Claas DISCO 8550 C PLUS / 8550 C 8550 PLUS / 8550 8550 C-T 8500 C Assembly and operator's manual -

DISCO 8550 C PLUS / 8550 C DISCO 8550 PLUS / 8550 DISCO 8550 C-T DISCO 8500 C

Assembly and operator's manual

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EC Declaration of Conformity according to EC Directive 98/37/EEC

CLAAS Saulgau GmbH Zeppelinstrasse 2

D - 88348 Bad Saulgau

declare under their sole responsibility that the product

Disc mower - Type 652 »DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C« to which this declaration refers corresponds to the pertinent basic safety and health requirements of EC Directive 98/37/EEC, Appendix 1 and to the requirements of the other pertinent EC Directives.

-/-

For the correct implementation of the safety and health requirements mentioned in the EC Directives, the following standard(s) and/or technical specification(s) has (have) been applied:

EN 745 - August 1999

Bad Saulgau, 10.03.2006 Product Development (M. Geng)

Supply Chain Management (A. Fetscher)

Quality Management (J. Switalski)

Introduction

Introduction

1 Introduction INTRODUCTION This operator's manual provides information concerning the use, adjustment, setting and operation of the CLAAS disc mower.

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

In addition, assembly of your machine and regular inspections must be 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.

Make use of the experience and latest knowledge embodied in this machine by operating and maintaining it properly, then your cutting mechanism, mower unit will always produce good results.

This operator's manual applies to Disc mower:

• DISCO 8550 C Plus / 8550 C from serial no.652 0 1001,

• DISCO 8550 Plus / 8550 from serial no.652 0 1001 to 652 0 2101,

• DISCO 8550 C Plus / 8500 C from serial no.652 0 1001,

Your CLAAS Service Department

1.1

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Table of contents

Table of contents

2 Table of contents 1. Introduction Introduction ............................................................................... 1.1

2. Table of contents 3. Preface Of special importance ............................................................... 3.1 Identification plate ..................................................................... 3.1

4. Safety Rules Intended use ............................................................................. 4.1 Identification of warning and danger signs ................................ 4.1 General safety and accident prevention instructions ................ 4.1 Attached machines ................................................................... 4.3 Attached devices ...................................................................... 4.3 PTO Operation .......................................................................... 4.3 Hydraulic system ....................................................................... 4.3 Tyres ......................................................................................... 4.4 Maintenance ............................................................................. 4.4 Sound pressure level ................................................................ 4.4 Safety decals with pictorials ...................................................... 4.5

5. Specifications Calculating the axial loads, minimum ballast and total weight .. 5.2 Calculation of the minimum front ballast ............................. 5.3 Calculation of the minimum rear ballast .............................. 5.3 Calculation of the actual front axle load .............................. 5.3 Calculation of the actual overall weight .............................. 5.3 Calculation of the actual rear axle load .............................. 5.4 Carrying capacity of the tyres ............................................. 5.4 Noise level ................................................................................ 5.5

6. Prior to Operation Assembly .................................................................................. 6.1 Side mower safety frame DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C ........ 6.1 Side mower safety frame DISCO 8550 Plus / 8550 ................................................ 6.3 Mounting the fitting frame ................................................... 6.4 Fitting the controller DISCO 8550 C Plus / 8550 C / 8550 C-T ....................... 6.6 Fitting the controller DISCO 8550 C Plus / 8550 C / 8500 C-T ....................... 6.7 Use as a pushed combination ............................................ 6.8 Fitting the adapter (B03 0030) ............................................ 6.9 Fitting the Accord coupling ............................................... 6.13 Fitting the lighting unit on the front mower unit ................. 6.15 Use as a towed front - rear combination ........................... 6.19 Fitting the lighting unit ....................................................... 6.21 Fitting the middle mower unit rotation sensor DISCO 8550 C Plus / 8550 C / 8550 C-T ..................... 6.23 Setting the clearance height DISCO 8550 C Plus / 8550 C / 8550 C-T ...................................................................... 6.27 Fitting the blades .............................................................. 6.28 Matching the universal drive shaft .................................... 6.30

Loading/unloading the machine DISCO 8550 Plus / 8550 .....

Check and observe the following before putting into operation! ...............................................................................

Attachment to the tractor ........................................................

Hooking up the fitting frame .............................................

Hooking up the front mower unit to the fitting frame ........

Setting the upper link .......................................................

Weight relief .....................................................................

Connecting the universal drive shaft ................................

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

Electrical system ..............................................................

Removing the machine ...........................................................

Lowering the machine in the unfolded condition ..............................................

Lowering the machine in the folded condition ..................................................

Conversion from front - rear combination to pushed combination ............................................................................

Conversion from pushed combination to front - rear combination ......................................................

Prior to transportation .............................................................

Driving on public roads .....................................................

6.31 6.33 6.34 6.35 6.36 6.36 6.37 6.37 6.38 6.38 6.39 6.39 6.40 6.43 6.45 6.46 6.46

7. Operation Control system DISCO 8550 C Plus / 8550 C / 8550 C-T ........ 7.1 General .............................................................................. 7.3 Working position ................................................................. 7.4 Transport position .............................................................. 7.5 Mowing with individual units raised .................................... 7.6 Headland setting ................................................................ 7.8 Rotation monitoring ............................................................ 7.9 Bridging out switch ........................................................... 7.10 Control system DISCO 8550 Plus / 8550 / 8500 C ................ 7.11 Working position ............................................................... 7.11 Transport position ............................................................ 7.12 Mowing without side mowing units ................................... 7.12 Operation ................................................................................ 7.13 Setting the cutting height .................................................. 7.13 Safety equipment ............................................................. 7.13 Conditioner ....................................................................... 7.14 Chicane plates ................................................................. 7.14 Changing the conditioner speed ...................................... 7.14 Changing the swathe width .............................................. 7.14 Mowing ............................................................................. 7.15 Recommendations for environmental protection .............. 7.16 Collision protection ........................................................... 7.18 Emergency functions .............................................................. 7.19 Optional equipment ................................................................ 7.20 High cutting runners ......................................................... 7.20 Push-on runners ............................................................... 7.20

8. Maintenance Important maintenance instructions .........................................

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

Energy accumulators .........................................................

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

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

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

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.1 8.1 8.1 8.1 8.1 8.1

2.1

Table of contents Drive System ............................................................................. 8.2 Tensioning the conditioner drive belt .................................. 8.2 Main gearbox DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C ............................................................................ 8.3 Main gearbox DISCO 8550 Plus / 8550 .............................. 8.3 Side gearbox ....................................................................... 8.4 Universal drive shaft ................................................................. 8.5 Mower head .............................................................................. 8.6 Mower blades ............................................................................ 8.8 Mower blade box ................................................................ 8.9 Changing mower blades DISCO 8550 C Plus / 8550 Plus / 8550 C-T ...................................................................... 8.10 Changing mower blades DISCO 8550 Plus / 8550 / 8500 C .......................................................................... 8.15 Mower discs ............................................................................ 8.18 Replacing cutting discs ..................................................... 8.18 Suspension springs ................................................................. 8.19 Quick setting of the spring length ..................................... 8.19 Final setting of the spring length ....................................... 8.19 Conditioner tines ..................................................................... 8.20 Fitting / removing the tines ................................................ 8.20 Electrical system ..................................................................... 8.20 Setting the rotation sensors .............................................. 8.20 Setting the lift sensors ...................................................... 8.21 Replacing the wiring loom ................................................. 8.22 Hydraulic system ..................................................................... 8.23 Hydraulic hoses ................................................................ 8.23 Hydraulic cylinder with vacuum valve ............................... 8.23 Lubrication openings ............................................................... 8.24 Clutches .................................................................................. 8.25 Maintenance of the friction and overrunning clutch .......... 8.25 Torque .............................................................................. 8.25 Screw connections .................................................................. 8.26 Connecting elements .............................................................. 8.26 End of season storage ............................................................ 8.26 Malfunctions ............................................................................ 8.27

9. Lubrication chart Safety Rules .............................................................................. 9.1 Lubricants ................................................................................. 9.1 Lubrication ................................................................................ 9.1

2.2

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Preface

Preface

3 Preface OF SPECIAL IMPORTANCE Please note that, in the following chapters, the CLAAS disc mower is also referred to as the machine or just the mower unit.

To prevent accidents, these instructions must be read by everyone who uses the machine and who deals with maintenance, servicing or inspection.

For improved illustration, some of the guards and covers have been removed for just this reason. All guards and covers must be fitted before the machine can be used!

Pay particular attention to the chapters "Safety Rules« and »Prior to Operation«.

The use of spare parts, accessories and additional equipment which is not originally manufactured, checked and released by CLAAS can have a negative effect on specific design features of the CLAAS machine or on its operability, thereby impairing 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 unoriginal CLAAS parts, accessories and additional equipment.

Technical specifications, dimensions and weights are understood with the usual tolerances.

IMPORTANT: Front, rear, right and left are always understood as in the direction of travel.

1

IDENTIFICATION PLATE 1 1

When placing orders for spare parts and for technical queries, quote the machine number (Fz-Ident-Nr.) (2), the type and the serial number. This is necessary to ensure that the correct spare parts are delivered.

The identification plate (1) with the machine number (Fz-Ident-Nr.) (2) is fixed on the left side of the frame.

(Fig. 1, 2)

2

2

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

3.1

Safety Rules

Safety Rules

4 Safety Rules

Attention!

Before putting the machine into operation, read the operator's manual and follow the safety precautions!

Sign to indicate instructions which must be observed. Failure to do so could result in damage to the machine.

INTENDED USE

– Measures to prevent damage to the machine.

The CLAAS disc mower is built exclusively for normal agricultural work (intended use).

The mower unit is intended for cutting stalked crops growing on the ground in natural or seeded fields.

Use in any other way is considered as contrary to the intended use. The manufacturer accepts no responsibility for damage resulting from this; the user bears the sole risk.

Designated use also includes observing the service, maintenance and repair conditions as prescribed by the manufacturer.

The CLAAS mower unit may only be used, maintained and repaired by persons who are familiar with the equipment and who have been advised of the dangers involved.

Observe the pertinent accident prevention regulations and other generally acknowledged regulations regarding safety and occupational health, as well as the regulations and standards relevant to motor vehicles and traffic.

Any arbitrary modifications carried out will relieve the manufacturer of all liability for any resulting damage or injury.

Note!

Sign to indicate instructions for a more efficient and economic use of the machine.

Environment!

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

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

The warning and instruction signs on the machine provide important recommendations for safe operation. These instructions involve your safety – observe them at all times!

GENERAL SAFETY AND ACCIDENT PREVENTION INSTRUCTIONS

IDENTIFICATION OF WARNING AND DANGER SIGNS

Basic rule:

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

General:

Danger!

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

– Preventive measures.

Always check the operating and road safety of tractor and machine before starting up!

In addition to the advice contained in this operator's manual, comply with the general rules on safety and accident prevention.

The warning and information labels provide important information for safe operation; These instructions involve your safety – observe them at all times!

Follow the regulations in force when using public roads!

Before starting work, familiarise yourself with all the controls and instruments and their functions, as it will be too late once you have set off.

An adequate safe distance must be maintained from the cutting tools while working!

4.1

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Safety Rules Safe operation of the mower unit is only possible through appropriate use of the cutting blades according to directions.

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

Ensure that you have an adequate view!

Check the mower unit every time for damaged, missing and worn cutting blades and replace cutting blades if necessary!

Passengers must not be carried on the machine while working or during transport!

Only replace missing and damaged mower blades in sets as specified by the manufacturer to prevent danger resulting from imbalance !

Check the parts fastening the blades on every change of the cutting blades according to regulations specified by the manufacturer and replace if necessary!

It is particularly important to check how far the blade retaining pin has been grooved on its internal radius by the blade. Replace the blade holder with a new one with an unused blade retaining pin latest after achieving a groove depth of 3 mm, i.e. if the internal radius is reduced by 3 mm.

Similarly, check the riveting of the blade pin in the blade holder and the wear on the blade holder outer edge. If necessary, replace all the blade holders on the mower discs with new blade holders.

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

Protective equipment on the mower unit, for example canvases and hoods, protect against flying stones and the like as well as from access to dangerous areas. For this reason they must be placed in safety position before starting work!

Squashing and shearing points arise while the mower unit is being swivelled from the transport position into the working position and vice versa.

For this reason, do not stand between the tractor and mower. The swing process must be undertaken with the mower in horizontal position.

The glide discs must be on the ground before putting into operation and while working!

Stones and similar objects can be flung about even when the mower unit is being used correctly. Therefore, nobody should remain in the danger zone.

Special care is required when working near roads and buildings!

The working tools of the cutter bar continue to run even after switching off the drive. Do not stay close to them until they have stopped.

If you have encountered an obstacle, stop the mower unit immediately and check for damage!

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

Always connect the machine correctly to the tractor and connect and secure the machine to the prescribed couplings!

Always place the jack in the appropriate position when hitching and unhitching the machine – stability!

Use special care when hitching the machine to the tractor and when unhitching the machine!

Make sure that balance weights are correctly fixed at the provided points!

Observe the permissible transport dimensions!

Observe the maximum permissible axle loads and total weights!

Check and mount transport equipment – such as lights, warning devices, and if required protecting devices and guards!

Operating devices (ropes, chains, linkages etc.) of remotely controlled mechanisms must be positioned in such a way that they do not trigger unintentional operation in any transport or operating position!

For road travel, prepare the machine and lock any moving parts as prescribed by the manufacturer!

Never leave the operator's platform when driving!

Always adapt your ground speed to the ground conditions! Avoid making sharp turns when driving up or down slopes or when driving across the slope!

The operating, steering and braking behaviour will be affected by the trailed machine! Therefore ensure adequate steering and braking power!

When making turns, always take into consideration the width and/or inertia of the machine!

Use the mower unit only when all the guards are fitted and in the protection position!

Ensure all persons stand clear of the operating area and of the area of danger!

Do not stand in the rotation area or swing area of the machine.

Check for pinch and shear points on parts that are operated with external force, for instance by hydraulics!

Secure the machine before leaving the tractor!

Lower mounted attachments fully to the ground!

Switch off the engine and remove the ignition key.

Keep the machine clean to prevent fire!

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

4.2

Safety Rules Never let anyone stand between the tractor and the machine without securing the vehicle against rolling away by putting on the parking brake and/or through the use of wheel chocks!

ATTACHED MACHINES Before attaching the machines or detaching the machines from the 3-point linkage, move the control lever to a position in which unintentional raising or lowering is not possible!

When attaching mounted machines to the 3-point linkage, the linkage categories of tractor and machine must match, otherwise make necessary modifications!

There is risk of injury due to crushing or shearing in the area of the 3-point linkage!

Do not stand between tractor and machine when operating the remote control unit for the 3-point linkage!

Always ensure that there is adequate sideways locking of the tractor three point rod when the machine is in transport position!

When driving on the road with the machine lifted, the operating lever must be secured against falling down.

ATTACHED DEVICES Secure the devices from rolling away.

Observe maximum permissible load capacity of couplings and swinging drawbar or hitch facility!

When hitching the machine to the drawbar, ensure that there is sufficient movement at the hitch point!

Secure universal drive shaft gear against rotating by hanging the chains.

Before engaging the PTO shaft, ensure that the selected speed and the direction of rotation of the tractor's PTO shaft matches the permissible speed and the direction of rotation of the drive assembly of the machine!

Always ensure that nobody is in the danger zone of the machine before switching on the p.t.o.shaft!

Never engage the PTO shaft when the engine has stopped!

When operating the PTO shaft nobody must stand in the vicinity of the rotating PTO stub shaft or universal drive shaft!

Always disengage the PTO shaft when the turn angle is extreme or when the PTO drive shaft is not used!

Attention, after the PTO has been disengage, flywheel mass continues to run! Do not step too close to the machine during this time! You are only allowed to work on the machine when everything has stopped moving Cleaning, lubricating or adjustment of the p.t.o. shaft driven machine or universal drive shaft is only permitted when the p.t.o. shaft and engine are switched and the ignition key is removed!

When the universal drive shaft is not connected to the tractor, it must be kept on the storage yoke or suspended with a chain!

After uncoupling the universal drive shaft, push the protective guard on to the PTO stub shaft!

In the event of damage, this must be rectified immediately, before commencing work with the machine.

PTO OPERATION Only use universal drive shafts specified by the manufacturer!

Always ensure that the guards for the universal drive shaft and PTO stub shaft are installed and in a good condition! Ensure that the guards properly cover the universal drive shafts, both, in the transport and in the working position!

HYDRAULIC SYSTEM The hydraulic system is under high pressure!

When attaching hydraulic cylinders and motors, ensure the stipulated connection of the hydraulic hoses!

Always disengage the PTO shaft, stop the engine and remove the main switch key before attaching or detaching the universal drive shaft!

When connecting the hydraulic hoses to the tractor hydraulics, it is important to ensure that the hydraulics are depressurised both on the tractor side and the machine side!

An overload or free running coupling is to be attached on the device side when using universal drive shafts with overload or free running couplings which are not covered by the protective equipment on the tractor!

For hydraulic function connections between the tractor and the machine, the coupling sleeves and plugs should be marked to avoid incorrect operation! Interchanging connections causes reversed functions (e.g. raise/lower) – Safety hazard!

Always ensure that the universal drive shaft is correctly installed and securely fastened!

4.3

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Safety Rules Check hydraulic lines at regular intervals, and replace them in case of damage or ageing!

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

Checking for leaks is hazardous. Use suitable aids to check for leaks!

Fluid escaping under high pressure (hydraulic oil) can penetrate the skin and cause serious injuries. If any fluid penetrates the skin, consult a doctor immediately!

– Risk of infections!

Before performing any work on the hydraulic system, lower the machine, release the pressure from the hydraulic system and stop the engine!

Guards and protecting devices that are subject to wear must be checked at regular intervals and replaced in time!

Spare parts must at least comply with the technical standards required by the manufacturer of the machine! Original spare parts, for instance, are manufactured to meet these standards!

Before performing electrical welding work on the tractor and mounted machines, always disconnect the leads from the battery and alternator!

SOUND PRESSURE LEVEL If the sound pressure level at the driver's ear exceeds 85 dB (A) (see Specifications), wear ear protection.

TYRES When working on tyres make sure the machine is safely parked and secured so that it will not roll away (use wheel chocks)!

Fitting tyres and wheels requires special training and expert knowledge and the correct tools!

Repair work on tyres on wheels must only be carried out by professionals and with correct tools!

Check the air pressure regularly! Observe the recommended tyre pressure!

MAINTENANCE Repair, service and cleaning work and elimination of malfunctions should only be performed when the drive and the are engine switched off!

– Remove the ignition key!

Wait until the cutting discs and knives are completely motionless!

Repair work on prestressed energy accumulators (springs, hydraulic accumulators etc.) requires adequate knowledge and should be carried out in specialist workshops and with approved tools!

Regularly check nuts and screws for tight fit and tighten them, if necessary!

When performing maintenance work on the raised machine, ensure that it is supported safely using suitable supports!

Use suitable tools and wear safety gloves when replacing working parts!

Dispose of used oil, grease and filters in accordance with regulations!

Always disconnect the power supply before working on the electrical system!

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

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 provide instructions to avoid the hazard.

These safety signs, 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 figure in ( ) refers to the adjacent picture and indicates the correct location of the decal on the machine.

Safety decals that are damaged or cannot be recognized any more must be replaced immediately by new ones.

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

1

64523

1

2 Safety decals 514 945.0 (1) Before putting the machine into operation, read the operator's manual and follow the safety precautions (Fig. 1, 2)

4.5

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Safety Rules

2

64523

3

4 Safety decals 514 826.0 (2) Before carrying out maintenance and repair work switch off engine and remove ignition key.

(Fig. 3, 4)

3

64522

5

6 Safety decals 514 815.0 (3) Do not open or remove the safety guard with the engine running.

(Fig. 5, 6)

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

4.6

Safety Rules DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C

4

5

6

64525 66367

7

8 Safety decals 514 825.0 (4) DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C: Maintain your distance when the engine is running.

(Fig. 7, 8, 9)

DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C

6

64526

5

4

9

10 Safety decals 514 744.1 (5) DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C: Do not touch moving machine parts. Wait until they have come to a complete standstill.

(Fig. 7, 9, 10)

4.7

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Safety Rules

11 Safety decals 514 821.0 (6) DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C: Maintain sufficient distance from the blades when the engine is running.

(Fig. 7, 9, 11)

A

B

C 12 Safety decals 936 915.0 (7) DISCO 8550 Plus / 8550:

7

Figure (A): Maintain sufficient distance from the blades when the engine is running.

Figure (B): Do not touch moving machine parts. Wait until they have come to a complete standstill.

Figure (C): 68471

13

Maintain your distance when the engine is running.

(Fig. 12, 13)

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

4.8

Safety Rules

10 64527

14

15 Safety decals 514 814.0 (10) Do not put hands in the trapping danger area while the parts are still moving.

(Fig. 14, 15, 16)

10

11 64524

16

17 Safety decals 514 898.0 (11) Do not stand in the swing area of the working units.

(Fig. 16, 17)

4.9

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Safety Rules

12 19 Safety decals 516 254.0 (12) 68472

18

Do not stand in the bending area with the engine running.

(Fig. 18, 19)

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

4.10

Specifications

Specifications

5 Specifications Note!

Technical specifications, dimensions and weights are understood with the usual tolerances.

DISCO 8550 Plus DISCO 8550

Required tractor power

DISCO 8550 C Plus DISCO 8550 C DISCO 8550 C-T DISCO 8500 C

KW (HP)

110 (150)

140 (190)

mm

3000

3000

– pulled front - rear combination

mm

8000

8000

– pushed combination

mm

-

8300

P.T.O. speed

rpm

1000

1000

Cutting disc speed

rpm

3200

3200

metres/second

87

87

– pulled front - rear combination

rpm

-

900

– pushed combination

rpm

-

770

mm

40

40

– pulled front - rear combination

kg

-

2950

– pushed combination

kg

-

3150

– pulled front - rear combination without front mower unit

kg

1920

-

Number of cutting discs per mower unit

-

7

7

Number of cutting blades per mower unit

-

14

14

Transport width Working width

Circulation speed of the mowing blades Conditioner speed

Cut height (bar horizontal) Weight

5.1

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Specifications

Specifications CALCULATING THE AXIAL LOADS, MINIMUM BALLAST AND TOTAL WEIGHT The front axle of the tractor must always be loaded with at least 20% of the empty weight of the tractor.

The fitting of machines on the front or rear three point linkage must not result in exceeded permissible overall weight, permissible axial loading or carrying capacity of the tractor tyres.

Check that these preconditions are fulfilled by performing the following calculations or by weighing the tractor-machine combination.

You will need the following data to be able to perform the calculation:

G

Empty weight of the tractor - see tractor operating instructions

TV (kg)

Front axle loading of the empty tractor - see tractor operating instructions

TV (kg)

Rear axle loading of the empty tractor - see tractor operating instructions

H

GV

TH

TV a

68704

TL (kg)

b

GH (kg) Total weight rear fitting machine / rear ballast With towed machine, GH = Support load – see »Specifications«, page 5.1

c

d 1

GV (kg) Total weight front fitting machine / front ballast – see »Specifications«, page 5.1 a (m)

Distance between the centre of gravity front fitting machine / front ballast and the centre of the front axle - to be measured

b (m)

Tractor wheelbase, - see tractor operator's manual

c (m)

Distance between centre of rear axle and centre of lower steering ball - to be measured

d (m)

Distance between centre of lower steering ball and the centre of gravity of the rear mounted machine / rear ballast - measure In the case of a towed machine, d = 0

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

5.2

Specifications G H × ( c + d ) – T V × b + 0, 2 × T L × b G Vmin = --------------------------------------------------------------------------------------------a+b

Calculation of the minimum front ballast Rear mounting machine or front - rear combination

Note!

Enter the calculated minimum ballast required by the front of the tractor in the table.

G Hmin

G V × a – T H × b + 0, 45 × T L × b = --------------------------------------------------------------------------------b+c+d

Calculation of the minimum rear ballast Front mounting machine

Note!

Enter the calculated minimum ballast required by the rear of the tractor in the table.

T Vtat

GV × ( a + b ) + TV × b – GH × ( c + d ) = ---------------------------------------------------------------------------------------------b

Calculation of the actual front axle load In the case of a front mounted machine (GV), if the required minimum ballast value at the front (GVmin) is not reached, the weight of the front mounted machine must be increased to that of the minimum front ballast weight.

Note!

Enter the calculated permissible actual front axle load and that given in the operator's manual in the table.

Calculation of the actual overall weight

G tat = G V + T L + G H

With the rear mounted machine (GH), if the minimum rear ballast value (GHmin) is not reached, then the weight of the rear mounted machine must be increased to the value of the minimum ballast weight.

Note!

Enter the calculated actual permissible overall weight and that given in the tractor operator's manual in the table.

5.3

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Specifications Calculation of the actual rear axle load

T Htat = G tat – T Vtat

Note!

Enter the calculated permissible actual front axle load and that given in the operator's manual in the table.

Carrying capacity of the tyres Enter double the value (2 tyres) of the permissible tyre carrying capacity in the table (see, for example, the data provided by the tyre manufacturer).

TABLE

Actual value from calculation

Permissible weight from operator's manual

Double permissible tyre carrying capacity (two tyres)

Minimum ballast front / rear

/ ......

kg

---

---

Overall weight

kg ≤

kg

Front axle load

kg ≤

kg ≤

kg

Rear axle load

kg ≤

kg ≤

kg

---

Note!

The minimum ballast must be fitted as a mounted machine or ballast weight on the tractor.

The calculated values must be less than or equal to (≤) the permissible values.

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

5.4

Specifications

Specifications NOISE LEVEL Microphone location 1

The noise level measurement is to be carried out in accordance with the measuring procedure given in the document

Microphone location 2

HM Agricultural Inspectorate AGRICULTURAL MACHINERY NOISE Legislation and guidance on methods of testing (Annex to AIC 1986/117 REV) February 1988 Health and Safety Executive

Horizontal level Tractor Machine

M62120-01

The measuring procedure used is in accordance with procedure No. 4 described in this document.

1

The trial conditions are identical to those specified in ISO Standard 5131 unless defined otherwise.

The tractor used for the measurements has a power output of 110 KW (150 HP).

During measurement, the machine is standing stationary on a surface with short grass, and is running at an operating speed of 1000 rpm.

A-weighted equivalent continuous sound pressure level Tractor without machine

Cabin window

Tractor with machine

open

closed

open

closed

Microphone location 1 - L(A) eq

dB (A)

89.1

74.6

94.0

78.4

Microphone location 2 - L(A) eq

dB (A)

91.3

91.2

98.8

98.4

5.5

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation

Prior to Operation

6 Prior to Operation ASSEMBLY Side mower safety frame DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C

4 4

2

Fit the safety frame in accordance with Fig. 4 and fix to the conditioner framework.

Place the safety guards (1) over the safety frames (2) of the side mowers and secure with the belts (4).

1

(Fig. 1, 2) 1

Note!

For ease of fixing the belts, the lower screws (3) can be removed and the safety frame swung upwards out of the way (Fig. 4).

4 4

2

6 6

Fix the safety curtains (1) to the conditioner framework with the rails (5), coach bolts (6) (M8x20x13), contact washers (B8) and lock-nuts (VM8).

7

Push the spring tines (7) from above through the openings in the safety curtain and fix with the self-locking nuts of the safety curtain.

7

(Fig. 3) 5

1 3

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.1

Prior to Operation

M10x30 M10x30

M10x35 B10

M10x30

M12x30 B12 Vm12

M12x30 Vm12 B12 B10 Vm10

B10 Vm10

B10 Vm10

B10 Vm10

VM10

A10 M10x25

M10x30

3 M12x55

A10 M10x25

3

B12 Vm10

B10

66404R/02

4

6.2

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation Side mower safety frame DISCO 8550 Plus / 8550 Fit the safety frame in accordance with Fig. 9 and secure.

1

Place the safety curtains (1) over the safety frames (2) of the side mowers and secure with the belts (4).

4

(Fig. 5-8)

2 5

4

2

4

6

2

4 7

8

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.3

Prior to Operation

Note!

For ease of fixing of the belts, the lower screws (3) can be removed and the safety frame swung upwards out of the way (Fig. 9).

M10x30 M10x30 M10x35 B10

B10 Vm10

B10 Vm10

B12

B10 Vm10 B10 Vm10 M10x30 Vm10 A10 M10x30

M12x55

B10

Vm10 M10x40

3

M10x25 A10 M10x30 Vm10 M10x30 B10

Vm12 M12x60 M12x60

Vm12 B10 Vm10

68483

M12x60

Vm12

9

Mounting the fitting frame Hook the fitting frame (1) into the lower link pin of the tractor. Secure the pin with the linch pin. Also fit the upper link (Fig. 10).

Note!

If the play in the pins is too great, use the washers provided (37x56x5).

6.4

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation

Note!

The DISCO 8550 Plus / 8550 cannot be used as a pushed combination and can only be used as a towed front - rear combination (– see , page 619.).

Position A: Use as a pushed combination Position B: Use as a towed front - rear combination.

(Fig. 10)

1

B

A

67216R/01

A 10

Connect the hydraulic hose to the single-acting control valve of the tractor.

Push the two-pole connection for the control system power supply into the appropriate receptacle on the tractor.

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.5

Prior to Operation Fitting the controller DISCO 8550 C Plus / 8550 C / 8550 C-T Fit the bracket (12) within reach of the driver.

11

Screw the control terminal bracket (13) to the bracket (12) with the set screws (M5x16) and self-locking nuts (VM5).

12

Push the control terminal (11) into the control terminal bracket (13).

13

(Fig. 11)

11 Push the plug (13) into the socket (14).

(Fig. 12) 14 Push the electrical connection cable into the socket on the tractor.

13 Connect the hydraulic hose to the connection of a single-acting control valve on the tractor.

12 Push this button on the control terminal for 1.5 seconds.

Push this button. The lamp lights up green. Set the tractor hydraulics control lever to the floating position.

(Fig. 13)

When fitting for the first time, the weight of the side mower unit is not available to swing the arm downwards. For this reason, the arms must be pulled downwards.

CONTROL TERMINAL

6.6

13

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation Fitting the controller DISCO 8550 C Plus / 8550 C / 8500 C-T Push both buttons (7) on the operating box at the same time - the red LEDs (8) light up. Lower the arms on the left and right hand sides with the single-acting control valve.

7

When fitting for the first time, the weight of the side mower unit is not available to swing the arm downwards. For this reason, the arms must be pulled downwards.

8

(Fig. 14) 14

15

16

17

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.7

Prior to Operation Use as a pushed combination Note!

The DISCO 8550 Plus / 8550 cannot be used as a pushed combination and can only be used as a towed front - rear combination (– see , page 619.).

74224

18 Fix the two side mower units onto the arms. To do this, fit the pin (3) into the outer drilled hole of the arms and secure with the strap (5). Fit the locking screws (4).

(Fig. 19)

3

4 5

19 Push on the universal drive shafts (6) with the clutch side to main gearbox and then onto the side mower units and secure with the clamping screws.

Secure universal drive shaft against rotating by hanging in the chains.

(Fig. 20) 6

20 Suspension springs Basic setting X = approx. 80 mm (Fig. 21)

X

1

21

6.8

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation Fitting the adapter (B03 0030) 1

In order to be able to hang the front mower unit onto the fitting frame, the adapter B03 0030 must be fitted.

• Fit the carrier (1) for the front mower suspension fixings with the hex head screws (M16x 130), washers (A16) and self-locking nuts (VM16).

• Pull the connecting rod out of the hydraulic cylinder (2). To do this, unscrew the vacuum valve (V) complete with male connector – see page 6.10, »Hydraulic cylinder with vacuum valve«.

CAUTION: The vacuum valve is glued to the male connector. This connection must not be released!

22

• Hook the hydraulic cylinder (2) in with the pin (3) and secure with split pin.

CAUTION: The vacuum valve (V) on the hydraulic cylinder must point to the back to avoid the ingress of water.

V

• Fit the adapter (4) in the rear drilled hole with the pin (5) and secure with the linch pin.

For higher front mower cutting heights, the adapter may be inserted into the front drilled hole.

• Fit the hydraulic cylinder (2) to the straps on the adapter with the pins (6) and secure with the split pin.

(Fig. 22-24)

23

5x40

V

26x40x1

1

2

3

M16x130 A16

A16 VM16

5x40

6

26x40x1

4

12x45

5

65420R02

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

24

6.9

Prior to Operation Hydraulic cylinder with vacuum valve V

The following notes refer to the mower units from serial no. 652 0 1961.

Danger!

The vacuum in the hydraulic cylinder (2) can cause unexpected retraction of the piston during dismantling.

69175 69175

25

– Before dismantling the cylinder unscrew the hex head screw (V) on the cylinder barrel!

(Fig. 24, 25)

6.10

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation DISCO 8550 C Plus / 8550 C / 8550 C-T:

DISCO 8550 C Plus / 8550 C / 8550 C-T

• Fit the hydraulic lines (7) to the hydraulic cylinders (2).

• Unscrew the plug from the elbow unions (10) and 10

connect the hydraulic hoses (7) to the middle mower unit.

7

(Fig. 26, 27) DISCO 8500 C:

• Fit the hydraulic lines (7) to the hydraulic 10

cylinders (2).

7

• Fit the hydraulic lines (7) in front of the flow divider (9) with a T-union (8).

26

(Fig. 28) DISCO 8550 C Plus / 8550 C / 8550 C-T

7

10

2

68291M01

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

27

6.11

Prior to Operation DISCO 8500 C

7

8 9

2

65421R01

6.12

28

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation Fitting the Accord coupling Fit the Accord coupling (4) in the upper drilled hole on the adapter (6) with the pin (5) and secure with the spring clip. (Fit the adapter – see »Fitting the adapter (B03 0030)«, page 6.9).

3 2

4

1

If there is insufficient clearance height at the headland with deep cutting, the adapter (6) is to be fitted into the front drilled hole (7) of the fitting frame.

Plug the upper link (2) into the rear drilled hole (1) on the fitting frame with the pin and secure with the spring clip.

4

5 7

(Fig. 29)

6

29 DISCO 3050 FC Plus: Plug the upper link into the upper drilled hole (3) on the Accord coupling with the pin (Fig. 29).

CORTO 3150 F Profil: 8

Plug the upper link into the third drilled hole (8) on the Accord coupling with the pin (Fig. 30).

30 Hook the front mower unit (9) into the Accord coupling (4) and secure – see »Hooking up the front mower unit to the fitting frame«, page 6.36.

9

4

(Fig. 31) The chains of the suspension springs (10) should be inserted into the eighth link in the straps (12) and secured with spring clips .

10

12

Push the front mower universal drive shaft (11) on with the clutch side to the gearbox, and then onto the front mower unit.

11 31

Secure universal drive shaft against rotating by hanging in the chains.

(Fig. 31)

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.13

Prior to Operation

Note!

When using the mower unit as a pushed combination, the front mower unit requires universal drive shaft M04 0160 (0937 043.3)!

M04 0160 937 043.3 74224

32

Caution!

If the mower unit is operated as a pushed combination, a flat bar (1) must be screwed to the braces of the collision protection. Only in this way can an adequate separation between the tractor and the mower unit be maintained.

1 (Fig. 33) 33

6.14

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation Fitting the lighting unit on the front mower unit DISCO 3050 FC: Fit the lighting unit (1) to the front mower unit with the lighting brackets (2) provided.

3

(Fig. 36) 45 m

m

To do this, cut the safety curtain (3) on the right hand and left hand side accordingly.

(Fig. 34) 34 Fit the lighting brackets (2) on the right and left hand sides.

(Fig. 35, ) 2

35 A10 M10x40 M8x25

2

2

M10x40 A10

M8x25

A8 VM8

M8x25

11x40x4 A8 VM8 A8 VM8

VM10

VM8 A8

1 M8x25

11x40x4

65921&/01

1

VM10

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

36

6.15

Prior to Operation CORTO 3150 F Profil: Fit the lighting unit (1) to the front mower unit with the lighting brackets (2) provided.

(Fig. 37)

1

M10x40 A10 M8x25

2

11x40x4 A8 VM8

VM10

2

M10x40 A10 M8x25

A8 VM8

VM10 11x40x4

69379F

1

6.16

37

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation Fitting the cable Run the cable for the lighting bar to the fitting frame (4) via the cable bracket. In this position, attach to the hydraulic lines using cable ties.

(Fig. 38, 39) 4

38 Caution!

Run the cable under the hydraulic line so that the spring release lever does not pinch the cable (see arrow). +

(Fig. 39)

39

Caution!

Run the cable at the transfer point from the adapter to the front mower unit in such a way that there is no tension over the full movement range of the cylinders.

(Fig. 40)

40

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.17

Prior to Operation Run the cable to the mounting block. Screw the cable to the cover and the fitting block with retaining fitting (D=10) (M6x16) (5). Use the existing washers.

(Fig. 41)

5

41 The wiring loom is pre-assembled with the lighting bar using cable ties (6). Take up the excess cable length in the lighting bar with cable ties.

6

(Fig. 42)

42

6.18

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation Use as a towed front - rear combination

74228

43 Fix the two side mower units onto the arms. To do this, fit the pin (3) into the inner drilled hole of the arms and secure with the strap (5). Fit the locking screws (4).

Hook the front mower unit into the Accord coupling and secure.

3

(Fig. 44)

4

5

44 DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C

DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C Basic setting X = approx. 80 mm (Fig. 45)

X

1

45 DISCO 8550 Plus / 8550

DISCO 8550 Plus / 8550 Basic setting X = approx. 50 mm 1

(Fig. 46)

X 46

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.19

Prior to Operation Dismantle the left (7) and right (8) hydraulic lines and close off the elbow unions (9) using plugs (10).

(Fig. 47, 48) 7

9 8

9

47 10 9

48 Push on the universal drive shafts (11) with the clutch side to the main gearbox and then onto the side mower units and secure with the clamping screws.

11

(Fig. 49)

Push the front mower universal drive shaft on with the coupling side to the gearbox and then onto the front mower unit.

Secure universal drive shaft against rotating by hanging in the chains.

49

Note!

When using the mower unit as a towed front rear combination, the front mower unit requires universal drive shaft M04 0080 (0947 117.5)!

M04 0080 0947 117.5

74228

6.20

50

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation Fitting the lighting unit Fit the lighting unit to the back of the fitting frame using the small brackets (3) supplied. Drill two holes (∅ 10 mm) in the braces (2). The separation of the holes from the centre of the rail is 435 mm on both the right and left hand sides.

(Fig. 51) M12x35

1b 1a A 16 M10x40 A10

VM12 13x40x6 VM12

A 12 VM12

M16x30

VM12 13x40x6

3 13x62x6

VM12 13x62x6 M12x40 M10x40 A10 11x40x4 VM10

3 M12x40 11x40x4 VM10

2

65920&/02

51 Fitting the cable Dismantle cable retainer and bracket (1a/dashed line).

Place in position 1b and secure with the pre-mounted screws.

(Fig. 52)

1b

52

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.21

Prior to Operation Run the wiring loom from the fitting frame to the cable retainer (4). Fix the wiring loom to the hydraulic lines which run parallel with cable ties (5).

4

5

Run the wiring loom from the cable retainer through the upper tube of the fitting frame.

(Fig. 53)

53 The excess length of the wiring loom should be stowed within the fitting frame.

(Fig. 53, 54)

54

55 56

6.22

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation Fitting the middle mower unit rotation sensor DISCO 8550 C Plus / 8550 C / 8550 C-T

57 6

1

11

1 Sensor DW 60

1x

2 Sensor bracket GT 41

1x

3 Hex head bolt

M8x20

2x

4 Contact washer

B8

2x

5 Pipe clamp

1x

6 Front cable DW 60

2x

7 Clamp

5x

8 Serrated lock washer A6,4

6x

9 Contact washer

A6

1x

10 Set screw

M6x12

6x

11 Extension cable DW 60

1x

(Fig. 58) 10

5

3

4

9

10

8

2

7 58 Unscrew the bolts from the mitre gear.

(Fig. 59)

59

60

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.23

Prior to Operation Push back the universal drive shaft guard (S).

(Fig. 61)

S 61

3

Fit the sensor (1) to the gearbox with the sensor bracket (2), hex head bolts (3) and contact washers (4).

4

1

(Fig. 62) 3 4 2 L G

62 Setting the height of the sensor (1).

M

To do this, release the hex nuts (M), move the sensor (1) in the required direction and re-tighten the hex nuts (M).

1

The distance between the sensor (1) and a tooth on the universal drive shaft (W) should be approx. 4 mm.

4 mm

(Fig. 63)

W 63

A

Then set the distance from the sensor (1) to the slip-on coupling (A) of the universal drive shaft. This is done by displacing the sensor bracket (2) in the slotted hole (Fig. 64, 65).

1

The distance between the sensor (1) and the slip-on coupling (A) should be 2-4 mm.

(Fig. 64)

2-4 mm 64

6.24

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation The universal drive shaft guard (S) should be cut to suit and be pushed back in position.

2

Caution!

Note the position of the lubrication points (O)!

L

S

(Fig. 65) O 65 Connect the front cable (6) to the pin of the sensor (1) plug.

9 7

8

Run the front cable (6) to the back.

8

9 7

To do this, fit the pipe clamp (5) and clamps (7) with the serrated lock washers (8) and set screws (9) in the drilled holes provided.

6

Make sure that the cable forms a slight loop on the fitting frame (see arrow).

5

8

(Fig. 66)

9

66

6

7

8

Note!

Lift the middle mower unit and check the cable length by moving it.

9

(Fig. 66-69)

67

6

7 8

9

68

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.25

Prior to Operation

6 7

8

9

69 Pushed combination Connect the plug of cable (11) with the plug of cable (K). Make sure that cable (K) is long enough to ensure that it is not pulled or damaged when moving through the entire range of the folding motion (see arrow).

11 K

(Fig. 70)

70 Towed front - rear combination Connect the plug of cable (11) with the plug of the front cable (6a).

Connect the plug of the second front cable (6b) with the plug of the first front cable (6a).

11

(Fig. 71) 6b 6a

71 Run the front cable (6b) along the tractor through the cab to the back to the side mower units.

(Fig. 72)

6b

72

6.26

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation

Note!

If the middle mower unit is not fitted with the speed monitor, switch (1) can be switched to the left or right in order to turn off the warning signal tone – see »Bridging out switch«, page 7.10.

(Fig. 73)

1 73

Setting the clearance height DISCO 8550 C Plus / 8550 C / 8550 C-T

1

To adjust the clearance height, release the bolts (2) and displace the sensor bracket (1) in the slotted holes. Re-tighten the bolts.

Moving the sensor bracket upwards: Side mower units lift higher.

Moving the sensor bracket downwards: Side mower units lift lower.

2

(Fig. 74) 74

75 76 77 78

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.27

Prior to Operation Fitting the blades DISCO 8550 C Plus / 8550 Plus / 8550 C-T The blades must be fitted before operating the machine for the first time. To do this, move the fitting lever between the cutting disc and the blade carrier.

Push the fitting lever downwards and remove the mower blade – see »Changing mower blades DISCO 8550 C Plus / 8550 Plus / 8550 C-T«, page 8.10.

Note the direction of rotation of the cutting disc.

(Fig. 79, 81, 82) 68482

79 DISCO 8550 C / 8550 / 8500 C

4 4

Fit the new blades with the cutting edge facing downwards. The direction of rotation of each disc is marked by an arrow on the blade.

Tightening torque of the mower blade securing bolt (4) = 120 Nm. (Fig. 80, 81, 82)

120 Nm

64258

80

DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C

68480

6.28

81

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation DISCO 8550 Plus / 8550

68481

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

82

6.29

Prior to Operation Matching the universal drive shaft Before using the mower unit for the first time, the hitch and universal drive shaft must be adjusted to suit the tractor.

Caution!

The maximum universal drive shaft inclination and quiet running of the mower unit can only be achieved by correct hitching.

It will often be necessary to change the length of the universal drive shaft because of the different locations of p.t.o. shaft on the various tractor types.

Matching the length: Pull the universal shaft apart and push the universal drive shaft halves onto the drive shaft of the machine and the other half onto the tractor PTO shaft using the long protective funnel.

Swing the machine into the working position. Hold the universal drive shaft halves next to each other and check the length with the machine in the lifted out and lowered positions.

(Fig. 83) Observe the maximum permissible shaft length (LB).

83 84

Try to ensure maximum possible overlapping of profile tubes. The universal drive shaft must only be pulled apart when operating by half the size of the sliding profile cover (PU) when in a compacted condition (LZ).

At the shortest operating length, the universal drive shaft halves must not collide against each other. A minimum clearance (a) = 40 mm must still be available.

Cut the male and the female guard tubes uniformly.

Cut the same length from the male and female profile tubes.

File the cut area to remove any metal burrs, remove any metal filings.

Grease the sliding surfaces of the profile tubes.

(Fig. 85)

85 86

6.30

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation LOADING/UNLOADING THE MACHINE DISCO 8550 PLUS / 8550 Danger!

Incorrect loading and transport of the front attachment involves danger of accidents taking place!

– Suspend the machine only from the left and right slinging points (1) for loading!

87

– Make sure the slings are sufficiently dimensioned!

Weight of the machine – see »Specifications«, page 5.1.

(Fig. 87-92)

1

88

1

89

90

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.31

Prior to Operation

1

91

1

92

6.32

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation CHECK AND OBSERVE THE FOLLOWING BEFORE PUTTING INTO OPERATION! 1. Check the oil levels in the gearboxes and in the cutter bar.

2. Lubricate the mower unit thoroughly before operation.

3. Check that the mower blades are properly fastened.

4. Check bolts for tightness.

5. Check the safety features (e.g. overload clutches, covers over drive components, .....) for correct function and correct location.

6. Only switch on the mower unit when in the lowered position.

7. Switch on the tractor PTO shaft only in idle speed and with the machine in the swung-in working position.

8. Do not exceed the permissible p.t.o. shaft speed of the mower unit (1000 rpm.)

9. After hooking up the mower unit and engaging the universal drive shaft, by carefully lifting out and lowering the mower unit, check that the universal drive shaft rotates freely.

10. Secure universal drive shaft gear against rotating by hanging in the chains.

11. Check the safety guards for wear and damage.

12. Check the lighting, turn flashers and brake lights for correct function.

13. Instruct persons to leave the danger area; if persons approach the danger area then turn off the mower unit immediately.

14. Never let the mower unit run without being supervised.

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.33

Prior to Operation ATTACHMENT TO THE TRACTOR The DISCO 8550 C Plus / 8550 C / 8550 C-T and 8500 C can be operated as a large area mowing combination in two types of mountings:

A

Note!

The DISCO 8550 Plus / 8550 cannot be used as a pushed combination and can only be used as a towed front - rear combination.

93

64461R/01

As a towed combination, the fitting frame is hooked in with the side mower units in Position A. The front mower unit is mounted on the front on the tractor.

(Fig. 93)

As a pushed combination, the fitting frame is hooked in Position B on a tractor with reversing facility. In this case, the front mower unit is mounted onto the fitting frame via an adapter.

B

(Fig. 94)

94

64462R/01

Caution!

If the mower unit is operated as a pushed combination, a flat bar (1) must be screwed to the braces of the collision protection. Only in this way can an adequate separation between the tractor and the mower unit be maintained.

(Fig. 95)

1 Note: 95

6.34

– see »Conversion from front - rear combination to pushed combination«, page 6.43.

– see »Conversion from pushed combination to front rear combination«, page 6.45.

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation Hooking up the fitting frame Hook the fitting frame into the lower link pin of the tractor. Use the lower drilled hole (2) for this (Fig. 96).

Secure the pin with the linch pin.

Fit the upper link and adjust so that the adapter is almost vertical - see also »Setting the cutting height« on page 7.13.

2

96

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.35

Prior to Operation Hooking up the front mower unit to the fitting frame In order to be able to hook the front mower unit into the fitting frame, the adapter B03 0030 must first be fitted – see »Fitting the adapter (B03 0030)«, page 6.9.

Completely drain the hydraulic system of the adapter with the single-acting control valve of the tractor.

Drive up to the machine and insert the Accord coupler into the three point frame using the hydraulic system.

The latch (1) should snap into the strap (2).

64460R/01

97

The strap (2) can be adjusted after releasing the bolts (3).

(Fig. 97, 98)

Adjust the strap (2) so that it is in contact with the latch (1) of the Accord coupler.

2

Adjust the stop bolt (4) accordingly.

1

(Fig. 98)

3

65869F

4

Caution!

98

This setting is to be undertaken with the mower unit in the lifted out position. .

1 Caution!

5 Secure the latch (1) with the spring plug (5) (Fig. 99).

3 74012

99

Setting the upper link Set the upper link so that the front mower unit is almost vertical - see also »Setting the cutting height« on page 7.13.

6.36

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation Weight relief The weight relief of the mower unit can be varied using the hooking point of the suspension springs. In the basic setting, the chains (1) of the suspension springs (2) should be inserted into the eighth link in the straps (3) and secured with spring clips . Push the straps (3) onto the upper pin and secure with the spring pin.

1

3

(Fig. 100) 2 100 Connecting the universal drive shaft Danger!

8

4

Never remove the safety devices (8) from the universal drive shaft!

– Check that all locks are securely engaged before starting work with the PTO drive shaft.

1

– Hang up the fixing chains (4) for the universal drive shaft guard using the hook on the machine and on the tractor.

101 Push the locking pin and simultaneously push the universal drive shaft (1) onto the p.t.o. shaft until the locking mechanism engages.

(Fig. 101) Attention!

Always engage the PTO shaft slowly to save the drive mechanism. Observe the recommendations of the PTO shaft manufacturer.

Observe maximum p.t.o. shaft speed – see »Specifications«, page 5.1!

102

The p.t.o. shaft may only be switched on with the machine swung into the working position!

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.37

Prior to Operation Hydraulic system Danger!

For driving on the road and before de-coupling the hydraulic hose, the cock (1) (Fig. 103) must always be switched off.

1

B

A

Attention!

4

103

There is a danger of contamination of the tractor hydraulic system!

– Clean the male coupling of the hydraulic hose and the oil socket before each connection operation.

Connect the hydraulic hose (4) to the connection of a single-acting control valve on the tractor.

(Fig. 103)

104

Stop cock During operation, when lifting out and lowering the cutter bar, the stop cock (1) must be open.

Position (A):

Stop cock open

Position (B):

Stop cock closed

Electrical system Plug the electrical connection cable into the socket on the tractor.

6.38

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation REMOVING THE MACHINE Note!

Park the mower unit on solid flat ground.

Lowering the machine in the unfolded condition

• Fold the side mower units down to the ground.

• Slide the stands (1) downwards and locate in

1

1

position with the pin (Fig. 105).

105

• Lower the mower unit down to the ground using the three point linkage.

DISCO 8550 C Plus / 8550 C / 8550 C-T

• Unhook the upper and lower links.

• Uncouple the universal drive shaft and suspend on the three point stand using the chain .

• Disconnect the hydraulic and electrical connections. Unplug the pin, hydraulic hose and control desk on the hose bracket (3). Make sure that the control desk is located vertically in the hose bracket (Fig. 106, 107).

3

CAUTION! Protect the control terminal from moisture!

106

• Drive the tractor away.

DISCO 8550 Plus / 8550 / 8500 C

Note!

3 DISCO 8550 Plus / 8550 / 8500 C: If the machine is at a standstill for a longer period of time, both check lamps (7) on the control terminal must be out. The electrical connection to the tractor must be interrupted.

7

(Fig. 107)

107

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.39

Prior to Operation DISCO 8550 C Plus / 8550 C / 8550 C-T

Note!

DISCO 8550 C Plus / 8550 C / 8550 C-T: If the machine is at a standstill for a longer period of time, the check lamp (6) on the control terminal must be out. The electrical connection to the tractor must be interrupted.

6

(Fig. 108)

108

Lowering the machine in the folded condition

Danger!

Gusts of wind and uneven or soft ground can cause the lowered machine to tip over.

– Only store the machine in the folded condition in an equipment shed.

109 DISCO 8550 C Plus / 8550 C / 8550 C-T

•

Hinge the mower unit into the transport position

• Slide the stands (1) downwards and locate in position with the pin (Fig. 110).

• Lower the mower unit down to the ground using the three point linkage.

• Move the single-acting control valve to the 0-posi1

tion (neutral).

1

• 110

•

6.40

Push this button. The lamp lights up green.

Push both these buttons. Both lamps light up red.

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation • Set the single-acting control valve to the floating

DISCO 8550 C Plus / 8550 C / 8550 C-T

position. Lower the middle mower unit down to the ground.

•

Turn off the control system.

• Unhook the upper and lower links.

• Uncouple the universal drive shaft and suspend

3

on the three point stand using the chain .

• Disconnect the hydraulic and electrical connec-

111

tions. Unplug the connector, hydraulic hose and control terminal on the hose bracket (3). Make sure that the control terminal is located vertically in the hose bracket (Fig. 111).

CAUTION! Protect the control terminal from moisture!

• Drive the tractor away.

112

Note!

If the machine is at a standstill for a longer period of time, the check lamp (6) on the control terminal must be out. The electrical connection to the tractor must be interrupted.(Fig. 113)

6

113

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.41

Prior to Operation DISCO 8550 Plus / 8550 / 8500 C

• Swing the mower unit into the transport position with the single-acting control valve. Apply pressure until the side mower units are hinged up completely and the lamps (7) on the control terminal go out (Fig. 115).

• Slide the stands (1) downwards and locate in position with the pin (Fig. 114).

• Lower the mower unit down to the ground using the three point linkage.

• Set the single-acting control valve to the floating

1

1

114 DISCO 8550 Plus / 8550 / 8500 C

position. Lower the middle mower unit down to the ground.

• Turn off the control system.

• Unhook the upper and lower links.

• Uncouple the universal drive shaft and suspend

3

on the three point stand using the chain .

• Disconnect the hydraulic and electrical connections. Unplug the connector, hydraulic hose and control terminal on the hose bracket (3). Make sure that the control terminal is located vertically in the hose bracket (Fig. 115).

7

CAUTION!: Protect the control terminal from moisture!

115

• Drive the tractor away.

116

Note!

If the machine is at a standstill for a longer period of time, both check lamps (7) on the control terminal must be out. The electrical connection to the tractor must be interrupted.

(Fig. 115)

117

6.42

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation

118

CONVERSION FROM FRONT - REAR COMBINATION TO PUSHED COMBINATION Note!

The DISCO 8550 Plus / 8550 cannot be used as a pushed combination and can only be used as a towed front - rear combination.

3 Danger!

Before starting the fitting work, turn the tractor engine off.

1

– Remove the ignition key!

2 Danger!

4

119

Before starting the fitting work, release the suspension springs on both sides.

Hinge up the side mower units.

Release the lock nuts (1).

Completely unscrew the bolts (2) out of the suspension springs (3).

Tie the levers (4) of the suspension together using suitable straps (e.g. cable ties).

Lower the side mower units.

(Fig. 119)

5 120

Remove the bolt (5) with washers, bush and nut.

Unscrew the strap (6).

Remove pin (7).

6

Fit the side mower units into the outer drilled holes of the arms.

Fit the bolts (5) with washers, bushes and nuts into the outer drilled holes.

7

(Fig. 120, 121) 5 Hinge up the side mower units.

121

Release the fixing of the lever (4) of the suspension.

Screw the bolts (2) into the suspension springs (3).

Set the spring tension.

Tighten the lock nuts (1).

(Fig. 119)

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.43

Prior to Operation For additional fitting and setting instructions: – see Use as a pushed combination on page 6.8, – see Use as a towed front - rear combination on page 6.19, – see Working position on page 7.4.

6.44

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation

122

CONVERSION FROM PUSHED COMBINATION TO FRONT - REAR COMBINATION Danger!

Before starting the fitting work, turn the tractor engine off.

– Remove the ignition key!

3

Danger!

Before starting the fitting work, release the suspension springs on both sides.

1

Hinge up the side mower units.

2

Release the lock nuts (1).

4

123

Completely unscrew the bolts (2) out of the suspension springs (3).

Tie the levers (4) of the suspension together using suitable straps (e.g. cable ties).

Lower the side mower units.

(Fig. 123)

Remove the bolt (5) with washers, bush and nut.

Unscrew the strap (6).

Remove pin (7).

5 124

Fit the side mower units into the inner drilled holes of the arms.

Fit the bolts (5) with washers, bushes and nuts into the inner drilled holes.

(Fig. 124, 125)

6 Hinge up the side mower units.

Release the fixing of the lever (4) of the suspension.

Screw the bolts (2) into the suspension springs (3).

7

Set the spring tension.

5

Tighten the lock nuts (1).

(Fig. 123) 125

For additional fitting and setting instructions: – see Use as a pushed combination on page 6.8, – see Use as a towed front - rear combination on page 6.19, – see Working position on page 7.4.

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.45

Prior to Operation PRIOR TO TRANSPORTATION 1. Hook up the mower unit.

2. Connect the universal drive shaft and hydraulic hose.

3. Connect the electrical connection cable.

4. Lift out the mower unit with the three point linkage.

5. Retract the stands and interlock.

6. Hinge the mower unit into the transport position 7. Close the stop cock on the hydraulic hose.

126 Caution!

Only transport the mower unit in the switched off condition. During the travel, make sure that the control lever of the hydraulic system is not actuated inadvertently!

127

Driving on public roads Danger!

With the machine fitted, the front axle of the tractor must always be loaded with at least 20% of the empty weight of the tractor (Fig. 128) – If required, use compensating weights.

– Observe the maximum permissible axle loads and total weights!

When driving on public roads with the raised machine, the control lever of the hydraulics must be secured against lowering.

128

– Secure the control lever!

• The applicable laws and regulations must be observed when travelling on public roads!

• Observe the applicable regulations in your country.

The corresponding national (country-specific) provisions apply in other countries.

6.46

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Prior to Operation • The vehicle ground speed must conform to the traffic and road conditions. Observe national (country-specific) provisions concerning the maximum permitted vehicle ground speed! Reduce speed as appropriate when going around curves.

• Prepare machine for transport – see »Prior to transportation«, page 6.46.

• For travel on the road, the lighting unit must be fitted to the mower unit – see page 6.15, »Fitting the lighting unit on the front mower unit« or »Fitting the lighting unit« on page 6.21.

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.47

Operation

Operation

7 Operation CONTROL SYSTEM DISCO 8550 C PLUS / 8550 C / 8550 C-T Switch the control system on/off (actuate for approx. 1.5 seconds).

Note!

The control system switches off after 120 min. if no function is activated.

Caution!

First select the desired function on the control terminal by pushing the button. After pressing, the button lights up red. The green check lamp on the lower button goes out. The function is carried out by actuating the control lever (lifting, lowering or floating position).

CONTROL TERMINAL

1 Swing the mower unit into the working position / mower operation of all three mower units.

Raise / lower left hand mower unit.

2 Raise / lower middle mower unit.

3

7.1

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Operation Raise / lower right hand mower unit.

Note!

The check lamp of the relevant button lights up red after having been selected. The green check lamp on the lower button goes out.

4 Hinge the mower unit into the transport position The check lamp of the button lights up red.

After actuation of this button, the control system automatically switches off after 2 minutes.

5 The check lamp lights up if a universal drive shaft coupling is stalled.

Raise the relevant mower unit immediately and turn the mower unit off. Remove blockage.

Danger!

When removing blockages, or when removing foreign bodies, turn the drive off, stop the engine and do not leave the tractor until the cutting discs and the conditioner drums have come to a complete standstill.

CONTROL TERMINAL

6

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

7.2

Operation General Caution!

Firstly select the desired function on the control terminal by pushing the button. The check lamp lights up red. The function is carried out by actuating the control lever (lifting, lowering or floating position).

2

Raising individual mower units: 3

1

The check lamps (1) to (3) light up red depending upon the selection: The mower unit has been selected. The "LOWER" function of the relevant mower unit is blocked. The "RAISE" function is activated.

4

4

5 CONTROL TERMINAL

7

When the control lever is moved to "RAISE" only the mower unit selected by push-button lifts. Then move the control lever to the floating position. The selected mower unit remains raised and the other mower units automatically lower to the floating position.

The "RAISE" function of the other two mower units is then blocked. The relevant check lamps on the lower button (5) light up green.

All check lamps (4) on the lower button light up green: The mower units are in the floating position.

The pre-selected functions can be cancelled by pushing the same button once more or by pushing the lower button (5).

8

(Fig. 7)

Caution!

If the control unit is in the floating position, the raised mower units lower automatically. The red check lamps go out. The check lamps of the lower button (5) light up green again (Fig. 7).

Caution!

9

7.3

Never switch on the p.t.o. shaft drive when the mower unit is in the folded condition.

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Operation Working position Switch on the control system (actuate for approx. 1.5 seconds).

Push this button. The check lamps light up green. Set the single-acting control valve to the floating position. The mower unit hinges into the working position.

(Fig. 10) 10 The distance from the headstock to the ground should be approx. 450 mm. The bolt (2) should be in the centre of the slotted hole (3) in the mowing position.

(Fig. 11, 12)

If the mower unit is used as a pushed machine, the front mower unit must be hung into the fitting frame. A sequence controller lowers the front mower unit when the side mower units are lowered.

ca. 450 mm

11

3

2

12 13

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

7.4

Operation Transport position On the middle mower unit, first hinge up the safety curtains (2) on both sides. Lift up the mower unit (Fig. 15).

Caution!

Hinging is only possible if the p.t.o. shaft drive is switched off.

14

2

15 Push this button. The lamp lights up red. The "LOWER" function is blocked for all mower units. Swing the mower unit into the transport position with the single-acting control valve. Actuate the control lever until the mower unit is fully folded.

Turn off the control system. (actuate for approx. 1.5 seconds).

Note: After actuation of this button, the control system automatically switches off after 2 minutes.

(Fig. 16)

CONTROL TERMINAL

7.5

16

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Operation Mowing with individual units raised When mowing narrow residual strips the mower units can be raised individually (Fig. 17).

The mower unit is in working position (floating position): All check lamps of the button (5) light up green.

17

1. Select the mower unit which is to be individually raised by actuation of the relevant button.

The check lamp (1), (2) or (3) of this button lights up red.

2. Raise the selected mower unit using the single-acting control unit.

3. Set the control unit back to the floating position afterwards.

4. Before lifting the entire mower unit at the headland the pre-selection of the selected mower unit must be cancelled so that all three units can be lifted together at the headland. To do this, push the button of the selected mower unit again or push the the lower button (5). The check lamp (1), (2) or (3) of the button of the selected mower unit goes out. The relevant check lamp on the lower button (5) lights up green. The mower unit lowers automatically.

2

3

1

4

4

Note:

5 CONTROL TERMINAL

18

By pushing this button, all preselected functions for which the check lamps (1), (2) or (3) light up red are cancelled.

The check lamps of button (5) light up green.

(Fig. 18)

19

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

7.6

Operation The mower units are in the headland position: All check lamps of the button (5) light up green.

1. Select the mower unit which is to remain raised by actuation of the relevant button. The check lamp (1), (2) or (3) of this button lights up red.

2

3

1

2. Set the control unit back to the floating position afterwards. The other mower units lower automatically.

4

4

5 CONTROL TERMINAL

20

3. Before lifting the entire mower unit at the headland the pre-selection of the selected mower unit must be cancelled so that all three units can be lifted together at the headland. To do this, push the button of the selected mower unit again or push the the lower button (5). The check lamp (1), (2) or (3) of the button of the selected mower unit goes out. The relevant check lamp on the lower button (5) lights up green. The mower unit lowers automatically.

Note: By pushing this button, all preselected functions for which the check lamps (1), (2) or (3) light up red are cancelled.

The check lamps of button (5) light up green.

(Fig. 20) 21

22

7.7

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Operation Headland setting At the end of the field swing the mower unit into the headland position with the control lever.

The check lamp of this button lights up green (Fig. 23).

23 When driving into the crop, set the control lever to floating position. The mower unit automatically swings downwards.

(Fig. 24)

24

25

26

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

7.8

Operation Rotation monitoring Note!

The check lamps do not light up when the control system is switched on. If, however, lamps do light up, then one or more rotation sensors is not activated (see note, page 7.9).

27

If the rotation speed on one of the mower units falls (e.g. mower unit is blocked) or one of the rotation sensors is not activated (e.g. rotation sensor is faulty or out of position), then an acoustic signal is produced.

The relevant check lamp on the control desk lights up (Fig. 29).

The mower unit should be switched off immediately and the fault cleared! If the fault is not cleared the clutches can be damaged!

1

Note!

28

If the drive is switched off (speed < 600 rpm.) the check display of the check lamps is reversed. If the rotation sensors are faulty or incorrectly positioned then the check lamps light up on the rotation sensors which are intact (active). The check lamps of the inactive rotation sensors do not light up. Check the sensor distance or replace the defective rotation sensor.

Danger!

When removing blockages, or when removing foreign bodies, turn the drive off, stop the engine and do not leave the tractor until the cutting discs and the conditioner drums have come to a complete standstill.

CONTROL TERMINAL

7.9

29

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Operation Bridging out switch If one of the rotation sensors is not activated e.g. if the rotation sensor is out of operation or if the middle mower unit does not have a rotation sensor fitted, then an acoustic signal is produced when the control system is switched on. The other two check lamps on the control terminal light up and the relevant check lamp does not light up.

In order to be able to carry on using the mower unit, the acoustic signal can be interrupted by pushing the switch (1) in the corresponding direction. This bridges out the inactive rotation sensor.

1 30

When the switch is in the mid-position: All sensors are operating separately.

Switch to the left: The left and the middle sensors are bridged out, i.e. one of the two can be out of action. left = toggle switch points in the direction of the left-hand mower unit.

31

Switch to the right: The right and the middle sensors are bridged out, i.e. one of the two can be out of action. right = toggle switch points in the direction of the right-hand mower unit.

Note!

In the event of two inactive rotation sensors, the rotation sensors cannot be entirely bridged out.

All the rotation sensor plugs must be disconnected.

32 Caution!

To ensure that all three mower units continue to be monitored, the switch should only be actuated in exceptional circumstances.

(Fig. 30)

33

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

7.10

Operation CONTROL SYSTEM DISCO 8550 PLUS / 8550 / 8500 C Working position In order to switch off the transport safety equipment, push the two buttons (1) (Fig. 34) on the control box simultaneously. Lower the side mower units down to the ground with the single-acting control valve of the tractor.

1

The distance from the headstock to the ground should be approx. 450 mm. The bolt (2) should be in the centre of the slotted hole (3) in the mowing position.

34

(Fig. 35, 36)

DISCO 8500 C If the mower unit is used as a pushed machine, the front mower unit must be drawn into the fitting frame. A sequence controller lowers the front mower unit when the side mower units are lowered. ca. 450 mm

35

3

2

36 37

7.11

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Operation Transport position On the middle mower unit, first hinge up the safety curtains on both sides. Lift up the mower unit.

Next, swing the mower unit into the transport position with the single-acting control valve. Apply pressure until the side mower units are hinged up completely and the lamps on the control desk go out.

(Fig. 38)

38

Mowing without side mowing units When starting to mow a field or when mowing narrow residual strips, operation without side mowing units is possible even when in the pushed combination.

This is achieved by raising the side mower units and the front mower unit using the single-acting control valve of the tractor. Turn off the control system by pushing a button on the control box. Now the front mower unit can be lowered individually using the control valve of the tractor.

(Fig. 39) 39 Because of the angular offset of the universal drive shafts only work in this position for a short period of time.

To lower the side mower units push both buttons (1) on the control box simultaneously and switch the control valve to lowering.

1

(Fig. 40)

40 41

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

7.12

Operation OPERATION 4

Setting the cutting height The cutting height of the side mower units and the front mower unit is adjusted via the upper link (4) (Fig. 42).

Use as a pushed combination

42

The cutting height of the side mower units must first be set. This is done by changing the length of the upper link between the tractor and the fitting frame. Increasing the length of the upper link reduces the cutting height and reducing the length increases the cutting height. In the basic setting, the fitting frame is horizontal.

Then set the upper link between the fitting frame and the front mower unit. Here again, increasing the length of the upper link reduces the cutting height of the front mower unit and reducing the length increases the cutting height.

Use as a towed combination Reducing the upper link reduces the cutting height and extending increases the cutting height.

43

Safety equipment Middle mower unit Before entering the field to be mowed, the safety guards (2) must be swung down on both sides.

(Fig. 44) 2

Danger!

44

During operation, it is imperative that the mower units are operated with the safety guards in position.

– Under no circumstances should you lean against the safety guards or walk on the safety guards.

– Damaged or worn safety guards must be replaced without delay.

45

7.13

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Operation Conditioner DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C 1

Chicane plates The chicane plates can be adjusted by the lever (1).

If the lever is pulled backwards, in other words in the direction "+”, the conditioner effect is increased. In the direction "-” it is decreased.

(Fig. 46)

46 Changing the conditioner speed The conditioner speed is adjusted by changing the belt pulleys of the drive. Before doing this, the drive belts must be released and the belt guards removed.

The arrangement of the pulleys in relation to the conditioner speed is shown in Fig. 47.

47

Changing the swathe width Increased swathe width is achieved by removing the outer larger swathe plates (3) and by moving the inner smaller swathe plates (4) to the outside (Fig. 48, 49).

3

Even greater swathe width is achieved by removing all the swathe plates behind the conditioner.

48

4

49

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

7.14

Operation Mowing Caution!

The ground to be mowed must be kept free from foreign objects.

Caution!

50

When mowing with the front mower unit, the suction screens and coolers of the tractor engine can become very contaminated. The tractor engine and the hydraulic unit can overheat and be damaged.

– The suction screens and coolers of the tractor should be cleaned several times per day!

• Lower the mower unit to the ground • When operating, the single-acting control valve must be set to floating position (free-wheel).

• Before entering the field to be mowed, turn on the 51

tractor PTO shaft and slowly accelerate to the maximum permitted PTO shaft speed 1000 rpm).

The whistling noise is completely normal and is considerably damped down during the mowing operation.

• Move into the forage.

• Always operate using the hand throttle while mowing to avoid fluctuations in the rotational speed.

• The driving and crawling speed are to be set according to the respective operating condition (condition of the ground, density, height and nature of the forage).

• Reduce ground speed when working in dense or 52

flattened forage and when mowing around a curve.

• At the edge of the field the mower units should be lifted up with the single-acting control valve on the tractor.

• Mowing in the opposite direction to the direction of travel is not possible with the mower units. Raise the mower unit when reversing.

• Do not mow on rocky ground!

53

7.15

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Operation

Caution!

Wear ear muffs when mowing with a tractor without a cab, or with open cab windows and doors.

Remove the ear muffs when driving on the road.

Danger!

When removing blockages, or when removing foreign bodies, turn the drive off, stop the engine and do not leave the tractor until the cutting discs and the conditioner drums have come to a complete standstill.

Recommendations for environmental protection A simple change in the way we normally mow can help to reduce the loss of wild animals.

At the same time, the quality of the mowed crop is increased.

Environment!

If we mow from the outside inwards, wild animals have hardly any chance of escape!

– Mow from the inside outwards.

Drive to the middle of the lot and mow from the inside outwards.

The centre can be mowed if there is enough room to turn.

Wild animals thus have the chance of escaping outwards.

(Fig. 54)

69018

54

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

7.16

Operation In the case of thin long lots, mow the turns first and then mow the longitudinal sides outwards.

(Fig. 55, 56)

69019

55

69020

56 For especially long lots near the road, this technique is useful, especially with front mower units.

(Fig. 57)

69021

7.17

57

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Operation Collision protection If an obstruction is encountered, the overload protection feature is actuated and the cutter bar can swing away to the back.

6 7

After collision with an obstruction, turn the p.t.o. shaft off immediately and turn the tractor engine off.

Check the cutterbar for damage.

5

A short jerk reset of the tractor will relocate the collision protection. The mower unit is back in the working position.

58

Note!

In the case of a tractor with hydraulic upper link it is beneficial to extend the upper link to prevent the centre of gravity from being moved to the front.

If the collision protection responds frequently, the springs (5) can be adjusted slightly. Release the lock nut (6) and rotate the nut (7) through one revolution and re-tighten the lock nut (6).

(Fig. 58)

59

Note!

If required, the spring (5) can be adjusted several times. Each time the adjustment is carried out, the nut (7) may only be adjusted by half a turn!

Before using the machine for the first time, check the function of the collision protection. In order to do this, take two spanners (SW 24) along for setting the springs (5).

(Fig. 58)

Caution!

If the mower unit is operated as a pushed combination, a flat bar (1) must be screwed to the braces of the collision protection. Only by doing this will there still be a sufficient distance between the tractor and the mower unit in the event of a response from the safety device (Fig. 60).

1

60 61

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

7.18

Operation EMERGENCY FUNCTIONS DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C In the event of a fault in the electrical system, the functions "swing the mower unit into transport position" and "swing the mower unit into working position" can be actuated by manual operation of the individual valves.

The relevant valves can be actuated by releasing the hexagon head (1) or by pushing in with a pointed instrument (see arrow).

(Fig. 62)

1 62

In order to supply oil to the individual cylinder, the corresponding button on the control terminal must be actuated.

Danger!

When manually actuating the the valves, turn off the mower unit drive!

Maintain an adequate distance from the moving parts!

63 Functions of the valves: M3

M1

M4

M2

Valve

function

M1

Raise middle mower unit

M2

Lower middle mower unit

M3

Raise left mower unit

M4

Raise right mower unit

M5

Lower left mower unit

M6

Lower right mower unit

64

M5 M6 65

7.19

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Operation OPTIONAL EQUIPMENT High cutting runners (B03 0020)

1

High cutting runners with a height of 30 mm can be installed for high cutting or for operating on aggressive types of ground.

The high cutting runners (1) are mounted on the right and the left on the runners.(Fig. 66) 66

Order number 0306 768.0

Push-on runners (C03 0030) 2

Additional runners (2) (Fig. 67)can be screwed on if the slide runners have suffered much wear.

Order number 0938 966.0

67

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

7.20

Maintenance

Maintenance

8 Maintenance

Energy accumulators Danger!

IMPORTANT MAINTENANCE INSTRUCTIONS

Danger of injury by sudden release of pre-tensioned components!

Danger!

– Before fitting work, all pre-tensioned energy accumulators (springs, pressure accumulators etc.) must be released in accordance with the regulations.

Repair, maintenance and cleaning work and troubleshooting should only be performed when the drive and engine are switched off!

– Remove the ignition key and uncouple the universal drive shaft!

Danger!

Repair work on pre-tensioned energy accumulators (springs, pressure accumulators, gas springs etc.) should be carried out in specialist workshops and with approved tools!

Bolts

Undertake repair, maintenance and cleaning work on the raised machine only when it is securely supported.

Check all bolts for tightness and retighten if necessary.

– Use suitable stands!

Lubrication

Hydraulic system Danger!

When working on the hydraulic system always release the hydraulic pressure and lower the machine if it is swung up!

Fluid escaping under high pressure (hydraulic oil) can penetrate the skin and cause serious injuries. In the case of injury consult a doctor immediately otherwise serious infections can ensue.

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

Observe the oil change intervals and the oil quality specified by the manufacturer. Use only good quality grease or oil to lubricate the machine. Clean the grease nipples before applying the grease gun.

Grease all points that require lubrication, observing the intervals specified in the lubrication chart.

The stipulated lubrication intervals apply to normal service conditions only. Lubricate more frequently if the machine is used under severe conditions.

Environment!

Dispose of oil and grease according to regulations!

Safety devices

Environment!

Dispose of oil and grease according to regulations!

Check hydraulic lines at regular intervals, and replace them in case of damage or ageing! Replaced hydraulic lines must conform to the technical requirements of the equipment manufacturer!

Repair work to the hydraulic system may only be performed by authorised specialised workshops.

Danger!

Safety guards may only be opened when the drive is switched off and the engine is at a standstill.

– Remove the ignition key!

Mount the guards again after completion of maintenance and repair work.

Check the guards at regular intervals.

Worn or damaged safety devices must be replaced by new ones.

8.1

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Maintenance

Maintenance DRIVE SYSTEM Tensioning the conditioner drive belt DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C Danger!

L

Carry out work on V belts only when the mower unit is switched off and when it is secured against being switched on again.

Check the belt tension after 5 working hours after initial commissioning.

1

Retighten the V-belt if necessary.

Then conduct regular checks after that.

The belts are correctly tensioned if the spring length L=190 mm. The end of the spring (3) must coincide with the mark (4). Check the belt tension on a regular basis.

3 4

(Fig. 1, 2)

Caution!

If a V belt is worn or broken, the complete set of V belts must be replaced.

2 3 4

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.2

Maintenance Main gearbox DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C

DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C

3

Only use EP SAE 90 gear oil to lubricate the gearbox.

To check the oil level, lower the mower unit onto flat ground. Check the oil level in the gearbox by unscrewing the oil level check plug (2).

1

2

Oil filling quantity: 5.0 litres (1) = Oil filler cap and breather valve

2

(2) = Oil level check plug (3) = Oil drain plug (Fig. 5) 3

5 Oil change: After commissioning or after a gearbox overhaul, perform the first oil change after 50 working hours, then every 500 working hours and, at the latest, after each harvesting season.

Main gearbox DISCO 8550 Plus / 8550

DISCO 8550 Plus / 8550

Only use EP SAE 90 gear oil to lubricate the gearbox.

To check the oil level, lower the mower unit onto flat ground.

4 6

Note!

The oil bubble must be in the centre of star in the oil sight glass (6) (Fig. 6).

Oil filling quantity: 2.0 litres 5 6

(4) = Oil filler cap (remove the right universal drive shaft) (5) = Oil drain plug (remove the right universal drive shaft) (6) = Oil sight glass (Fig. 6)

7 Oil change: After commissioning or after a gearbox overhaul, perform the first oil change after 50 working hours, then every 500 working hours and, at the latest, after each harvesting season.

8

8.3

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Maintenance Side gearbox Only use EP SAE 90 gear oil to lubricate the gearbox.

To check the oil level, lower the mower unit onto flat ground. Check the oil level in the gearbox by unscrewing the oil level check plug (2).

1

Oil filling quantity: 1.0 litre 2 (1) = Oil filler cap and breather valve (2) = Oil level check plug

3

(3) = Oil drain plug 9

(Fig. 9)

Oil change: After commissioning or after a gearbox overhaul, perform the first oil change after 50 working hours, then every 500 working hours and, at the latest, after each harvesting season.

10

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.4

Maintenance UNIVERSAL DRIVE SHAFT Danger!

Only undertake work on the universal drive shafts if the drive is switched off and if the engine is at a standstill.

– Remove the ignition key!

Service the PTO drive shaft in accordance with the instructions of the PTO drive shaft manufacturer (see operator's manual of the manufacturer).

Observe the safety instructions of the manufacturer!

Operate the universal drive shaft only in good condition.

General information concerning the universal drive shafts Danger!

Never operate the universal drive shaft without the guard or if the guard is damaged.

– Mounting shaft guard and protective tube.

– Secure the guard against rotation.

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

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

Protect the universal drive shaft from the effects of the weather.

After the working season clean all the parts of the universal drive shaft thoroughly and grease.

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

After longer periods of standstill, relubricate the universal drive shaft and check the readiness for operation.

8.5

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Maintenance MOWER HEAD Danger!

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

– Do not touch the bar!

– Wear safety gloves!

Note!

If the maintenance instructions are observed, there is no reason to worry if the header becomes very hot as long as the cutting disks can still be easily rotated manually with the machine at operating temperature. An operating temperature of approx. 60° C must be considered normal.

Only use EP SAE 90 gear oil to lubricate the cutting disk gearbox. Check the oil level in the mower head daily and if necessary, correct.

1

Oil filling quantity: 4.5 litres

(1) = Oil filling and oil level check plug (Fig. 11) (2) = Oil drain plug (Fig. 13)

Checking the oil level: 11

Warm the machine up. After the cutter bar has been swung in position vertically for approx. 10 minutes, check the oil level through the monitoring opening (1).

Oil filling:

12

Swing the cutter bar into the horizontal position. Pour oil through the opening (1) up to the level of the monitoring opening (1).

(Fig. 11)

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.6

Maintenance Oil change: After commissioning or after a gearbox overhaul, perform the first oil change after 50 working hours, then every 200 working hours and, at the latest, after each harvesting season.

2 Draining oil: Swing the cutter bar into the horizontal position. Warm the cutterbar up for approx. 8 - 10 minutes.

13

Lift the beam and drain the oil out via the magnetic plug opening (2). Clean the magnetic plug before reinstalling it.

(Fig. 13)

14

8.7

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Maintenance MOWER BLADES Danger!

15

The protective guards of the mower unit may only be opened when the PTO shaft is switched off and when the engine and mower discs are at a standstill.

Work on the mower blades or their fasteners only when the drive has stopped and the engine and cutting discs are switched off.

– Switch off mower drive.

– Switch off engine.

16

– Wait until the mower discs have come to a complete standstill before leaving the tractor!

– Remove the ignition key!

– Wear gloves when working on the mower blades!

17

Danger!

Replace damaged mower blades, mower blade holders and mower discs!

– Do not weld or straighten!

18

Attention!

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

– Always check that the mower blades are correctly seated!

19

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

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

20

Replacement blades must meet the minimum technical requirements specified by CLAAS. This is always achieved by using original CLAAS mower blades!

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.8

Maintenance

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 disk so the other blade is used for cutting.

Mower blade box There is a mower blade box (1) on the right hand side of the fitting frame which can store spare mower blades.

4

(Fig. 21) 1

21 2 = Stowage space for mower blades 0952 043.0 1 3 = Stowage space for mower blades 0952 042.0

(Fig. 22, 23) 2

3

5

22

2

The mower blade box (1) can be taken out of its holder by loosening the spring (4)5.

3

(Fig. 21, 22)

23

8.9

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Maintenance The mower blade box full of mower blades (1) should be used to change mower blades on the mower head.

(Fig. 24)

1

24

Changing mower blades DISCO 8550 C Plus / 8550 Plus / 8550 C-T 2

To change the mower blades move the fitting lever (1) between the cutting disc (2) and the mower blade holder (3).

(Fig. 25-27)

1 4 66602F/01

25

Caution!

Pull the fitting lever (1) outwards parallel to the mower disc axis to the stop.

(Fig. 26) Rotate the mower disc so that the mower blade holder (3), when pushing down the fitting lever (1), fits exactly into the depression (5) on the skid (Fig. 27).

1

Clean the depression (5) before changing the mower blade.

4 26

66603F/01

Push the fitting lever (1) downwards and remove the mower blade (4). Fit the new mower blade.

(Fig. 27, 28)

2

Fit the new blades with the cutting edge facing downwards. The direction of rotation of each disc is marked by an arrow on the blade.

1

(Fig. 29)

3 66604F/01

4 27

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.10

Maintenance 2

1

3 4 66605F/01

28

68480

29 Danger!

Take extra care to ensure that the mower blades and the mower blade retaining pins are correctly located! The mower blade retaining pin (5) must be in contact (see arrow) and must sit straight in the locating hole of the disc (Fig. 30).

5

66606F

8.11

30

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Maintenance The fitting lever (1) can also be used as a stop for the mower discs when undertaking maintenance work on the mower head. For this, the pin (2) of the fitting lever (1) should be inserted into the hole of a skid. The handle of the fitting lever (1) must be parallel to the mower head when doing this. Attach the mower disc (3) to the fitting lever (1) and stop in this manner.

1

3

(Fig. 31)

2 31

66615F

After changing the mower blades, and after maintenance work, the fitting lever (1) can be inserted in the bracket (4) on the headstock or in the stand (5).

(Fig. 32, 33)

1 4

32

1 5

33

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.12

Maintenance 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, measured 10 mm from the edge of the disc, should be at least 3/4 of the normal width (Bn).

Bn 10 mm

(Fig. 34) B 34

66614F

– If the drilled hole in the blade is widened.

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

(Fig. 35)

35

The attachment parts of the mower blades must be checked before every use.

Danger!

Replace damaged mower blades, mower blade holders and mower discs!

– Do not weld or straighten!

15 mm 12 mm

The mower blades must be replaced under the following conditions: – If wear is apparent on the mower blade holder shape.

36

66612F

(Fig. 36) – If wear is apparent on the mower blade holder thickness.

– If there are visible cracks or excessive wear on the weld beads (S) at the mower blade retainer pin..

(Fig. 37)

S Caution!

4 mm

3 mm 66610F

8.13

Check the weld beads before each commissioning!

S

37

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Maintenance – If there is deformation (bending) of the mower blade holder – If the mower blade retaining pin (5) no longer sits straight in the locating hole of the disc.

(Fig. 38) 5

66607F

38 – If there is a gap between the mower blade retainer pin (5) and the locating hole (see arrow) of the disc.

(Fig. 39)

5

39

66608F

– If the mower blade retainer pin (5) is worn down to X = 13 mm.

X

(Fig. 40) Danger!

5

Replace damaged mower blades, mower blade holders and mower discs!

– Do not weld or straighten!

– Use only original CLAAS mower blade holders.

66609F

40 The discs must be replaced under the following conditions: – If the locating hole shows expansion, wear or damage over the entire diameter area.

(Fig. 41)

66613F

41

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.14

Maintenance Changing mower blades DISCO 8550 Plus / 8550 / 8500 C

4

To replace blades, first clean the seat of the nut (4) and loosen the nut with the socket wrench. Fit the new blades with the cutting edge facing downwards. The direction of rotation of each disc is marked by an arrow on the blade.

(Fig. 42, 43) 120 Nm

Caution!

64258

42

Secure the nuts with DELO ML 5328 single-component liquid plastic (part no. 201 802.1) or Loctite (Type 242) (part no. 666 285.0) every time they are replaced.

Tightening torque of the mower blade securing bolt (4) = 120 Nm.

68480

43

Danger!

Replace damaged mower blades, mower blade holders and mower discs!

– Do not weld or straighten!

8.15

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Maintenance 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, measured 10 mm from the edge of the disc, should be at least ¾/of the normal width (Bn).

(Fig. 44)

44 – If the drilled hole in the blade is widened.

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

(Fig. 45)

45 The attachment parts of the mower blades must be checked before every use.

The mower blade securing bolts must be replaced under the following conditions: – Visible deformation of the securing bolt (e.g. after running into an obstacle).

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

– In the case of serious wear of the bolt head to the blade surface.

(Fig. 46) 46

– If the bolt shaft is worn from Dn = 18 mm to D = 15 mm.

(Fig. 47)

47

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.16

Maintenance

Caution!

Always ensure proper seating when installing the securing screws.

The blade securing nuts must be replaced in the following cases: – If the spring contact washer (1) has lost its elastic properties or has become detached from the nut.

48

– If the nut has worn out so much that dimension a = H/2.

(Fig. 48)

49

8.17

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Maintenance MOWER DISCS Danger!

Replace damaged mower blades, mower blade holders and mower discs!

– Do not weld or straighten!

Replacing cutting discs 50

Attention!

The discs must be arranged so the long dimension is at right angles to the adjacent disc. The discs must always be arranged like this to prevent the mower blades from colliding.

(Fig. 50) The cutting discs are fastened to one flange each.

The bolts (C) for securing the cutting discs must be tightened as specified (80 Nm).

Tightening torque of the nut (E) = 350 Nm. (Fig. 51)

Attention!

51

Replace a missing damaged cover immediately, otherwise the attachment could fill up with material. This could lead to an imbalance and severe consequential damage.

2

– The cutting discs with attachment (1) must always be covered with a plastic cover (2).

1

Ensure that the drainage opening (3) 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).

3

(Fig. 52) 52

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.18

Maintenance SUSPENSION SPRINGS 4 The weight relief of the cutter bar by the suspension springs should be adjusted so that the cutter bar does not exert too much pressure on the ground.

If required, the suspension springs can be adjusted.

5

Quick setting of the spring length The sliding collar (4) can be set in three different plug positions. In the top position the weight relief is increased and in the bottom position the relief is reduced. Secure in position using the spring clip (5).

53

(Fig. 53) Caution!

Check the adapting to ground contours after setting. If required, correct the setting of the suspension springs.

DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C

Final setting of the spring length For increased relief, screw the threaded rod (3) further into the spring, for reduced relief, screw the threaded rod out (X is between 5 - 120 mm).

3

(Fig. 54, 55)

DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C

X

Basic setting X = ca. 80 mm (Fig. 54) 54

DISCO 8550 Plus / 8550

DISCO 8550 Plus / 8550 Basic setting X = ca. 50 mm (Fig. 55) 3

X 55

8.19

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Maintenance CONDITIONER TINES DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C

Fitting / removing the tines In the accessories, there is a pin (1) with which the clamping pin (2) can be knocked in or knocked out.

Caution!

Fit the tines in accordance with the fitting diagram.

(Fig. 56) DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C

c d

24

1

2

c d

c d

63622F

56

ELECTRICAL SYSTEM

M

DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C

Setting the rotation sensors

1

Front mower unit 4 mm

First set the height of the sensor (1).

To do this, release the nuts (M), move the sensor (1) in the required direction and re-tighten the nuts (M).

The distance between the sensor (1) and a tooth on the universal drive shaft (W) should be 4 mm.

W 57

(Fig. 57)

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.20

Maintenance Then set the distance from the sensor (1) to the carrier bracket (A) of the universal drive shaft. This is done by displacing the sensor bracket (2) in the slotted holes.

2

The distance between the sensor (1) and the carrier bracket (A) should be 2-4 mm.

A 1

(Fig. 58)

2-4 mm 58 Side mower units First set the height of the sensor (3).

B

K

To do this, release the nuts (M), move the sensor (3) in the required direction and re-tighten the nuts (M).

The distance between the sensor (3) and one of the bushes (B) of the clutch (K) should be 4 - 5 mm.

4-5 mm 3

(Fig. 59)

M

59 Then set the distance between the sensor (3) and the clutch (K). This is done by displacing the sensor bracket (4) in the slotted holes (L).

4-5 mm

The distance between the sensor (3) and the clutch (K) should be 4 - 5 mm.

3

4

(Fig. 60)

K L 60

Setting the lift sensors The distance to the edge of the sensor bracket should be 0.5 - 1 mm. If necessary, release the bolts and displace the sensor in the slotted holes. Then re-tighten the bolts.

0.5-1 mm

(Fig. 61)

61

8.21

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Maintenance Replacing the wiring loom When replacing the wiring loom, note the marking and correct positioning of the individual cable connections.

y2.2 y1.2

(Fig. 62-65)

y1.1 62

y2.1 y3.2

y3.1

63

R1

64

L1

65

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.22

Maintenance HYDRAULIC SYSTEM Repair work on the hydraulic system should only be carried out by authorised specialist workshops, preferably your CLAAS dealer.

Hydraulic hoses Check the hydraulic hoses before initial use of the machine and then at least once a year.

In the event of damage or ageing the hydraulic hoses must be replaced!

Note!

66

Hydraulic hoses may only be used for a maximum of 6 years from the date of manufacture.

The date of manufacture (month and year) can be seen on the hydraulic hose.

Example: The marking »1 Q-98« signifies manufacture in the 1st. quarter of 1998.

67

Hydraulic cylinder with vacuum valve 1

The following notes refer to the mower units from serial no. 652 0 1961.

Danger!

The vacuum in the hydraulic cylinder can cause unexpected retraction of the piston during dismantling.

69175 69175

– Before dismantling the cylinder unscrew the hex head screw (1) on the cylinder barrel!

68

Fitting or removing the cylinder: 1. Unscrew the hex head bolt (1) on the cylinder barrel.

2. The piston can now be extracted or inserted by hand.

3. Screw the hex head bolt (1) back in.

(Fig. 68)

8.23

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Maintenance LUBRICATION OPENINGS Open the cover to allow lubrication work.

4 2

Release the self-locking nuts (4) for this. Displace the cover (1) to the left in the slotted hole (2). Push the cover (1) on downwards.

3 4

After lubrication, push the cover (1) upwards and to the right under the disc (3).

1

Re-tighten the self-locking nuts (4).

(Fig. 69) 69

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.24

Maintenance CLUTCHES Maintenance of the friction and overrunning clutch After longer periods of standstill, the coupling should be released.

To do this, tighten the hex nuts of the studs completely.

Stuck friction linings should be released by rotating the coupling hub by hand.

70

Then turn back the hex nuts or studs to the end of the thread again.

(Fig. 70)

Fig. 71 = new condition

Replace worn friction discs in good time.

The friction discs are worn if the pressure washer edge (arrow) is no longer visible.

(Fig. 72) 71

Note!

After the friction discs have slipped, the linings must be cooled down. Otherwise, the full torque will not be available.

72

Torque Left and right hand mower unit cutter bar drive: Torque setting of the cam-type cut-out clutch = 1200 Nm. (Fig. 73)

The setting of the cam-type cut-out clutch must not be modified since otherwise considerable damage may be caused to the universal drive shaft, gearbox etc.

67833

73

8.25

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Maintenance SCREW CONNECTIONS After 10 operating hours, check all bolts and nuts throughout the machine and retighten.

Then check at regular intervals.

CONNECTING ELEMENTS All connecting elements which affect safety such as bolts, screws, pins etc. should be checked regularly for wear and deformation.

If necessary, replace the connecting elements by new ones.

END OF SEASON STORAGE 1. Clean the dirt from the mower unit.

2. Drain the oil from the angle gearbox and from the mower head and refill with new oil to the prescribed oil level.

3. Grease all the lubrication points thoroughly until the grease exudes from the bearings – see »Lubrication chart«, page 9.1.

Let the mower unit run for a short time.

4. Check the mower unit for wear and damage and repair if required.

5. Remove the V-belts and store in a dry location, de-tension the suspension springs.

6. Clean mower unit and all rust marks and repair any paint damage.

7. Store the mower unit in a dry, weather-protected room where no artificial manure is stored.

8. Store in working position.

9. Remove the control terminal from the mower unit and store in a weather-protected room at room temperature (approx. 18ºC).

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.26

Maintenance MALFUNCTIONS Problem Vibration

Remedy

• Clean the attachment on the

Cause – Plastic cover missing.

cutting disc and the plastic cover immediately.

Poor adaptation to ground contours

Safety cut-out responding too often

• Clean the feeder drum.

– Feeder drum dirty.

• – see »Suspension springs«,

– Wrongly adjusted frame.

page 8.19.

• Clean the links and lubricate

– Joints on mower head seized.

• Increase spring load – see

– Insufficient tension in the rubber spring

»Collision protection«, page 7.18.

Wrong tilting angle of the mower head

• Turn the upper link out or in.

– Upper link length wrongly adjusted.

Poor cutting quality (for overly high forage/storage forage)

• Reduce tilt of the mower head

– Tilt of mower head too large.

– see »Setting the cutting height«, page 7.13.

• Reduce ground speed.

• Replace mower blades – see »Mower blades«, page 8.8.

– PTO speed too low.

– Ground speed too high.

– Blunt or damaged mower blades.

• Reduce the speed with light fodder.

Stubble too high

• Change tilt of the mower head by adjusting the upper link – see »Setting the cutting height«, page 7.13.

Formation of stripes at transition between front and side mower units

– Wrongly adjusted tilt of the mower head.

• Reduce spring relief.

– Spring relief set too strong

• Change tilt of the mower head

– Beam inclined too much to the front

by adjusting the upper link.

• Reduce ground speed.

– Ground speed too slow.

• Clean mower unit.

– Build-up of dirt between the skids.

– Blunt mower blades.

• Change mower blades.

• Correct the speed.

Fodder pushed forwards before being cut (creating stripes)

8.27

• Reduce p.t.o. speed and increase ground speed.

– Speed too high with light fodder, too low with heavy fodder.

– Swirling effect of the mower blades in light crops.

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Maintenance Problem

Remedy

Cause

Swathe too small

• Remove the guide plates

– Crops growing too thickly.

Build-up of dirt in the front cutter area

• Increase cutting height – see

– Very moist working conditions.

»Setting the cutting height«, page 7.13.

– Mole hills

• Fit wear slide skids.

• If necessary, lift mower unit up and down

• Clean mower unit.

• Increase mower unit relief

– Insufficient load relief for the machine.

– see »Suspension springs«, page 8.19.

Increased wear on cutting disc and mower blades

• Fit wear or high cut slide skids.

• Increase mower unit relief

– Very difficult working conditions.

– see »Suspension springs«, page 8.19.

Increased wear on skids

• Screw wear slide skids in position

• Increase mower unit relief

– Stony, sandy ground – Runners not lying parallel to the ground.

– see »Suspension springs«, page 8.19.

• Adjust the skids flat to the ground (in the case of extreme high cut point wear of the skid) Mower unit lifted into working position: Mower unit folds downwards so that the outer cutting disc is touching the ground.

• Swing the mower head up

Build up of piles in the swathe

• Mount an additional conveyer

slightly (approx. 10 - 20º).

• Reduce spring loading – see

– Ground speed too high over uneven ground, extreme jolting.

»Suspension springs«, page 8.19.

hat.

– Light and wet crops.

– Sloping ground

• Reduce ground speed.

Plugs on the swathe plate

• Remove swathe plate.

– Wrong mounting of the swathe plate.

– Strong crops

Winding of the outer conveyer drum

• Check rotational speed,

– Strong and flattened crops.

increase if necessary.

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.28

Maintenance Problem Preparer wound

Remedy

• Increase the belt tension • Check rotational speed,

Cause – Large drop in engine speed.

– Strong and flattened crops.

increase if necessary.

• Reduce the traverse speed.

• Open the chicane wider.

• Swing swathe plate outwards.

Continuous signal tone from the rotation sensor

• Check rotation sensors.

• Check the location of the rotation sensors

• Temporarily unplug all the

– Rotation sensors faulty.

– Position of the rotation sensors incorrect.

– Mower unit blocked.

rotation sensor.

• Actuate the bridging out switch.

Side mower units lifting unevenly

• Correct the position of the lifting sensors – see »Setting the lift sensors«, page 8.21.

Mower unit does not swing into transport position

8.29

• Check rotation sensors.

– Lifting sensors are set at different levels.

– All rotation sensors out of commission.

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Lubrication chart

Lubrication chart

9 Lubrication chart SAFETY RULES Danger!

Lubrication of the mower unit only when the tractor engine is at a standstill.

– Remove the ignition key!

LUBRICANTS Trademarked lubrication grease e. g.

FINA

“Marson EPL 2”

ARAL

“Aralub HLP 2”

FUCHS “Rendit TEP 2” SHELL

“Retinax EP 2” or “Alvania G3”

DEA

“Glisando EP”

FAG

“Arcanol L 135 V”

SKF

“LGEP2”

Trademarked gearbox oil SAE90 - API GL 4

LUBRICATION

Lubricate these grease points every 20 working hours.

Lubricate these grease points every 100 working hours.

Lubricate these grease points every 250 working hours.

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

9.1

Lubrication chart

Lubrication chart

4 2

1

3

Pushed combination

1

2 Towed front - rear combination

3

9.2

4

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Lubrication chart

7

5

6

8

DISCO 8550 C Plus DISCO 8550 C DISCO 8550 C-T DISCO 8500 C

5

6

7

8

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

9.3

Lubrication chart

10 9 11

11

9

9

10

10

11

9.4

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

Lubrication chart

12 13

15

12

12

14

13

14

15

0293 653.9 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

9.5

Lubrication chart

16

16

17

16

17

9.6

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.9

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 operator's manual 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 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 D - 33426 HARSEWINKEL Germany

CLAAS KGaA mbH Postfach 1163 33426 Harsewinkel - Germany Tel.: +49 (0) 5247 12-0 www.claas.com

0293 653.9 ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C EN - 03.06 Printed in Germany