CLAAS DISCO 8550 C PLUS/ 8550 C DISCO 8550 PLUS DISCO 8550 C-T DISCO 8500 C Assembly instructions an

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

Assembly instructions and operator’s manual

Pl ea se r

ea da nd ob se rv et he sa fet y

ins tru cti on s!

EC Declaration of Conformity according to EC Directive 89/392/EEC

CLAAS Saulgau GmbH Zeppelinstraße 2

D - 88348 Bad Saulgau

declare under their sole responsibility that the product

Disc mower - model »DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C« to which this declaration refers corresponds to the applicable basic safety and health requirements of EC Directive 89/392/EEC, and to the requirements of the other applicable 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 - 1999

Bad Saulgau, 07.05.2004 Development Manager (Geng)

Production Manager (Fetscher)

Quality Assurance (Switalski)

Introduction

Introduction

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

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

Also ensure that the assembly of your machine and regular inspections are carried out by a 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 applied in this machine by operating and caring for it properly. Your mower unit will always produce good results.

These operating instructions apply for disc mower:

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

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

• DISCO 8550 C-T / 8500 C from machine 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 653.8

Contents

Contents

2 Contents 1. Introduction Introduction ............................................................................... 1.1

2. Contents 3. Preface Of special importance ............................................................... 3.1 Type plate ................................................................................. 3.1

4. Safety rules Designated use ......................................................................... 4.1 Identification of warning and danger signs ................................ 4.1 General Safety and Accident Prevention Instructions ............... 4.1 Attached machines ................................................................... 4.3 Machines as trailers .................................................................. 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 Calculation of axle loads, minimum ballasting and total weight ......................................................... 5.2 Calculation of minimum ballasting at the front .................... 5.3 Calculation of minimum ballasting at the rear ..................... 5.3 Calculation of the real front axle load ................................. 5.3 Calculation of the real total weight ...................................... 5.3 Calculation of the real rear axle load .................................. 5.4 Tyre load carrying capacity ................................................. 5.4 Noise level ................................................................................ 5.5

6. Prior to operation Assembly instructions ............................................................... 6.1 Safety Guards Side Mowers DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C ............. 6.1 Safety Guards Side Mowers DISCO 8550 Plus / 8550 .................................................... 6.3 Installing the Mounting Frame ............................................ 6.4 Fixing the Controller DISCO 8550 C Plus / 8550 C / 8550 C-T ........................... 6.6 Fixing the Controller DISCO 8550 Plus / 8550 / 8500 C ...................................... 6.7 Application as Shunted Combination Unit .......................... 6.8 Installation of Adapter (B03 0030) ...................................... 6.9 Installing the Lighting Unit ................................................ 6.15 Application as Towed Front / Rear Combination Unit ....... 6.18 Installing the Lighting Unit ................................................ 6.21 Installing a rotation sensor on the central mower DISCO 8550 C Plus / 8550 C / 8550 C-T ......................... 6.23 Adjusting the Cutting Height DISCO 8550 C Plus / 8550 C / 8550 C-T ......................... 6.27 Installation of Cutting Knives ............................................ 6.28 Checking the PTO Shaft for Correct Length ..................... 6.30

Loading and Unloading Machine DISCO 8550 Plus / 8550 ...

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

Coupling .................................................................................

Attaching the Mounting Frame .........................................

Attaching the Front Mower to the Mounting Frame ..........

Adjusting the Upper Control Arm .....................................

Weight Suspension ..........................................................

Fitting the PTO Drive Shaft ..............................................

Hydraulics ........................................................................

Electric Connection ..........................................................

Dismantling the Mower ...........................................................

Parking the Machine in a Folded-Out Condition ..............

Parking the Mower in a Folded Condition ........................

Conversion from Front/Rear Combination Unit to Shunted Combination Unit .................................................

Conversion from Shunted Combination Unit to Front/Rear Combination Unit ..............................................

Prior to Transport ...................................................................

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 6.41 6.43 6.45 6.46 6.46

7. Operation Controller DISCO 8550 C Plus / 8550 C / 8550 C-T ................ 7.1 General ..................................................................................... 7.3 Working Position ................................................................ 7.4 Transport Position .............................................................. 7.5 Mowing with Single Mower Extended ................................ 7.6 Headland Position .............................................................. 7.8 Speed Monitoring System .................................................. 7.9 Bridge Connector Switch .................................................. 7.10 Controller DISCO 8550 Plus / 8550 / 8500 C ......................... 7.11 Working Position .............................................................. 7.11 Transport Position ............................................................ 7.12 Mowing Without Side Mowers .......................................... 7.12 Operation ................................................................................ 7.13 Adjusting Cutting Height ................................................... 7.13 Safety Frame .................................................................... 7.13 Conditioner ....................................................................... 7.14 Conditioning Plates .......................................................... 7.14 Variation of the Conditioner Speed .................................. 7.14 Varying the Swath Width .................................................. 7.14 Mowing ............................................................................. 7.15 Recommendation for environmental protection ............... 7.16 Overload Safeguard ......................................................... 7.18 Emergency Functions ............................................................. 7.19 Optional Equipment ................................................................ 7.20 High Cut Skids ................................................................. 7.20 Additional Skids ................................................................ 7.20

8. Maintenance Important Maintenance Instructions .........................................

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

Pretensioned or prestressed energy aumulators ...............

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

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

Guards ...............................................................................

Drive Mechanism ......................................................................

Tensioning the Drive Belts .................................................

0293 653.8 - 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 8.2 8.2

2.1

Contents Maindrive DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C .............................................................. 8.3 Maindrive DISCO 8550 Plus / 8550 .................................... 8.3 Sidedrive ............................................................................. 8.4 Cutterbar ................................................................................... 8.5 Universal Drive Shaft ................................................................ 8.7 Mower blades ............................................................................ 8.8 Blade box ............................................................................ 8.9 Knife Replacement DISCO 8550 C Plus / 8550 Plus / 8550 C-T ........................................................ 8.10 Knife Replacement DISCO 8550 C / 8550 /8500 C .......... 8.15 Cutting Discs ........................................................................... 8.18 Replacing Cutting Discs .................................................... 8.18 Floatation Springs ................................................................... 8.19 Quick Adjustment of the Spring Length ............................ 8.19 Fine Adjustment of the Spring Length .............................. 8.19 Conditioner Tines .................................................................... 8.20 Installation and Removal of the Tines ............................... 8.20 Electric .................................................................................... 8.20 Adjusting the Speed Sensors ........................................... 8.20 Adjusting Extension Sensors ............................................ 8.21 Replacing the Wiring Harness .......................................... 8.22 Hydraulics ............................................................................... 8.23 Hydraulic Hose Connections ............................................ 8.23 Hydraulic Cylinder with Vacuum Valve ............................. 8.23 Lubrication Doors .................................................................... 8.24 Clutches .................................................................................. 8.25 Maintenance of the Friction-Type 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 653.8

Preface

Preface

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

The instructions set forth in this manual must be read carefully and followed by all persons concerned with operation, maintenance, repair or inspection of this machine in order to prevent accidents.

Some safety guards and covers have been removed for illustration in this manual. All protective equipment and covers must be attached before the machine is started up!

Please particularly read the sections »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 non-original CLAAS parts, accessories and additional equipment.

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

Front, rear, right and left always imply the direction of travel.

1

TYPE PLATE 1 1

For all orders for spare parts and for technical queries, please specify the machine number (Fz-Ident-Nr.) (2), the type and the serial number. This is required as otherwise it can cause incorrect deliveries.

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

(Fig. 1, 2)

2

2

0293 653.8 - 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 and follow the safety precautions!

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

DESIGNATED USE

– Measures to prevent damage to the machine.

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

The mower unit is suitable and intended for cutting crops growing from the ground in wild or seeded fields.

Use in any other way is considered as contrary to the intended use. The manufacturer is not liable for damage resulting from such uses; the user is solely responsible for such risks.

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

The CLAAS mower unit may only be used, serviced and repaired by persons who are familiar with and trained in the dangers involved.

Observe the applicable 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.

Modification of the machine without proper authority precludes any manufacturer's liability for damage resulting from any such modifications.

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 placed 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 of 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 information set forth in this operator's manual, also follow the general instructions for safety and accident prevention.

The warning and information signs provide important instructions for the safe operation of the machine; compliance with these instructions ensures your safety!

Follow the regulations in force when you use 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 653.8

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

Before operation, always inspect the mower unit for damaged, missing and worn cutter blades and if necessary, replace blades!

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 each time you change the cutting blades according to regulations specified by the manufacturer and replace if necessary!

It is most of all important to check the extent to which the blade retaining bolt has been worn on the inner radius by the blade. It must be replaced by a new unused blade retaining bolt at the latest when a groove depth of 3 mm has been reached, that is a reduction of the inner radius by 3 mm.

The riveting on the blade bolt in the knife holder as well as the wear on the knife holder on the outer edge are to be checked. All knife holders on the cutting disc must be replaced by new knife holders if necessary.

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.

This is why one should not step between the tractor and the mower unit. The swivelling process must take place with the mower unit in a horizontal condition.

The glide discs must be in contact with the ground before putting into operation and while working!

Stones and similar objects can be thrown out even when the mower unit is being used correctly. Therefore, no-one should be in the danger zone.

Special care is required when working near roads and buildings!

The working tools can run on after switching off the drive. Do not approach them until they have stopped.

If an obstacle is run over, stop the mower unit immediately and check for damage!

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

Keep the machine clean to prevent fire!

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

Ensure that you have an adequate view!

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

Always connect the implement correctly to the tractor and connect and secure the machine using 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 implement!

Only operate the machine when all guards are fitted and in the correct position!

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

Keep clear of the swivelling range of the operating machine.

Watch for pinch and shear points on parts that are operated, for instance by hydraulics!

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

4.2

Safety rules Before leaving the tractor, ensure that the machine cannot roll away! Lower any mounted implements fully to the ground! Switch off the engine and remove the ignition key.

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

ATTACHED MACHINES

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!

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

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

Before attaching the machines to 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!

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!

When attaching mounted machines to the 3-point linkage, the linkage categories of tractor and machine must correspond or the necessary modifications must be performed!

Always ensure that no-one is in the danger zone of the machine before switching on the PTO shaft!

A risk of injury due to crushing or shearing exists in the vicinity 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 wen the machine is in the transport position!

During road transport with the machine raised, the control lever must be locked to prevent unintentional lowering of the machine!

MACHINES AS TRAILERS Secure the machine to prevent it from rolling away.

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

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

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!

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

4.3

Never engage the PTO shaft while the engine is stopped!

When operating the PTO shaft no-one must ever 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 required!

Danger: rotating masses run on after the PTO has been disengaged! 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 PTO shaft driven machine or universal drive shaft is only permitted with a switched off PTO shaft, switched off engine and the ignition key removed!

Whenever 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 the protective guard must be pushed on to the PTO stub shaft!

In case of damage, the defective parts must immediately be repaired before working with the machine!

HYDRAULIC SYSTEM The hydraulic system is under high pressure!

When attaching hydraulic cylinders and motors, take note if the prescribed connection of the hydraulic hoses!

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!

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Safety rules When making hydraulic function connections between the tractor and machine, the female couplings and pins must be marked so that false operation is impossible! Mixing the coupling reverses the function (e.g. raise/lower) – Safety hazard!

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

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

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

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

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

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

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

Fluid escaping under high pressure (hydraulic oil) can penetrate the skin and cause serious injuries. In the event of any injury 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!

SOUND PRESSURE LEVEL If the sound pressure level at the driver's ear exceeds 85 dB (A) (see »Specifications«) then ear muffs must be worn.

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 the elimination of malfunctions should only be performed with the drive and the engine switched off!

– Remove the ignition key!

Wait until the cutting discs are completely motionless!

Repair work on pretensioned energy accumulators (springs, hydraulic accumulators etc.) should be carried out in specialist workshops and with suitable tools!

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

When performing service 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 and grease according to regulations!

0293 653.8 - 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 Warning symbol 514 945.0 (1) Read and observe the operator's manual and the safety instructions before putting machine into operation!

(Fig. 1, 2)

4.5

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Safety rules

2

64523

3

4 Warning symbol 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 Warning symbol 514 815.0 (3) Do not attempt to remove guard while the engine is running.

(Fig. 5, 6)

0293 653.8 - 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 Warning symbol 514 825.0 (4) DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C: Stay clear while engine is running.

(Fig. 7, 8, 9)

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

6

64526

5

4

9

10 Warning symbol 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 653.8

Safety rules

11 Warning symbol 514 821.0 (6) DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C: Maintain sufficient distance to the cutter blades when the motor is running.

(Fig. 7, 9, 11)

A

B

C 12 Warning symbol 936 915.0 (7) DISCO 8550 Plus / 8550:

7

Figure (A): Maintain sufficient distance to the cutter blades when the motor is running.

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

Figure (C): 68471

13

Stay clear while engine is running.

(Fig. 12, 13)

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

4.8

Safety rules

10 64527

14

15 Warning symbol 514 814.0 (10) Keep hands out of hazardous crush or pinch areas as long as parts may move on.

(Fig. 14, 15, 16)

10

11 64527

16

17 Warning symbol 514 799.0 (11) Keep clear of the swing area of the operating machine.

(Fig. 16, 17)

4.9

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Safety rules

12 19 Warning symbol 516 254.0 (12) 68472

18

Stay clear while engine is running.

(Fig. 18, 19)

0293 653.8 - 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

Power requirement

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

KW (HP)

110 (150)

146 (200)

mm

3000

3000

– towed front rear combination unit

mm

8000

8000

– shunted combination unit

mm

-

8300

PTO speed

rpm

1000

1000

Disc speed

rpm

3200

3200

Knive speed

m/s

87

87

– towed front rear combination unit

rpm

-

900

– shunted combination unit

rpm

-

770

mm

40

40

– towed front rear combination unit

kg

-

2950

– shunted combination unit

kg

-

3150

– trailed front/rear combination without front mower

kg

1920

-

Number of discs

-

7

7

Cutter blades per disc

-

14

14

Transport width Working width

Conditioner speed

Cutting height (horizontal) Weight

5.1

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Specifications

Specifications CALCULATION OF AXLE LOADS, MINIMUM BALLASTING AND TOTAL WEIGHT The front axle of the tractor must always to be loaded with at least 20% of the unladen weight of the tractor.

The mounting of implements on the front or rear three point linkage must not result in exceeding the maximum permissible weight, the permissible axle loads and the tyre load carrying capacities of the tractor.

Make sure before buying an implement that these conditions are fulfilled by carrying out the following calculations or by weighing the tractor/implement combination.

For the calculation you need the following data:

GH

GV

a 68704

T

H

TV b

c

TL (kg)

unladen weight of tractor, - see Operator’s manual tractor

TV (kg)

front axle load of unladen tractor, - see Operator’s manual tractor

TH (kg)

rear axle load of unladen tractor, - see Operator’s manual tractor

GH (kg)

combined weight of rear mounted implement/rear ballast In case of trailed machines GH = load on hitch point – see »Specifications«, page 5.1

GV (kg)

combined weight of front mounted implement/front ballast, – see »Specifications«, page 5.1

a (m)

distance from centre of gravity for combined front mounted implement/front ballast to front axle centre, - to be measured

b (m)

tractor wheelbase, - see Operator’s manual tractor

c (m)

distance from rear axle centre to centre of lower link balls, - to be measured

d (m)

distance from centre of lower link balls to centre of gravity for combined rear mounted implement/rear ballast, - to be measured In case of trailed machines d = 0

d

1

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

5.2

Specifications

G Vmin

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

Calculation of minimum ballasting at the front Consideration of rear mounted implement and front/ rear combinations

Note: Record the calculated minimum ballasting which is needed at the front of the tractor into the table.

G Hmin

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

Calculation of minimum ballasting at the rear Front mounted implement

Note: Record the calculated minimum ballasting which is needed at the rear of the tractor into the table.

T Vtat

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

Calculation of the real front axle load If with the front mounted implement (GV) the required minimum front ballasting (GVmin) cannot be reached, the weight of the front mounted implement has to be increased to the weight of the minimum ballasting at the front.

Note: Record the calculated real front axle load and the permissible front axle load of the tractor into the table.

Calculation of the real total weight

G tat = G V + T L + G H

If with the rear mounted implement (GH) the required minimum rear ballasting (GHmin) cannot be reached, the weight of the rear mounted implement has to be increased to the weight of the minimum ballasting at the rear.

Note: Record the calculated real front axle load and the permissible total weight of the tractor into the table.

5.3

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Specifications Calculation of the real rear axle load

T Htat = G tat – T Vtat Note: Record the calculated real front axle load and the permissible rear axle load of the tractor into the table.

Tyre load carrying capacity Record double the value (two tyres) of the permissible load carrying capacity into the table (see, e.g. Documentation from the tyre manufacturer).

TABLE

Minimum ballasting front/rear

Real value according to calculation

/ ......

kg

Permissible value according to operating instructions

Double permissible tyre load carrying capacity (two tyres)

---

---

Total weight

kg ≤

kg

Front axle load

kg ≤

kg ≤

kg

Rear axle load

kg ≤

kg ≤

kg

---

Note: The minimum ballasting has to be attached to the tractor either in the form of a mounted implement or ballasting weight.

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

0293 653.8 - 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

Version of measurement of the sound level according to the measurement procedure specified 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 adapted measurement procedure corresponds to Procedure 4 described in this document.

1

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

The tractor used for measurements has a power output of 110 kW (150 PS).

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

A-evaluated equivalent constant sound pressure levels 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 653.8

Prior to operation

Prior to operation

6 Prior to operation ASSEMBLY INSTRUCTIONS Safety Guards Side Mowers DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C

4 4

2

Install the safety guards as shown in Fig. 4 and secure them to the conditioner housing.

Position the safety guards (1) over the safety guards (2) for the side mowers and fasten in position using the belts (4).

1

(Fig. 1, 2) 1

Note: To make fixing the drive belts easier, you can remove the bottom screws (3) and swivel the safety guards upwards (Fig. 4).

4 4

2

6 6

Install the guard cloths (1) to the conditioner housing using strips (5), square neck coach bolts (6) (M8x20x13), contact washers (B8) and securing nuts (VM8).

7

7

Push the sprung tines (7) to the opening in the protective cloth from above, and fix using the protective cloth locknuts.

(Fig. 3)

5

1 3

0293 653.8 - 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 653.8

Prior to operation Safety Guards Side Mowers DISCO 8550 Plus / 8550 Install the safety guards as shown in fig. 9 and secure them.

1

Position the safety guards (1) over the safety guards (2) for the side mowers and fasten in position using the belts (4).

4

(Fig. 5-8)

2 5

4

2

4

6

2

4 7

8

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.3

Prior to operation Note: To make fixing the drive belts easier, you can remove the bottom screws (3) and swivel the safety guards upwards (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

Installing the Mounting Frame Attach the mounting frame (1) to the lower control arm pins for the tractor. Secure the pins with linchpins. Also mount the upper control arm (Fig. 10).

Note: If there is a lot of play in the bolts, use the washers provided (37x56x5).

6.4

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Prior to operation Note: DISCO 8550 Plus / 8550 cannot be used as a pushed combination, but only as a trailed front/ rear combination (see page 6.18).

Position A: for use as shunted combination.

Position B: for use as towed front-rear combination.

(Fig. 10)

B

A

A 67216C

10

Connect the hydraulic line to a single-acting hydraulic valve on the tractor.

Insert the two-pole connection for the electrical power supply for the controls system in the corresponding tractor socket.

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.5

Prior to operation Fixing the Controller DISCO 8550 C Plus / 8550 C / 8550 C-T Fix the holder (2) within reach of the driver.

11

Screw the operating console holder (18) with machine screws (M5x18) and locknuts (VM5) to the holder (12).

Slot the operating console (11) in the operating console holder.

12

(Fig. 11)

13

11 Insert the plug (13) in the socket (14).

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

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

12 Press the keys on the operating console for 1.5 seconds.

Press this key.

The indicator lamp illuminate green.

Move the tractor hydraulics control lever to the floating position.

(Fig. 13)

When you assemble the device for the first time, the side mower weight is not available to help swivel the extension arm downwards. For this reason you will have to pull the extension arm down.

CONTROL TERMINAL

6.6

13

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Prior to operation Fixing the Controller DISCO 8550 Plus / 8550 / 8500 C Press both buttons (7) for the control box simultaneously, the red LED lamps (8) illuminate. Lower the left and right arms using the single-acting valve.

When you assemble the device for the first time, the side mower weight is not available to help swivel the extension arm downwards. For this reason you will have to pull the extension arm down.

7

8

(Fig. 14)

14

15

16

17

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.7

Prior to operation Application as Shunted Combination Unit Note: DISCO 8550 Plus / 8550 cannot be used as a pushed combination, but only as a trailed front/ rear combination (see page 6.18).

74224

18 Fasten both side mowers to the arms. To do this, mount the pins (3) in the outer bore of the arm and secure in position using the strap (5). Mount the retaining screws (4).

(Fig. 19)

3

4 5

19 Attach the universal drive shafts (6) to the main gearbox with the clutch end and then attach them to the side mowers and secure in position with the clamping screws.

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

(Fig. 20)

6

20 Floatation springs Basic value 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 653.8

Prior to operation Installation of Adapter (B03 0030) 1

The adapter B03 0030 must be fitted in order to be able to attach the front mower to the mounting frame.

• Install support (1) for the flotation spring attachment using hex. head bolts (M 16x130), washers (A 16) and securing nuts (VM 16).

• Withdraw the piston rod from hydraulic cylinder (2). For this unscrew the complete vacuum valve (V) with male connector – see page 6.10, »Hydraulic cylinder with vacuum valve«.

NOTE: The vacuum valve is stuck together with the male connector. These parts must not be detached from each other!

22

• Attach hydraulic ram (2) with pin (3) and secure using a split pin.

NOTE: The vacuum valve (V) of the hydraulic cylinder must face rearward to prevent any risk of water ingress.

V

• Fit adapter (4) to the rear hole with pin (5) and secure using a linch pin. To achieve a higher cut of the front mower it may be necessary to attach the adapter to the front hole.

• Fit hydraulic ram (2) with pin (6) to the straps of the adapter and secure using a split pin.

(Fig. 22-24) 23 5x40

V

26x40x1

1

2

3

M16x130 A16

A16 VM16

5x40

6

26x40x1

4

12x45

5

65420R01

0293 653.8 - 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 information concerns the mowers from machine no. 652 0 1961 onward.

Danger!

Because of vacuum in the hydraulic cylinder (2), it can lead to unexpected retraction of the piston while dismantling.

69175 69175

25

– Before dismantling the cylinder, remove the hexagon bolt (V) on the cylinder tube!

(Fig. 24, 25)

6.10

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

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

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

• Connect the hydraulic lines (7) to hydraulic ram (2).

• Unscrew the drain plugs from the elbow 10

support (10) had and connect the hydraulic hoses (7) to the centre mower.

7

(Fig. 26, 27) DISCO 8500 C:

• Connect the hydraulic lines (7) to hydraulic 10

ram (2).

7

• Connect the hydraulic lines (7) to flow divider (9) using T-union (8).

26

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

7

10

2

68291M01

0293 653.8 - 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 653.8

Prior to operation

1

Mount one quick-release coupling to the available headstock of the adapter. Attach upper link (1) to the rear hole using the hitch pin (Fig. 29).

8

Attach the lower links (5) to the top hole of the quick-release coupling (6) and the rear hole (4) of the adapter (7) using the pins. If there should not be sufficient lifting height in the headland with a low cutting height, the lower links (5) should be attached to the front hole of the adapter (7).

7

6 4

Attach the front mower (8) to the quick-release coupling (6) and secure in position.

(Fig. 29)

5 29

Attach the universal shaft (9) to the main gearbox with the clutch end and then attach it to the front mower.

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

8

(Fig. 30) 9

Note: If you are using the mower as shunted combination, you will require propeller shaft M04 0160 (0937 043.3) for the front mower!

30

M04 0160 937 043.3

64531F

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

31

6.13

Prior to operation

Caution!

If the mower is driven as a shunted combination unit, one flat connector (1) must be bolted to each of the rods for the loading elevator retainers. This ensures the distance between the tractor and the mower is adequate.

1 (Fig. 32) 32

6.14

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Prior to operation Installing the Lighting Unit Install lighting unit (1) to the front mounted mower using the big supports (2) supplied.

(Fig. 35) 3 45 m m

Cut the protective cloth (3) right and left to fit.

(Fig. 33)

33 Install the lighting unit holders (2) right and left.

(Fig. 34, 35)

2

34 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 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

35

6.15

Prior to operation Installation of cable: Route the cable for the light set to the middle frame (4), via the cable support. Secure it in this position to the hydraulic lines with self-locking straps.

(Fig. 36, 37) 4

36 Caution!

Route the cable underneath the hydraulic line to prevent the compensating spring levers from squeezing the cable (see arrow). +

(Fig. 37)

37

Caution!

Route the cable in the intermediate area between adapter and front mower unit so that there is no tension within the entire folding range of the cylinders.

(Fig. 38)

38

6.16

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Prior to operation Route the cable to the mounting frame. Use a clamp (D=10) to bolt (M6x16) the cable onto the cover and the mounting frame (5). Use existing washers.

(Fig. 39)

5

39 The wiring loom is preassembeld on the light set with self-locking straps (6). Use self-locking straps to secure excess cable inside the light set.

6

(Fig. 40)

40

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.17

Prior to operation Application as Towed Front / Rear Combination Unit Fasten both side mowers to the arms. To do this, mount the pins (3) in the inner bore of the arm and secure in position using the strap (5). Mount the retaining screws (4).

Attach the front mower in the quick release coupling for the front hydraulic system and secure in position.

(Fig. 41, 42) 74228

41

3

4

5

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

DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C Basic value X = approx. 80 mm (Fig. 43)

X

1

43 DISCO 8550 Plus / 8550

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

(Fig. 44)

X 44 6.18

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Prior to operation Remove the hydraulic hose on the left (7) and right (8) and close off the elbow support (9) with stoppers (10).

(Fig. 45, 46) 7

9 8

9

45 10 9

46

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.19

Prior to operation Attach the universal drive shafts (11) to the main gearbox with the clutch end and then attach them to the side mowers and secure in position with the clamping screws.

11

(Fig. 46)

Attach the universal shaft to the main gearbox with the clutch end and then attach it to the front mower.

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

47

Note: If you are using the mower as a towed combination, you will require propeller shaft M04 0080 (0947 117.5) for the front mower.

M04 0080 0947 117.5

64532F

6.20

48

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Prior to operation Installing the Lighting Unit Install the lighting unit to the rear side of the central frame using the small supports (3) supplied. Drill two holes (diam. 10 mm) into brace (2). There must be a 435 mm distance between the centre of the brace and the holes at either side.

(Fig. 49) 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

49 Installation of cable: Remove the cable support and the angle (1a/dotted line). Bring to position 1b and secure with preassembled bolts.

(Fig. 50)

1b

50

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.21

Prior to operation Route the wiring loom from the middle frame to the cable support (4). Use self-locking straps (5) to secure the wiring loom parallel to the hydraulic hoses.

4

5

Route the wiring loom from the cable support through the upper tube of the middle frame.

(Fig. 51)

51 Place the excess length of the wiring loom inside the middle frame.

(Fig. 51, 52)

52

53 54

6.22

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Prior to operation Installing a rotation sensor on the central mower DISCO 8550 C Plus / 8550 C / 8550 C-T

55 6

1

11

1 Sensor DW 60

1x

2 Sensor bracket GT 41

1x

3 Hexagonal bolt

M8x20

2x

4 Contactwasher

B8

2x

5 Pipe clamp

1x

6 Front cable DW 60

2x

7 Clamp

5x

8 Serrated l. washer

A6,4

6x

9 Contactwasher

A6

1x

10 Socket hd. screw

M6x12

6x

11 Cable ext. DW 60

1x

(Fig. 56) 10

5

3

4

9

10

8

2

7 56 Remove the screws from the angular gear.

(Fig. 57)

57

58

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.23

Prior to operation Push the single-jointed shaft protection (S) back.

(Fig. 59)

S 59

3

Assemble sensor (1) with the sensor holders (2), hexagon head cap screws (3) and the contact disks (4) to the gear (G).

4

1

(Fig. 60) 3 4 2 L G

60 Set the height of the sensor (1).

M

To achieve this remove the hexagonal nuts (M), place the sensor (1) in the desired direction, and screw the hexagonal nuts (M) tight again.

1

The distance between the sensor (1) and a tooth of the cardan shaft (W) should amount to approx. 4 mm.

4 mm

(Fig. 61)

W 61

A

Following this set the distance of the sensor (1) to the slip-on fork (A) of the cardan shaft. To this end shift the sensor holder (2) in the elongated holes (L) (Fig. 63).

1

The distance between the sensor (1) and the slip-on fork (A) should amount to 2-4 mm.

(Fig. 62)

2-4 mm 62

6.24

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Prior to operation Cut into the cardan shaft protection (S) and slide on once more.

2

Caution!

Pay attention to the position of the lubrication openings (O)!

L

S

(Fig. 63) O 63 Plug the plug of the front cable (6) together with the cable of the sensor (1).

9 7

8

Shift the front cable (6) to the rear.

8

9 7

To this end install the pipe clamp (5) and clamps (7) with serrated lock washers (8) and cylinder screws (9) in the bore holes which are provided for them.

6

Pay attention that the cable on the mounting frame forms a slight loop (see arrow).

5

8

(Fig. 64)

9

64

6

7

8

Note: Lift up the central mower and check the cable length by moving it.

9

(Fig. 64-67)

65

6

7 8

9

66

0293 653.8 - 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

67 Pushed Combination Plug the plug of the front cable (11) together with the plug of the cable (K). Please pay attention that the cable (K) is so long so that it is not damaged during the folding process (see arrow).

11

(Fig. 68)

K

68 Towed Front-Rear Combination Connect the plug of the cable (11) with the plug of the front cable (6a).

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

11

(Fig. 69) 6b 6a

69 Place the cable (6b) along the tractor through the driver's cabin to the rear and up to the lateral mowing units.

(Fig. 70)

6b

70

6.26

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Prior to operation

Note: If the central mower is not fitted with the speed monitoring system, switch (1) can be moved to the left or the right to stop the audible warning – see »Bridge Connector Switch«, page 7.10.

(Fig. 71)

1 71

Adjusting the Cutting Height DISCO 8550 C Plus / 8550 C / 8550 C-T

1

To adjust the cutting height, loosen the screws (2) and move the centre holder (1) within the oval holes.

Tighten the screws again.

If the centre holder is moved upwards: the side mowers cut higher.

If the centre holder is moved downwards: the side mowers cut lower.

2

(Fig. 72) 72

73 74 75 76

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.27

Prior to operation Installation of Cutting Knives DISCO 8550 C Plus / 8550 Plus / 8550 C-T Before the first use of the machine the cutting knives must be installed. For this introduce the mounting lever between cutting disc and knife holder. Push down the mounting lever and install the cutting knife – see »Knife Replacement DISCO 8550 C Plus / 8550 Plus / 8550 C-T«, page 8.10.

Observe the rotational direction of knife and cutting disc.

(Fig. 77, 79, 80) 68482

77 DISCO 8550 C / 8550 / 8500 C

4 4

Install the new knife with the cutting edge facing to the bottom. The sense of rotation of the each disc is shown by an arrow.

Tightening torque for the knife securing bolts (4) = 120 Nm. (Fig. 78, 79, 80)

120 Nm

64258

78

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

68480

6.28

79

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Prior to operation DISCO 8550 Plus / 8550

68481

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

80

6.29

Prior to operation Checking the PTO Shaft for Correct Length Before the first operation of the mower make sure that the hitch and the PTO shaft suit the tractor.

Caution!

Modifying the hitch of the machine to suit the tractor will allow the mower to poerate smoothy and the PTO shaft joints to work at the maximum angle.

The PTO stub position varies with different tractors, and for this reason it may be necessary to shorten the drive shaft.

Adapting the PTO shaft length: Pull drive shaft sections apart and connect the section with the long guard to the PTO stub of the machine and the other section to the tractor PTO stub.

Swing the machine into working position, hold the two sections alongside each other and check the length with the machine lowered and raised.

(Fig. 81) Observe the maximum permissible shaft length (LB).

81 82

Try to reach the maximum possible overlap for the profile tubes. During field operation, the overlap (PU) of the tubes must never be inferior to 50% of the overlap which is available when the tubes are fully compressed (LZ).

In the shortest operating length the tubes must not buttom against each other. A minimum clearance (a) = approx. 40 mm must still be available.

Cut the male and female guard tubes to the correct length.

Then cut the same length from the male and female profile tubes. File the cut area to remove any metal burrs and wipe off any metal fillings.

Grease the sliding surface of the profile tubes.

(Fig. 83) 83 84

6.30

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Prior to operation LOADING AND UNLOADING MACHINE DISCO 8550 PLUS / 8550 Danger!

Incorrect loading and transport can result in accidents!

– Load the machine only by hitching it onto the left and right hoisting points (1)!

85

– Make sure the slings are sufficiently dimensioned!

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

(Fig. 85, 90)

86

87

88

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.31

Prior to operation

89

90

6.32

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Prior to operation CHECK AND OBSERVE THE FOLLOWING BEFORE PUTTING INTO OPERATION 1. Check the oil level in the angle gearboxes and the cutterbar.

2. Before the first use lubricate the mower abundantly.

3. Check that all blades are correctly installed.

4. Check bolts for tightness.

5. Check all safety devices (e.g. overload clutches, covers of drive elements, ...) for correct function and installation.

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

7. Only engage the tractor PTO with the tractor engine at idling speed and the mower in working position.

8. Never exceed the maximum permissible PTO speed (1000 rpm).

9. After the mower has been hitched to the tractor and the PTO drive shaft has been connected, raise and lower the mower slowly to check that the PTO drive shaft is freely movable throughout its working range.

10. Connect the safety chains to prevent guard tubes rotating.

11. Check guard cloths periodically for wear and damage.

12. Check lighting equipment, turn flasher and stop light for proper function.

13. Ensure all persons stand clear of the danger area.

If anyone should approach the danger area switch off the cutting unit immediately.

14. Never leave the mower unattended as long as the tractor engine is running.

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.33

Prior to operation COUPLING The DISCO 8550 C Plus / 8550 C / 8550 C-T and 8500 C can be operated as a large-scale mowing combination unit using two mounting methods:

A

Note: DISCO 8550 Plus / 8550 cannot be used as a pushed combination, but only as a trailed front/ rear combination.

64461F

91

The mounting frame is attached with the side mowers in Position A when used for a towed combination unit.

The front mower is mounted at the front of the tractor.

(Fig. 91)

The mounting frame is attached in Position B on a tractor with reversing equipment when used for a shunted combination unit. In this case, the front mower is attached to the mounting frame using an adapter.

B

(Fig. 92)

64462F

92

Caution!

If the mower is driven as a shunted combination unit, one flat connector (1) must be bolted to each of the rods for the loading elevator retainers. This ensures the distance between the tractor and the mower is adequate.

(Fig. 93)

1 Note: 93

6.34

– see »Conversion from Front/Rear Combination Unit to Shunted Combination Unit«, page 6.43.

– see »Conversion from Shunted Combination Unit to Front/Rear Combination Unit«, page 6.45.

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Prior to operation Attaching the Mounting Frame Attach the mounting frame to the lower control arm pins of the tractor. For this use the lower hole (2) (Fig. 94). Secure the pins with linchpins.

Mount the upper control arm and adjust so that the adapter is nearly vertically positioned – see »Adjusting Cutting Height«, page 7.13.

2

94

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.35

Prior to operation Attaching the Front Mower to the Mounting Frame The adapter B03 0030 must be previously fitted in order to be able to attach the front mower to the mounting frame.

The three-point linkage for the adapter must be completely lowered using the single acting control valve.

Drive up to the machine and insert the Accord coupling in the three-point frame of the front mower using the hydraulics.

64460F

The locking pin (1) must engage in the strap (2).

95

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

(Fig. 95, 96)

2

Adjust the strip (2) so that it rests against the locking pin (1) of the Accord coupling.

1

Turn stop screw (4) as far as possible.

3

65869F

4

(Fig. 96)

Caution!

96

Perform this adjustment with the mower raised. .

Caution!

Secure the latch (1) with a spring clip (4) (Fig. 97).

Adjusting the Upper Control Arm 97

6.36

Adjust the upper control arm so that the front mower is approximately vertical – see »Adjusting Cutting Height«, page 7.13.

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Prior to operation Weight Suspension The flotation for the mower can be varied using the attachment points for the flotation springs. The chains (1) for the flotation springs (2) are attached to the fifth link in the straps and secured in position with spring connectors. Slide the straps (3) on the upper pins and secure in position with spring connectors.

1

3

(Fig. 98)

2 98 Fitting the PTO Drive Shaft Danger!

8

4

Never remove the guards (8) from the universal drive shaft!

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

1

– Attach the safety chains (4) for the universal drive shaft guard to the machine and the tractor with the hook.

99 Press q.-d. pin and simultaneously push PTO drive shaft (1) onto PTO shaft until pin engages.

(Fig. 99) Attention!

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

Observe max. power takeoff shaft speed – see »Specifications«, page 5.1!

100

Only engage the tractor PTO with the machine in working position!

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.37

Prior to operation Hydraulics Danger!

The stopcock (1) (Fig. 101) must always be closed for driving on public roads and before uncoupling the hydraulic hose.

1

B

A

Attention!

4

101

Risk of contamination of the tractor hydraulics system!

– Clean the male coupling on the hydraulic hose and the oil plug each time before connecting.

Connect the hydraulic hose (4) to the single-acting control valve connection.

(Fig. 101)

102 Stop valve Open the stop valve (1) when using the machine.

Position (A):

valve open

Position (B):

valve closed

Electric Connection Connect th electric cable to the plug on the tractor.

6.38

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Prior to operation DISMANTLING THE MOWER Note: Only store the cutting unit on a firm and level area.

Parking the Machine in a Folded-Out Condition

• Fold the side mowers down onto the ground.

• Slide the stabiliser feet (1) down and secure in

1

1

103

position with the pins (Fig. 103).

• Lower the mower onto the ground using the

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

three-point linkage.

• Detach the upper and lower control arms.

• Uncouple the universal drive shaft and suspend from the headstock with the chain.

• Disconnect hydraulic and electrical connections.

Attach plug, hydraulic hose and control box to hose support (3). Ensure that the operating console is located vertically in the hose holder (Fig. 104, 105).

3

ATTENTION! Protect control box from moisture!

104

• Drive tractor away.

DISCO 8550 Plus / 8550 / 8500 C

Note: 3 DISCO 8550 Plus / 8550 / 8500 C: When storing the machine for a prolonged idle period be sure that both indicator lamps (7) of the control box are not illuminated. The electric connection to the tractor must be cut.

7

(Fig. 105)

105

0293 653.8 - 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: When storing the machine for a prolonged idle period be sure that the indicator lamp (6) of the control box is not illuminated. The electric connection to the tractor must be cut.

6

(Fig. 106)

106

6.40

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Prior to operation Parking the Mower in a Folded Condition DISCO 8550 C Plus / 8550 C / 8550 C-T Note: Only store the disc mower on a firm and level area.

•

Swivel the mower into the transport position.

1

1

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

• Push the supporting foot (1) downwards and secure with the bolt (Fig. 107).

• Lower the mower to the ground using the headstock hydraulic system.

• Set the single-acting control valve to the 0 position (neutral).

• 3

•

108

Press this key. The indicator lamp illuminates green.

Press both these keys. Both indicator lamps illuminate red.

• Set the single-acting control valve to the floating position. Lower the central mower to the ground.

• 109

Switch off the controller.

• Unhinge the top and bottom guide rods.

• Uncouple the propeller shaft and hang it up to the headstock using the chain.

• Disconnect the hydraulic and electrical connections. Disconnect the plug, hydraulic hoses and operating console at the hose holder (3). Ensure that the operating console is located vertically in the hose holder (Fig. 108).

6

ATTENTION! Protect the operating console from moisture!

• Drive the tractor away.

110 Note: If machine is a standstill for longer periods the indicator lamp (6) on the operating console must be off. The electrical connection from the tractor must be interrupted (Fig. 110).

0293 653.8 - 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 into the transport position using the single-acting control valve. Apply pressure until the side mower is completely raised and the lamps (7) on the control panel are extinguished (Fig. 112).

• Slide the stabiliser feet (1) down and secure in position with the pins (Fig. 111).

• Lower the mower onto the ground using the three-point linkage.

• Set the single-acting control valve to the floating

1

1

111 DISCO 8550 Plus / 8550 / 8500 C

position. Lower the central mower to the ground.

• Switch off the controler.

• Detach the upper and lower control arms.

• Uncouple the universal drive shaft and suspend from the headstock with the chain.

3

• Disconnect hydraulic and electrical connections.

Attach plug, hydraulic hose and control box to hose support (3). Ensure that the operating console is located vertically in the hose holder (Fig. 112).

7

ATTENTION! Protect control box from moisture!

• Drive tractor away.

112 113 Note: When storing the machine for a prolonged idle period be sure that both indicator lamps (7) of the control box are not illuminated. The electric connection to the tractor must be cut.

(Fig. 112)

114

6.42

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Prior to operation

115

CONVERSION FROM FRONT/REAR COMBINATION UNIT TO SHUNTED COMBINATION UNIT Note: DISCO 8550 Plus / 8550 cannot be used as a pushed combination, but only as a trailed front/ rear combination.

3 Danger!

Stop the tractor engine before performing any assembly work on the machine.

1

– Remove the ignition key.

2 Danger!

4

116

Release the stress-relief springs at either side before performing any assembly work on the machine.

Fold up the lateral mower units.

Release locknuts (1).

Drive bolts (2) totally out of the stress-relief springs (3).

Tie together levers (4) of the flotation system using an appropriate tape (e.g. self-locking straps).

Lower the lateral mower units.

(Fig. 116)

5 117

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

Unscrew strap (6).

Remove pin (7).

6

Fit lateral mower units to the outer holes of the carrier arms.

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

7

(Fig. 117, 118) 5 Fold up the lateral mower units.

118

Release levers (4) of the flotation system.

Drive bolts (2) into the stress-relief springs (3).

Adjust the spring tension.

Tighten the locknuts (1).

(Fig. 116)

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.43

Prior to operation

For more assembly and adjustment instructions: – see »Application as Shunted Combination Unit« on page 6.8, – see »Application as Towed Front / Rear Combination Unit« on page 6.18, – 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 653.8

Prior to operation

119

CONVERSION FROM SHUNTED COMBINATION UNIT TO FRONT/REAR COMBINATION UNIT Danger!

Stop the tractor engine before performing any assembly work on the machine.

– Remove the ignition key.

3

Danger!

Release the stress-relief springs at either side before performing any assembly work on the machine.

1 2

Fold up the lateral mower units.

4

Release locknuts (1).

120

Drive bolts (2) totally out of the stress-relief springs (3).

Tie together levers (4) of the flotation system using an appropriate tape (e.g. self-locking straps).

Lower the lateral mower units.

(Fig. 120)

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

Unscrew strap (6).

Remove pin (7).

5 121

Fit lateral mower units to the inner holes of the carrier arms.

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

(Fig. 121, 122)

6 Fold up the lateral mower units.

Release levers (4) of the flotation system.

Drive bolts (2) into the stress-relief springs (3).

7

Adjust the spring tension.

5

Tighten the locknuts (1).

(Fig. 120) 122

For more assembly and adjustment instructions: – see »Application as Shunted Combination Unit« on page 6.8, – see »Application as Towed Front / Rear Combination Unit« on page 6.18, – see »Working Position« on page 7.4.

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.45

Prior to operation PRIOR TO TRANSPORT 1. Hitch the mower to the tractor.

2. Connect the PTO drive shaft and the hydraulic hose.

3. Connect the electric cable.

4. Raise mowing unit using the hydraulic front power lift.

5. Raise the prop stands and lock in position.

6. Swing the machine into transport position.

123

7. Close the shut-off tap located on the hydraulic hose.

Caution!

Always disengage the mower drive before transporting the mower. During transport avoid operating inadvertently the control levers of the tractor hydraulics.

124

Driving on public roads Danger!

At least 20% of the empty weight of the tractor must be acting on the front axle when the machine is attached (Fig. 125).

– If necessary install balance 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.

125

– 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 (nation-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 653.8

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

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

• When moving the machine on public roads, the light set (1) must be fixed on the mower – see page 6.15, »Installing the Lighting Unit« and »Installing the Lighting Unit« on page 6.21.

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

6.47

Operation

Operation

7 Operation CONTROLLER DISCO 8550 C PLUS / 8550 C / 8550 C-T Switch the controller on and off (press for approx.1.5 seconds).

Note: The controller switches off after 120 minutes if no functions are activated.

Caution!

First select the required function by pressing the key on the operating console. The key pressed illuminates red. The green indicator lamp on the lower keys goes out. If you operate the control lever (lift, lower or floating position) the function will be carried out.

CONTROL TERMINAL

1 Swivel mower to working position / mowing drive to all three mowers.

Raise / lower left mower.

2 Raise / lower middle mower.

3

7.1

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Operation Raise / lower right-hand mower.

Note: After selection the indicator lamp for the key pressed illuminates red. The green indicator lamp on the lower key goes out.

4 Swivel the mower to transport position.

The key indicator lamps illuminate red.

After pressing this key, the controller will automatically switch off after 2 minutes.

5 The indicator lamps illuminate if a propeller shaft joint blocks.

Lift up the corresponding mower immediately and switch off the mower. Rectify the blockage.

Danger!

Always switch off the drive and the motor before removing blockages or foreign bodies. Only leave the machine when all mowing blades and conditioning drums have come completely to a standstill.

CONTROL TERMINAL

6

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

7.2

Operation GENERAL Caution!

First select the required function by pressing the key on the operating console. The key pressed illuminates red. If you operate the control lever (lift, lower or floating position) the function will be carried out.

2

Select single mower extended: 3

1

The indicator lamps (1) to (3) illuminate red depending on selection: The mower is now selected. The "LOWER" function for the corresponding mower is now blocked. The "RAISE" function is activated.

4

4

5 CONTROL TERMINAL

7

If you now activate the control lever to "RAISE", only the mower you have selected by pressing the key will lift. After this, returned the control lever to floating position. The selected mower will remain raised, the other mowers will automatically lower to the floating position.

The "RAISE" function for the other two mowers is then blocked. The corresponding indicator lamps on the lower keys (5) illuminate green.

All control lamps (4) for the lower keys illuminate green: The mowers are now in floating position.

You can cancel preselected functions by pressing the same key or the bottom key (5) once again.

(Fig. 7) 8 Caution!

When the controller is in floating position, all raised mowers will automatically lower. The red indicator lamps will go out. The indicator lamps for the bottom key (5) illuminate green again (Fig. 7).

Caution!

9

7.3

Never switch the power takeoff shaft drive on when the mowers are in a folded condition.

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Operation Working Position Switch on controller (press for approx.1.5 seconds).

Press this key. The indicator lamps illuminate green. Set the single-acting control valve to floating position. The mower will swivel out to the working position.

(Fig. 10) 10 The distance from the headstock to the ground should be approx. 450 mm. With the mower in cutting position, screw (2) should be in the centre of slotted hole (3).

(Fig. 11, 12)

The front mower must be attached to the mounting frame if the mower is used as a shunted machine. The front mower is lowered via a sequential control system when the side mower is lowered.

approx. 450 mm

11

3

2

12 13

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

7.4

Operation Transport Position Fold up the guard cloths (2) at either side. Then lift the mowing unit (Fig. 15).

Caution!

Swivelling is only possible when the power takeoff shaft is switched off.

14

2

15 Press this key.

The indicator lamps illuminate red. The "LOWER" function is blocks for all mowers.

Swivel the mower into transport position with the single-acting control valve. Press the control lever for until the mower has completely folded in.

Switch off the controller. (Press for approx.1.5 seconds).

Note: After this key has been pressed, the controller switches off automatically 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 653.8

Operation Mowing with Single Mower Extended The mowers can be extended individually when mowing narrow residual strips (Fig. 17).

Mower is in working position (floating position): All indicator lamps for key (5) illuminate green.

17

1. Select the mower which should be individually extended by pressing the appropriate key.

The indicator lamps for this key (1), (2) or (3) illuminate red.

2. Lift up the selected mower using the single-acting controller.

3. Set the controller to floating position after this.

4. Before extending all the mowing units you will have to delete the preselection of all selected mowers so that all three units can be extended simultaneously. To this, press the key for the selected mower again or press the bottom key (5).

The indicator lamps (1), (2) or (3) for the selected mower key will go out. The indicator lamps corresponding to the bottom key (5) illuminate green.

The mowers now lower automatically.

2

3

1

4

4

Note: If you press this key all preselected functions whose indicator lamps (1), (2) or (3) are illuminated red will be deleted.

The indicator lamps for key (5) illuminate green.

5 CONTROL TERMINAL

18

(Fig. 18)

19

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

7.6

Operation Mower is in headland position: All indicator lamps for key (5) illuminate green.

1. Select the mower which should be extended by pressing the appropriate key. The indicator lamps for this key (1), (2) or (3) illuminate red.

2

3

1

2. After this, set the controller to floating position.

The other mowers will lower automatically.

4 4

5 CONTROL TERMINAL

20

3. Before extending all the mowing units you will have to delete the preselection of all selected mowers so that all three units can be extended simultaneously. To this, press the key for the selected mower again or press the bottom key (5).

The indicator lamps (1), (2) or (3) for the selected mower key will go out. The indicator lamps corresponding to the bottom key (5) illuminate green.

The mowers now lower automatically.

Note: If you press this key all preselected functions whose indicator lamps (1), (2) or (3) are illuminated red will be deleted.

The indicator lamps for key (5) illuminate green.

(Fig. 20)

21

22

7.7

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Operation Headland Position Swivel the mowers round to the headland position using the control lever at the end of the field.

The indicator lamps corresponding to this key illuminate green (Fig. 23).

23 When attracting the mowers, set the control lever to floating position. The mowers will automatically lower.

(Fig. 24)

24

25

26

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

7.8

Operation Speed Monitoring System Note: When switching the controller on, the indicator lamps do not illuminate. If lights should nonetheless illuminate, then this indicates that one or more speed sonsors are not activated (see note on page 7.9).

27

An audible warning will sound in case of a speed drop of one of the mower units (e.g. caused by a blockage) or if one of the speed sensors is not operative (e.g. in case of defective or wrongly positioned sensors).

The respective indicator light of the control box will become illuminated (Fig. 29).

Stop the mower immediately and eliminate the problem! If the problem is not eliminated, the clutches might be damaged!

1

Note: 28

The function of the indicator lights is inverted with the drive switched off (speed < 600 1/min).

Should speed sensors be defective or in the wrong positions, the indicator lights with intact (active) speed sensors will illuminate. Indicator lights with not intact speed sensors will not illuminate. Check adjustment of the sensor or replace defective speed sensor.

Danger!

Always switch off the drive and the motor before removing blockages or foreign bodies. Only leave the machine when all mowing blades and conditioning drums have come completely to a standstill.

CONTROL TERMINAL

7.9

29

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Operation Bridge Connector Switch If one of the rotation sensors is not activated, i.e. when the rotational sensor is not working although a rotation sensor has been installed on the middle mower, you will hear an acoustic signal when you switch the controller on. Both other indicator lamps on the operating console illuminate, the corresponding indicator lamp does not illuminate.

So that you can continue to use the mower, you can interrupt the acoustic signal by pressing the switch (1) in the corresponding direction. This bridges over the inactive rotation sensor.

1 30

If the switch is in its centre location: all sensors are working separately.

If the switch is to the left: the left-hand and middle sensor are bridged over, i.e. either of these could be not working. left side = switch shows to the left mower unit.

31

If the switches to the right: the right hand and middle sensor are bridged over, i.e. either of these could be not working. right side = switch shows to the right mower unit.

Note: If two rotation sensors are inactive, the rotation sensors cannot have been completely bridged over. All rotation sensor plugs must be pulled out.

Caution!

32

This switch should only be operated in exceptional circumstances so that monitoring of all three mowers is guaranteed.

(Fig. 30)

33

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

7.10

Operation CONTROLLER DISCO 8550 PLUS / 8550 / 8500 C Working Position Press both buttons (1) (Fig. 34) on the control box simultaneously in order to deactivate the transport safety equipment. Lower the side mower onto the ground using the single-acting tractor control valve.

1

The distance from the headstock to the ground should be approx. 450 mm. With the mower in cutting position, screw (2) should be in the centre of slotted hole (3).

34

(Fig. 35, 36)

DISCO 8500 C The front mower must be attached to the mounting frame if the mower is used as a shunted machine. The front mower is lowered via a sequential control system when the side mower is lowered. approx. 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 653.8

Operation Transport Position Fold up the guard cloths at either side. Then lift the mowing unit.

Swing the mower into the transport position using the single-acting control valve. Apply pressure until the side mower is completely raised and the lamps on the control panel are extinguished.

(Fig. 38)

38

Mowing Without Side Mowers The shunted combination unit can also be used without side mowers to mow the edge of a meadow or narrow residual strips.

To do this, lift the side mowers and the front mower using the single-acting tractor control valve. Deactivate the controls by pressing a button on the control box.

The front mower can now be lowered individually using the tractor control valve.

(Fig. 39)

39

The unit can only be used temporarily in this position as a result of the angular position of the universal drive shaft.

In order to lower the side mowers, press both buttons (1) on the control box simultaneously and switch the control valve to the "lower" position.

(Fig. 40)

1

40 41

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

7.12

Operation OPERATION 4

Adjusting Cutting Height The cutting height of the side mower and the front mower is adjusted using the upper control arm (4) (Fig. 42).

Application as Shunted Combination Unit

42

The cutting height of the side mower must be adjusted first. The length of the upper control arm between the tractor and the mounting frame is altered to do this.

The cutting height is reduced by extending the upper control and increased by retracting the control arm.

The mounting frame is horizontal in the basic setting.

Then adjust the upper control arm between the mounting frame and the front mower. The cutting height is reduced by extending the upper control and increased by retracting the control arm in this case as well.

Application as Towed Combination Unit The cutting height of the front mower is reduced by retracting the upper control arm and increased by extending the upper control arm.

43

Safety Frame Center Mower After the cutting unit has been lowered, fold the front safety frame section (2) to the front.

(Fig. 44) 2

Danger!

During work the cutting unit must be covered with the guard cloths.

44

– Avoid leaning against or standing on the guard cloths.

– Replace the guard cloths immediatly when damaged or worn.

45

7.13

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

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

Conditioning Plates The conditioning plates can be adjusted by means of lever (1): Moving lever in the direction of „+“ increases and in the direction of „-“ reduces the conditioning intensity.

(Fig. 46)

46 Variation of the Conditioner Speed The conditioner speed can be varied by interchanging the V-belt drive pulleys. To da this release the drive beldts and remove the V-belt guard.

Fig. 47 shows the positioning of the belt pulleys and the corresponding conditioner speed.

47

Varying the Swath Width A wider swath can be obtained by removing the big outer swath plates and installing the small inner swath plates at the outside (Fig. 48, 49).

3

Swath width can be further increased by removing all swath plates located behind the conditioner.

48

4

49

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

7.14

Operation Mowing Caution!

The terrain to be mown must be kept free from foreign objects!

Caution!

50

Using the front-mounted mower in the field can cause the intake screens and the radiator of the tractor to get heavily dirtied with consequent damage. Tractor engine and hydraulic system can suffer from overheating.

– Clean intake screens and radiator of the tractor several times a day.

• Lower the mowing units onto the ground.

• During operation the single acting control valve of the tractor must be set to „flotation position“.

• Before driving the machine into the crop to be

51

mown engage the tractor PTO and slowly increase the number of revolutions up to the maximum permissible speed (1000 rpm). The noise caused by the cutting discs is not alarming; it will considerably be deadened during work.

• Drive the machine into the crop.

• Always use the hand throttle lever when mowing to prevent speed fluctuations.

• The forward and cutting speed depends on the working conditions (ground conditions, density, height and state of the crop to be mown).

• Reduce the working speed when mowing very dense or laid crop and when negotiating curves.

• Raise the mower using the single-acting tractor 52

control valve when at the edge of the field.

• Reverse mowing is not possible. Before backing up the tractor always raise the mower.

• Never use the machine on stony fields!

Caution!

An ear protection should be used if the tractor is not fitted with a cab or the cab windows and doors are opened.

Remove ear protection before travelling on public roads 53

7.15

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Operation Danger!

Disengage the PTO and stop the tractor engine before clearing a blockage or before removing a foreign object. Only leave the tractor after the cutting discs have come to a complete stop.

Recommendation for environmental protection A simple change in the regular mowing technology helps reduce losses in nature.

At the same time, the quality of the mowed material increases.

Environment!

While mowing from outside to inside, wild animals hardly have the opportunity to escape!

– Mow from inside to outside.

Move to the centre of the plot of land and mow from inside to outside.

The centre can be mowed when there is sufficient space to turn.

Then wild creatures have the opportunity to escape towards the outside.

(Fig. 54)

69018

54 In small and long plots of land, first mow the headland and then the side elevations outwards.

(Fig. 55, 56)

69019

55

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

7.16

Operation

69020

56 For special plots of land and those close to the street, this technique - especially for front mower units - is practical.

(Fig. 57)

69021

7.17

57

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Operation Overload Safeguard Safety release allows the mowing unit to swivel to the rear if an obstruction is met.

6

When the mowing unit hits a solid obstruction disengage the PTO immediately and stop the tractor engine.

7

Check cutting unit for damage.

5

To re-engage the mechanism reverse the tractor. The mower is now in the working position again.

Note: 58

If the unit is to be towed with a hydraulic top guide bar it can be useful to extend the top guide bar so that the centre of gravity is moved towards the front.

If the break-away mechanism reacts too often, the spring (5) can be tightened. For this release the locknut (6), release the nut (7) one turn and tighten the locknut (6) again.

(Fig. 58) Note:

59

The spring (5) can be re-adjusted several times if necessary. At each adjustment the nut (7) may be moved a half turn only.

Check the function of the obstacle protection before the first use of the machine. For a possible adjustment of the spring you need two spanners (span of jaw: 24).

(Fig. 58)

Caution!

If the mower is driven as a shunted combination unit, a flat connector (1) must be bolted to each of the rods for the loading elevator retainers.

This ensures that the distance between the tractor and the mower remains adequate even if the retainer is actuated (Fig. 60).

1

60 61

0293 653.8 - 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 case of malfunction of the electric system, the functions "moving the unit to transport position" and "moving the unit to working position" can be operated manually using different valves.

To operate the respective valves, release hexagon (1) or press in the valve using a pointed object (see the arrow).

(Fig. 62)

1 62

Press the respective key of the control panel to ensure that oil is supplied to the cylinders.

Danger!

Switch off the drive system of the mowing unit before any manual operation of the valves.

Hold an adequate safety distance to all moving parts

63 Valve function: M3

M1

M4

M2

Valve

Function

M1

Lifts the central mower unit

M2

Lowers the central mower unit

M3

Lifts the l.h. mower unit

M4

Lifts the r.h. mower unit

M5

Lowers the l.h. mower unit

M6

Lowers the r.h. 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 653.8

Operation OPTIONAL EQUIPMENT High Cut Skids (B03 0020)

1

For high cut and for working on abrasive ground the mower can be fitted with 30 mm high cut skids.

Install the high cut skids (1) on right and left onto the lower side of the standard skids (Fig. 66).

66

Order number: 0306 768.0

Additional Skids (C03 0030) 2

Additional skids (2) can be bolted onto the standard skids if the latter are exposed to high wear (Fig. 67).

Order number: 0938 966.0

67

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

7.20

Maintenance

Maintenance

8 Maintenance

Pretensioned or prestressed energy aumulators

IMPORTANT MAINTENANCE INSTRUCTIONS Danger!

Components under tension can get loose unexpectedly and cause serious injury!

– Before the start of assembly work, all components under tension (springs, pressure accumulators etc.) must be released according to instructions.

Danger!

Always switch off the drive and the tractor engine for troubleshooting, and for repair, maintenance and cleaning work.

– Always remove ignition key and detach the drive shaft!

Danger!

Carry out repairs, maintenance and cleaning work on the raised machine only with secure support.

Do not attempt to repair pretensioned or prestressed energy accumulators (springs, hydraulic accumulators, etc.) unless you have the proper equipment and experience to perform the job safely. Such repairs should preferably be performed only in specialist workshops.

Bolts Check all bolts for tightness and retighten if necessary.

– Use suitable stands!

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

Lubrication

Hydraulic system Danger!

Always depressurise the hydraulic system when working on it and lower the machine!

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

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

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

Environment!

Dispose of oil and grease according to regulations!

Environment!

Dispose of oil and grease according to regulations!

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

Repair work on the hydraulic system must be carried out by authorised specialised workshops only.

Danger!

Only open guards with the drive switched off and the engine at a standstill.

– Remove the ignition key!

Mount the complete guards again after all maintenance and repair work.

Check the guards at regular intervals.

Check the protective curtains regularly and renew them if damaged or worn.

8.1

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Maintenance

Maintenance DRIVE MECHANISM Tensioning the Drive Belts DISCO 8550 C Plus / 8550 C / 8550 C-T / 8500 C Danger!

L

Before performing any repair work on the Vbelts disengage the mower drive and be sure that the machine cannot be reset into operation by other persons.

1

After the first use of the mower check the tension of the belts after the first five operating hours and retension if necessary.

After this first check the belt tension has to be checked regularly.

3

The belts are correctly tensioned if the length of the spring is L = 190 mm. The end of spring (3) must be flush with mark (4). Check the belt tension regularly.

4

(Fig. 1, 2)

Caution!

2

Always replace the complete set of belts if one belt is broken or worn.

3 4

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.2

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

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

3

The angle gearbox must only be filled with EP SAE 90 gear oil. To check the oil level store the machine on al level area. The oil level can be checked after oil level check plug (2) has been removed.

1

2

Oil capacities: 5.0 litres 2 (1) = Oil filler plug and breather (2) = Oil level check plug (3) = Oil drain plug 3

5

(Fig. 5)

Gear oil change: After the first use or when the gearbox has been overhauled, change the oil after 50 operating hours, but at least after every 500 operating hours, but at least every campaign.

Maindrive DISCO 8550 Plus / 8550

DISCO 8550 Plus / 8550

The angle gearbox must only be filled with EP SAE 90 gear oil. To check the oil level store the machine on al level area.

4 6

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

Oil capacities: 2.0 litres 5 6

(4) = Oil filler plug and (Dismantle PTO shaft r.h.)

(5) = Oil drain plug (Dismantle PTO shaft r.h.)

(6) = Oil sight glass (Fig. 6)

7 Gear oil change: After the first use or when the gearbox has been overhauled, change the oil after 50 operating hours, but at least after every 500 operating hours, but at least every campaign.

8

8.3

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Maintenance Sidedrive The angle gearbox must only be filled with EP SAE 90 gear oil. To check the oil level store the machine on al level area. The oil level can be checked after oil level check plug (2) has been removed.

1

Oil capacities: 1.0 litre 2 (1) = Oil filler plug and breather (2) = Oil level check plug

3

(3) = Oil drain plug 9

(Fig. 9)

Gear oil change: After the first use or when the gearbox has been overhauled, change the oil after 50 operating hours, but at least after every 500 operating hours, but at least every campaign.

10

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.4

Maintenance CUTTERBAR Danger!

After extended operation the cutter bar can reach temperatures up to around 80° C. – Danger of burning!

– Do not touch the cutter bar!

– Wear safety gloves

Note: If the above maintenance instructions are observed, there is no reason to be alarmed about the considerable heating of the cutterbar, provided that the discs can easily be rotated by hand when the machine is warm. A temperature of approx. 60° C may be considered normal.

The cutterbar may only be filled with EP SAE 90 gear oil. Check the oil level in the cutterbar daily and top up as required.

1

Oil capacities: 4.5 litres

(1) = Oil filler and oil level plug (Fig. 11) (2) = Drain plug (Fig. 13)

Oil level check: 11

Allow the machine to warm up, swing cutterbar into vertical position and wait approx. 10 min. Then check the oil level in level plug (1).

Topping up: Move cutterbar into vertical position. Top up with fresh oil trough hole (1) until the oil reaches oil level plug hole (1).

12

8.5

(Fig. 11)

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Maintenance Gear oil change: After the first use or when the gearbox has been overhauled, change the oil after 50 operating hours, but at least after every 200 operating hours, but at least every campaign.

2 Draining the oil: Swing cutterbar into horizontal position. Run machine for approx. 8 to 10 minutes to allow the oil to warm up.

13

Lift up the cutterbar and drain the oil through the hole of the magnetic plug (2). Clean the magnetic plug before reinstalling.

(Fig. 13)

14

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.6

Maintenance UNIVERSAL DRIVE SHAFT Danger!

Only work on the universal drive shafts with the drive and engine switched off.

15

– Remove the ignition key!

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

Observe the safety instructions of the manufacturer!

16

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

General information on universal drive shafts Danger!

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

17

– Mounting shaft guard and protective tube.

– Secure guard against turning!

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

18

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

Protect the universal drive shafts against the weather.

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

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

19

After long periods of disuse lubricate the universal drive shafts before using them again and check their functioning.

20

8.7

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Maintenance MOWER BLADES Danger!

The protective guard on the mower unit should only ever be opened when the PTO shaft is switch off and the engine and cutting discs stationary!

Only work on the mower blades or their fasteners with the drive stopped and the engine and cutting discs switched off.

– Switch off mower drive.

– Switch off engine.

– Wait until the cutting discs have come to a complete stop before leaving the tractor!

– Remove the ignition key!

– Wear gloves when working on the mower blades!

Danger!

Always replace knives, knife holders and cutting discs if damaged.

– Never try to weld or straighten them!

Attention!

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

– Always check that the mower blades are correctly seated!

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

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

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

0293 653.8 - 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.

Blade box Spare blades can be stowed in a special box (1) located on the right hand side of the mounting frame.

4

(Fig. 21) 1

21 2 = Compartment for blades PN 0952 043.0 1 3 = Compartment for blades PN 0952 042.0

(Fig. 22, 23) 2

3

5

22

2

Blade box (1) can be removed from support (5) by unhooking spring (4).

3

(Fig. 21, 22)

23

8.9

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Maintenance Always take the box (1) with you to the cutterbar when replacing blades.

(Fig. 24)

1

24

Knife Replacement DISCO 8550 C Plus / 8550 Plus / 8550 C-T 2

For knife replacement introduce mounting lever (1) between cutting disc (2) and knife holder (3).

(Fig. 25-27)

1 4 66602F/01

25

Caution!

Move mounting lever (1) outwards up to the limit stop keeping it parallel to the axis of the mowing disc.

(Fig. 26) Turn the cutting disc until knife holder (3) accurately fits recess (5) of the skids when mounting lever (1) is pushed down (Fig. 27).

1

Clean recess (5) before replacing the knife.

4 26

66603F/01

Push down mounting lever (1) and remove cutting knife (4). Install the new knife.

(Fig. 27, 28)

2

Install the new cutting knives with the cutting edge facing the bottom. The sense of rotation of the corresponding disc is shown on each knife by an arrow.

1

(Fig. 29)

3 66604F/01

4 27

0293 653.8 - 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!

It is essential to check both the knives and the knife retaining pins for correct seat. Knife retaining pin (5) must be seated in a straight position and fully rest against its contact area inside the disc (see the arrow) (Fig. 30).

5

66606F

8.11

30

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Maintenance Mounting lever (1) can also be used to lock the mowing discs for maintenance. For this introduce peg (2) of mounting lever (1) into the hole of one of the skids.

The handle of mounting lever (1) must be parallel to the cutterbar. To lock the discs rotate cutting disc (3) until it bottoms against mounting lever (1).

1

3

(Fig. 31)

2 31

66615F

After knife replacement or maintenance the mounting lever (1) can be secured to support (4) located on the 3-pt headstock or in the prop stand (5).

(Fig. 32, 33)

1 4

32

1 5

33

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.12

Maintenance The cutting knives must be replaced: – If they shown cracks or if they are deformed.

Never try to straighten a deformed knife.

– If they are worn. Measured at 10 mm distance from the disc edge, width (B) of the knife should at least be equal to 3/4 of the nominal width (Bn).

Bn

(Fig. 34) 10 mm

B 34

66614F

– If the hole of the knife has widened. Permissible widening: from Ln = 18 mm to L = 20 mm.

(Fig. 35)

35 The knife securing parts must be checked before each operation of the mower.

Danger!

Always replace knives, knife holders and cutting discs if damaged.

15 mm

– Never try to weld or straighten them!

12 mm

The knife holders must be replaced in the following cases: 36

66612F

– If the knife holder is worn in its shape (Fig. 36).

– If the knife holder is worn in its thickness (Fig. 37).

– If the weld seams (S) of the knife holder pin show visible cracks or if they are heavily worn (Fig. 37).

Caution!

S

Check weld seams each time before setting the machine into work!

4 mm

3 mm 66610F

8.13

S

37

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Maintenance – If the knife holder is deformed (bent) – In this case knife retaining pin (5) is no longer properly seated in its mounting inside the disc.

(Fig. 38)

5

66607F

38 – If there is a clearance between knife retaining pin (5) and its contact area inside the disc (see the arrows).

(Fig. 39)

5

39

66608F

– If knife retaining pin (5) is worn down to X = 13 mm.

(Fig. 40)

X

Danger!

5

Always exchange damaged or worn knife holders.

– Never try to weld or straighten them!

– Use only original CLAAS knife holders.

66609F

40 The cutting discs must be replaced in the following cases: – If the mounting hole is expanded, worn or damaged.

(Fig. 41)

66613F

41

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.14

Maintenance Knife Replacement DISCO 8550 C / 8550 / 8500 C

4

To change a knife first clean the surrounding area of nut (4) and release the nut using the socket wrench.

Install the new knife with the cutting edge facing to the bottom. The sense of rotation of the each disc is shown by an arrow.

(Fig. 42, 43) 120 Nm

Caution!

64258

42

Apply DELO ML 5328 (ET-No. 201 802.1) single component liquid plastics or Loctite (Typ 242) (ET-No. 666 285.0) to the nuts each time same have been released.

Tightening torque for the knife securing bolts (4) = 120 Nm.

68480

43

Danger!

Always replace knives, knife holders and cutting discs if damaged!

– Never try to weld or straighten them!

8.15

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Maintenance The cutting knives must be replaced: – If they shown cracks or if they are deformed.

Never try to straighten a deformed knife.

– If they are worn. Measured at 10 mm distance from the disc edge, width (B) of the knife should at least be equal to 3/4 of the nominal width (Bn).

(Fig. 44)

44 – If the hole of the knife has widened. Permissible widening: from Ln = 18 mm to L = 20 mm.

(Fig. 45)

45 Before each use of the machine also check all knife securing bolts.

Same have to be replaced: – If they show any visible deformation (e.g. after the cutterbar has struck an obstacle).

– If the coating on the bolt thread is worn or missing (water, oil or dirt).

– If the bolt head is worn down to the knife contact surface.

(Fig. 46) 46 – If the shank of the bolt is worn from Dn = 18 mm to D = 15 mm.

(Fig. 47)

47

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.16

Maintenance

Caution!

When installing the knife securing bolts make sure they are properly seated.

The securing nuts have to been replaced: – If the contact washer (1) has lost its elasticity or gets loose from the nut.

– If the nut is worn down to a = H/2.

48

(Fig. 48)

49

8.17

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Maintenance CUTTING DISCS Danger!

Always replace knives, knife holders and cutting discs if damaged!

– Never try to weld or straighten them!

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 fitted on a flange.

Tighten the srcews (C) of the cutting discs correctly (80 Nm).

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

Attention!

51

Replace missing or damaged plugs immediately to prevent crop or soil entering the cone. This would cause imbalance which in turn damages the machine.

2

– Make certain that all the discs with cone (1) are fitted with their plastic plug (2).

1

Make sure that the drain openings (3) in the lower part of the feed cones are not plugged. This will allow the water inside the cones to run off (e.g. after the use of a high pressure steam cleaner).

3

(Fig. 52) 52

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.18

Maintenance FLOATATION SPRINGS 4 The relieving of pressure on the cutter bar by the floatation springs should be set in such a way that the cutter bar is not pressing too strongly on the ground.

The flotation springs can be readjusted as required.

5

Quick Adjustment of the Spring Length Sliding sleeve (4) can be secured in three different positions. The top position gives an increased spring length (increased flotation). The lower position reduces the spring length (reduced flotation). Secure using R-clip (5).

53

(Fig. 53) Caution!

Check adapting to ground contours the setting has been made. Correct the setting of the floatation springs if necessary.

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

Fine Adjustment of the Spring Length Screw the threaded rod (3) into the spring to increase the flotation. Screw out the threaded rod to reduce the flotation (X = 5 - 120 mm).

3

(Fig. 54, 55)

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

X

Basic value X = approx. 80 mm (Fig. 54) 54

DISCO 8550 Plus / 8550

DISCO 8550 Plus / 8550 Basic value X = approx. 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 653.8

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

Installation and Removal of the Tines Pin (1) supplied with the accessories can be used to drive out expansion pin (2).

Caution!

Install tines as show in the fitting diagramm.

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

c d

24

1

2

c d

c d

63622F

56

ELECTRIC

M

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

Adjusting the Speed Sensors

1

Front Mower 4 mm

Sensor (1) must first be adjusted for height.

For this release the nuts (M), move the sensor as required and retighten nuts (M).

There should be a 4 mm clearance between sensor (1) and one of the teeth of universal drive shaft (W).

W 57

(Fig. 57)

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.20

Maintenance Then adjust the distance between sensor (1) and the universal drive shaft coupling yoke (A). For this move sensor support (2) in the slotted holes (L).

2

There should be a 2 - 4 mm clearance between sensor (1) and coupling yoke (A).

A 1

(Fig. 58)

2-4 mm 58 Side Mowers Sensor (3) must first be adjusted for height.

B

K

For this release the nuts (M), move the sensor (3) as required and retighten nuts (M).

There should be a 4 - 5 mm clearance between sensor (3) and one of the bushings (B) of the clutch (K).

4-5 mm 3

(Fig. 59)

M

59 Then adjust the distance between sensor (3) and the clutch (K). For this move sensor support (4) in the slotted holes (L).

4-5 mm

There should be a 4 - 5 mm clearance between sensor (3) and the clutch (K).

3

4

(Fig. 60)

K L 60

Adjusting Extension Sensors The distance to the edge of the sensor bracketshould be between 0.5 and 1 mm. If necessary, loosen the screws and move the sensor within the oval holes.

Retighten the screws afterwards.

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 653.8

Maintenance Replacing the Wiring Harness Observe the labelling and correct positioning of individual cable connections when replacing the wiring harness.

y2.2 y1.2

(Fig. 62-65)

y1.1 62

y2.1 y3.2

y3.1

63

R1

64

L1

65

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.22

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

Hydraulic Hose Connections Check hydraulic hoses before putting the machine into operation for the first time and afterwards at least once a year.

Replace hydraulic hoses when damaged or aged!

Note:

66

Hydraulic hoses may be used for a maximum period of 6 years after production.

The production date (month and year) is shown on the hydraulic hose.

Example: The indication „1 Q 98“ signifies manufacture in the first quarter of 1998.

67

Hydraulic Cylinder with Vacuum Valve 1

The following information concerns the mowers from machine no. 652 0 1961 onward.

Danger!

Because of vacuum in the hydraulic cylinder, it can lead to unexpected retraction of the piston while dismantling.

69175 69175

– Before dismantling the cylinder, remove the hexagon bolt (1) on the cylinder tube!

68 Dismantle and assemble the cylinder: 1. Unscrew the hexagon bolt (1) on the cylinder tube.

2. The piston can now be pulled out or pushed in by hand.

3. Screw in hexagon bolt (1) again.

(Fig. 68)

8.23

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Maintenance LUBRICATION DOORS Open the cover for lubrication.

4 2

For this release securing nuts (4), move cover (1) to the left in the slotted hole (2) and push cover (1) open to the bottom.

3 4

After lubrication slide cover (1) to the top and to the right under disc (3).

1

Retighten the securing nuts (4).

(Fig. 69) 69

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.24

Maintenance CLUTCHES Maintenance of the Friction-Type Overrunning Clutch After prolonged idle periods it will be necessary to bleed the clutch.

To this end tighten up the hexagon nuts on the stud bolts.

Turn the clutch hub by hand to loose the discs which might have seized solid.

70

Then release again the hexagon nuts of the stud bolts up to the end of the thread.

(Fig. 70)

Fig. 71 = Original condition

Renew worn discs in due course.

The discs are worn if the edge of the thrust disc is invisible.

(Fig. 72) 71

Note: The linings must cool down after the discs have slipped. Otherwise the full torque is not available.

72

Torque Universal drive shaft cutterbar drive l.h. and r.h. mowing unit:

Torque setting of cam-type cut-out clutch = 1200 Nm. (Fig. 73) The setting of the cam-type cut-out clutch must not be varied as otherwise heavy damage can occur to the universal drive shaft, the gearbox an other components.

67833

73

8.25

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Maintenance SCREW CONNECTIONS Check all screws and nuts on the entire machine again after 10 service hours and retighten if necessary.

Thereafter check the screws regularly for tightness.

CONNECTING ELEMENTS All connecting elements which effect safety such as bolts, screws, pins etc. should be checked regularly for wear and deformation.

Replace connecting elements with new ones where necessary.

END OF SEASON STORAGE 1. Clean the mower thoroughly.

2. Drain oil from gearboxes and the cutterbars and fill with fresh oil up to the prescribed level.

3. Lubricate all grease points thoroughly until the grease protrudes from the bearings – see »Lubrication Chart«, page 9.1.

Run the mower for a short time.

4. Have mower checked for worn and damaged parts and repaired if necessary.

5. Remove V-belts and store them in a dry place.

6. Clean cutterbars and rusty areas and repair damaged paintwork.

7. Store the mower under cover in a dry place away from stored fertilizer.

8. Store the mower in working position.

9. Remove the control unit from the mower and store it in a dry place at room temperature (approx.

18° C)

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.26

Maintenance MALFUNCTIONS Malfunction Vibration

Remedy

• Clean the attachment on the

Cause – Plastic cover missing.

cutting disc and the plastic cover immediately.

Poor adaptation to ground contours

• Clean the feeder drum.

– Feeder drum dirty.

• – see »Floatation Springs«,

– Wrongly adjusted frame.

page 8.19.

– Joints on mower head seized.

• Clean joints and lubricate.

The safety shutoff is triggered too often

• Increase spring tension – see

Wrong tilting angle of the mower head

• Turn the upper link further out

Poor cutting quality (for overly high forage/storage forage)

• Reduce tilt of the mower head

»Overload Safeguard«, page 7.18.

or in.

– see »Adjusting Cutting Height«, page 7.13.

• Reduce ground speed.

• Replace mower blades.

– see »Mower blades«, page 8.8.

– Inadequate tension of the rubber spring.

– Upper link length wrongly adjusted.

– Tilt of mower head too large.

– PTO speed too low.

– Ground speed too high.

– Blunt or damaged mower blades.

• Reduce speed for light forage.

Stubble too high

• Change tilt of the mower head by adjusting the upper link – see »Adjusting Cutting Height«, page 7.13.

Unmown strips between the front and the rear mounted mowers

• Reduce the tension of the

the top link.

8.27

– Excessive flotation.

compensating springs.

• Adjust the cutterbar tilt using

Fodder pushed forwards before being cut (creating stripes)

– Wrongly adjusted tilt of the mower head.

– Cutterbar excessively tilted to the front.

• Increase travel speed.

– Too slow a travel speed.

• Clean the mower.

– Dirt accumulation between the skids.

• Replace the knives.

• Adjust the rpm.

– Blunt knives.

• Reduce PTO speed and

– Swirling effect of the mower blades in light crops.

increase ground speed.

– Excessive rpm in light crops, insufficient rpm in heavy crops.

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Maintenance Malfunction

Remedy

Cause

Too narrow a swath

• Remove guide boards.

– Very high crop density.

Dirt collected in front cutter area

• Increase cutting height – see

– Very moist working conditions.

»Adjusting Cutting Height«, page 7.13.

• Attach wear runners.

• Raise and lower mower unit as

– Mole hills

required.

• Clean mower unit.

• Increase load relief on mower unit – see »Floatation Springs«, page 8.19.

Increased wear on cutting disc and mower blades

• Attach wear or high cutting runners.

– Insufficient load relief for the machine.

– Very difficult working conditions.

• Increase load relief on mower unit – see »Floatation Springs«, page 8.19.

Excessive wear of skids

• Bolt on wearing soles.

• Increase the tension of the

– Stony and sandy soil.

– Skid not parallel to the soil.

compensating springs – see »Floatation Springs«, page 8.19.

• Adjust skids parallel to the ground (punctual wear of skids in case of extremely high cut).

Mower unit being raised into working position: Mower head falls down so that the outer cutting disc touches the ground.

• Swing up the mower head somewhat using the hydraulic cylinder (about 10 - 20°).

– Driving too fast over uneven ground, extreme knocks.

• Reduce spring tension – see »Floatation Springs«, page 8.19.

Build up of piles in the swath

Plugging on the swath board

• Install additional feed cones.

• Reduce ground speed.

– Light and wet crops.

• Remove swath board.

– Swath board not correctly installed.

– Hilly terrain.

– High crop density.

Wrapping on the outer feed cone

• Check rpm and increase as

– High crop density, laid crop.

required.

0293 653.8 - ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C

8.28

Maintenance Malfunction Wrapping on the conditioner

Remedy

• Increase the belt tension.

• Check rpm and increase as required.

Cause – Excessive drop of the tractor speed (rpm).

– High crop density, laid crop.

• Reduce the travel speed.

• Open wider the conditioning plates.

• Swivel swath plates outwards.

The speed monitoring system creates a permanent audible warning

• Check the speed sensors.

• Check the position of the speed sensors.

• Disconnect all speed sensors

– Defective speed sensors.

– Speed sensors not correctly positioned.

– Blocked mowing unit.

temporarily.

• Press the bridge connector switch.

Side mowers extend unevenly

• Correcting extension sensor adjustments – see »Adjusting Extension Sensors«, page 8.21.

The mower cannot be swivelled to the transport position

8.29

• Check the rotation sensors.

– Extension sensors are adjusted differently.

– None of the rotation sensors are working.

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

Lubrication Chart

Lubrication Chart

9 Lubrication Chart SAFETY RULES Danger!

Only ever lubricate the mower unit when the tractor engine is off.

– Remove the ignition key!

LUBRICANTS Lubricant brands, 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”

Gear oil brand 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 653.8 - 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

Shunted combination unit

1

2 Towed front/rear combination unit

3

9.2

4

ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C - 0293 653.8

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 653.8 - 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 653.8

Lubrication Chart

12 13

15

12

12

14

13

14

15

0293 653.8 - 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 653.8

At CLAAS KGaA mbH we are constantly improving our products to reflect the latest technological developments.

For this reason, we may from time to time need to make changes to diagrams and descriptions in this documentation which do not reflect products which have already been delivered and which will not be implemented on these machines.

Technical specifications, 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 33426 Harsewinkel Germany

CLAAS KGaA mbH Postfach 1163 33426 Harsewinkel - Germany Tel.: +49 (0) 5247 12-0 www.claas.com

0293 653.8 ZBA+BA DISCO 8550 C Plus / 8550 C / 8550 Plus / 8550 / 8550 C-T / 8500 C EN - 06.05 Printed in Germany