CLAAS DISCO 9100 C AUTOSWATHER Assembly instructions Manual_DE_FR_EN_IT_ES - PDF DOWNLOAD

DISCO 8550 Plus DISCO 8550 TYPE 652 TYPE 652 TYPE 652 TYPE 652

UTYP 600 UTYP 610 UTYP 620 UTYP 630

GRP A02 GRP A02 GRP A02 GRP A02

ASF 1200 ASF 1210 ASF 1250 ASF 1220

Assembly and operator's manual

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

CLAAS Saulgau GmbH Zeppelinstraße 2

D - 88348 Bad Saulgau

declare under their sole responsibility that the product

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

-/-

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

EN 745 - August 1999

Bad Saulgau, 03.07.2006 Product Development (M. Geng)

Supply Chain Management (A. Fetscher)

Quality Management (J. Switalski)

Introduction

Introduction

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

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

In addition, assembly of your machine and regular inspections must be carried out by your specialist workshop. Failure to carry out maintenance work, or incorrect operation will result in poor machine efficiency and loss of valuable time.

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

This operator's manual applies to Disc mower: DISCO 8550 Plus / 8550 from serial number 652 0 2102

Your CLAAS Service Department

1.1

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Contents

Contents

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

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

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

5. Specifications Calculating the axial loads, minimum ballast and total weight .. 5.2 Noise level ................................................................................ 5.5

6. Assembly Loading/unloading machine ...................................................... 6.1 Fit guard frames for side disc mowers ...................................... 6.3 Mounting the fitting frame ......................................................... 6.5 Fit operating terminal ................................................................ 6.6 Use as a pushed combination ................................................... 6.7 Fitting the adapter (B03 0030) .......................................... 6.10 Fitting the Accord coupling ............................................... 6.12 Fitting the lighting unit on the front mower unit ................. 6.14 Use as a towed front - rear combination ................................. 6.18 Fitting the lights unit .......................................................... 6.21 Fit speed sensor for centre mower unit ................................... 6.23 Set clearance height ............................................................... 6.27 Fitting blades .......................................................................... 6.28 Adjust universal drive shaft ..................................................... 6.29 Attaching machine for first time ............................................... 6.30

7. Prior to Operation Check and observe the following before putting into operation! 7.1 Attachment to the tractor ........................................................... 7.2 Hooking up the fitting frame ................................................ 7.2 Hooking up the front mower unit to the fitting frame ........... 7.3 Setting the upper link .......................................................... 7.3 Weight relief ........................................................................ 7.4 Connecting the universal drive shaft .................................. 7.4 Hydraulic system ................................................................ 7.5 Electrical system ................................................................. 7.5 Removing the machine ............................................................. 7.6 Lowering the machine in the unfolded condition ................ 7.6 Lowering the machine in the folded condition .................... 7.7

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

Conversion from front - rear combination to pushed combination ....................................................... 7.9 Conversion from pushed combination to front-rear combination .................................................... 7.9 Prior to transportation ............................................................. 7.10 Driving on public roads ..................................................... 7.10

8. Operation Controls .................................................................................... 8.1 General .............................................................................. 8.3 Working position ................................................................. 8.4 Transport position .............................................................. 8.5 Mowing with individual units raised .................................... 8.6 Headland setting ................................................................ 8.8 Rotation monitoring ............................................................ 8.9 Speed monitor override switch ......................................... 8.11 Operation ................................................................................ 8.12 Setting the cutting height .................................................. 8.12 Safety equipment ............................................................. 8.12 Mowing ............................................................................. 8.13 Recommendations for environmental protection .............. 8.14 Collision protection ........................................................... 8.16 Emergency functions .............................................................. 8.17 Optional equipment ................................................................ 8.18 High cutting runners ......................................................... 8.18 Push-on runners ............................................................... 8.18

9. Maintenance Important maintenance instructions ......................................... 9.1 Hydraulic system ................................................................ 9.1 Energy accumulators ......................................................... 9.1 Bolts ................................................................................... 9.1 Lubrication .......................................................................... 9.1 Safety devices .................................................................... 9.1 Gearboxes ................................................................................ 9.2 Main gearbox ..................................................................... 9.2 Side gearbox ...................................................................... 9.3 Mower head ....................................................................... 9.3 Universal drive shaft ................................................................. 9.5 Clutches ................................................................................... 9.6 Maintenance of the friction and overrunning clutch ............ 9.6 Torque ................................................................................ 9.6 Mower blades ........................................................................... 9.7 Mower blade box ................................................................ 9.8 Change mower blades. ...................................................... 9.9 Mower blade quick-change system .................................. 9.10 Mower blade holder (Mower-blade quick-change system) 9.14 Bolted mower blades ........................................................ 9.16 Fastening mower blades (bolted mower blades) ............. 9.17 Mower discs ........................................................................... 9.18 Replacing cutting discs .................................................... 9.18 Mower disc cap ................................................................ 9.19 Fitting pinion units ............................................................ 9.20 Suspension springs ................................................................ 9.21 Quick setting of the spring length ..................................... 9.21 Final setting of the spring length ...................................... 9.21 Electrical system .................................................................... 9.22 Setting the lift sensors ...................................................... 9.22 Replace wiring loom for ejection sensors ......................... 9.22

2.1

Contents Setting the rotation sensors .............................................. 9.23 Hydraulic system ..................................................................... 9.25 Hydraulic hoses ................................................................ 9.25 Hydraulic cylinder with vacuum valve ............................... 9.25 Safety devices ......................................................................... 9.26 Fold-away guard frames ................................................... 9.26 Sleeve protector ................................................................ 9.26 Lubrication openings ............................................................... 9.28 Screw connections .................................................................. 9.28 Connecting elements .............................................................. 9.28 End of season storage ............................................................ 9.28 Malfunctions ............................................................................ 9.29

10. Lubrication chart Safety Rules ............................................................................ 10.1 Lubricants ............................................................................... 10.1 Lubrication .............................................................................. 10.1

2.2

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Preface

Preface

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

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

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

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

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

CLAAS will in no way be liable for damage or personal injury caused by the use of unoriginal CLAAS parts, accessories and additional equipment.

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

1

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

IDENTIFICATION PLATE 1 1

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

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

(Fig. 1, 2)

2

2

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

3.1

Safety Rules

Safety Rules

4 Safety Rules

Attention!

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

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

INTENDED USE

– Measures to prevent damage to the machine.

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

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

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

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

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

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

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

Note!

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

Environment!

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

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

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

GENERAL SAFETY AND ACCIDENT PREVENTION INSTRUCTIONS

IDENTIFICATION OF WARNING AND DANGER SIGNS

Basic rule:

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

General:

Danger!

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

– Preventive measures.

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

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

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

Follow the regulations in force when using public roads!

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

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

4.1

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

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

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

Ensure that you have an adequate view!

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

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

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

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

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

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

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

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

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

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

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

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

Special care is required when working near roads and buildings!

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

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

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

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

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

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

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

Observe the permissible transport dimensions!

Observe the maximum permissible axle loads and total weights!

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

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

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

Never leave the operator's platform when driving!

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

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

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

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

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

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

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

Secure the machine before leaving the tractor!

Lower mounted attachments fully to the ground!

Switch off the engine and remove the ignition key.

Keep the machine clean to prevent fire!

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

4.2

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

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

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

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

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

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

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

ATTACHED DEVICES Secure the devices from rolling away.

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

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

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!

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

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

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

Never engage the PTO shaft when the engine has stopped!

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

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

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

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

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

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

HYDRAULIC SYSTEM The hydraulic system is under high pressure!

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

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

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

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

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

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

4.3

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

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

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

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

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

– Risk of infections!

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

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

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

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

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

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

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

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

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

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

– Remove the ignition key!

Wait until the cutting discs and knives are completely motionless!

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

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

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

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

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

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

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

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 recognised any more must be replaced immediately by new ones.

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

1

64523

1

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

(Fig. 1, 2)

4.5

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Safety Rules

2

64523

3

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

(Fig. 3, 4)

3

64522

5

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

(Fig. 5, 6)

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

4.6

Safety Rules

A

B

C 7 Safety decals 936 915.0 (4) Figure (A):

4

Maintain sufficient distance from the blades when the engine is running.

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

Figure (C): Maintain your distance when the engine is running.

5 8

(Fig. 7, 8, 9, 10, 12)

4

5 9 11 Safety decals 515 380.0 (5)

4

Do not put hands in the trapping danger area while the parts are still moving.

(Fig. 8-12)

5 10

4.7

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Safety Rules

4

5 12

6 64527

13

15 Safety decals 514 814.0 (6)

6

Do not put hands in the trapping danger area while the parts are still moving.

(Fig. 13, 14, 15)

64524

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

14

4.8

Safety Rules

7 64524

16

17 Safety decals 514 898.0(7) Do not stand in the swing area of the working units.

(Fig. 16, 17)

8 19 Safety decals 516 254.0 (8) 68472

18

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

(Fig. 18, 19)

4.9

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Specifications

Specifications

5 Specifications Note!

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

DISCO 8550 Plus DISCO 8550 Required tractor power

KW (HP)

110 (150)

Transport width

mm

3000

Working width

mm

8000 / 8300

P.T.O. speed

rpm

1000

Cutting disc speed

rpm

3200

metres/ second

87

mm

40

kg

1920

Number of cutting discs per mower unit

-

7

Number of cutting blades per mower unit

-

14

Circulation speed of the mowing blades Cut height (bar horizontal) Weight (without front mower unit)

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

5.1

Specifications

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

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

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

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

G TH

TV a

5.2

Empty weight of the tractor - see tractor operating instructions

TV(kg)

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

TH(kg)

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

H

GV

68704

TL(kg)

b

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

c

d 1

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

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

b (m)

Tractor wheelbase, - see tractor operator's manual

c (m)

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

d (m)

Distance between lower steering ball and centre of gravity of rear fitting machine/rear ballast – measure When machine is being pulled, d = 0

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Specifications G x (c + d) - TV x b + 0.2 x TL x b GV min = H a+b

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

In the table, enter the calculated ballast required in the tractor's front section.

GH min =

GV x a - TH x b + 0.45 x TL x b b+c+d

Calculation of the minimum rear ballast Front mounting machine Note!

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

TV act =

GV x (a + b)- TV x b - GH x (c + d) b

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

Note!

In the table, enter both the actual calculated front axle load and the front axle load specified in the Operator's Manual.

Calculation of the actual overall weight

G act = GV + TL + GH

If the required rear minimum ballast (GHmin) is not reached by rear fitting machine (GH), the weight of rear fitting machine must be increased to that of minimum ballast.

Note!

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

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

5.3

Specifications Calculation of the actual rear axle load TH act = G act - TV act Note!

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

Carrying capacity of the tyres In the table, enter the double weight (2 tyres) of the permitted load capacity (e.g. see tyre manufacturer's documents).

TABLE

Actual value from calculation

Permissible weight from operator's manual

Double permissible tyre carrying capacity (2 tyres)

---

---

Minimum ballast front / rear

kg

Overall weight

kg

≤

Front axle load

kg

≤

kg

≤

kg

Rear axle load

kg

≤

kg

≤

kg

---

Note!

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

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

5.4

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Specifications

Specifications NOISE LEVEL Microphone l ocation 1

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

Microphone location 2

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

Horizontal level Tractor Machine

M62120-01

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

1

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

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

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

A-weighted equivalent continuous sound pressure level Tractor without machine

Cabin window

Tractor with machine

open

closed

open

closed

Microphone location 1 - L(A) eq

dB (A)

89.1

74.6

94.0

78.4

Microphone location 2 - L(A) eq

dB (A)

91.3

91.2

98.8

98.4

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

5.5

Assembly

Assembly

6 Assembly LOADING/UNLOADING MACHINE Danger!

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

– Hitch machine for loading only at the fastening points (1) on the left and right.

– Make sure the slings are sufficiently dimensioned!

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

1

(Fig. 1-6) 1

2

1

3

4

6.1

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Assembly

1

5

1

6

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

6.2

Assembly FIT GUARD FRAMES FOR SIDE DISC MOWERS Fit the safety frame in accordance with Fig. 11 and secure.

1

Place protective cloths (1) over guard frames (2) of side mower units and secure with belts (3).

2

(Fig. 7-10)

3

7

3

2

3

8 2

3 9

10

6.3

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Assembly

M12x70 A12 13x26x6

M12x70 A12

Vm12 M12x80 Vm12 B12 M10x75

M10x35

Vm12 12 13x26x6

B10 Vm10 M8x60

Vm8 B8 M8x60

B8 Vm8 8,5x40x3 M8x60

M8x20 B8

B10 Vm10

M8x20 B8

B8 Vm8 M12x70

M8x25

12

A12

M6x20 6,5x30x3 Vm6

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

13x26x6 B12 M12x70

Vm10 B10

M12x60 13x26x6 74223R/01

Vm12 12

M10x35 12 Vm12 Vm12

M12x35

11

6.4

Assembly MOUNTING THE FITTING FRAME Hook the fitting frame (1) into the lower link pin of the tractor. Secure the pin with the linch pin. Also fit the upper link.

Note!

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

Note!

Mower units in version UTYP 610 cannot be used as a pushed combination but only as a front-rear towed combination (see page 6.18).

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

(Fig. 12)

1

B

A

67216R/01

A 12 Connect the hydraulic hose to the single-acting control valve of the tractor.

Insert the two-pole connector for the operating terminal power supply into the corrrect plug on the tractor.

6.5

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Assembly FIT OPERATING TERMINAL Fit bracket (2) within reach of driver.

1

Screw control terminal bracket (3) to bracket (2) with set screws (M5x16) and self-locking nuts (VM5).

2

Insert operating terminal (1) in operating terminal holder (3).

3

(Fig. 13)

67341

13 Insert plug (5) in socket (4).

(Fig. 14) 4 Plug the electrical connection cable into the socket on the tractor.

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

67219

14 Hold down this button on the operating terminal for 1.5 seconds.

Push this button. The lamp lights up green. On tractor, set hydraulic controls for ejection cylinder to floating position.

(Fig. 15)

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

CONTROL TERMINAL

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

15

6.6

Assembly USE AS A PUSHED COMBINATION Only for machines in versions UTYP 600, UTYP 620 and UTYP 630: Note!

Mower units in version UTYP 610 cannot be used as a pushed combination but only as a front-rear towed combination (see page 6.18).

74224

16 Fix the two side mower units onto the arms, fitting pin (2) in inner hole (1) of each arm.

• • • •

1

(2) pin D40x350 (3) spring pin 10x60-N (4) spring pin 16x65-N (5) washer 40.5x75x1

• (6) block pulley LS4060 • (7) washer 41x62x3 2

(Fig. 17-19) 17

3

2

4

3 4 5 74225

7

5

6

18

7 5

2

3 4 19

6.7

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Assembly Assemble safety bolts as follows:

• • • •

(8) bolt M20x110 (9) bush 45x20x50 (10) spring washer 20 Dac 320/5-7m (11) spring-action locknut Vm20

Observe correct positioning of spring washers (10).

Tightening torque of nut (8) = 600 Nm. 8

9

10

(Fig. 20-22)

11

74243

20

9 8

21

11

10

22 Basic setting for flotation springs X = approx. 50 mm (Fig. 23)

X 23

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

6.8

Assembly Push on universal drive shafts (12) with clutch side against main gearbox and then against side mower units and secure with locking screws.

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

12

(Fig. 24)

24

6.9

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Assembly Fitting the adapter (B03 0030)

13

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

• Fit the carrier (13) for the front mower suspension 16

fixings with the hex head screws (M16x 130), washers (A16) and self-locking nuts (VM16).

15

• Pull connecting rod out of hydraulic cylinder (15).

17 19

18

25

To do this, unscrew vacuum valve (14) complete with male connector – see page 6.11, »Hydraulic cylinder with vacuum valve«.

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

• Attach hydraulic cylinder (15) with pin (16) and 14

secure with split pin.

CAUTION: The vacuum valve (14) on the hydraulic cylinder must point to the back to avoid the ingress of water.

15

• Fit adapter (18) in rear drilled hole with pin (19) and secure with linch pin.

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

• Fit hydraulic cylinder (15) to straps on adapter with pins (17) and secure with split pin.

68292

26

(Fig. 25-27)

5x40

14

26x40x1

13

15

16

M16x130 A16

A16 VM16

5x40

17

26x40x1

18

12x45

19

65420R02

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

27

6.10

Assembly Hydraulic cylinder with vacuum valve 20 Danger!

Vacuum in the hydraulic cylinder (15) can cause unexpected retraction of piston during dismantling.

– Before dismantling the cylinder unscrew the hex head screw (20) on the cylinder barrel!

69175 69175

28

(Fig. 27, 28) Hydraulic system

• Fit hydraulic lines (22) to hydraulic cylinders (15).

• Unscrew plug from elbow unions (21) and connect

21 22

hydraulic hoses (22) to centre mower unit.

(Fig. 29, 30)

21

22

67336

29 22

21

15

68291M01

6.11

30

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Assembly Fitting the Accord coupling Fit Accord coupling (23) in upper drilled hole on the adapter (18) with pin (24) and secure with spring clip.

(Fit the adapter – see »Fitting the adapter (B03 0030)«, page 6.10).

22 23

21 20

If there is insufficient clearance height at the headland with deep cutting, the adapter (18) is to be fitted into the front drilled hole (25) of the fitting frame.

23

Plug upper link (21) into rear drilled hole (20) on fitting frame with pin and secure with spring clip.

24 25

(Fig. 31)

18

31 DISCO 3050 FC Plus: Plug upper link (21)into upper drilled hole (22) on Accord coupling with pin (Fig. 31).

CORTO 3150 F Profil: 21

26

Plug upper link (21) into third drilled hole (26) on Accord coupling with pin (Fig. 32).

32 Hook the mower unit (27) into Accord coupling (23) and secure – see »Hooking up the front mower unit to the fitting frame«, page 7.3.

27

23

(Fig. 33)

28

30

64446

The chains of the suspension springs (28) should be inserted into the eighth link in the straps (30) and secured with spring clips.

Push the front mower universal shaft (29) on with the coupling side against the gearbox and then against the front mower unit.

29 33

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

(Fig. 33)

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

6.12

Assembly

Note!

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

M04 0160 937 043.3 74224

34

Caution!

If mower unit is driven as a pushed combination, a flat iron bar (31) must be bolted onto struts of start-up safeguard device. Only in this way can an adequate separation between the tractor and the mower unit be maintained.

31 (Fig. 35) 65922

6.13

35

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Assembly Fitting the lighting unit on the front mower unit DISCO 3050 FC: 32 45 m

Fix lighting unit (34) on the front mower unit, using the larger lighting brackets (33) supplied.

m

(Fig. 38)

To do this, cut safety curtain (32) on the right and left hand sides.

67128

36

(Fig. 36)

Fit lighting brackets (33) on right and left hand sides.

(Fig. 37, 38) 33

67130

37

A10 M10x40 M8x25

33

33 A8 VM8

M10x40 A10

M8x25

M8x25

11x40x4 A8 VM8 A8 VM8

VM10

VM8 A8

34 M8x25

11x40x4

65921&/01

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

34

VM10

38

6.14

Assembly CORTO 3150 F Profil: Fix lighting unit (35) on the front mower unit, using the larger lighting brackets (36) supplied.

(Fig. 39)

35

M10x40 A10 M8x25

36

11x40x4 A8 VM8

VM10

36

M10x40 A10 M8x25

A8 VM8

VM10 11x40x4

69379F

35

6.15

39

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Assembly Fitting cable Run cable for light bar over wiring bracket to fitting frame (37). In this position, attach to the hydraulic lines using cable ties.

(Fig. 40, 41)

37

67822

40

Caution!

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

(Fig. 41)

67821

41

Caution!

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

(Fig. 42)

67825

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

42

6.16

Assembly Run the cable to the mounting block. Screw cable to cover and fitting block with retaining fitting (D=10) (M6x16) (38). Use the existing washers.

(Fig. 43)

38

67293

43 The wiring loom is pre-assembled with the lighting bar using cable ties (39). Take up the excess cable length in the lighting bar with cable ties.

39

(Fig. 44)

67826

6.17

44

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Assembly USE AS A TOWED FRONT - REAR COMBINATION

74228

45 Fix the two side mower units onto the arms, fitting pin (2) in inner hole (1) on arms.

• • • •

1

(2) pin D40x350 (3) spring pin 10x60-N (4) spring pin 16x65-N (5) washer 40.5x75x1

• (6) block pulley LS4060 • (7) washer 41x62x3 2

(Fig. 46-48) 46

3

2

4

3 4 5 74225

7

5

6

47

7 5

2

3 4 48

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

6.18

Assembly Assemble safety bolts as follows:

• • • •

(8) bolt M20x110 (9) bush 45x20x50 (10) spring washer 20 Dac 320/5-7m (11) spring-action locknut Vm20

Observe correct positioning of spring washers (10).

Tightening torque of nut (8) = 600 Nm. 8

9

10

11

74243

49

(Fig. 49-51)

9 8

50

11

10

51 Hook the front mower unit into the front hydraulics quick coupling and secure .

Basic setting for flotation springs X = approx. 50 mm (Fig. 52)

X 52

6.19

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Assembly Remove hydraulic hoses left (12) and right (14) and close elbow unions (13) with plugs (15).

(Fig. 53, 54) 12

13 14

13

67336

53

15 13

67334

54 Push on universal drive shafts (16) with clutch side against main gearbox and then against side mower units and secure with locking screws.

(Fig. 55) 16 Push the front mower universal drive shaft on with the coupling side to the gearbox and then onto the front mower unit.

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

55

Note!

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

M04 0080 0947 117.5

74228

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

56

6.20

Assembly Fitting the lights unit Fit lights unit (18) to rear of fitting frame using brackets supplied (17).

(Fig. 57) Vm10 A10

M12x35

1a

1b

17

A 16

A 12 Vm12

M16x30

Vm12 B12

D42x22 12,2x30x3 M12x80 12,2x30x3 D42x22 B12 Vm12

11x40x4 M10x75

74229R/01

18 57

6.21

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

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

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

(Fig. 58)

1b

67334

58 Run wiring loom from fitting frame to wiring bracket (19). Fix wiring loom to parallel hydraulic lines with cable ties (20).

19

20

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

(Fig. 59)

67824

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

(Fig. 59, 60)

67823

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

60

6.22

Assembly FIT SPEED SENSOR FOR CENTRE MOWER UNIT

6

1

11

Only for machines in versions UTYP 600, UTYP 620 and UTYP 630: 10

5

3

67338

4

9

10

8

2

7

61

• • • • • • • • • • •

(1) Sensor DW 60

1x

(2) Sensor bracket GT 41

1x

(3) Hex head bolt

M8x20

2x

(4) Contact washer

B8

2x

(5) Pipe clamp

1x

(6) Front cables DW 60

2x

(7) Clamp

5x

(8) Serrated lock washer

A6.4

6x

(9) Contact washer

A6

1x

(10) Set screw

M6x12

6x

(11) Extension cable DW 60

1x

(Fig. 61) Unscrew the bolts from the mitre gear.

(Fig. 62)

66990

62 Push back the universal drive shaft guard (S).

(Fig. 63)

S 66992

6.23

63

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Assembly

3

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

4

(Fig. 64)

1 3 4 2 L G

66991

64 Set height of sensor (1).

M

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

1

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

4 mm

(Fig. 65)

W

66992

65 Then set distance from sensor (1) to slip-on coupling (A) of universal drive shaft. This is done by moving sensor bracket (2) in slotted holes (L) (Fig. 66, 67).

1

A

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

(Fig. 66)

2-4 mm 66992

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

2

Caution!

S

L

Note the position of the lubrication points (O)!

(Fig. 67)

O 66991

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

67

6.24

Assembly Connect front cable (6) to pin of sensor plug (1).

9 7

8

Run front cable (6) to the back.

8

9

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

7 6

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

(Fig. 68) 5

466994

8

9 68

6

7

8

Note!

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

9 (Fig. 68-71)

66995

69

6

7 8

9

66993

70

6 7

66996

6.25

8

9

71

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Assembly Pushed combination Connect plug of cable (11) with plug of cable (K).

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

11 K

(Fig. 72)

66997

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

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

11

(Fig. 73) 6b 6a 67001

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

(Fig. 74)

6b 67002

74

Note!

If the middle mower unit is not fitted with a speed monitor, switch (12) can be switched to the left or right in order to turn off the warning signal tone – see »Speed monitor override switch«, page 8.11.

(Fig. 75) 12 67347

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

75

6.26

Assembly SET CLEARANCE HEIGHT To adjust clearance height, release bolts (2) and move sensor bracket (1) in slotted holes. Re-tighten the bolts.

1

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

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

2

(Fig. 76) 67335

6.27

76

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Assembly FITTING BLADES DISCO 8550 Plus: Blades (1) must be fitted before operating machine for first time. To do this, move fitting lever (2) lever between cutting disc and blade carrier.

Push the fitting lever downwards and remove the mower blade – see »Mower blade quick-change system«, page 9.10.

2

Note the direction of rotation of the cutting disc.

1 66605F/01

77

(Fig. 77, 79)

DISCO 8550:

43

Fit the new blades with the cutting edge facing downwards – see »Bolted mower blades«, page 9.16.

The direction of rotation of each disc is marked by an arrow on the blade.

Tightening torque of mower blade fastening bolt (3) = 120 Nm.

120 Nm

(Fig. 78, 79) 64258

78

68481R01

79

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

6.28

Assembly ADJUST UNIVERSAL DRIVE SHAFT Before using the mower unit for the first time, the hitch and universal drive shaft must be adjusted to suit the tractor.

Caution!

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

80

Because of the different PTO shaft positions in the various models of tractor, it is necessary to adjust the universal drive shaft, if possible.

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

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

(Fig. 80)

Observe the maximum permissible shaft length (LB).

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

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

Cut the male and the female guard tubes uniformly.

81

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

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

Grease the sliding surfaces of the profile tubes.

(Fig. 81)

6.29

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Assembly ATTACHING MACHINE FOR FIRST TIME Before operating machine for first time, adapt linkage and universal drive shaft to tractor.

1. Hitch on machine or adapt linkage – see »Attachment to the tractor«, page 7.2.

2. Adjust/fit universal driveshaft – see »Connecting the universal drive shaft«, page 7.4.

3. Connect hydraulic line – see »Hydraulic system«, page 7.5.

4. Carry out necessary procedures »Check and observe the following before putting into operation!« on page 7.1.

5. Start operating machine – see »Operation«, page 8.12.

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

6.30

Prior to Operation

Prior to Operation

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

2. Lubricate the mower unit thoroughly before operation.

3. Check that the mower blades are properly fastened.

4. Check bolts for tightness.

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

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

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

8. Do not exceed disc mower's permitted PTO shaft speed (1000 rpm).

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

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

11. Check the safety guards for wear and damage.

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

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

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

7.1

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Prior to Operation ATTACHMENT TO THE TRACTOR The DISCO 8550 Plus / 8550 may be operated as a wide area mowing combination in the following two fitting versions:

A

Note!

Mower units in version UTYP 610 cannot be used as a pushed combination but only as a front-rear towed combination 1

64461R/01

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

(Fig. 1)

B

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

(Fig. 2)

64462R/01

2

Caution!

If the mower unit is driven as a pushed combination, a flat bar (1) must be bolted to the struts of the start-up safeguard device. Only in this way can an adequate separation between the tractor and the mower unit be maintained.

(Fig. 3) 1 Note: 65922

3

– see »Conversion from front - rear combination to pushed combination«, page 7.9.

– see »Conversion from pushed combination to front-rear combination«, page 7.9.

Hooking up the fitting frame Hook the fitting frame into the lower link pin of the tractor. Use the lower drilled hole (2) for this (Fig. 4).

Secure the pin with the linch pin.

Fit the upper link and adjust so that the adapter is almost vertical - see also »Setting the cutting height« on page 8.12.

2

64572

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

4

7.2

Prior to Operation Hooking up the front mower unit to the fitting frame In order to be able to hook the front mower unit into the fitting frame, the adapter B03 0030 must first be fitted – see »Fitting the adapter (B03 0030)«, page 6.10.

Completely drain the adapter's three-point hydraulics with the tractor's single-acting control valve.

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

The latch (3) should snap into the strap (4).

64460

5

Strap (4) can be adjusted after bolts are released (5).

(Fig. 5, 6)

4

Adjust the strap (4) so that it is in contact with the latch (3) of the Accord coupler.

3

Adjust stop bolt (6) accordingly .

5

(Fig. 6) Caution!

65869 65869F 6

6

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

Caution!

Secure latch (3) with spring plug (7) (Fig. 7).

3 7

Setting the upper link Set the upper link so that the front mower unit is almost vertical - see also »Setting the cutting height« on page 8.12.

4 74012

7.3

7

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Prior to Operation Weight relief The weight relief of the mower unit can be varied using the hooking point of the suspension springs. In the basic setting, the chains (9) of the suspension springs (10) should be inserted into the eighth link in the straps (8) and secured with spring clips. Push the straps (8) onto upper pin and secure with spring pin.

9

8

(Fig. 8) 10 67340

8

Connecting the universal drive shaft 11

Danger!

12

Never remove the safety devices (12) from the universal drive shaft!

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

13 64433

– Using the hook, hang up the fixing chains (11) for the universal drive shaft guard on the machine and on the tractor.

9

Push locking pin and universal drive shaft simultaneously (13) onto PTO shaft until locking mechanism engages.

(Fig. 9) Attention!

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

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

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

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

7.4

Prior to Operation Hydraulic system Danger!

B

A 61358

14

For driving on the road and before de-coupling the hydraulic hose, the cock (14) (Fig. 10) must always be switched off.

15

Attention!

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

10

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

Connect the hydraulic hose (15) to the connection of a single-acting control valve on the tractor.

(Fig. 10)

Stop cock During operation, when lifting out and lowering the cutter bar, the stop cock (14) must be open.

Position (A):

Stop cock open

Position (B):

Stop cock closed

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

7.5

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Prior to Operation REMOVING THE MACHINE Note!

Park the mower unit on solid flat ground.

Lowering the machine in the unfolded condition

• Fold the side mower units down to the ground.

• Push down prop stands (1) and secure with pin (Fig. 11).

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

65946

• Unhook the upper and lower links.

• Uncouple the universal drive shaft and suspend

1

1

11

on the three point stand using the chain.

• Disconnect the hydraulic and electrical connections. Unplug connector, hydraulic hose and control terminal on hose bracket (2). Make sure that the control terminal is located vertically in the hose bracket (Fig. 12).

CAUTION! Protect the control terminal from moisture!

2

67337

• Drive the tractor away.

12

Note!

If machine is at a standstill for a fairly long period, check-lamp (3) on control terminal must be off. The electrical connection to the tractor must be interrupted.

3

(Fig. 13)

13

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

7.6

Prior to Operation Lowering the machine in the folded condition Danger!

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

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

(Fig. 14) 74242

14

•

Hinge the mower unit into the transport position.

• Push down prop stands (1) and secure with pin (Fig. 15).

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

• Put hydraulic controls for ejection cylinder into neutral.

1

1 65946

• 15

•

Push this button. The lamp lights up green.

Push both these buttons. Both lamps light up red.

• Set hydraulic controls for ejection cylinder to floating position. Lower the middle mower unit down to the ground.

•

Switch off operating terminal.

• Unhook the upper and lower links.

• Uncouple the universal drive shaft and suspend

2

on the three point stand using the chain .

• Disconnect the hydraulic and electrical connec67337

16

tions. Unplug connector, hydraulic hose and control terminal on hose bracket (2). Make sure that the control terminal is located vertically in the hose bracket (Fig. 16).

CAUTION! Protect the control terminal from moisture!

• Drive the tractor away.

7.7

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Prior to Operation

Note!

If machine is at a standstill for a fairly long period, check-lamp (3) on control terminal must be off. The electrical connection to the tractor must be interrupted.

3

(Fig. 17)

17

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

7.8

Prior to Operation CONVERSION FROM FRONT - REAR COMBINATION TO PUSHED COMBINATION Danger!

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

– Remove the ignition key!

Side mower units must always remain fitted in the inner hole (1).

(Fig. 18) 1

For additional fitting and setting instructions: – see »Use as a pushed combination« on page 6.7.

18

CONVERSION FROM PUSHED COMBINATION TO FRONT-REAR COMBINATION Danger!

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

– Remove the ignition key!

Side mower units must always remain fitted in the inner hole (1).

(Fig. 19) 1 Dismantle front mower unit and attach to front of tractor.

For additional fitting and setting instructions: 19

7.9

– see »Use as a towed front - rear combination« on page 6.18.

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

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

2. Connect the universal drive shaft and hydraulic hose.

3. Connect the electrical connection cable.

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

5. Retract the stands and interlock.

6.

Hinge the mower unit into the transport position

7. Close the stop cock on the hydraulic hose.

Caution!

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

Driving on public roads Danger!

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

– Observe the maximum permissible axle loads and total weights!

62972

20

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

– Secure the control lever!

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

• Observe the applicable regulations in your country.

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

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

• Prepare machine for transport – see »Prior to transportation«, page 7.10.

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

7.10

Prior to Operation • For travel on the road, the lighting unit must be fitted to the mower unit – see »Fitting the lighting unit on the front mower unit«, page 6.14 or »Fitting the lights unit«, page 6.21.

7.11

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Operation

Operation

8 Operation CONTROLS Switch control system on/off (actuate for approx. 1.5 seconds).

Note!

Operating terminal switches off after 120 minutes, if no function is enabled.

Caution!

Firstly select the desired function on the control terminal by pushing the button. After pressing, the button lights up red. The green check lamp on the lower button goes out. The function is performed by actuating the hydraulic controls for ejection cylinders (raising, lowering or floating position).

CONTROL TERMINAL

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

Raise / lower left hand mower unit.

2 Raise / lower middle mower unit.

3

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

8.1

Operation Raise / lower right hand mower unit.

Note!

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

4 Hinge the mower unit into the transport position.

The check lamp of the button lights up red.

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

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

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

Danger!

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

CONTROL TERMINAL

8.2

6

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Operation General Caution!

Firstly select the desired function on the control terminal by pushing the button. The check lamp lights up red. The function is performed by actuating the hydraulic controls for ejection cylinders (raising, lowering or floating position).

2

Raising individual mower units: 3

1

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

4

4

5 CONTROL TERMINAL

7

When "RAISE" is pressed on hydraulic controls for ejection cylinders, only the mower unit selected by the button lifts up. Then you must set the hydraulic controls for ejection cylinders back to the floating position.

The selected mower unit remains raised and the other mower units automatically lower to the floating position.

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

Cancelling single lift: Pre-selected functions can be cancelled by pushing same button once more or by pushing lower button (5).

Caution!

If the hydraulic controls for ejection cylindersare in floating position, the raised mower units descend automatically. The red check lamps go out. The check lamps for the lower button (5) light up green again.

Normal operation: All check lamps (4) for the lower key light up green: The mower units are in the floating position.

(Fig. 7) Caution!

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

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

8.3

Operation Working position Switch on operating terminal (hold down for approx. 1.5 seconds).

Push this button. The check lamps light up green. Set hydraulic controls for ejection cylinder to floating position. The mower unit hinges into the working position.

(Fig. 8) 8 Lower fitting frame by means of three-point hydraulics, until pin (7) is in centre of elongated hole (6). The red arrow (9) thus points to the metal indicator (8).

6

(Fig. 9, 10)

7

9

8

9

10 Distance from headstock to ground should be approx.

450 mm.

Lock three-point hydraulics in this position.

(Fig. 11)

ca. 450 mm

64572

8.4

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

11

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Operation Transport position On middle mower unit, first hinge up safety curtains (10) on both sides. Lift up the mower unit (Fig. 13).

Caution!

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

12

10

64435

13 Push this button. The lamp lights up red. The "LOWER" function is blocked for all mower units. Using hydraulic controls for ejection cylinders swing mower unit into transport position. Actuate hydraulic controls for ejection cylinders until mower unit is in totally collapsed state.

Switch off operating terminal. (actuate for approx. 1.5 seconds).

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

(Fig. 14)

CONTROL TERMINAL

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

14

8.5

Operation Mowing with individual units raised When mowing narrow residual strips the mower units can be raised individually (Fig. 15).

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

64438

15

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

Check lamp (1), (2) or (3) for this button lights up red.

2. Using hydraulic controls for ejection cylinders raise selected mower unit.

3. Then set hydraulic controls for ejection cylinder back to floating position.

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

2

3

1

4

4

Note: 5 CONTROL TERMINAL

16

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

Check lamps for button (5) light up green.

(Fig. 16)

8.6

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

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

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

Check lamp (1), (2) or (3) for this button lights up red.

2

3

1

2. Then set hydraulic controls for ejection cylinder to floating position. The other mower units lower automatically.

4

4

5 CONTROL TERMINAL

17

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

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

Check lamps for button (5) light up green.

(Fig. 17)

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

8.7

Operation Headland setting Swing mower unit at field end into headland position with hydraulic controls for ejection cylinders.

The check lamp of this button lights up green (Fig. 18).

18 When driving into the crop, set hydraulic controls for ejection cylinders to floating position. The mower unit automatically swings downwards.

(Fig. 19)

19

8.8

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Operation Rotation monitoring Only for machines in versions UTYP 600, UTYP 620 and UTYP 630: Attention!

12 11

If a fault is displayed on speed monitor, immediately switch off PTO drive and remedy fault.

13

If fault is not cleared, clutches can be damaged!

Danger!

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

CONTROL TERMINAL

20

The three control lamps on the operating terminal are allocated to the mower units.

Control lamp (11) for speed sensor (16) Control lamp (12) for speed sensor (15) Control lamp (13) for speed sensor (14) (Fig. 20, 21)

Note!

14

15

16 21

The fault display for faulty or wrongly-adjusted speed sensors is different between a PTO speed of less than 730 rpm and one greater than 730 rpm.

Display when PTO speed is less than 730 rpm or PTO drive is switched off:

• No check lamp lit up: all speed sensors intact.

If a speed sensor is faulty or wrongly-adjusted, control lamps light up and an audio signal sounds.

Fault display:

• Check lamps which light up indicate the intact speed sensors.

• Check lamps which do not light up indicate the faulty or wrongly adjusted speed sensors.

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

8.9

Operation Display when PTO shaft speed is greater than 730 rpm:

• No check lamp lit up: all speed sensors intact.

If a mower unit is blocked, a mower unit speed drops or a speed sensor is faulty or wrongly adjusted, check lamps light up and an audio signal sounds.

Fault display:

• The check lamps that light up indicate the blocked mower units or the faulty or wrongly adjusted speed sensors.

• Check lamps which do not light up indicate the intact speed sensors.

Note!

On transfer to PTO shaft speed 730 rpm an audio signal may sound briefly. This is caused by speed sensor switch tolerances.

8.10

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Operation Speed monitor override switch If one of the speed sensors is not enabled, e.g. when the speed sensor is not working or if the middle mower unit has no speed sensor attached, an audio signal sounds after the operating terminal has been switched on. The other two check lamps on the control terminal light up and the relevant check lamp does not light up.

So that the mower unit may continue to be used, the audio signal can be interrupted, if the switch (17) is actuated in the right direction. This overrides the disenabled speed sensor.

17 67347

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

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

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

Note!

If two speed sensors are disenabled, the speed sensors cannot be totally overridden. All the rotation sensor plugs must be disconnected.

Caution!

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

(Fig. 22)

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

8.11

Operation OPERATION 1

Setting the cutting height The cutting height of the side and front mower units is adjusted by the top bar (1) (Fig. 23).

Use as a pushed combination

64433

23

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

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

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

Safety equipment Middle mower unit Before enrtering the crop to be cut, pull down and fasten the protective curtains (2) on both sides.

(Fig. 24)

2

Danger!

67354

24

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

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

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

8.12

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Operation Mowing Caution!

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

Caution!

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

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

• Lower the mower unit to the ground • During working, hydraulic controls for ejection cylinders must be set to floating position (free float).

• Before entering forage, switch on tractor PTO and gradually increase speed to the maximum permittted PTO speed (1000 rpm). The whistling noise is completely normal and is considerably damped down during the mowing operation.

• Move into the forage.

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

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

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

• At the edge of the field, lift up mower units with hydraulic controls for ejection cylinders.

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

• Do not mow on rocky ground!

Caution!

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

Remove the ear muffs when driving on the road.

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

8.13

Operation

Danger!

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

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

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

Environment!

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

– Mow from the inside outwards.

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

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

Wild animals thus have the chance of escaping outwards.

(Fig. 25)

69018

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

(Fig. 26, 27)

69019

8.14

26

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Operation

69020

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

(Fig. 28)

69021

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

28

8.15

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

4 5

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

3

Check the cutterbar for damage.

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

67150

29 Note!

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

If start-up safeguard responds frequently, spring (3) can be adjusted slightly. To do this, slacken counternut (4), turn nut (5) one revolution and retighten counternut (4).

(Fig. 29) Note!

If necessary, spring (3) may be readjusted several times. For each readjustment, the nut (5) must only be readjusted half a turn each time.

Before using the machine for the first time, check the function of the collision protection. For this purpose, take two spanners (size 24) with you for adjusting springs (3).

(Fig. 29)

Caution!

If mower unit is used as a pushed combination, a flat bar (6) must be bolted to struts of start-up safeguard device. Only by doing this will there still be a sufficient distance between the tractor and the mower unit in the event of a response from the safety device (Fig. 30).

6

65922

8.16

30

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

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

Relevant valves may be actuated by slackening hex bolt (1) or by pressing with a sharp object (see arrow).

(Fig. 31) 1 68296

31

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

Danger!

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

Maintain an adequate distance from the moving parts!

M3

M1

Functions of the valves:

M4

M2

68294

Valve

function

M1

Raise middle mower unit

M2

Lower middle mower unit

M3

Raise left mower unit

M4

Raise right mower unit

M5

Lower left mower unit

M6

Lower right mower unit

32

M5 M6 68295

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

33

8.17

Operation OPTIONAL EQUIPMENT High cutting runners 1

(B03 0020)

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

High cutting runners (1) are fitted on right and left of skids (Fig. 34).

64867

34 Order number 0306 768.0

Push-on runners (C03 0030) 2 If skids are exposed to heavy wear, additional runners (2) may be bolted onto them (Fig. 35).

Order number 0938 966.0

66363

8.18

35

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Maintenance

Maintenance

9 Maintenance

Energy accumulators Danger!

IMPORTANT MAINTENANCE INSTRUCTIONS

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

Danger!

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

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

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

Danger!

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

Bolts

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

Check all bolts for tightness and retighten if necessary.

– Use suitable stands!

Lubrication

Hydraulic system Danger!

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

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

Environment!

Dispose of oil and grease according to regulations!

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

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

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

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

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

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

Environment!

Dispose of oil and grease according to regulations!

Safety devices Danger!

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

– Remove the ignition key!

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

Check the guards at regular intervals.

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

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

9.1

Maintenance

Maintenance GEARBOXES Main gearbox

For machines in versions UTYP 600, 620, 630:

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

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

1

For machines in versions UTYP 600, 620, 630 (main gearbox GT60): Oil filling quantity: 5.0 litres

2

(1) = Oil filler cap and breather valve (2) = Oil level check plug 1

(3) = Oil drain plug (Fig. 1, 2)

For machines in versions UTYP 610 : Oil filling quantity: 2.0 litres (4) = Oil filling plug (5) =Bleeder valve (6) = Oil level check plug 3

(7) = Oil drain plug (Fig. 3) 2

For machines in versions UTYP 610, , :

4

6

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

5

7 3

9.2

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Maintenance Side gearbox 8

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

To check the oil level, lower the mower unit onto flat ground. Check oil level (9) in gearbox by unscrewing oil level check plug.

Oil filling quantity: 1.0 litre (8) = Oil filler cap and breather valve

9

(9) = Oil level check plug 10 4

(10) = Oil drain plug (Fig. 4)

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

Mower head Danger!

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

– Do not touch the bar!

– Wear safety gloves!

Note!

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

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

9.3

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

11

Oil filling quantity: 4.5 litres

(11) = Oil filling and oil level check plug (Fig. 5) (12) = Oil drain plug (Fig. 6)

Checking the oil level: 67342

5

Warm the machine up. After the cutter bar has been swung in position vertically for approx. 10 minutes, check the oil level through the monitoring opening (11).

Oil filling: Swing the cutter bar into the horizontal position. Pour oil through hole (11) up to level of monitoring hole (11).

(Fig. 5)

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

12

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

63098

6

Lift beam and drain oil out via magnetic plug opening (12). Clean the magnetic plug before reinstalling it.

(Fig. 6)

9.4

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Maintenance UNIVERSAL DRIVE SHAFT Danger!

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

– Remove the ignition key!

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

Observe the safety instructions of the manufacturer!

Operate the universal drive shaft only in good condition.

General information concerning the universal drive shafts Danger!

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

– Mounting shaft guard and protective tube.

– Secure the guard against rotation.

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

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

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

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

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

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

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

9.5

Maintenance CLUTCHES Maintenance of the friction and overrunning clutch Bleed clutch after any fairly long period of inactivity.

1 2

• • • •

Tighten nuts (1) fully.

Tighten clutch hub (2) manually.

Stuck friction discs are loosened.

Tighten nuts (1) back to end of thread again.

(Fig. 7) 7 New status Edge of pressure disc (arrow) is visible.

(Fig. 8)

The friction discs are worn if the pressure washer edge (arrow) is no longer visible.

Note!

8

Replace worn friction discs in good time.

Note!

After the friction discs have slipped, the linings must be cooled down. Otherwise, the full torque will not be available.

(Fig. 9)

9

Torque 3

Left and right hand mower unit cutter bar drive: Torque setting of the cam-type cut-out clutch (3)= 1200 Nm. (Fig. 10)

The setting of the cam-type cut-out clutch must not be modified since otherwise considerable damage may be caused to the universal drive shaft, gearbox etc.

67833

10

9.6

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Maintenance MOWER BLADES Danger!

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

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

– Switch off mower drive.

– Switch off engine.

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

– Remove the ignition key!

– Wear gloves when working on the mower blades!

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 imbalanced blades.

Note!

Use only sharp mower blades for neat cutting.

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

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

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

9.7

Maintenance Mower blade box There is a mower blade box (2) on the right hand side of the fitting frame which can store spare mower blades.

1

(Fig. 11)

2

(3) = Stowage space for mower blades 0952 043.0 (4) = Stowage space for mower blades 0952 042.0 (Fig. 12, 13) 67831

11 The mower blade box (2) can be taken out of its holder (5) by loosening the spring (1).

2

(Fig. 11, 12)

3

4

5

67832

12

3

9368731

4

13 The mower blade box full of mower blades (2) should be used to change mower blades on the mower head.

(Fig. 14) 2

67378

9.8

14

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Maintenance Change mower blades.

Danger!

Mower blades working loose present a high injury risk!

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

Do not weld or straighten!

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

Order No.: Mower blade (clockwise)

0952 042.0

Mower blade (anticlockwise)

0952 043.0

The mower blades must be replaced under the following conditions: – If the blades are cracked or bent. Never attempt to straighten a bent blade.

– If the blades are worn.

The width (B) of the blade, measured 10 mm from the edge of the disc, should still be at least 36 mm.

(Fig. 15)

10 mm

B 68777

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

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

L

(Fig. 16)

Procedure for changing mower blades: – see »Mower blade quick-change system«, page 9.10 bzw. »Bolted mower blades«, page 9.16.

Ln 61623

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

16

9.9

Maintenance Mower blade quick-change system DISCO 8550 Plus: 6

For changing mower blades:

• Introduce fitting lever (7) between mower blade (6) and mower blade holder (9).

(Fig. 17, 19)

7

68985

17

Note!

Pull fitting lever (7) outwards parallel to mower disc axis to stop .

7

(Fig. 18)

18

68986

• Clean groove (8) in runner.

• Place mower blade holder (9) precisely over groove (8) by turning mower blade.

• Push down fitting lever (7).

7

9

(Fig. 19)

8

68987

19

• Take out mower blade (10).

• Remove forage residue and dirt from around mower blade holder.

(Fig. 20)

10

68979

9.10

20

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Maintenance

68481R01

21

Note!

Mower blades are different for anticlockwise and clockwise discs. Pay attention to direction of rotation for fitting blades.

Arrow on mower blade must correspond to direction of rotation of the particular mower disc.

(Fig. 21)

• Insert new mower blade (10) with sharp edge downwards.

• Alternatively, turn mower blade round, if second edge is still not used, and insert with sharp edge downwards.

(Fig. 22)

10

68980

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

22

9.11

Maintenance • Take weight off fitting lever (7).

Danger!

Mower blades working loose present a high injury risk!

– Ensure that mower blades and mower blade retainer pins fit properly.

Mower blade retainer pin (11) has to abut (see arrows) and lie straight in locating hole of mower disc (6).

7 68981

23 (Fig. 23, 24) 6

11 68984

24

• Take fitting lever (7) out of mower disc.

(Fig. 25)

7

68982

25

Danger!

Mower blades working loose present a high injury risk!

– Ensure that mower blades and mower blade retainer pins fit properly.

Mower blade must rotate freely and be able to be moved easily in both directions.

(Fig. 26) 68983

9.12

26

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Maintenance Fitting lever (7) can also be used as a stop for mower discs during maintenance tasks on mower head. To do this:

7 6

• Insert tail (12) of fitting lever (7) into hole of a runner. Fitting lever (7) handle must bear on mower head, parallel to it.

• Strike mower disc (6) against fitting lever (7), thus stopping it.

(Fig. 27) 12

66615F

27 After changing mower blades, and after maintenance work, fitting lever (7) can be inserted in bracket (13) on the headstock or in the stand (14).

7

(Fig. 28, 29) 13

67151

28

7 14

67352

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

29

9.13

Maintenance Mower blade holder (Mower-blade quick-change system) The attachment parts of the mower blades must be checked before every use.

Danger!

Mower blades working loose present a high injury risk!

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

Do not weld or straighten!

It is essential to change damaged or worn blades.

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

The mower blades must be replaced under the following conditions: – abrasion (wear) to profile of mower bladeholder.

Wear limit:

X = 15 mm Y = 12 mm

(Fig. 30)

X X

YY 69049

30 – Wear is apparent on the mower blade holder thickness.

Wear limit:

W = 3 mm Z = 4 mm

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

S Danger!

69050

W W

Z Z

Mower blades working loose present a high injury risk!

31

– Check weld beads before each commissioning!

(Fig. 31)

9.14

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Maintenance – Distortion (bending) of mower bladeholder, or if mower blade retainer pin (11) no longer sits straight in locating hole on disc.

(Fig. 32)

11 69051

32 – There is a gap between mower blade retainer pin (11) and locating hole (see arrow) on disc.

(Fig. 33)

11 69052

33 – There is abrasion to mower blade retainer pin (11).

VV

Wear limit: (Fig. 34)

11

69053

V = 13 mm

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

(Fig. 35)

35

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

9.15

Maintenance Bolted mower blades DISCO 8550: Danger!

Mower blades working loose present a high injury risk!

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

Do not weld or straighten!

• To replace blades, first clean seat of nut (15) and loosen nut with socket wrench.

15

• Fit the new blades with the cutting edge facing downwards.

• Alternatively, turn mower blade round, if second edge is still not used, and insert with sharp edge downwards.

• Refit bolt/nut (15).

Tightening torque of mower blade fastening bolt = 120 Nm. 72187

120 Nm

36

(Fig. 36)

68481R01

37 Note!

Mower blades are different for anticlockwise and clockwise discs. Pay attention to direction of rotation for fitting blades.

Arrow on mower blade must correspond to direction of rotation of the particular mower disc.

(Fig. 37)

9.16

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Maintenance

Attention!

Each time after slackening, secure nuts again using the single-component plastic adhesive DELO ML 5328 (Order No. 0201 802.1) or Loctite Typ 242 (Order No. 0666 285.0).

Fastening mower blades (bolted mower blades) The attachment parts of the mower blades must be checked before every use.

Attention!

Mower blades working loose present a high injury risk!

– Always ensure proper seating when installing the securing screws.

Mower blade replacement fastening bolts/nuts must meet the technical requirements specified by CLAAS, at the least. This is always guaranteed by using original CLAAS mower blades!

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

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

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

(Fig. 38) 38 – If the bolt shaft is worn from Dn = 18 mm to D = 15 mm.

(Fig. 39)

39

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

9.17

Maintenance The blade securing nuts must be replaced in the following cases: 16

– Spring contact washer (16) has lost its elastic properties or has become detached from nut.

– The nut is worn.

Wear limit:

a = H/2

(Fig. 40)

40

MOWER DISCS Danger!

Mower blades working loose present a high injury risk!

– Replace damaged mower blades, mower blade holders and mower discs! Do not weld or straighten!

Replacing cutting discs 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. 41) 41

9.18

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Maintenance The cutting discs are fastened to one flange each.

Up to Machine No.: 652 0 2307:

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

2 1

Tightening torques: Bolts (1) = 80 Nm Nut (2) = 380 Nm (Fig. 42, 43)

69058

42

From Machine No.: 652 0 2308:

2 1

69574

43

Mower disc cap 3

Attention!

Caps (4) fill up with material if lid (3) is missing or damaged. This could lead to an imbalance and severe consequential damage.

4

– Renew missing or damaged lids immediately.

44

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

(Fig. 44, 45)

5 45

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

9.19

Maintenance Fitting pinion units Seven pinion units A are fitted in mower head.

(Fig. 46, 47)

A

A

A

A

A

A

A

75220 46 A

6

7

47 Up to Machine No.: 652 0 2307

Up to Machine No.:

A 6

Notch (K) on pinion shaft (7) must align with hole (X) of flange (6).

X

(Fig. 47, 48)

K

7 69573

48

652 0 2307

From Machine No.: 652 0 2308

From Machine No.: 652 0 2308:

A

Notch (K) on pinion shaft (7) must point precisely at centre of marking countersink (X).

X

(Fig. 47, 49)

K

7 75305

9.20

49

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Maintenance SUSPENSION SPRINGS

1

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

If required, the suspension springs can be adjusted.

2

Quick setting of the spring length Sliding collar (1) can be set in three different plug positions. In the top position the weight relief is increased and in the bottom position the relief is reduced. Secure in position using spring clip (2).

66362

50

(Fig. 50) Caution!

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

Final setting of the spring length 3

To relieve threaded rod more (3), tighten spring further, and untighten threaded rod to relieve it less.

Basic setting for flotation springs X = approx. 50 mm.

(Fig. 51)

X 51

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

9.21

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

0.5-1 mm

(Fig. 52)

67332

52

Replace wiring loom for ejection sensors y2.2

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

y1.2

(Fig. 53-56)

y1.1 67344

53

y2.1 y3.2

y3.1

67343

54

R1

67349

9.22

55

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Maintenance

L1

67348

56

Setting the rotation sensors

M

Only for machines in versions UTYP 600, UTYP 620 and UTYP 630: 1

Front mower unit First set height of sensor (1).

4 mm

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

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

W 66992

57

(Fig. 57) Then set distance from sensor (1) to slip-on coupling (A) of universal drive shaft. This is done by moving sensor bracket (2) in slotted holes (L).

2 A

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

1

(Fig. 58)

2-4 mm 66992

58 Side mower units B

First set height of sensor (3).

K

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

4-5 mm

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

3

(Fig. 59) M 67332

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

59

9.23

Maintenance Then set distance between sensor (3) and clutch (K).

This is done by moving sensor bracket (4) in slotted holes (L).

4-5 mm

Distance between sensor (3) and clutch (K) should be 4 - 5 mm.

3

4

(Fig. 60)

K 67332

9.24

L 60

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

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

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

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

61

Note!

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

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

Example: The designation »2Q-02« signifies manufacture in the second quarter of 2002.

Hydraulic cylinder with vacuum valve 1 Danger!

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

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

69175 69175

62

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

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

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

(Fig. 62)

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

9.25

Maintenance SAFETY DEVICES Fold-away guard frames 1

Danger!

If disc units (1) are insufficiently pretensioned, there is the risk of an accident from side guard frames swinging down suddenly.

– Check pretensioning of disc units (1) regularly and adjust if necessary.

63 1

2

Pretension disc units (1) of side guard frames, enough for guard frames to stay up by themselves even under bad road conditions.

Tighten counter nuts (2) on disc units (1) well.

(Fig. 63, 64)

64

Sleeve protector After repair work to mower head drive, position of sleeve guard (3) must be checked and adjusted if necessary.

3

The winding drum (4) must in the dead centre of the sleeve protector (3). Between sleeve protector (3) and winding drum (4) an equal gap (X) must be set.

X

(Fig. 65, 66)

4 65

3 4

X

66

9.26

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Maintenance The holder (5) is used for setting. In order to do this, proceed as follows:

6

• slacken bolts (6), • move sleeve protector (3) as necessary; • retighten (6) bolts.

5 6

6

(Fig. 67) 3 67 Gap size (X) = 8 – 10 mm (Fig. 68)

3 4

X

68

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

9.27

Maintenance LUBRICATION OPENINGS For greasing tasks, remove plastic plug (1).

(Fig. 69)

1

SCREW CONNECTIONS After 10 operating hours, check all bolts and nuts throughout the machine and retighten.

Then check at regular intervals.

69

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

If necessary, replace the connecting elements by new ones.

END OF SEASON STORAGE 1. Clean the dirt from the mower unit.

2. Drain the oil from the angle gearbox and from the mower head and refill with new oil to the prescribed oil level.

3. Grease all the lubrication points thoroughly until the grease exudes from the bearings – see »Lubrication chart«, page 10.1.

Let the mower unit run for a short time.

4. Check the mower unit for wear and damage and repair if required.

5. Remove the V-belts and store in a dry location, de-tension the suspension springs.

6. Clean mower unit and all rust marks and repair any paint damage.

7. Store the mower unit in a dry, weather-protected room where no artificial manure is stored.

8. Store in working position.

9. Remove the control terminal from the mower unit and store in a weather-protected room at room temperature (approx. 18° C).

9.28

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Maintenance MALFUNCTIONS Problem

Vibration

Cause

– Plastic cover missing.

Remedy

• Immediately replace cap on cutting disc and plastic lid – see »Mower disc cap«, page 9.19

Poor adaptation to ground contours

– Feeder drum dirty.

• Clean the feeder drum.

– Wrongly adjusted frame.

• – see »Suspension springs«, page 9.21.

– Joints on mower head seized.

• Clean the links and lubricate

– Insufficient tension in the rubber spring

• Increase spring load – see

Wrong tilting angle of the mower head

– Upper link length wrongly adjusted.

• Turn the upper link out or in.

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

– Tilt of mower head not enough.

• Increase tilt of mower head

– PTO speed too low.

• Increase speed with light fod-

Safety cut-out responding too often

»Collision protection«, page 8.16.

– see »Setting the cutting height«, page 8.12 der.

– Ground speed too high.

– Blunt or damaged mower blades.

Stubble too high

Formation of stripes at transition between front and side mower units

• Change tilt of the mower head

– Spring relief set too strong

• Reduce spring relief.

– Beam inclined too much to the front

• Change tilt of the mower head

– Ground speed too slow.

• Reduce ground speed.

• Clean mower unit.

– Blunt mower blades.

– Speed too high with light fodder, too low with heavy fodder.

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

– see »Mower blades«, page 9.7.

– Wrongly adjusted tilt of the mower head.

– Build-up of dirt between the runners.

Fodder pushed forwards before being cut (creating stripes)

• Reduce ground speed.

• Replace mower blades

– Swirling effect of the mower blades in light crops.

by adjusting the upper link – see »Setting the cutting height«, page 8.12

by adjusting the upper link.

• Change mower blades.

• Correct the speed.

• Reduce p.t.o. speed and increase ground speed.

9.29

Maintenance Problem

Cause

Remedy

Swathe too small

– Crops growing too thickly.

• Remove the guide plates

Build-up of dirt in the front cutter area

– Very moist working conditions.

• Increase cutting height – see

– Mole hills

»Setting the cutting height«, page 8.12

• Fit wear slide runners.

• If necessary, lift mower unit up and down – Insufficient load relief for the machine.

Increased wear on cutting disc and mower blades

– Very difficult working conditions.

• Clean mower unit.

• Increase mower unit relief – see »Suspension springs«, page 9.21.

• Fit wear or high cut slide runners.

• Increase mower unit relief – see »Suspension springs«, page 9.21.

Increased wear on runners

– Stony, sandy ground

• Screw wear slide runners in position

• Increase mower unit relief – see »Suspension springs«, page 9.21.

– Runners not lying parallel to the ground.

• Adjust the runners flat to the ground (in the case of extreme high cut point wear of the runner)

Mower unit lifted into working position: Mower unit folds downwards so that the outer cutting disc is touching the ground.

– Ground speed too high over uneven ground, extreme jolting.

Build up of piles in the swathe

– Light and wet crops.

• Swing the mower head up slightly (approx. 10 - 20o).

• Reduce spring loading – see »Suspension springs«, page 9.21.

– Sloping ground

• Mount an additional conveyer hat.

• Reduce ground speed.

Plugs on the swathe plate

– Strong crops

• Remove swathe plate.

– Wrong mounting of the swathe plate.

Winding of the outer conveyer drum

9.30

– Strong and flattened crops.

• Check rotational speed, increase if necessary.

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Maintenance Problem

Side mower units lifting unevenly

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

Cause

– Lifting sensors are set at different levels.

Remedy

• Correct the position of the lifting sensors – see »Setting the lift sensors«, page 9.22.

9.31

Lubrication chart

Lubrication chart

10 Lubrication chart SAFETY RULES Danger!

Lubrication of the mower unit only when the tractor engine is at a standstill.

– Remove the ignition key!

LUBRICANTS Trademarked lubrication grease e. g.

FINA

“Marson EPL 2”

ARAL

“Aralub HLP 2”

FUCHS “Rendit TEP 2” SHELL

“Retinax EP 2” or “Alvania G3”

DEA

“Glisando EP”

FAG

“Arcanol L 135 V”

SKF

“LGEP2”

Trademarked gearbox oil SAE90 - API GL 4

LUBRICATION

Lubricate these grease points every 20 working hours.

Lubricate these grease points every 100 working hours.

Lubricate these grease points every 250 working hours.

10.1

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Lubrication chart

Lubrication chart

2 6 4

3

5

1

1

2

3

4

5

6

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

10.2

Lubrication chart

9 8

7

7

9

10

8

9

10

10.3

ZBA+BA DISCO 8550 Plus / 8550 - 0294 181.1

Lubrication chart

11

11

12

11

12

0294 181.1 - ZBA+BA DISCO 8550 Plus / 8550

10.4

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

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

Technical 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

0294 181.1 ZBA+BA DISCO 8550 Plus / 8550 EN - 07.06 Printed in Germany