actively pick up crop.

If the working height deviates from that set, this value is automatically reset to the full quantity.

Call up working position menu and display settings.

Teaching working position.

Follow the CEBIS instructions.

Setting the working position.

The working position is the cutting height from which the front attachment engages in the crop.

The set cutting height is shown as a bar in the pre-set cutting height control display.

The area counting function only becomes active when the working position has been reached and the front attachment switched on.

If the front attachment is raised from this position, the active partial widths are again reset to the full quantity.

Call up front attachment limit stops menu.

Teach front attachment height limit stops.

Follow the CEBIS instructions.

6.11

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Prior to operation

Prior to operation

7 Prior to operation DANGER! Work on the front attachment and/or the forage harvester should only ever be undertaken when the drive is disconnected and the motor is at standstill.

– Remove the ignition key!

– Switch off the battery isolating switch!

CHECK AND OBSERVE THE FOLLOWING BEFORE PUTTING INTO OPERATION 1. Check oil level in the gearboxes – see Gearbox, page 9.2.

2. Lubricate front attachment thoroughly before putting into operation – see Lubrication Chart, page 10.1.

3. Check bolts for tightness.

4. Check that the mower blades are properly fastened.

5. Secure power take-off shaft guard against rotating by attaching the chains.

6. Check safety guards and safety bar for wear and damage.

7. Mount and lock all safety devices – see Safety devices, page 9.1.

8. Remove prop stands from mower head – see Attaching / removing prop stands, page 6.4.

9. Check coupling flange and adjust if necessary – see Checking the setting of the coupling flange to the quick-fit coupling, page 7.7.

10. Check vehicle for any loose parts before moving off. Firmly attach or cover parts which can fall off during travel.

11. Make sure no-one is in the area of danger. If any person approaches the danger area, switch off the front attachment immediately.

12. Never let the front attachment run without proper supervision.

13. Switch on the front attachment only in working position and at idle speed – see Working position, page 7.14.

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

7.1

Prior to operation FITTING FRONT ATTACHMENT DANGER! Danger of injury while fitting the front attachment!

– Nobody must stand between the forage harvester and the front attachment.

There is a danger of injury when working on or under the raised front attachment.

– Never work under the raised front attachment unless it is safely supported.

– Provide secure support / propping for the front attachment.

– Use appropriate supports.

Never work on the front attachment unless the drive is switched off and the engine has stopped.

– Remove the ignition key!

– Switch off the battery isolating switch!

ATTENTION! Ensure that the lock is open before fitting the front attachment.

Proceed as follows to fit the front attachment: 1. Setting the drop rate (JAGUAR Type 493 only), see page 6.8.

2. Opening the lock, see page 7.3.

3. Greasing the coupling flange, see page 7.3.

4. Hitching up the front attachment, see page 7.3.

5. Closing the lock, see page 7.4.

6. Check that the front attachment is safely locked, if necessary adjust lock – see Adjusting the lock, page 9.51.

7. Checking the setting of the coupling flange to the quick-fit coupling, see page 7.7.

8. Connecting hydraulics, see page 7.5.

9. Connect power supply – see Connecting electric system, page 7.5.

10. Setting the paddle roller, see page 7.8.

11. Hydraulic adjustment of the paddle roller (additional equipment), see page 7.9.

12. Adjusting cutterbar skids, see page 7.10.

7.2

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Prior to operation 13. Remove prop stands from mower head – see Attaching / removing prop stands, page 6.4.

Opening the lock – Remove the spring clip (2).

– Push the lever (1) downwards.

(Fig. 1)

1 2 1

Greasing the coupling flange – Grease the coupling flange (3) using a good quality branded grease.

For grease specification, see Lubricants, page 10.1.

3

2

Hitching up the front attachment DANGER! Danger of injury while fitting the front attachment!

– Nobody must stand between the forage harvester and the front attachment.

ATTENTION! Ensure that the lock is open before fitting the front attachment.

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

7.3

Prior to operation – Move the forage harvester towards the front attachment until the location spigots (5) of the feed are located below the location pockets (4) of the front attachment.

4 5

– Hoist the front attachment using the forage harvester's hydraulics.

(Fig. 3)

3

Closing the lock 6

ATTENTION!

7

Machines which are not locked / secured can work loose from the retainer during the journey.

– Close lock.

– Ensure that the front attachment is securely locked to the coupling shaft (8)!

4

– Lift lever (7) on the front attachment and secure with the spring clip (6).

NOTE!

8

The interlocking bars must be adjusted to allow the coupling hooks (9) to surround the coupling shaft (8) from the feeder housing of the forage harvester under pre-tension.

9 5

– Adjust lock mechanism if necessary – see Adjusting the lock, page 9.51 or adjust interlocking bars – see Adjusting interlocking bars, page 9.52.

(Fig. 4, 5)

7.4

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Prior to operation Connecting hydraulics ATTENTION! The hydraulic system may be contaminated by dirty hydraulic connectors or hydraulic coupling sockets.

– Always clean the male couplings of the hydraulic hoses and the hydraulic coupling sockets before connecting them.

– Beware of friction and jamming!

– Switch off the engine and remove the ignition key.

– If required, connect the hydraulic hoses for the hydraulic paddle roller adjustment (additional equipment) – see Hydraulic adjustment of the paddle rollers (R03/0100), page 8.11.

Connecting electric system

JAGUAR Type 494

ATTENTION!

11

Beware of friction and jamming!

– Insert plug (11) for drive monitoring of the mower drive.

– Auto-Contour plug socket – see forage harvester operator's manual.

6

(Fig. 7, 6)

JAGUAR Type 493

11

7

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

7.5

Prior to operation – If necessary, insert plug (12) for the side lights (USA only) – see forage harvester operator's manual.

JAGUAR Type 494

12

(Fig. 9, 8)

8 JAGUAR Type 493

12

9

– If necessary, insert plug (13) for the laser pilot (additional equipment, JAGUAR Type 493 only).

JAGUAR Type 493

– Autopilot socket – see operator's manual for forage harvester or laser pilot.

13

(Fig. 10)

10

7.6

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Prior to operation Checking the setting of the coupling flange to the quick-fit coupling – Check the installation position of the coupling flange (18).

The coupling flange (18) of the initial gearbox must have full contact with the quick-fit coupling on all sides.

DANGER! 11

There is a danger of injury when working on or under the raised front attachment.

– Never work under the raised front attachment unless it is safely supported.

18

– Provide secure support / propping for the front attachment.

– Use appropriate supports.

– If necessary, adjust the coupling flange.

– Raise front attachment to the highest position.

12

– Provide secure support / propping for the front attachment.

– Use suitable supports.

– Loosen bolts (17), – Release nut (16).

15 16 17

15

– Using nut (15, 16), adjust the height of the coupling flange (18).

16

– Tighten nut (16) and bolts (17) again.

(Fig. 11, 12, 13)

17

18 13

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

7.7

Prior to operation Setting the paddle roller The height of the paddle roller (20) above the mower head must be adjusted to suit the fodder level, the fodder conditions and the application conditions.

Four drilled holes (Fig. 15) are available for adjustment.

Hole A = short fodder Hole B = normal fodder conditions

20

Hole C/D = long fodder (longer than approx. 800 mm) 14

72794

21

22

D

26 25 D 24

D

DANGER! Never work on the front attachment unless the drive is switched off and the engine is stopped.

A B

– Remove the ignition key!

C

– Switch off the battery isolating switch!

Both sides must be adjusted. To adjust the paddle roller (20), proceed as follows:

23

– Lower front attachment to the ground.

15

– Switch off the engine and remove the ignition key.

– Switch off the battery isolating switch!

– Open the side panelling and secure in position – see Panelling, page 9.49.

– Remove bolts (22, 23, 24).

– Loosen lock nut (26) on the adjusting screw (21).

NOTE! When using drilled hole (D), the chain must be extended with an offset link.

– Using the adjusting screw (21) and the nut (25), bring the paddle roller to the desired position.

– Replace all screws and tighten them.

– Close side panelling.

Order no.: Offset link (L-12 A-1)

00 0767 147 0

(Fig. 14, 15)

7.8

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Prior to operation Hydraulic adjustment of the paddle roller (additional equipment)

A 30

Setting the stroke limits The straps (30) serve as stroke limiters for the adjustment plates. The straps (30) can be fitted in two different positions, depending upon the application.

Y X

Position A – low clearance height For low or flat crops.

Stroke Y = 60 mm 16

Position B – high clearance height For tall crops.

Stroke X = 90 mm – Move the paddle roller to the lowest position – see Hydraulic adjustment of the paddle rollers (R03/0100), page 8.11.

Trough left – Position A

A 30

– Fit the straps (30) in the corresponding position (A or B) using hexagon head bolts (31) (M12x35MK) and contact washers (32).

B

31 32

CAUTION! The straps must be mounted in the same positions on both sides!

17

Trough left – Position B

A

(Fig. 16, 17, 18)

B

30

31 32

18

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

7.9

Prior to operation Adjusting cutterbar skids DANGER! There is a danger of injury when working on or under the raised front attachment.

36

– Never work under the raised front attachment unless it is safely supported.

35

– Provide secure support / propping for the front attachment.

37 36

– Use appropriate supports.

19

ATTENTION! Adjust cutterbar skids to the same height on each side – if a cutterbar skid is set higher it will be subject to increased wear!

The minimum cutting height is set by the cutterbar skids (37) as follows: – Raise front attachment completely.

– Switch off the engine and remove the ignition key.

– Switch off the battery isolating switch!

– Provide secure support / propping for the front attachment.

Use appropriate supports.

– Loosen bolts (36).

– Set minimum cutting height with the straps (35) and drilled holes.

– Replace bolts (36).

(Fig. 19)

Setting mower head inclination The inclination of the mower head can be set to an angle 3º greater by removing the wedges (40) and wheel chocks (41). This is advisable in extreme operating conditions.

41

Keep wheel chocks for later use.

40

(Fig. 20)

41

40 72790

7.10

41

20

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Prior to operation Required parts 42

42

43 43

44 45

42

44 42 43 44

43 44 45

77253

21

22285

Image no.

Designation

Quantity

Order no.

42

Countersunk screw M10x35-10.9

24

00 0214 002 0

43

Contact washer A10

16

00 0239 388 0

44

Hex. nut M10

16

00 0952 053 0

45

Bushing

4

00 0935 041 0

The required parts can be ordered from the CLAAS spare parts service.

(Fig. 21) Setting the mower head to a steeper angle – Remove the mower head.

– Remove the wedges.

– Carefully lift the mower head into the machine with suitable lifting equipment.

CAUTION! Do not fit wheel chocks (41) (Fig. 20). These would place a false load on the high-strength bolts and might break them.

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

7.11

Prior to operation – Screw the mower head to the frame using bolt (42), contact washers (43) and nuts (44).

– Tighten nuts (44).

Tightening torque = 70 Nm (Fig. 21) – Fit cutterbar skids (46) with bushing (45), contact washers (43) and nuts (44).

45

46

– Observe correct installation position of the cutterbar skids (46)!

– Tighten nuts (44).

Tightening torque = 85 Nm (Fig. 22)

43 44 22

77254

– Fit wear skids (45) with contact washers (43) and nuts (44).

47

– Tighten nuts (44).

Tightening torque = 70 Nm (Fig. 23) 43 44

23

77255

Setting inclination of mower head to a smaller angle – Remove the mower head.

– If necessary, remove the bushing (45).

– Unscrew nut (44).

– Remove bushing (45).

– Fit and tighten nuts (44).

Tightening torque = 70 Nm

45 44

(Fig. 24)

45 44

77256

24

– Fit mower head with wedges.

7.12

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Prior to operation Setting the safety bars After removal or installation of the wedges and wheel chocks, adjust the safety bar (52) on both sides as follows: 50

A

– Unfasten bolt (51).

– Release bolts (50).

B

– Fix safety bar (52) in the appropriate drilled hole.

52

– Hole (A) = flatter

51

– Hole (B) = steeper – Tighten all bolts again.

25

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

(Fig. 25)

7.13

Prior to operation WORKING AND TRANSPORT POSITION Transport position

NOTE! The front attachment must be removed and loaded and secured on a suitable vehicle for transport on public roads and tracks. Install and fasten safety device on feeder housing – see Transport on public roads, page 3.3.

26

– Raise front attachment completely for transport – see Raising and lowering the front attachment, page 8.3.

– Lock the pendulum frame – see Locking / unlocking the pendulum frame, page 8.9.

(Fig. 26)

Working position – Remove safety device on feeder housing – see operator's manual for forage harvester.

– Hitching up the front attachment, see page 7.3.

– Remove prop stands from mower head – see Attaching / removing prop stands, page 6.4.

– If necessary, unlock the pendulum frame – see Locking / unlocking the pendulum frame, page 8.9.

– Lower front attachment to working height – see Raising and lowering the front attachment, page 8.3.

7.14

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Prior to operation REMOVING AND STORING THE FRONT ATTACHMENT DANGER! There is a danger of injury when working on or under the raised front attachment.

– Never work under the raised front attachment unless it is safely supported.

– Provide secure support / propping for the front attachment.

– Use appropriate supports.

Never work on the front attachment unless the drive is switched off and the engine has stopped.

– Remove the ignition key!

– Switch off the battery isolating switch!

ATTENTION! Always lower the front attachment on firm and level ground!

Under difficult conditions (e.g. max. cutting height), the front attachment can only be refitted with great difficulty.

– Before removal, attach prop stands to mower head.

Proceed as follows to store the front attachment: – Switch off the engine and remove the ignition key.

– Switch off the battery isolating switch!

– Attach prop stands (1) to mower head to ensure that the front attachment can always be reattached – see Attaching / removing prop stands, page 6.4.

– Lock the pendulum frame – see Locking / unlocking the pendulum frame, page 8.9.

1 27

– Lower front attachment to the ground.

– If necessary, disconnect the hydraulic hoses for the hydraulic paddle roller adjustment at the quick release couplings (additional equipment) – see Hydraulic adjustment of the paddle rollers (R03/0100), page 8.11.

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

7.15

Prior to operation

NOTE! Lay out hydraulic hoses to prevent the quick release couplings from becoming dirty.

– Remove the electrical plug (2) for drive monitoring from the forage harvester.

JAGUAR Type 494

2

28 JAGUAR Type 493

2

29

7.16

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Prior to operation – Disconnect plug (3) for side lights (USA only).

JAGUAR Type 494

3

30 JAGUAR Typ 493

3

31

– If necessary, pull out plug (4) for the laser pilot (additional equipment, JAGAUAR Type 493 only).

JAGUAR Type 493

4

NOTE! Lay out cables to prevent the plugs from becoming dirty.

– Unlock front attachment – see Opening the lock, page 7.3.

32

– Lower forage harvester feeder housing completely.

ATTENTION! Ensure that the coupling hooks do not catch on the coupling pins when reversing the combine harvester!

– Cautiously reverse the forage harvester.

(Fig. 27-32)

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

7.17

Operation

Operation

8 Operation OPERATION DANGER! Nobody must stand in the danger area while the front attachment is being raised or lowered.

– Direct all persons away from the danger area!

Precondition – Prepare forage harvester for field travel.

– see operator's manual for forage harvester.

– Observe the safety instructions in the operator's manual for the forage harvester.

To activate the necessary components for operation of the front attachment:

JAGUAR Type 494

– Turn on safety switch (1).

1

(Fig. 1, 2)

1 JAGUAR Type 493

1

2

8.1

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Operation Multifunction handle

JAGUAR Type 494

Function 6 3 7

2

Front attachment: raise quickly / slowly

3

Front attachment: lower quickly / slowly

4

Pre-set cutting height control: switch on and off

5

Contour, ground pressure, oscillation damper: switch on and off

6

Feeder unit: switch off and reverse

7

Feeder unit: switch on and off

5 4

2

3

JAGUAR Type 493

(Fig. 3, 4)

6

3

7

5 2

4 4

JAGUAR Type 494

Function 8

Compressing roller, reel: raise and lower

(Fig. 5, 6) 8

5 JAGUAR Type 493

8

6

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

8.2

Operation Raising and lowering the front attachment

JAGUAR Type 494

With the multifunction lever: – Press push switch (3) ) – lower front attachment.

4 3

– Press push switch (2) ) – raise / extend front attachment.

5

– Switch on the “contour system” by pressing the push switch (5).

– Switch on the “pre-set cutting height control” by pressing the push switch (4).

2 7

NOTE!

JAGUAR Type 493

The “contour system” and the “pre-set cutting height control” are switched off by pressing the push switch (3, 2).

R

4 3

Set the working height or cutting height – see Adjusting cutting height, page 8.8.

5

(Fig. 7, 8)

2 70798A

8.3

8

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Operation Operating front attachment DANGER! Danger from flying objects.

– Direct all persons away from the danger area!

– If necessary, switch off front attachment immediately!

Danger of injury when working on the mower blades or their fastening elements!

Only work on the mower blades or their fastening elements if the drive and cutting discs are at standstill!

– Switch off mower drive.

– Switch off engine.

– Do not leave the forage harvester until the cutting discs have come to a complete stop!

– Remove the ignition key!

– Switch off the battery isolating switch!

– Remove universal drive shaft!

– Wear gloves!

ATTENTION! Keep the area to be mowed free of foreign objects!

Before operation and after driving into an obstacle check the cutter head for damaged, missing or worn mower blades and check the mower blade fastening elements.

– Check that the mower blades are correctly seated – see Mower blades, page 9.30.

Extended overloading of the universal drive shaft coupling will burn out the clutches.

– Avoid frequent extended overloading of the universal drive shaft couplings.

1. Carry out steps “Prior to operation” – see Check and observe the following before putting into operation, page 7.1.

2. Bring the front attachment into working position and check – see Working position, page 7.14.

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

8.4

Operation 3. If necessary, unlock the pendulum frame – see Locking / unlocking the pendulum frame, page 8.9.

4. Prepare forage harvester for field travel.

– see operator's manual for forage harvester.

5. Activate necessary components for operation of the front attachment – see Precondition, page 8.1.

6. Start the engine.

7. Check drop rate of front attachment and adjust if necessary – see Setting the drop rate (JAGUAR Type 493 only), page 6.8.

8. Set the cutting height – see Adjusting cutting height, page 8.8.

9. Before moving into the forage, switch on the front attachment at idle speed.

10. Switch on the front attachment.

The front attachment is switched on together with the feeder unit.

JAGUAR Type 494

JAGUAR Type 494

– Unlock and turn on switch (12).

12

– Briefly press switch (6) to engage the quick-fit coupling in the coupling flange (switch on reversing function).

– Turn on switch (7).

The feed rollers of the feeder unit and the feeder mechanisms of the front attachment are switched on.

(Fig. 9, 10) 9

JAGUAR Type 494

6

7

10

8.5

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Operation JAGUAR Type 493 – Squeeze the releasing ring (E) and the selector knob (11) (main drive ON/OFF) together and lift as one.

JAGUAR Type 493

11

– Briefly press switch (6) to engage the quick-fit coupling in the coupling flange (switch on reversing function).

E

– Turn on switch (7).

The feed rollers of the feeder unit and the feeder mechanisms of the front attachment are switched on.

(Fig. 11, 12) 11 JAGUAR Type 493

6 7

12

11. Lower front attachment to working height – see Raising and lowering the front attachment, page 8.3.

12. Accelerate to working speed.

NOTE! The whistling noise of the cutting discs at high speed is completely normal and is generally muffled during actual mowing.

13. Move into the forage.

14. Set the ground speed as required for the working conditions (ground conditions, density, height and quality of the forage).

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

8.6

Operation Instructions for mowing DANGER! Clearing blockages or removing foreign objects: – Switch off mower drive.

– Switch off engine.

– Do not leave the forage harvester until the cutting discs have come to a complete stop!

– Remove the ignition key!

– Switch off the battery isolating switch!

– Wear gloves!

After extended operation, the mower head can reach temperatures of up to approx. 80° C. – Danger of burns!

– Do not touch the bar!

• Reduce ground speed when working in dense or downed forage and when mowing around a curve.

• Adjust the height of the paddle roller above the mower head to suit the application conditions – see Setting the paddle roller, page 7.8.

• The cutterbar cannot mow backwards. Raise cutterbar when moving backwards.

• Do not mow on rocky ground!

• When mowing for longer periods in hilly terrain, especially when mowing across the slope, do not always mow the same way, but alternate to mow in the opposite direction.

8.7

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Operation Difficult application conditions DANGER! Be particularly cautious when working in difficult conditions or on uneven ground. To prevent flying objects, note the following points: – Direct all persons away from the danger area!

– If necessary, switch off front attachment immediately!

– Increase cutting height – see Adjusting cutting height, page 8.8.

– If necessary, set mower head to a flatter angle – see Setting mower head inclination, page 7.10.

– Reduce ground speed.

– Check that the mower blades can swing back if they hit an obstacle.

Adjusting cutting height The cutting height is adjusted with the forage harvester contour system. Two operating modes are available:

• Pre-set cutting height control and • contour system (ground pressure control), with a

JAGUAR Type 493

recommended ground pressure of approx. 470 kg (potentiometer (4) stage 3, JAGUAR Type 493).

NOTE! 4

13

To allow the “contour system” (automatic ground pressure control) to operate properly, fitting the “additional damping” accessory is recommended. Further information – see Additional damping (R05/0060, JAGUAR Type 493 only), page 8.13.

For more information, see operator's manual for forage harvester - contour system or pre-set cutting height control.

The minimum cutting height is set by the cutterbar skids – see Adjusting cutterbar skids, page 7.10.

(Fig. 13)

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

8.8

Operation Locking / unlocking the pendulum frame DANGER! The trough is maintained horizontal via springs. Danger of crushing at pinch points on pretensioned components.

Serious injuries.

– Never reach in between pretensioned components.

– Only unlock the pendulum frame if the front attachment is fitted and locked.

Unlock the pendulum frame for better adaptation to ground contours: – Turn lever (5) to position (A).

5

NOTE! When using “pre-set cutting height control”, the pendulum frame must be locked.

A 14

Lock the pendulum frame.

B

– Turn lever (5) to position (B).

– Check that the frame is locked, if necessary move the front attachment up and down slightly.

5

(Fig. 14, 15)

15

8.9

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Operation Adjusting length of cut

II

DANGER!

I

Work on the front attachment and/or the forage harvester should only be undertaken when the drive is disconnected and the motor is at standstill.

6

– Remove the ignition key!

– Switch off the battery isolating switch!

16

To adjust the length of the cut, the universal drive shaft (6) (Fig. 16) can be changed on the gearbox for the intake auger. The gearbox affects the speed of the intake auger only.

Length and height of cut range Gearbox input I:

4 to 10 mm

Gearbox input II:

10 to 21 mm

If the number of knives is halved, the length of the cut doubles.

(Fig. 16, 17) 17

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

8.10

Operation ADDITIONAL EQUIPMENT Hydraulic adjustment of the paddle rollers (R03/0100) The height of the paddle roller above the mower head must be adjusted to suit the fodder level, the fodder conditions and the application conditions. Hydraulic paddle roller adjustment can be carried out during operation without any problems. This is particularly important when the operation conditions vary greatly.

Necessary settings before operation – see Hydraulic adjustment of the paddle roller (additional equipment), page 7.9.

18 JAGUAR Type 494

ATTENTION! The hydraulic system may be contaminated by dirty hydraulic connectors or hydraulic coupling sockets.

– Always clean the male couplings of the hydraulic hoses and the hydraulic coupling sockets before connecting them.

1

19 JAGUAR Type 493

NOTE! If the hydraulic lines are connected wrong, the mower drive will not function!

Note the colour coding on the hydraulic lines and sockets.

– Connect the hydraulic hoses to the quick-fit couplings (1).

1

(Fig. 18, 19, 20)

20

8.11

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Operation Operation takes place using the multifunction lever.

JAGUAR Type 494

Lift or lower the paddle roller by actuating the switch (2). h

Position (s) = lowering paddle roller Position (h) = lifting paddle roller

2

Further information – see operator's manual for the forage harvester.

Order no.:

s

Add-on kit 21

00 0495 508 0

(Fig. 18-21)

JAGUAR Type 493

h 2 s 70799

22

Laser pilot (R03/0090, DIRECT DISC 520 Comfort only)

JAGUAR Type 493

For optimum exploitation of the full working width and to make work easier for the driver, the DIRECT DISC can be fitted with the laser pilot (5) as a steering aid.

The laser pilot automatically guides the DIRECT DISC along the edge of the crop. The driver monitors the machine and needs to take action only at the headland or in the event of a malfunction.

5

Order no.: Add-on kit 23

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

00 0495 424 0

(Fig. 23)

8.12

Operation Feed hats (D03/0080) To improve the crop infeed, the cutting discs can be fitted with feed hats. Proceed as follows: – Remove cap 4).

3

– Fit feed hats (3) in accordance with Fig. 24.

Order no.: 4

Installation kit

00 0495 509 0

(Fig. 24) 74001

24

Additional damping (R05/0060, JAGUAR Type 493 only)

JAGUAR Type 493

When operating the front attachment, we recommend fitting the forage harvester with the “additional damping” for medium duty front attachments (DIRECT DISC). This ensures that the “contour system” works properly and that the front attachment presses down on the ground with the preset ground pressure.

75085

25

If the front attachment is operated only with the “pre-set cutting height control”, this additional equipment is not required.

Order no.: Add-on kit

00 0495 510 0

(Fig. 25) 3-groove belt drive (D03/0090) On forage harvesters with 2-groove belt drive on the feeder unit, we recommend changeover to a 3-groove belt drive for operation of the front attachment. This greatly reduces the wear on the multiple belt.

For further information, – see Boosted drive feeder unit, page 6.6 or page 6.10.

Installation kit JAGUAR Type 494

JAGUAR Type 494

Order no.: Installation kit, complete

00 1312 373 0

(Fig. 26)

77391

8.13

26

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Operation Installation kit JAGUAR Type 493

JAGUAR Type 493

Order no.: Installation kit, complete

00 0495 820 2

(Fig. 27)

75084

27

Speed sensor Each front attachment is designed for use with a specific forage harvester type. If the front attachment is to be used on another forage harvester type, it is necessary to replace the speed sensor.

For further information, – see Using the front attachment, page 6.5.

Modification kit for JAGUAR Type 494

JAGUAR Type 494

Order no.: Add-on kit

00 1312 127 0

(Fig. 28)

77392

28

Modification kit for JAGUAR Type 493

JAGUAR Type 493

Order no.: Add-on kit

00 1312 128 0

(Fig. 29)

77393

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

29

8.14

Maintenance

Maintenance

9 Maintenance IMPORTANT MAINTENANCE INSTRUCTIONS DANGER!

Check hydraulic hose connections at regular intervals, and replace them in the event of damage or ageing!

Replaced hydraulic lines must correspond to the technical requirements of the equipment manufacturer!

Repair work on the hydraulic system must be carried out by authorised workshops, if possible your CLAAS partner.

Always switch off the drive and the forage harvester for troubleshooting, repair, maintenance and cleaning work.

Bolts

– Remove the ignition key!

Check that all split pins and roll pins are in place.

– Switch off the battery isolating switch!

Lubrication

DANGER!

Observe the oil change intervals and the oil type specified by the manufacturer. Use only good quality grease or oil to lubricate the front attachment. Clean the grease nipples before applying the grease. Grease all points that require lubrication, observing the intervals specified in the lubrication chart.

Carry out repair, maintenance and cleaning work on or under the raised front attachment or feeder housing only when they are securely supported.

– Never work under the raised front attachment unless it is safely supported.

– Provide secure support / propping for the front attachment.

– Use suitable supporting elements.

Hydraulic system DANGER! Always depressurise the hydraulic system before working on it.

Check all bolts for tightness and retighten if necessary.

The lubrication intervals stated apply to normal service conditions only. Lubricate more frequently if the front attachment is used in severe conditions.

ENVIRONMENT! Dispose of oil and grease according to regulations!

NOTE! The quoted filling quantities are approximate values, the oil level check is always decisive for the correct oil level.

Safety devices Fluid escaping under high pressure (hydraulic oil etc.) can penetrate the skin and cause serious injuries.

Immediately consult a doctor in case of injury, otherwise serious infections can set in.

Open folding safety devices only when the drive is switched off and the engine is at standstill.

– Remove the ignition key!

– Switch off the battery isolating switch!

ENVIRONMENT! Dispose of oil and grease according to regulations!

Mount all safety devices again after completing any maintenance and repair work.

Regularly check safety guards.

Replace worn or damaged safety guards with new ones.

9.1

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance

Maintenance DRIVE SYSTEMS Gearbox DANGER! There is a danger of injury when working on or under the raised front attachment.

– Provide secure support / propping for the front attachment.

– Use suitable supporting elements.

Work on the front attachment and/or the forage harvester should only be undertaken when the drive is disconnected and the motor is at standstill.

– Remove the ignition key!

– Switch off the battery isolating switch!

– Uncouple the universal drive shaft!

NOTE! When checking the oil level for all gearboxes, the front attachment must be raised until the mounting frame is vertical.

The quoted filling quantities are approximate values, the oil level check is always decisive for the correct oil level.

1. Raise / lower the front attachment until the mounting frame (R) is vertical – see Raising and lowering the front attachment, page 8.3.

(Fig. 1) 2. Switch off drive and engine.

R

3. Remove the ignition key.

4. Switch off battery isolating switch.

5. Secure forage harvester against rolling away.

1

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

6. Provide secure support / propping for the front attachment.

Use suitable supporting elements.

9.2

Maintenance

A

2 ENVIRONMENT! 1

Dispose of drained oil according to regulations.

Unless specified otherwise, change all gear oils every 500 working hours - at the end of every season at the latest. Check all gearboxes for leaks once a week and check the oil level if necessary.

2

Intake auger gearbox (A) 3

Filling capacity and specification – see Lubricants chart, page 9.55 1 = oil filler cap 2 = oil level check plug 3 = oil drain plug (Fig. 2, 3, 4)

3 4

9.3

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance

C B

5 Angle drive – mower drive / feeder unit drive (B) 4

Filling capacity and specification – see Lubricants chart, page 9.55 4 = oil top-up hole and breather valve 5 = oil level check plug 6 = oil drain plug

5

(Fig. 5, 6) 6

6

Angle drive - mower drive (C) Filling capacity and specification – see Lubricants chart, page 9.55

7

7 = oil top-up hole and breather valve 8 = oil level check plug 9 = oil drain plug

8

(Fig. 5, 7) 9 7

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

9.4

Maintenance

D

D

10

10

8 Angle drive - mower drive (D) Filling capacity and specification – see Lubricants chart, page 9.55

11 10

10 11 12 13 13

= breather valve (DIRECT DISC 610) = oil filler cap = oil level check plug = oil drain plug

12

9

To change the oil or check its level, the upper side panelling – see Top side panelling, page 9.51 must be removed.

(Fig. 8, 9) Breather valve Unscrew the breather valves (4, 7, 10) and clean them after the first 10 working hours. Then repeat at regular intervals.

– Check breather valve for correct functioning and clean it.

(Fig. 6, 7, 9)

9.5

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance MOWER HEAD DANGER! After extended operation, the mower head can reach temperatures of up to approx. 80° C. – Danger of burns!

– Do not touch the bar!

– Wear safety gloves!

NOTE! If the maintenance instructions are observed, there is no reason to worry if the cutterbar becomes very hot, so long as the cutting discs can still be easily rotated manually on the warm machine. An operating temperature of approx. 60° C must be considered normal.

DIRECT DISC 610:

DIRECT DISC 610

1 = oil filler cap and oil level check plug 2 = oil drain plug (Fig. 10, 11)

1

10 DIRECT DISC 610

2 11

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

9.6

Maintenance DIRECT DISC 520 Comfort:

DIRECT DISC 520 Comfort

1 = oil filler cap and oil level check plug 2 = oil drain plug

1

(Fig. 12, 13)

12 DIRECT DISC 520 Comfort

2 13

Oil level check DANGER! There is a danger of injury when working on or under the raised front attachment.

– Provide secure support / propping for the front attachment.

– Use suitable supporting elements.

Work on the front attachment and/or the forage harvester should only be undertaken when the drive is disconnected and the motor is at standstill.

– Switch off mower drive.

– Switch off the engine and do not leave the forage harvester until the cutting discs have come to a complete stop.

– Remove the ignition key!

– Switch off the battery isolating switch!

9.7

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance

NOTE! Only undertake the oil level check on solid flat ground!

– Warm up front attachment for 8 - 10 minutes.

– Lower front attachment until the mower head is horizontal in the direction of travel.

(Fig. 14)

74892

14

– Secure forage harvester against rolling away.

– Switch off drive and engine.

– Remove the ignition key.

– Switch off battery isolating switch.

– Unlock pendulum frame – see Locking / unlocking the pendulum frame, page 8.9.

DIRECT DISC 610 left:

DIRECT DISC 610 left

– Place support under front attachment on the right raising it by dimension (h).

Dimension h = 260 mm (Fig. 15)

1

h 77373

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

15

9.8

Maintenance DIRECT DISC 610 right:

DIRECT DISC 610 right

– Place support under front attachment on the left raising it by dimension (h).

Dimension h = 260 mm (Fig. 16)

1

h 16

77397

DIRECT DISC 520 Comfort:

DIRECT DISC 520 Comfort

– Place support under front attachment on the right raising it by dimension (h).

Dimension h = 230 mm 1

(Fig. 17)

1

h

17

77374

– Provide secure support / propping for the front attachment.

Use suitable supporting elements.

– Wait approx. 10 - 15 minutes before checking the oil level to allow the oil to collect.

– Check oil level through the opening (1).

X

1 NOTE! If the oil level cannot be determined exactly, all oil must be drained and the specified amount of fresh oil must be added.

Oil level X = approx. 5 mm from the lower edge of the oil level check hole

77396

9.9

18

(Fig. 10-18)

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance Oil change DIRECT DISC 610 left

DANGER!

1

Never work on the front attachment unless the drive is switched off and the engine has stopped.

– Switch off mower drive.

– Switch off engine.

– Do not leave the forage harvester until the cutting discs have come to a complete stop!

2 19 DIRECT DISC 610 right

– Remove the ignition key!

– Switch off the battery isolating switch!

1 After initial operation or after an overhaul of the mower head, the first oil change must be made after 50 working hours, then every 200 working hours and at the latest after every season.

Filling capacity: Filling capacity and specification – see Lubricants chart, page 9.55 2 20 DIRECT DISC 520 Comfort

1

– Warm up front attachment for 8 - 10 minutes.

– Lower front attachment until the mower head is tilted slightly to the rear in the direction of travel.

1

– Unlock pendulum frame – see Locking / unlocking the pendulum frame, page 8.9.

– Swivel front attachment – see illustrations.

– Provide secure support / propping for the front attachment.

Use suitable supporting elements.

2 ENVIRONMENT! 21

Dispose of drained oil according to regulations.

– Drain oil through the opening of the magnetic plug (2).

– Clean the magnetic plug before reinstalling it.

– Top up with the prescribed quantity of oil through the oil filler cap (1).

– Check oil level.

(Fig. 19, 20, 21)

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

9.10

Maintenance

E

F

G

22

CLUTCHES Clutches (E, G) The friction clutch (E) and overload clutch (G) must be opened and serviced by a specialist every 500 working hours - at the latest at the end of every second season - as prescribed in the manufacturer's operator's manual.

ATTENTION! The torque setting of the clutches must not be changed, as this could cause serious damage to the universal drive shaft, gearbox etc.

– Check friction plates regularly for wear and replace if necessary.

NOTE! After extended downtime, the clutches must be vented before operating the front attachment again – clutch manufacturer's operator's manual.

(Fig. 22)

9.11

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance Torque setting Friction clutch (E) mower drive DIRECT DISC 520 Comfort

DIRECT DISC 520 Comfort

Torque: 1450 Nm (Fig. 22, 23)

23

DIRECT DISC 610

DIRECT DISC 610

Torque: 1650 Nm (Fig. 22, 24)

77370

24

Overload clutch (G) feeder units Torque: 1400 Nm (Fig. 22, 25)

77368

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

25

9.12

Maintenance Free wheel (F) mower drive maintenance-free (Fig. 22, 26)

26

77380

Venting the friction clutch DANGER! Pinch points during assembly.

Danger of crushing limbs.

– Keep limbs clear of danger zone.

– Use suitable hand tools.

– Tighten nuts (6).

DIRECT DISC 610

– Rotate pulley several times.

– Back off nuts (6) to end of thread.

(Fig. 27) 6

27

9.13

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance CHAINS Lubricating the drive chain DANGER! Never work on the front attachment unless the drive is switched off and the engine has stopped.

1

– Remove the ignition key!

– Switch off the battery isolating switch!

28

Open and secure the side panelling (1) to lubricate the drive chains – see Side panelling, page 9.50.

(Fig. 28)

Tensioning steel roller chains Check the tension of the steel roller chains: Load the tight span slightly.

A

Using your thumb, press slack span in the centre between the sprockets.

It should be possible to press the slack span in by approx. 2 % of the axle spacing.

Check the tension more frequently on new chains.

Example:

x

Axle spacing (A) = 500 mm 29

75174

Push-in (x) (2 %) = approx. 10 mm (Fig. 29)

Tensioning drive chain Tensioning drive chain with clamping bracket The clamping bracket (1) is only fitted on front attachments without additional equipment “hydraulic paddle adjustment”.

without additional equipment “Hydraulic paddle adjustment”

(Fig. 30)

1

30

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

9.14

Maintenance

DANGER! Danger of crushing at pinch points on pretensioned components.

Serious injuries.

– Never reach in between pretensioned components.

– Use suitable aids to secure pretensioned components or relieve them.

– Follow the instructions.

The help of another person is required here.

– Open left side panelling – see Side panelling, page 9.50.

– Unscrew nut (2).

without additional equipment “Hydraulic paddle adjustment”

– Loosen bolt (3) slightly.

(Fig. 31) 2

3

31

– Grip clamping bracket (5) by the square tube using a suitable tool (e.g. side levelling width across flats 55).

without additional equipment “Hydraulic paddle adjustment”

– Remove bolt (4).

5

(Fig. 32)

4

32

9.15

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance – Using a suitable tool (for example side levelling width across flats 55), tension the clamping bracket at the clamping bracket square tube (5).

without additional equipment “Hydraulic paddle adjustment”

– Turn square tube clockwise until the mark (M) is between 5° and 15°.

– Relieve clamping bracket: – Turn square tube anticlockwise.

(Fig. 33, 34) 5 33 without additional equipment “Hydraulic paddle adjustment”

M 34

– Insert bolt (4) through the next adequately sized drilled hole (B).

without additional equipment “Hydraulic paddle adjustment”

– Secure bolt (4) with contact washer (6) and nut (2).

– Remove tool.

4

(Fig. 35, 36)

35 without additional equipment “Hydraulic paddle adjustment”

2 6 B 4

76925

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

36

9.16

Maintenance – Check adjustment at the display (7) on the clamping bracket.

without additional equipment “Hydraulic paddle adjustment”

Possible positions for the mark (M): 7

M

Mark

Chain tension

between 5° / 15°

OK

less than 5°

too low

Displace bolt (3) by one drilled hole (+) or replace or shorten chain

greater than 15°

too high

Displace bolt (3) by one drilled hole (-) or replace or lengthen chain

37 without additional equipment “Hydraulic paddle adjustment”

2

Remedy

– Correct as necessary.

6

(Fig. 37, 38)

B 4 38

76925

– Tighten nut (2).

without additional equipment “Hydraulic paddle adjustment”

– Tighten bolt (3).

(Fig. 39) 2

3

39

– Close left side panelling – see Side panelling, page 9.50.

9.17

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance Tensioning drive chain with chain tensioner The chain tensioner (10) is only fitted on front attachments with additional equipment “hydraulic paddle adjustment”.

with additional equipment “Hydraulic paddle adjustment”

10

(Fig. 40)

DANGER! Danger of crushing at pinch points on pretensioned components.

Serious injuries.

40

– Never reach in between pretensioned components.

– Use suitable aids to secure pretensioned components or relieve them.

– Follow the instructions.

– Open left side panelling – see Side panelling, page 9.50.

– If necessary, attach spring (12) on the bracket (11).

with additional equipment “Hydraulic paddle adjustment”

(Fig. 41)

11

12

41

– Fully screw nut (14) onto the eye bolt (13).

with additional equipment “Hydraulic paddle adjustment”

– Attach eye bolt (13).

12

– Tension spring (12) with nut (15).

– Tighten nut (15).

(Fig. 42)

13 14 15 42

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

9.18

Maintenance – Check chain tension – see Tensioning steel roller chains, page 9.14.

– Correct as necessary.

If chain is too slack: – Replace spring or – shorten or replace chain.

– Close left side panelling – see Side panelling, page 9.50.

V-BELTS DANGER! Never work on the front attachment unless the drive is switched off and the engine has stopped.

– Remove the ignition key!

– Switch off the battery isolating switch!

Tensioning V-belts NOTE! If a V-belt breaks, the forage harvester feeder drive and thus the cutterbar are shut down immediately!

When the mower unit is put into service for the first time, check the tension of the v-belts after the first 5 working hours and tighten if necessary.

After this, check at regular intervals.

The belts are correctly tensioned when the projection of the spring guide (4) is set to dimension Z. To retension: – Switch off drive and engine.

– Remove the ignition key.

– Switch off battery isolating switch.

– Secure forage harvester against rolling away.

9.19

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance – Open the hood (1) and secure – see Hood, page 9.50.

1

(Fig. 43)

43

– Loosen nut (3).

– Screw in or back off spring guide (4) to dimension (Z).

2 3

– Tension spring (2) with nut (3).

– Check dimension (Z).

– Repeat procedure if necessary.

– Tighten nut (2).

Dimension Z = 47 mm (Fig. 44)

Z

4 44

Checking V-belts Check the V-belts of the mower drive regularly for wear, breakage and other damage and replace if necessary.

NOTE! Replace V-belts in sets only.

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

9.20

Maintenance SPRING ADJUSTMENT DANGER! Danger of crushing at pinch points on pretensioned components.

Serious injuries.

– Never reach in between pretensioned components.

– Use suitable aids to secure pretensioned components or relieve them.

– Follow the instructions.

Spring tension of intake auger The intake auger is pressed on to the crop on the left with springs (3). The pressure is regulated by spring tension. Proceed as follows:

1 X

– Open the side panelling and secure in position – see Side panelling, page 9.50.

– Remove left plastic cover – see Top side panelling, page 9.51.

3

2 3

45

– Tension springs (3) evenly with bolts (1) to dimension (X). As you do so, exert pressure in opposite direction at the head (2) of the spring (3).

Dimension X = 30 mm (Fig. 45) – Fit left plastic cover – see Top side panelling, page 9.51.

– Close side panelling – see Side panelling, page 9.50.

9.21

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance Pendulum frame - adjusting the float springs The pendulum frame is held horizontal with the springs (4). The position of the front attachment is adjusted using spring tension. Proceed as follows:

Z 4

– Open the hood and secure – see Hood, page 9.50.

– Release nuts (5).

5

– Tension springs (4) evenly with bolts (6) to dimension (Z).

4 46

Basic setting: Dimension (Z) = 82.5 mm ± 2.5 mm – Tighten nuts (5).

– Check setting with front attachment fitted.

– Fit front attachment completely.

– Raise front attachment.

6

– Open lock.

The front attachment must be horizontal.

– If necessary, correct the setting until the front attachment is horizontal.

– Close hood – see Hood, page 9.50.

47

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

(Fig. 46, 47)

9.22

Maintenance UNIVERSAL DRIVE SHAFTS Servicing the universal drive shaft DANGER! Work on the universal drive shafts only when the drive and engine are switched off.

– Remove the ignition key!

– Switch off the battery isolating switch!

Never run universal drive shafts without their guards, or if the guards are damaged.

– Mounting shaft guard and protective tube.

– Fasten them to prevent them rotating!

– The universal drive shafts must only be operated when in perfect condition.

For lubrication intervals and lubricants, see Lubrication Chart, page 10.1.

In some cases, the universal drive shaft guards must be removed to lubricate the universal drive shafts – see Dismantling / fitting universal drive shaft guards, page 9.24.

Service the universal drive shafts in accordance with the instructions of the shaft manufacturer – see drive shaft manufacturer's operator's manual.

Observe the manufacturer's safety instructions!

9.23

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance General information on universal drive shafts DANGER! Never run universal drive shafts without their guards, or if the guards are damaged.

– Mounting shaft guard and protective tube.

– Fasten them to prevent them rotating!

– The universal drive shafts must only be operated when in perfect condition.

Immediately replace damaged or missing protective tubes, universal drive shaft guards and securing chains.

Protect the universal drive shafts against the elements.

After the working season, thoroughly clean and lubricate all components of the universal drive shafts.

The protective tubes must be greased to prevent freezing during winter.

After long periods of non-use, lubricate the universal drive shafts before using them again and check their functioning.

Dismantling / fitting universal drive shaft guards

1

Overview

2

3

Image no.

4

5 6

7 77003

48

Designation 1

Protective tube

2

Universal drive shaft guard

3

Race

4

Fork

5

Bolt

6

Annular-groove fork

7

Race grease nipple

(Fig. 48)

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

9.24

Maintenance Dismantling universal drive shaft guards 8

– Release hose clamp (8) or unhook safety chain.

– Back off bolts (5).

5

(Fig. 49)

5 49

– Pull off universal drive shaft guard and protective tube.

(Fig. 50)

50

Fitting universal drive shaft guards 7

– Grease annular groove in the fork.

For example with CLAAS multipurpose grease EP 2 (400 g) – Order no. 00 0147 451 0 – Insert race in the annular groove, – aligning the grease nipple (7) with the profile tube.

– Check that the race is securely seated in the annular groove.

51

– Slide universal drive shaft guard and protective tube over the race.

– Ensure that the grease nipple (7) protrudes through the corresponding drilled hole.

8

– Use bolts (5) to connect universal drive shaft guard, protective tube and race.

5

– Fasten them to prevent them rotating!

– Tighten hose clamp (8) or attach safety chain.

(Fig. 51, 52) 5 52

9.25

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance Guard cup, initial gearbox 9

Dismantling the guard cup

10

– Open quick-release couplings (9).

– Unhook safety chain (10).

– Slide guard cup (11) onto the universal drive shaft.

Fitting the guard cup 9 53

– Attach guard cup (11) to the bracket with the quick-release couplings (9).

– Check that the quick-release couplings have engaged securely and are closed.

– Attach safety chain (10).

11

(Fig. 53, 54)

54

Guard, universal drive shaft mower drive / initial gearbox Dismantling the guard 12

– Dismantle the universal drive shaft guard (13), see page 9.25.

13

– Unhook safety chain (15).

14

– Unscrew guard (16).

14

14

– Unscrew nuts.

– Remove contact washers.

15

– Take out bolts (14).

16 55

Slide protective tube (12) upwards.

Remove guard (16).

(Fig. 55)

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

9.26

Maintenance Fitting the guard – Grease annular groove in the fork.

For example with CLAAS multipurpose grease EP 2 (400 g) Order no. 00 0147 451 0

17

– Insert race (17) in the annular groove, – aligning grease nipple with profile tube.

– Check that the race is securely seated in the annular groove.

56

Fit guard (16) with bolts (14), contact washers and nuts.

Slide protective tube (12) over the race (17).

Turn the protective tube so that the grease nipple is easily accessible.

– Fitting the universal drive shaft guard (13), see page 9.25.

Attach safety chain (4).

(Fig. 55, 56)

9.27

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance Universal drive shafts with clamping screws Dismantling the universal drive shaft 18

– Dismantle the universal drive shaft guard see page 9.25.

19

– Unscrew nut (19) until flush with the end of the thread on the clamping screws.

– Release clamping screws (18) (conical) with a targeted blow.

– Screw nut (19) down.

– Remove contact washer.

57

– Take out clamping screw (18).

– Pull inboard yoke off profile shaft.

(Fig. 57) Fitting the universal drive shaft – Lightly grease profile shaft.

18

19

For example with assembly paste “Anti-Seize” (120 g) Order no. 00 0136 571 0 – Slide inboard yoke onto profile shaft.

– Fit clamping screw (18) with contact washer and nut (19).

– Tighten nut (19).

Tightening torque = 220 Nm 58

– Fit the universal drive shaft guard, see page 9.25.

(Fig. 58)

MOUNTING LEVER The mounting lever must be used for replacing mower blades on machines with mower blade quick replacement system.

– Handling – see Quick-change system for mower blades, page 9.33.

Locking the cutting discs The mounting lever can also be used to lock the cutting discs.

The mounting lever can also be used to lock the cutting discs.

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

9.28

Maintenance – Remove the mounting lever (h) from the bracket on the machine.

(Fig. 59)

h

59

S

The lever (h) can also be used to lock the cutting discs during maintenance work on the mower head. Proceed as follows:

h

– Insert the punch (D) of the mounting lever (h) into the drilled hole on the cutterbar skid.

The handle of the mounting lever must be positioned parallel to the mower head.

– Bring the cutting disc (S) into contact with the mounting lever (h) and lock in this position.

D

76191

(Fig. 60, 61) 60

– After use, replace the mounting lever in the bracket on the machine.

(Fig. 61)

h

61

9.29

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance MOWER BLADES DANGER! The safety device of the cutterbar must only be opened when the drive has stopped and the engine and cutting discs are switched off!

Only work on the mower blades or their fastening elements when the drive has stopped and the engine and cutting discs are switched off.

– Switch off mower drive.

– Switch off engine.

– Do not leave the forage harvester until the cutting discs have come to a complete stop!

– Remove the ignition key!

– Switch off the battery isolating switch!

– Wear gloves when working on the mower blades!

ATTENTION! Always check the mower blades before operation and after driving into an obstacle!

– Always check that the mower blades are correctly seated!

– Worn, damaged or bent blades must be replaced immediately.

– Both mower blades on every cutting disc must be attached or replaced, because otherwise the cutterbar may be damaged by unbalanced blades.

NOTE! Use only sharp mower blades for neat cutting.

Use of blunt blades requires more power and reduces the cutting quality.

Blunt blades can be reversed and fastened to the same disc so the other blade edge is used for cutting.

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

9.30

Maintenance Mower blade box There is a mower blade box (1) located on the left hand side of the back panel, in which replacement mower blades can be kept.

1

• Remove the mower blade box (1) from the bracket

2

by releasing the spring (2).

(Fig. 62)

62

3 = Stowage space for mower blades 00 0952 043 0 4 = Stowage space for mower blades 00 0952 042 0

3

• Take the box with mower blades (1) to the mower head when replacing mower blades.

4

(Fig. 63, 64)

00 0952 043 0

00 0952 042 0 63

4 3 1

9.31

64

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance Checking the mower blades DANGER! Extreme risk of injury by mower blades becoming loose.

– Replace damaged mower blades, mower blade brackets and cutting discs.

Do not weld or straighten.

Replacement blades must meet the minimum technical requirements specified by CLAAS. This is always ensured if you use original CLAAS spare parts.

Order no.: Mower blade (clockwise rotating)

00 0952 042 0

Mower blade (anti-clockwise rotating)

00 0952 043 0

– Check mower blades for wear, damage and deformation.

– Worn, damaged or bent blades must be replaced immediately.

– Replacing mower blades – see Quick-change system for mower blades, page 9.33 or Replacing screwed mower blades, page 9.38.

The mower blades must be replaced under the following conditions:

• If the blades are cracked or bent. Never attempt to straighten a bent blade.

• If the blades are worn.

The width (B) of the blade 10 mm from the edge of the disc should be a minimum of 36 mm.

10 mm

(Fig. 65) B

68777

65

• If the hole in the blade is widened.

Maximum permissible widening of the hole of Ln = 18 mm to L = 20 mm.

L

Ln 61623

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

66

9.32

Maintenance Quick-change system for mower blades To change the mower blades: 5

– Remove the mounting lever (5) from the bracket.

(Fig. 67)

67

– Insert the mounting lever (5) between the cutting disc (6) and the mower blade bracket (3).

6

(Fig. 68)

5

68

68985

NOTE! Pull the mounting lever (5) outwards parallel to the axis of the cutting disc up to the stop.

5

(Fig. 69)

69

68986

– Clean the recess (8) in the skid.

– Place the mower blade bracket (9) exactly over the recess (8) by turning the cutting disc.

– Push the mounting lever (5) downwards.

5

9 68987

9.33

(Fig. 70)

8 70

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance – Remove the mower blade (10).

– Remove crop remnants and dirt from the area around the mower blade bracket.

(Fig. 71)

10

71

68979

– Check mower blade bracket (h) for wear – see Checking the mower blade bracket (mower blade quick-change system), page 9.36.

F S

– Check cutting disc (S) or feed drum (F) for wear – see Checking the cutting discs, page 9.41 or Checking the feed drums, page 9.43.

(Fig. 72)

h h 72

77230 DIRECT DISC 520

R

NOTE! The mower blades for clockwise and anticlockwise rotating cutting discs are different. When fitting the mower blades, take the direction of rotation into account.

L

The arrow on the mower blade must correspond to the direction of rotation of the individual cutting disc.

73

71855

(Fig. 73, 74)

DIRECT DISC 620

R

L

77363

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

74

9.34

Maintenance – Insert a new mower blade (10) with the sharp edge pointing downwards.

Alternatively: – Check mower blade for wear – see Checking the mower blades, page 9.32.

– Turn mower blade over if the second edge is unused and insert with the sharp edge pointing downwards.

10

(Fig. 75) 75

68980

– Release the mounting lever (5).

DANGER! Extreme risk of injury by mower blades becoming loose.

– Ensure that the mower blades and blade mounting studs are fitted correctly.

The blade mounting stud (11) must fit snugly (see arrows) and lie straight in the locating hole of the cutting disc (6).

5 76

68981

(Fig. 76, 77) 6

11 77

68984

– Remove the mounting lever (5) from the cutting disc.

(Fig. 78)

5

68982

9.35

78

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance

DANGER! Extreme risk of injury by mower blades becoming loose.

– Ensure that the mower blades and blade mounting studs are fitted correctly.

The mower blade must rotate freely and move easily in both directions.

68983

79

– Check that the mower blades are correctly seated.

The mower blade must rotate freely and move easily in both directions.

(Fig. 79) – After use, replace the mounting lever in the bracket on the machine.

Checking the mower blade bracket (mower blade quick-change system)

DANGER! Extreme risk of injury by mower blades becoming loose.

– Replace damaged mower blades, mower blade brackets and cutting discs.

Do not weld or straighten.

Replacement mower blade brackets must meet the minimum technical requirements specified by CLAAS. This is always ensured if you use original CLAAS spare parts.

– Before each use, check the securing bolts of the mower blades.

– Always replace damaged or worn mower blade brackets.

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

9.36

Maintenance The mower blade brackets must be replaced under the following conditions:

• If the contour of the mower blade bracket shows signs of wear.

Wear limit:

X = 15 mm Y = 12 mm

X X

(Fig. 80)

Y Y 80

69049

• If the thickness of the mower blade bracket is reduced.

Wear limit:

W = 3 mm Z = 4 mm

• Visible cracks or serious wear of the welded seams (S) on the mower blade mounting stud.

S DANGER!

69050

W W

Z Z

Extreme risk of injury by mower blades becoming loose.

81

– Check the welded seams before each operation.

(Fig. 81)

• If the mower blade bracket is deformed (bent), or if the blade mounting stud (11) no longer sits straight in the locating hole in the disc.

(Fig. 82)

11 69051

9.37

82

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance • If there is a gap between the blade mounting stud (11) and the locating hole (see arrows) in the disc.

(Fig. 83)

11 83

69052

• If the blade mounting stud (11) is worn.

V V

Wear limit: V = 13 mm (Fig. 84) 11

84

69053

Replacing screwed mower blades DANGER! Extreme risk of injury by mower blades becoming loose.

– Replace damaged mower blades, mower blade brackets and cutting discs.

Do not weld or straighten.

– Clean the seat of the nut (1).

1

2

S

– Release nut (1) with a socket wrench.

F

– Take out bolt (3) and mower blade (2).

– Check cutting disc (S) or feed drum (F) for wear – see Checking the cutting discs, page 9.41 or Checking the feed drums, page 9.43.

3

– Check mower blade mounting bolt (3) and self-locking nut (1) for wear – see Mower blade fixing (bolted version), page 9.40.

1 2

3

77231

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

85

9.38

Maintenance DIRECT DISC 520

R

NOTE! Note the direction of rotation when mounting new mower blades!

• The direction of rotation of the disc is marked with

L

an arrow on the blade.

ATTENTION! 86

71855 DIRECT DISC 620

Reattach released nuts with liquid screw fastener, e.g. Loctite type 243 (Order no.

00 0666 285 1).

R

L

87

77363

– Fit new mower blades with the sharp edge pointing downwards.

1

Alternatively: – Check mower blade for wear – see Checking the mower blades, page 9.32.

2

– Turn mower blade over if the second edge is unused and insert with the sharp edge pointing downwards.

3

– Insert bolt (3).

77232

88

– Screw on nut (1) with liquid screw fastener.

For example Loctite 243 (50 ml) – Order no. 00 0666 285 1 – Tighten nut (1).

Tightening torque = 120 Nm

9.39

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance

DANGER! Extreme risk of injury by mower blades becoming loose!

– Ensure that the mower blades and mower blade mounting bolt are correctly seated.

– Check that the mower blades are correctly seated.

68983

89

The mower blade must rotate freely and move easily in both directions.

(Fig. 85-89)

Mower blade fixing (bolted version)

ATTENTION! Extreme risk of injury by mower blades becoming loose.

– Always ensure proper seating when installing the mounting bolts.

Replacement mounting bolts / nuts must at least comply with the technical requirements laid down by CLAAS. This is always ensured if you use original CLAAS spare parts.

– Before each use, check the securing bolts of the mower blades.

– Always replace damaged or worn securing bolts.

The mower blade mounting bolts must be replaced if any of the following occur:

• Visible deformation of the mounting bolt (e.g. after running into an obstacle).

• Missing or ineffective thread coating, caused by water, oil or dirt.

• If the screw head is worn down to the blade contact surface.

(Fig. 90) 90

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

9.40

Maintenance • if the screw shaft is worn from Dn = 18 mm to D = 15 mm.

(Fig. 91)

91

The securing nuts must be replaced in the following cases: 15

• If the spring contact washer (15) has lost its elastic properties or has become detached from the nut.

• If the nut shows signs of wear.

Wear limit:

a = H/2

(Fig. 92)

92

CUTTING DISCS Replacement cutting discs must meet the minimum technical requirements specified by CLAAS. This is always ensured if you use original CLAAS spare parts.

Checking the cutting discs The cutting discs must be replaced under the following conditions: – If the hole is widened, worn or damaged anywhere in its diameter.

(Fig. 93)

66613F

9.41

93

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance Replacing cutting discs ATTENTION! Z

V

Mower blades can collide.

Machine damage.

– Arrange cutting discs so that their longer dimension is at right angles to the adjacent disc.

Angle (V) = 90° 94

77012

Angle error: Tolerance (Z) = within 5° (opposed cutting disc / feed drum) (Fig. 94) The cutting discs are fastened to one flange each.

2

The bolts (1) for securing the cutting discs must be tightened as specified.

1

– Fit bolts (1) and nut (2) with liquid screw fastener.

For example Loctite 243 (50 ml) Order no.

000 666 285 1 – Tighten bolts (1) and nut (2) with torque wrench.

Tightening torque: Bolts (1) = 80 Nm 75630

95

Safety module: Nuts (2) = 380 Nm. (Fig. 95)

FEED DRUMS Replacement feed drums must meet the minimum technical requirements specified by CLAAS. This is always ensured if you use original CLAAS spare parts.

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

9.42

Maintenance Checking the feed drums The feed drums must be replaced under the following conditions: – If the hole is widened, worn or damaged anywhere in its diameter.

(Fig. 96)

96

66613F

Replacing feed drums ATTENTION! V

Mower blades can collide.

Machine damage.

– Arrange feed drum so that the longer dimension is at right angles to the adjacent feed drum / cutting disc.

Angle (V) = 90° 97

77372

Angle error: Tolerance (Z) = within 5° (opposed cutting discs / feed drum)

Z

Tolerance (X) = within 1.5° (synchronous cutting discs / feed drum)

X

(Fig. 97, 98)

77372

9.43

98

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance The feed drums are fastened to one flange each.

The bolts (1) for securing the feed drums must be tightened as specified.

1

2

– Fit bolts (1) and nut (2) with liquid screw fastener.

For example Loctite 243 (50 ml) Order no.

000 666 285 1 – Tighten bolts (1) and nut (2) with torque wrench.

Tightening torque: Bolts (1) = 80 Nm 99

77364

Initial module DIRECT DISC 520 Comfort: Nuts (2) = 450 Nm. Safety module DIRECT DISC 610: Nuts (2) = 380 Nm. (Fig. 99)

Feed drum cap DIRECT DISC 610

ATTENTION! 3

Imbalance through missing or damaged caps.

Machine damage.

– Replace missing or damaged caps (3) immediately.

4

– The outer feed drums (4) must always have the cap (3) fitted.

5 77365

100

Ensure that the drainage opening (5) at the bottom of the conveyor cones is always open. This is the only place for draining water that has collected here (e.g. high-pressure steam cleaning).

(Fig. 100)

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

9.44

Maintenance Removing / fitting wear bars – Check wear bars for wear.

– If necessary, replace wear bars.

Removing the wear bar:

DIRECT DISC 520 Comfort

– Unscrew nuts (6).

– Remove contact washers (7).

8

7

6

– Take out bolts (8).

– Remove wear bar (9).

9

Fitting the wear bar: – Fit wear bar (9) with bolts (8), contact washers (7) and nuts (6).

– Tighten nuts (6).

101

77228

(Fig. 101, 102)

DIRECT DISC 610

6

7

9 8 77367

9.45

102

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance ELECTRIC SYSTEM Setting the speed sensor Aligning the toothed lock washer – Loosen the headless screw (2).

– Centre the toothed lock washer (3) on the speed sensor (1).

1

– Tighten headless screw (2).

2

(Fig. 103, 104)

3

103

77013

1

3

104

Adjusting spacing speed sensor - toothed lock washer (DIRECT DISC 520 Comfort only)

DIRECT DISC 520 Comfort

The minimum spacing x between sensor (1) and toothed lock washer (3) must be observed.

4 1

Proceed as follows to adjust the sensor: – Open the hood and secure – see Hood, page 9.50.

5 x

3

– Loosen nut (4).

– Set speed sensor (1) with nut (4, 5) to dimension (x).

75090

105

Dimension (x) = 2 mm – Lock the nut (4, 5).

– Close hood – see Hood, page 9.50.

(Fig. 105)

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

9.46

Maintenance HYDRAULIC SYSTEM Hydraulic hose lines XXX / 250 bar / 09/07

NOTE!

1

Before working on the hydraulic system, lower machine, depressurise system and shut down motor.

XXX / 250 bar / 09/07 2

3

1

Check hydraulic hoses before initial operation, and then at least once a year.

XXX / 250 bar / 09/07

91115

106

Replace damaged and old hydraulic hose lines.

NOTE! Hydraulic hoses must not be used for longer than 6 years after date of manufacture.

The date of manufacture can be identified on the hose fitting (1).

(2) = Year (e.g. 09 = 2009) (3) = Month (e.g. 07 = July) (Fig. 106)

9.47

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance ANTI-WRAP GUARD Setting the anti-wrap guard The lower anti-wrap guard (1) must be centred on the feed drum (2). The gap between the anti-wrap guard (1) and the feed drum (2) at the front of the gap must be set to dimension (X).

1

(Fig. 107)

X 2

107

The gap (X) is set via the setting of the upper anti-wrap guard (4).

4 3

– Loosen bolts (3),

3

– Displace anti-wrap guard (4) as required.

– Tighten bolts (3).

Gap dimension (X) = 8-10 mm (Fig. 108) X 108

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

9.48

Maintenance – Loosen bolts (5).

– Displace anti-wrap guard (1) as required.

– Tighten bolts (5).

5

(Fig. 109, 110)

5

1

109

5

110

PANELLING DANGER! Never remove the panelling unless the drive is switched off and the engine has stopped.

– Remove the ignition key!

– Switch off the battery isolating switch!

9.49

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance Hood To open the hood (1): – Turn lock mechanism (2) to left and open hood.

1

– Remove support (4) from bracket (5) and prop hood with support (4).

To close the hood (1): 2

– Remove support (4) from retainer (3) and secure in bracket (5).

– Close hood.

111

– Check that the hood is securely locked.

(Fig. 111, 112)

3

4

5

112

Side panelling To open the side panelling (6): – Remove bolts (7).

– Turn bolt (8) to the back and open side panelling.

7

– Secure side panelling with bracket (9) in retainer (10).

6

To close the side panelling (6): – Remove bracket (9) from retainer (10) and close side panelling.

8 113

– Check that the lock mechanism has securely clicked into position.

– Replace bolts (7).

(Fig. 113, 114)

10

9 114

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

9.50

Maintenance Top side panelling Remove top side panelling (11) as follows:

11

– Loosen bolts (12).

– Open the side panelling and secure in position.

– Loosen bolts (13).

– Slide top side panelling (11) towards back and remove upwards.

12

Installing top side panelling (11):

13 115

– Install in reverse order of removal.

(Fig. 115)

LOCK Adjusting the lock

1

If the lock cannot be closed, adjust the cast iron bearing (1) on the front attachment.

2

DANGER! Never work under or on the raised front attachment unless it is safely supported.

116

– Provide secure support / propping for the front attachment.

– Use suitable supporting elements.

To adjust the lock: – Loosen bolts (2), – Adjust cast iron bearing (1) in the slotted holes, – Tighten bolts (2).

Check the lock adjustment after the first 10 working hours and adjust if necessary. After this, check at regular intervals.

(Fig. 116)

9.51

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance Adjusting interlocking bars NOTE!

3

The interlocking bars must be adjusted to allow the coupling hooks (4) to surround the coupling shaft (3) from the feeder housing of the forage harvester under pre-tension.

4

If necessary, readjust the interlocking bar (5). Proceed as follows: 117

– Loosen yoke (7) on the lever (6).

– Screw the yoke (7) in or out from the bar.

– Tighten yoke (7) on the lever (6).

Check the lock adjustment after the first 10 working hours and adjust if necessary. After this, check at regular intervals.

5

(Fig. 117, 118)

7

6

118

SCREW CONNECTIONS Check all bolts and nuts of the entire front attachment again after 10 working hours and retighten if necessary.

After this, check at regular intervals.

FASTENERS Check all safety relevant fasteners such as bolts, screws, pins etc. regularly for wear and deformation.

If necessary, replace the fasteners.

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

9.52

Maintenance CLEANING AND CARE ATTENTION! Cleaning of surfaces with decals using high-pressure jet cleaners.

The decals are damaged.

–Avoid cleaning with high-pressure cleaners.

–Clean surfaces only if a sufficient distance from the high-pressure jet cleaner is observed.

–Set the water pressure and the water temperature as low as possible.

–Do not subject the decals to mechanical loads during cleaning.

–Replace damaged and illegible decals (hazard warning signs / safety decals / letterings / identification plates) immediately.

• Remove harvesting residues and blades at regular intervals.

• Do not clean cut-out clutches, bearing, hydraulic system and electric parts with a high-pressure jet cleaner or steam cleaner.

– Danger of damage and corrosion.

• Cleaning at excessive pressure may cause paint damage.

• Before and after cleaning the machine with a high-pressure jet cleaner, grease bearings.

After this, carry out a short test run so that the water which has seeped in will be pressed out of the bearings.

• A grease collar should exist at the bearings. This protects the bearings against ingress of dirt, plant juice and water.

• When parking the machine outdoors for an extended period, clean the ram rods of hydraulic cylinders and then apply grease to them.

– Prior to putting the machine into operation, remove the grease from the ram rods hydraulic cylinders.

9.53

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance WINTER STORAGE 1. Clean dirt from the front attachment.

2. Drain oil from all gearboxes and refill with fresh oil to the specified levels.

3. Lubricate all lubrication points thoroughly until the grease comes out of the bearings (see Lubrication Chart, page 10.1). Run the front attachment for a short time.

4. Check front attachment for wear and damage and have it repaired.

5. Clean rust off and repair paint damage.

6. Store front attachment in a dry weatherproof space away from synthetic fertiliser.

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

9.54

Maintenance LUBRICANTS CHART DIRECT DISC 520 Comfort Component

Capacity

Type of lubricant specification

Intake auger gearbox (A)

3.50 litres

Angle drive – mower drive / feeder unit drive (B)

3.75 litres

Angle drive - mower drive (C)

3.25 litres

Angle drive - mower drive (D)

1.20 litres

Mower head gearbox left

3.50 litres

Mower head gearbox right

3.50 litres

Gear oil ISO VG 320

Viscosity

90 EP

DIRECT DISC 610 Component

Capacity

Intake auger gearbox (A)

3.50 litres

Angle drive – mower drive / feeder unit drive (B)

3.75 litres

Angle drive - mower drive (C)

3.25 litres

Angle drive - mower drive (D)

1.50 litres

Mower head gearbox left

4.00 litres

Mower head gearbox right

4.00 litres

Type of lubricant Specification

Gear oil ISO VG 320

Viscosity

90 EP

NOTE! The quoted filling quantities are approximate values, the oil level check is always decisive for the correct oil level.

9.55

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Maintenance Lubrication points Component

Type of lubricant specification

Viscosity

Grease nipples

High-quality multipurpose grease DIN 51825 - K2K see Lubrication Chart

CLAAS multipurpose grease AGRIPGREASE EP2 400 g cartridge Order no.: miscellaneous lubrication point

Intervals / check

000 147 437 0

bio-degradable lubricating oil CEC-L-33-A-93 > 80% see Lubrication Chart

CLAAS roller chain oil BIO HEES 46 5 ltr. PE canister Order no.:

000 147 457 0

MALFUNCTIONS Malfunction

Remedy

Cause

Vibration

• Clean the feed drum.

– Feed drum dirty.

Cutterbar does not run

• Check V-belts.

• Check forage harvester feed

– V-belt defective.

drive.

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

9.56

Lubrication Chart

Lubrication Chart

10 Lubrication Chart SAFETY RULES DANGER! Never lubricate the front attachment unless the drive is switched off and the engine has stopped.

– Remove the ignition key!

– Switch off the battery isolating switch!

LUBRICANTS Specifications – see Lubricants chart, page 9.55.

LUBRICATION

Lubricate these lubrication points every 50 working hours.

Lubricate these lubrication points every 250 working hours.

10.1

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Lubrication Chart

Lubrication Chart

1

3

4

2

5

6 7

75098 Additional equipment

1

2

3

4

5

Additional equipment

6

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

7

10.2

Lubrication Chart

9 8

10

11

75097

10.3

8

9

10

11

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Lubrication Chart

14

12

15

13

12

75099

12

13

14

15

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

10.4

Lubrication Chart

20 21

18

18

18 19

16 17

16

16

20 21

75097

77377

16

17

77368

Obs: Remove cover (A) to lubricate the universal drive shaft (18).

A

77379

18

19

Obs: Remove cover (B) to lubricate the universal drive shaft (20).

After installation Setting the anti-wrap guard, see page 9.48

77394

10.5

20

B

21

BA DIRECT DISC 610 / 520 Comfort - 00 0294 017 2

Lubrication Chart

22

23

25

24

75098

22

23

24

25

00 0294 017 2 - BA DIRECT DISC 610 / 520 Comfort

10.6

At CLAAS KGaA mbH we are constantly improving our products to reflect the latest technological developments.

For this reason, we may from time to time need to make changes to diagrams and descriptions in this documentation which do not reflect products which have already been delivered and which will not be implemented on these machines.

Technical data, dimensions and weights are understood with the usual tolerances. Responsibility for errors or omissions not accepted.

Reproduction or translation of this publication, in whole or in part, is not permitted without the written consent of the CLAAS KGaA mbH. All rights under the provision of the Copyright Act are reserved.

CLAAS KGaA mbH 33426 Harsewinkel Germany Our contribution to the environment: CLAAS have printed this manual on 100% chlorine free paper.

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

00 0294 017 2 BA DIRECT DISC 610 / 520 Comfort en - 01.10 Printed in Germany