Claas DISCO 8700 C Plus DISCO 8700 C JAGUAR 8700 / 900 - 820 MODEL 492 / 491 Operator’s Manual - PDF

DISCO 8700 C Plus DISCO 8700 C

JAGUAR 8700 / 900 - 820 MODEL 492 / 491

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 - Model 654 »DISCO 8700 C Plus / 8700 C« to which this declaration refers corresponds to the pertinent basic safety and health requirements of EC Directive 98/37/EEC, Appendix 1 and to the requirements of the other pertinent EC Directives.

-/-

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

EN 745 - August 1999

Bad Saulgau, 04.07.2006 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 mower unit will always produce good results.

This operator's manual applies to Disc mower: DISCO 8700 C Plus / 8700 C from serial no. 654 0 1001

Your CLAAS Service Department

ROAD TRAFFIC Legal requirements for driving on public roads General operating permit (ABE) The operating permit for the self-propelled forage harvester is invalidated as a consequence of fitting the "DISCO 8700 C PLUS / DISCO 8700 C" mower unit.

For this reason, application for a renewed operating permit should be made to your administration centre (licensing office), accompanied by a new certificate regarding the regulatory condition of the self-propelled forage harvester.

Driving on public roads When travelling on public roads, the applicable road traffic regulations must be observed.

For further information: – see »Prior to transportation«, page 6.19 and »Driving on public roads«, page 6.20.

1.1

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Contents

Contents

2 Contents 1. Introduction Introduction ............................................................................... 1.1 Road traffic ............................................................................... 1.1 Legal requirements for driving on public roads ................... 1.1 General operating permit (ABE) ......................................... 1.1 Driving on public roads ....................................................... 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 6. Prior to Operation Check and observe the following before putting into operation! 6.1 Adaptations to the forage harvester .......................................... 6.2 Conversion steps ................................................................ 6.2 Additional weights ............................................................... 6.2 Lighting ............................................................................... 6.3 Attachment to the tractor ........................................................... 6.4 Fitting the mounting frame .................................................. 6.4 Hydraulic system ................................................................ 6.6 Universal drive shaft ........................................................... 6.7 Electrical system ................................................................. 6.8 Driving lights ..................................................................... 6.11 Lowering speed ................................................................ 6.11 Adjusting the lowering speed of the mower unit suspension ....................................................................... 6.12 Increasing the lifting speed ............................................... 6.13 Safety devices .................................................................. 6.14 Suspension springs .......................................................... 6.15 Restricting the ground contour tracking (side mower units) ............................................................ 6.15 Checking the position of the upper link ............................. 6.16 Transport stop .................................................................. 6.16 Removing the machine ..................................................... 6.16 Removing the middle mower unit ..................................... 6.18 Prior to transportation ............................................................. 6.19 Driving on public roads ..................................................... 6.20 Reinstating .............................................................................. 6.21 Reinstating JAGUAR 900 / 890 / 870 / 850 / 830 ............. 6.21

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

Reinstating restrictors ......................................................

Reinstating the central electrics .......................................

Reinstating JAGUAR 880 / 860 / 840 / 820 ......................

Reinstating the hydraulic control ......................................

Reinstating the central electrics .......................................

Reinstating the pressure accumulators ............................

Reinstating the central lubrication ....................................

Miscellaneous ..................................................................

6.22 6.22 6.24 6.25 6.25 6.26 6.27 6.27

7. Operation Operation of JAGUAR 8700 / 900 / 890 / 870 / 850 / 830 ........ 7.1 Multifunction lever .............................................................. 7.1 Control terminal .................................................................. 7.2 Working position ................................................................. 7.3 Adjusting mower unit relief ................................................. 7.5 Setting the cutting height .................................................... 7.8 Changing the swath width ................................................ 7.10 Conditioner ....................................................................... 7.12 Baffle plates ..................................................................... 7.12 Changing the speed ......................................................... 7.12 Collision protection ........................................................... 7.13 Rotation monitoring .......................................................... 7.14 Mowing ............................................................................. 7.16 Recommendations for environmental protection .............. 7.17 Transport position ............................................................ 7.20 Emergency functions ........................................................ 7.23 Operating the JAGUAR 880 / 860 / 840 / 820 ........................ 7.25 Multifunction lever ............................................................ 7.25 Control terminal ................................................................ 7.26 Working position ............................................................... 7.27 Adjusting mower unit relief ............................................... 7.29 Setting the cutting height .................................................. 7.32 Changing the swath width ................................................ 7.34 Conditioner ....................................................................... 7.36 Baffle plates ..................................................................... 7.36 Changing the speed ......................................................... 7.36 Collision protection ........................................................... 7.37 Rotation monitoring .......................................................... 7.38 Mowing ............................................................................. 7.40 Recommendations for environmental protection .............. 7.42 Transport position ............................................................ 7.44 Emergency functions ........................................................ 7.47 Optional equipment ................................................................ 7.49 High cutting runners ......................................................... 7.49 Push-on runners ............................................................... 7.49

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

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

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

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

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

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

Drives .......................................................................................

Tensioning the drive belts (main gearbox) .........................

Tensioning the drive belt (Conditioner) ..............................

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

Drive diagram .....................................................................

Mounting frame ..................................................................

8.1 8.1 8.1 8.1 8.1 8.2 8.3 8.3 8.4 8.5 8.5 8.5

2.1

Contents Middle mower unit ............................................................... 8.6 Side mower units ................................................................ 8.7 Mower head ........................................................................ 8.8 Universal drive shaft ............................................................... 8.10 Clutches .................................................................................. 8.11 Maintenance of the plate clutch ........................................ 8.11 Torques ............................................................................. 8.12 Mower blades .......................................................................... 8.13 Mower blade box .............................................................. 8.14 Change mower blades. ..................................................... 8.15 Mower blade quick-change system .................................. 8.16 Mower blade holder (Mower-blade quick-change system) 8.19 Bolted mower blades ........................................................ 8.21 Fastening mower blades (bolted mower blades) .............. 8.21 Mower discs ............................................................................ 8.23 Replacing cutting discs ..................................................... 8.23 Mower disc cap ................................................................. 8.24 Fitting pinion units ............................................................. 8.25 Spring adjustment ................................................................... 8.27 Ground contour following (middle mower unit) ................. 8.27 Conditioner tines ..................................................................... 8.27 Fitting/removing tines ........................................................ 8.27 Electrical system ..................................................................... 8.28 Setting the rotation sensors .............................................. 8.28 Hydraulic system ..................................................................... 8.29 Hydraulic hoses ................................................................ 8.29 Hydraulic cylinder with vacuum valve ............................... 8.29 Pressure accumulators ..................................................... 8.30 Adjusting the safety pressure limiting valve ...................... 8.31 Safety devices ......................................................................... 8.32 Fold-away guard frames ................................................... 8.32 Sleeve protector ................................................................ 8.32 Lubrication openings ............................................................... 8.34 Screw connections .................................................................. 8.34 Connecting elements .............................................................. 8.34 End of season storage ............................................................ 8.34 Malfunctions ............................................................................ 8.35

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

2.2

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

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.

1

67681

1

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).

1

67680

2

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

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

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

IDENTIFICATION PLATE 1

Please provide the machine number (Fz-Ident-Nr.) (2) with all orders for replacement parts and technical queries.

67682

3

This is necessary to ensure that the correct replacement parts are delivered.

The identification plate (1) with the machine number (Fz-Ident-Nr.) (2) for the complete mower unit is attached to the side gearboxes.

1

(Fig. 1, 4) 654

020

A02 65401001

0570 2

4

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

3.1

Safety Rules

Safety Rules

4 Safety Rules

Attention!

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

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

INTENDED USE

– Measures to prevent damage to the machine.

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

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

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

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

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

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

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

Note!

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

Environment!

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

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

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

GENERAL SAFETY AND ACCIDENT PREVENTION INSTRUCTIONS

IDENTIFICATION OF WARNING AND DANGER SIGNS

Basic rule:

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

General:

Danger!

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

– Preventive measures.

Check the machine and the forage harvester for road and operational safety each time before using!

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

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Safety Rules Safe operation of the mower unit is only possible through appropriate use of the cutting blades according to directions. The special tools supplied must be used for assembly.

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

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 harvester and the 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.

Keep the machine clean to prevent fire!

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

Ensure that you have an adequate view!

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

Always connect the 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!

Take special care when hitching and unhitching the machine to and from the harvester!

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!

Special care is required when working near roads and buildings!

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

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.

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

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

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

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

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

4.2

Safety Rules Secure the machine before leaving the harvester!

Lower mounted attachments fully to the ground!

Switch off the engine and remove the ignition key.

Never let anyone stand between the harvester 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 harvester 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 harvester and machine when operating the remote control unit for the 3-point linkage!

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!

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

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 harvester!

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

4.3

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 harvester'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!

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

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

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

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 carrying out arc welding work on the harvester 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 175.2 - BA DISCO 8700 C Plus / 8700 C

4.4

Safety Rules

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

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

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

The figure in ( ) refers to the adjacent picture and indicates the correct location of the decal on the machine.

Safety decals that are damaged or cannot be 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

63848

1

2 Safety decals 0514 946.1 (1) Before putting the machine into operation, read the operator's manual and follow the safety precautions.

(Fig. 1, 2)

4.5

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Safety Rules

2

63848

3

4 Safety decals 0514 895.1(2) Before carrying out maintenance and repair work switch off engine and remove ignition key.

(Fig. 3, 4)

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

4.6

Safety Rules

3

63849

5

8 Safety decals 0516 039.0 (3) Do not open or remove the safety guard with the engine running.

3

(Fig. 5-8)

63849

6

3

65580

4.7

7

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Safety Rules

4

11 Safety decals 0514 842.0 (4) 65580

9

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

(Fig. 9-11)

4

65584

10

5

65583

12

13 Safety decals 0516 038.0 (5) Do not put hands in the trapping danger area while the parts are still moving.

(Fig. 12, 13)

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

4.8

Safety Rules

6

15 Safety decals 0514 887.0 (6) 65582

14

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

(Fig. 14, 15)

7 67679

16

17 Safety decals 0514 825.0 (7) Maintain your distance when the engine is running.

(Fig. 16, 17)

4.9

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Safety Rules

8 67679

18

STOP 19 Safety decals 0514 744.1 (8) Do not touch moving machine parts. Wait until they have come to a complete standstill.

(Fig. 18, 19)

9 67679

20

21 Safety decals 0514 821.0 (9) Maintain sufficient distance from the blades when the engine is running.

(Fig. 20, 21)

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

4.10

Specifications

Specifications

5 Specifications Note!

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

DISCO 8700 C Plus DISCO 8700 Transport width

mm

3000

Working width

mm

8500

P.T.O. speed

rpm

approx. 1130

Cutting disc speed

rpm

approx. 3200

Conditioner speed - middle mower unit

rpm

900

Conditioner speed - side mower units

rpm

950

metres/second

87

mm

40

kg

3800

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

5.1

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Prior to Operation

Prior to Operation

6 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. Only turn on the harvester PTO at idling speed.

8. Do not exceed disc mower's permitted PTO shaft speed.

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 guard 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.

Caution!

Always lower the mower unit to the ground when the harvester and attached mower unit is stopped.

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

6.1

Prior to Operation ADAPTATIONS TO THE FORAGE HARVESTER Conversion steps The DISCO 8700 C PLUS / DISCO 8700 C mower unit is intended for operation with Model 492 and Model 491 forage harvesters.

The following measures must be carried out on the forage harvester before fitting the DISCO 8700 C PLUS / DISCO 8700 C:

• • • •

Remove the feeder housing Remove the corn cracker Replace the lifting cylinder Modify the lubrication interval of the central lubrication system

• Reposition the electric cable harness • Connect the operating terminal • Connect the multifunction lever A detailed description of the conversion measures can be found in the fitting instructions.

Additional weights Additional weights must be fitted to the forage harvester to ensure adequate loading of the rear axle.

JAGUAR Model 491: JAGUAR 820 with four-wheel drive:

13 additional weights

JAGUAR 820 without four-wheel drive:

14 additional weights

JAGUAR 840, 860, 880 with four-wheel drive:

12 additional weights

JAGUAR 840, 860, 880 without four-wheel 13 additional weights drive: JAGUAR Model 491 Overdrive: with four-wheel drive:

13 additional weights

without four-wheel drive:

14 additional weights

JAGUAR Model 492 (40 km/h): with four-wheel drive:

12 additional weights

without four-wheel drive:

13 additional weights

JAGUAR Model 492 (20 km/h):

6.2

with four-wheel drive:

10 additional weights

without four-wheel drive:

11 additional weights

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Prior to Operation Ordering numbers: 4 additional weights 450 kg

S09 0030

7 additional weights 630 kg

S09 0045

12 additional weights 1332 kg

S09 0080

Lighting When driving on the road the headlamps are partially covered, with the result that additional headlamps are required on the cabin. Furthermore, additional flashing lights must be fitted at the sides.

Order number Upper headlamps and flashing lights

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

Q03 0020

6.3

Prior to Operation ATTACHMENT TO THE TRACTOR Fitting the mounting frame

1

Carefully drive the forage harvester up to the mounting frame. Insert the pivot bearings (2) of the mounting frame into the right and left hand receptacles (1).

2

(Fig. 1)

1 Using fitting bolts (3), fasten the pivot bearings (2).

(Fig. 2) 3

2

2 Pin the hydraulic cylinder (4) to the mounting frame on both sides with bolts (5). Secure the bolts on both sides with roll pins.

(Fig. 3) Connect the tank return line and the hydraulic hose.

4 5

3 Fit the power belt (6) for the drive to the v-belt pulley (7).

6

Re-tension the power belt (6) – see »Tensioning the drive belts (main gearbox)«, page 8.3.

(Fig. 4) Note!

The power belt must be aligned. Correct by means of the tapered bushing (8) if necessary.

7 8 4

Tightening torque of the fastening bolts = 170 Nm

6.4

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Prior to Operation Fit the v-belt guard (10) and safety covers (9) to both sides.

9

(Fig. 5)

10

5 JAGUAR 8700 / 900 / 890 / 870 / 850 / 830:

11

Fit linkage (11) in the upper hole (15) on the automatic lowering device. Fit the cut height indicator (12) into the upper hole (13).

13

12

14 JAGUAR 880 / 860 / 840 / 820: Fit linkage (11) in hole (16) on the automatic lowering device. Peg the cut height indicator (12) into the lower hole (14).

15 16

(Fig. 6) 6 Connect the central lubrication.

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

6.5

Prior to Operation Hydraulic system Connect both hydraulic hoses (2) on the mounting frame to the hydraulic couplings (1) on the forage harvester.

1

Pay attention to the "blue" and "red" markings.

(Fig. 7) 2 Caution!

7

Clean the hydraulic hose couplings and the oil connections each time before coupling.

Take care that the hydraulic hoses (2) are run in such a way that they are not damaged by the v-belt pulley.

(Fig. 8)

2

8

6.6

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Prior to Operation Universal drive shaft 1 Danger!

Never remove the safety devices (1) from the universal drive shaft!

Observe the recommendations of the drive shaft manufacturer.

2 9

On all three mower units, secure the drive shaft guards against moving by hooking on the anchoring chains (2).

(Fig. 9) Danger!

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

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

6.7

Prior to Operation Electrical system 1

Power supply for electro-hydraulic operation Connect the control cable plug to the socket (1) mounted on the forage harvester.

Connect the cable with the pressure switch (2) to the plug on the right hand inner panel.

(Fig. 10)

2 10 Hydraulic control - JAGUAR 880 / 860 / 840 / 820 Connect connectors (3) and (4) to connectors (5) and (6) of solenoid valves (1) and (2) (turret flap in/out).

1

To do this, remove existing connectors (5) and (6) from solenoid valves (1) and (2) (first pair from the right).

2 3

(Fig. 11) 4 5

6

11 Connect connectors (7) and (8) to solenoid valves (9) and (10) (raise/lower pickup hold down device).

7

To do this, remove the existing connectors from both solenoid valves (9) and (10) (third pair from top).

8

(Fig. 12)

10

9 12

6.8

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Prior to Operation Central electrics JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

M

(In this section, the item numbers in the pictures refer to the parts list in the fitting instructions.)

• Disconnect the connecting cable (J) for the multifunction lever from the circuit card (socket M).

J

(Fig. 13)

13

• Plug the connecting cable (J) for the multifunction lever into the control box (81).

J

(Fig. 14)

84

81

14

• Plug cable (84) into the circuit card (socket M).

M

(Fig. 15) 84

15

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

6.9

Prior to Operation Central electrics - JAGUAR 880 / 860 / 840 / 820 B

Open the central electrics unit in the driver's cab and switch around the following connectors.

3

• Unfasten the control unit (1) bracket.

• Remove connector (4) from cable link (B).

• Plug connector (4) of cable (3) into the control

1

unit.

• Re-fit the control unit.

(Fig. 16, 17, 18) 16 B

4

3 17

4

3

18

6.10

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Prior to Operation Driving lights Plug the 7-way connector (1) for the driving lights into the socket provided on the forage harvester.

(Fig. 19) 1

19

Lowering speed 1

Adjusting the lowering speed JAGUAR 8700 / 900 / 890 / 870 / 850 / 830: First, the shift linkage (1) of the front attachment change-over valve must be switched to position (S).

Position (S) = heavy front attachment S

L

Position (L) = light front attachment (Fig. 20) 20 The lowering speed of the mower unit can be set by adjusting knurled screw (2) on the flow divider. Check or set the lowering speed with the hydraulic oil at operating temperature so that the mower unit drops to the ground from a fully-raised position in approx. 5 to 6 seconds.

Lowering speed: 2

Faster = Turn knurled screw (2) in Slower = Turn knurled screw (2) out 21

Should the side mower units hit the ground too soon (too quickly) during the lowering procedure, the lowering speed must be reduced again.

(Fig. 21) For further information - see the forage harvester operating instructions.

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

6.11

Prior to Operation Adjusting the lowering speed - JAGUAR 880 / 860 / 840 / 820: The lowering speed of the mower unit can be set at the throttle (1) on the 3/3 solenoid valve. Check or set the lowering speed with the hydraulic oil at operating temperature so that the mower unit drops to the ground from a fully-raised position in approx. 5 to 6 seconds.

Basic settings: 1

67444

22

Lower the attached mower unit until it touches the ground and fully relieve the mower unit hydraulic cylinders.

First turn throttle (1) in to the end stop and then turn it back out by 1 3/4 turns.

Lowering speed: Faster = turn throttle (1) out Slower = turn throttle (1) in Should the side mower units hit the ground too soon (quickly) during the lowering procedure, the lowering speed must be reduced again.

(Fig. 22) For further information - see the forage harvester operating instructions.

Adjusting the lowering speed of the mower unit suspension The lowering speed is factory-set and can be changed by means of the adjustable throttle (1). To do this, release the lock nut. Turn the socket head cap screw in or out with an Allen key. Tighten the lock nut again.

Increase lowering speed = Turn cap screw out Reduce lowering speed = Turn cap screw in 23

(Fig. 23, 24)

1

24

6.12

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Prior to Operation Increasing the lifting speed 1

JAGUAR 880 / 860 / 840 / 820: 2

3 Danger!

Take particular care when working with pressure accumulators! Pressure accumulators are under high pressure! Assembly and repair work to the hydraulic system with pressure accumulator may only be carried out after releasing the fluid pressure.

68288

25 In order to increase the lifting speed of the complete mower unit (forage harvester lifting cylinder), pressure accumulators (1), (2) and (3) on the forage harvester can be removed. After removal, close the openings with screw plugs (4) (CLAAS ordering no.: 0213 101.0).

4

4

4

(Fig. 25, 26)

Note!

68289

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

26

Conversion work on the pressure accumulators may only be carried out by CLAAS specialist workshops.

6.13

Prior to Operation Safety devices Before driving into the forage, fold down the safety guards (1) on all mower units.

1

(Fig. 27)

67261

27 Remove the safety guards from the spike drums (3) on the side mower units.

Fold down the protective guard (2) of the conditioners on the side mower units.

2

(Fig. 28)

3

67671

Danger!

28

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.

6.14

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Prior to Operation Suspension springs Middle mower unit The springs controlling the tracking of ground contours lengthwise must be tensioned so that the distance between the washer and the end of the thread is X = 40 mm.

X

(Fig. 29)

29 Side mower units The springs (1) controlling the tracking of ground contours must be tensioned so that the side mower units are pushed inwards and upwards when in the raised state.

X

Basic setting of dimension X = 40 - 45 mm 1 Do not adjust the springs (1) too tightly, as the contour-tracking of the side mower units cannot be guaranteed otherwise.

30

(Fig. 30)

Restricting the ground contour tracking (side mower units) The end stops (1) and (2) must be adjusted so that the universal drive shaft (4) has sufficient clearance above and below the main frame (3) in all possible positions.

(Fig. 31, 32)

Basic settings:

2

1

End stop (1) inner = 2 washers 31

End stop (2) outer = 2 washers

3

4 32

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

6.15

Prior to Operation Checking the position of the upper link

X 1

Fit the upper link (2) in the upper hole of the quick-release coupler (1).

2

Caution!

Adjust the upper link (2) so that the quick-release coupler (1) is standing roughly vertically.

67262

33

Pre-adjustment: X = 800 mm (Fig. 33)

Transport stop If the side mower units knock together when the mower unit is folded up, the number of shims (3) can be increased.

(Fig. 34) 3 The shims can be ordered from the CLAAS replacement parts service.

CLAAS ordering no.: 0933 464.0 66533

34

Removing the machine Caution!

Only park the mower unit in the transport position on firm, level ground.

2

• Push the prop stands (1) on the right and left from

1

below into the holes and secure with spring clips (2) (Fig. 35).

66584

35

• Lower the mower unit in the transport position on to level ground.

• Disconnect the hydraulic hoses at the quick-release couplings and remove all electrical cables.

6.16

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Prior to Operation • Unscrew the safety cover (3) and the belt guard (4) (Fig. 36).

3

4

65635

36

• Release the belt tension and remove the power belt (5) (Fig. 37).

5

63716

37

• Detach the hydraulic cylinder (6) on both sides at the bolt (7) (Fig. 38).

6 7 67269

38

• Unscrew the fitting bolts (8) for the pivot bearings on each side (Fig. 39).

8

63714

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

39

6.17

Prior to Operation • Remove the cut height indicator (9) (Fig. 40).

• Carefully drive the forage harvester off in reverse.

9

67670

40

Removing the middle mower unit The middle mower unit can be attached separately in front of any tractor with front hydraulics.

Swing the mower unit into the working position and lower it to the ground.

To attach and detach the middle mower unit, the latch (1) must be folded in (Fig. 41).

1

Uncouple the universal drive shaft.

63854

41 Detach the arms (4) from under the headstock and the upper link (2) from above.

2

Remove the plug (3) for the speed monitoring.

(Fig. 42)

3

4 67262

6.18

42

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

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

2. Connect the hydraulic hoses and electrical cables.

1

2

3. JAGUAR 8700 / 900 / 890 / 870 / 850 / 830: Fit the cut height indicator (1) into the upper hole (2) (Fig. 43).

3

JAGUAR 880 / 860 / 840 / 820: Fit the cut height indicator (1) into the lower hole (3) (Fig. 43).

67670

43 4. Swing the safety guards (4) up (Fig. 44, 45).

5. Fold the side mower units together and lower the middle mower unit on to the side mower units.

4

67264

44

4 4

67674

45 6. Fold up the protective guards (5) of the conditioners on the side mower units.

Cover the spiked drums of the side mower units with the safety guards (6) (Fig. 46).

5

6

67671

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

46

6.19

Prior to Operation 7. When driving on the roads, hitch the safety chain (7) on to the side mower units. The safety chain (7) serves simultaneously as a restraint for the side mower units (Fig. 47).

8. Check the mower unit for roadworthiness and operational safety.

Caution!

7 Maintain a sufficient distance between the middle mower unit and the windscreen of the cab.

67675

47

Maintain a sufficient distance between the mower unit and the ground.

Ensure adequate vision when driving. If the field of vision is restricted by the mower unit, a person to direct at road crossings and openings will be required.

Driving on public roads When driving on public roads, observe the relevant road traffic regulations.

Do not exceed the technically permissible axle loads and total weight.

If the distance between the rear edge of the harvester's steered wheel and the front edge of the mower unit is more than 3.5 m, the restrictions in field of vision which arise when exiting yards, or at road crossings and openings, must be compensated, if need be, by suitable operational measures such as someone to direct.

Side lights / warning signs Side lights and warning signs must be attached facing forwards in accordance with regulations.

Adaptations to the forage harvester For further information: – see »Additional weights« on page 6.2 and »Lighting«, page 6.3.

6.20

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Prior to Operation

Prior to Operation REINSTATING Reinstating JAGUAR 900 / 890 / 870 / 850 / 830

48

(In this section, the item numbers in the pictures refer to the parts list in the fitting instructions.)

T

Unscrew the hydraulic hoses (H), (48) and (67) from the right-hand lifting cylinder (66).

Unscrew the T-piece (T) for fitting to the old hydraulic cylinder.

67

H

Close off the feed line (48) to the pressure switch.

66

67294

48

Remove the right-hand hydraulic cylinder (66).

Fit the old hydraulic cylinder on the right and connect.

(Fig. 48)

T S

Unscrew hoses (S) and (H) from the left-hand hydraulic cylinder and remove T-piece (T) for use on the old hydraulic cylinder.

66

Remove the left-hand hydraulic cylinder (66).

Fit the old hydraulic cylinder on the left and connect.

H

(Fig. 49) 67298

49 The tank return line (49) can remain on the valve block under the left-hand side cladding.

49

67299

(Fig. 50)

50 Separate the hydraulic line (H) from the mower unit, from the tank return line (49).

H

Close off the tank return line.

(Fig. 51)

49

67300

51

R

492 CONTROL TERMINAL

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

6.21

Prior to Operation Reinstating restrictors Exchange restrictor (36) on the small accumulator for the old restrictor.

36

Unfasten coupling (V) and screw out.

Remove restrictor (36); insert the old restrictor with the correct orientation.

The open end of the restrictor must point to the coupling, see Fig. 54.

67700

52

Note!

Incorrect orientation will cause malfunctions.

V Screw in coupling (V) again and tighten.

(Fig. 52, 53, 54)

67701

53

36

67723

54 Reinstating the central electrics Open the central electrics unit in the driver's cab and switch around the following connectors / modules:

61

1. Remove cable link (61) from "FD" and plug connector (FD) directly into the circuit card again.

(Fig. 55)

67718

FD

55

R

492 CONTROL TERMINAL

6.22

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

Prior to Operation 2. ESR module (A): If it was necessary to exchange the ESR module to operate the DISCO 8700 C Plus / 8700 C, the original ESR module will have to be refitted for normal forage harvester operation.

A

B 68287

Original ESR module (original state)

ESR module for operation with DISCO 8700

Exchange required?

014 213.0

014 243.0

yes

014 213.1

014 243.0

yes

014 213.2

014 243.0

yes

014 213.3 (*)

014 213.3 (*)

no

014 233.0

014 243.0

yes

014 233.1 (*)

014 233.1 (*)

no

014 243.0 (*)

014 243.0 (*)

no

56

84 J

(*) and higher suffix 67759

57 Note!

This work is not required on machines from serial No. 492 0 2315.

M

(Fig. 56)

3. CAC module (B): 84

The new CAC module 014 234.1 can remain in the machine.

(Fig. 56)

67715

58 4. Unplug the connector (J) for the multifunction lever from the control unit.

M

Unplug cable (84) from the circuit card (socket M).

Plug connector (J) directly into the circuit card (socket M) again.

J

67713

(Fig. 57, 58, 59)

59

R

492 CONTROL TERMINAL

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

6.23

Prior to Operation

Prior to Operation Reinstating JAGUAR 880 / 860 / 840 / 820 (In this section, the item numbers in the pictures refer to the parts list in the fitting instructions.)

Unscrew the hydraulic hoses (H) and (76) from the right-hand lifting cylinder (66).

Close off the feed line (76) to the pressure switch.

76

Remove the right-hand hydraulic cylinder (66).

(Fig. 60)

H

Unscrew the hydraulic hose at the left-hand hydraulic cylinder.

Fit the old hydraulic cylinders on the left and right hand sides and connect the hydraulic hoses.

66

67305

60 The tank return line (49) can remain on the valve block under the left-hand side cladding.

(Fig. 61)

49

67159

61 Separate the hydraulic line (H) from the mower unit, from the tank return line (49).

Close off the tank return line.

49

(Fig. 62)

H

67300

62

491 CONTROL TERMINAL

6.24

JAGUAR 880 / 860 / 840 / 820

Prior to Operation Reinstating the hydraulic control Disconnect the cable extension (93) at the valve block at the rear of the machine.

V

Plug the snap-on connections (S) back on to the control valves (V).

(Fig. 63)

93 S

67760

63

K

Remove the cable extension (93) at the valve block on the left side behind the driver's cab.

K

Insert the old connectors (K) again.

(Fig. 64)

93

93

67761

64 Reinstating the central electrics B

Open the central electrics unit in the driver's cab and switch around the following connectors.

Unfasten the control unit (59) bracket.

Remove the connectors from the control unit and plug them into the connectors for cable (85) on the cable link (B) attached to cable (85).

59

85

Re-fit the control unit.

(Fig. 65, 66)

67750

65

B

67706

66

491 CONTROL TERMINAL

JAGUAR 880 / 860 / 840 / 820

6.25

Prior to Operation Reinstating the pressure accumulators Danger!

Take particular care when working with pressure accumulators! Pressure accumulators are under high pressure! Assembly and repair work to the hydraulic system with pressure accumulator may only be carried out after releasing the fluid pressure.

68289

67

When operating front attachments with Autocontour (e.g. PICKUP), the removed pressure accumulators must be reinstalled.

(Fig. 67, 68)

Note!

Conversion work on the pressure accumulators may only be carried out by CLAAS specialist workshops.

68288

68

491 CONTROL TERMINAL

6.26

JAGUAR 880 / 860 / 840 / 820

Prior to Operation

Prior to Operation Reinstating the central lubrication If the connecting plugs of the central lubrication have been exchanged, it will be necessary to refit the old screw connections.

D

If the lubrication interval has been adjusted, it will have to be reset to the old setting. To do this, turn the left-hand rotary switch (blue) (D).

(Fig. 69)

66581

69

Miscellaneous Additional weights Remove the additional weights which were fitted to ensure adequate loading of the rear axle.

Feeder housing Refit the feeder housing (see Assembly Manual).

Cut height indicator Realign the cut height indicator according to the front attachment that has been fitted (see Assembly Manual).

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

6.27

Operation

Operation

7 Operation OPERATION OF JAGUAR 8700 / 900 / 890 / 870 / 850 / 830 Multifunction lever

5 2 R

10 1

3

9 4 6

8

(4) or (2) + (7)

– Swing the mower unit into the working position.

(2)

– Swing the mower unit into the transport position

(1)

– Raise left mower unit

(1) + (7)

– Lower left mower unit

(2)

– Raise middle mower unit

(2) + (7)

– Lower middle mower unit

(3)

– Raise right mower unit

(3) + (7)

– Lower right mower unit

(5)

– Increase mower unit relief – Raise all three mower units

(6)

– Reduce mower unit relief – Lower all three mower units

67236C

1

(8)

– Raise mower unit (headland)

(9)

– Lower mower unit

(10)

– Lower mower unit (headland)

The following functions must be selected from the operating terminal (– see »Control terminal«, page 7.2): - Switch control system on/off (actuate for approx. 1.5 seconds).

- Set down middle mower unit on the side units which have been swung together.

7

- Adjust mower unit relief.

67234C

2

R

492 CONTROL TERMINAL

7.1

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

Operation Control terminal - Switch control system on/off (actuate for approx. 1.5 seconds).

- Swing mower unit into working position - lower middle mower unit - Fold mower unit together

- Set down middle mower unit on the side units which have been swung together.

- Raise middle mower unit - Raise left mower unit CONTROL TERMINAL

3

- Lower left mower unit

- Raise right mower unit

- Lower right mower unit

- Adjust mower unit relief.

- Reduce mower unit relief - lower all three mower units - Increase mower unit relief - raise all three mower units The check lamp lights up if a universal drive shaft coupling is stalled. A 'beep' sounds. Raise the relevant mower unit immediately and turn the mower units off. Remove blockage.

R

492 CONTROL TERMINAL

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

7.2

Operation Working position Caution!

Raise the mower unit before swinging it into the working position!

Switch on control system (hold down for approx. 1.5 seconds).

4

Remove the safety chain (1) and stow it on the holder (2). Hitch hook (4) in the eyelet (3) (Fig. 5, 6).

Raise the mower unit with the hydraulics.

R

1

2 Swing the mower units apart.

5 or

R

3

4

2

66535

The middle mower unit lifts first. Then the side mower units swing apart and the middle mower unit is lowered.

6

Lower the mower unit with the hydraulics.

R

(Fig. 4)

R

492 CONTROL TERMINAL

7.3

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

Operation Raise or lower the mower unit with the hydraulics sufficiently that the mounting frame (5) and the swivel support (6) are lying approximately horizontally.

5

(Fig. 7, 8)

Program the preset cutting height control for this position (see JAGUAR operator's manual ).

67673

7

6

67672

8 The cutter bars can be moved both along and transversely to the direction of travel. In normal operation, turn out the latch (7).

(Fig. 9)

7

The latch (7) is only turned in for high cutting.

(Fig. 10) 63855

9

Afterwards, lower the mower units to the ground.

Caution!

Move the guards into the working position – see »Safety devices«, page 6.14.

7

63854

10

R

492 CONTROL TERMINAL

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

7.4

Operation Adjusting mower unit relief The basic setting for the mower unit relief is 55 bar.

Depending on the operating conditions and the ground conditions, the relief pressure can be varied in the range from 40 to 70 bar.

70 55 40

(Fig. 12)

11 To adjust the mower unit relief, observe the pressure gauge (1) on the mounting frame.

(Fig. 12)

Adjust the relief on the three mower units by using these buttons on the operating terminal.

1

65683

12 - Increase mower unit relief - Raise all three mower units (Fig. 13) or

R

13 - Reduce mower unit relief - Lower all three mower units (Fig. 14) or

R

14

R

492 CONTROL TERMINAL

7.5

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

Operation The relief on each mower unit can be corrected individually, as required.

Raise left mower unit (Fig. 15) or

R

15 Lower left mower unit (Fig. 16) or

R

+

67234C

16 Raise right mower unit (Fig. 17) or

R

17 Lower right mower unit (Fig. 18) or

R

+

67234C

18

R

492 CONTROL TERMINAL

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

7.6

Operation Raise middle mower unit (Fig. 19) or

R

19 Lower middle mower unit (Fig. 20) or

R

20

R

492 CONTROL TERMINAL

7.7

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

Operation Setting the cutting height The cutting height can be adjusted by altering the angle of tilt (Z) of the cutter bar (Fig. 21).

Middle mower unit High cut: Latch (1) must be turned in for this. The bar can no longer tilt downwards, with the result that a greater cut height is achieved (Fig. 22).

21

2

Shorten the upper link (3) until the desired cut height is attained (Fig. 23).

Low cut: Latch (1) must be turned out for this (Fig. 22). Increase the tension on springs (2). Lengthen the upper link (3) until the desired cut height is attained (Fig. 23).

1

Reduction of the cut height below the default height (40 mm) is not possible. In most applications, however, it is possible to mow with the default cut height.

The latch must then be turned out.

63854

22 Caution!

3

A cut height that is too low causes heavy wear to the cutting discs and mower blades.

Danger!

67262

23

With extremely uneven ground conditions, turn in the latch and reduce the angle of tilt (Z) of the mower unit. This leads to a greater cut height and reduces the risk of throwing out foreign objects (Fig. 21).

R

492 CONTROL TERMINAL

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

7.8

Operation Side mower units Adjust the cut height as required, using the spindle (4) (Fig. 24).

4 Note!

6 66525

Make the same setting on both sides! There is an adjustment aid (5) located on the side of the spring; using the notches it is possible to read off the setting at the rear edge of the U-bracket (6).

5 24

Caution!

A cut height that is too low causes heavy wear to the cutting discs and mower blades.

Danger!

With extremely uneven ground conditions, reduce the angle of tilt (Z) of the side mower units. This leads to a greater cut height and reduces the risk of throwing out foreign objects (Fig. 21).

R

492 CONTROL TERMINAL

7.9

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

Operation Changing the swath width Middle mower unit

1

The width of the swath can varied by adjusting the swath plates (1). To do this, unfasten the spring clip (2), reposition the swath plate and push the clip back in again.

2

If the swath width is insufficient, remove the swath plate (1).

(Fig. 25) 66524

25 Hitch the expander on to the bracket (3).

(Fig. 26)

3

65861

26

R

492 CONTROL TERMINAL

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

7.10

Operation Side mower units The width of the swath can be altered by altering the outer deflectors. To do this, loosen the star knob (4) and move the deflector (Fig. 27).

4 4

Basic settings: The slot in the cover flap (5) aligns with the slot in the deflectors (7) (Fig. 28, 29).

5

67676

On the left-hand side mower unit, the deflectors (6) are fitted in holes with the notch to the left (Fig. 28).

27

On the right-hand side mower unit, the deflectors (6) are fitted in holes with the notch to the right (Fig. 29).

6

67678

7

5

7

28

6

67677

7

5

7

29

R

492 CONTROL TERMINAL

7.11

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

Operation Conditioner Baffle plates

1

The baffle plates can be adjusted by lever (1).

If the lever is pulled to the rear, i.e. in the "+" direction, the effect of the conditioner is intensified. In the "-" direction it is diminished.

(Fig. 30)

63860

30 Changing the speed The belt pulleys on the drive can be changed to adjust the speed of the conditioner. First, release the tension from the drive belt and remove the belt guard.

The arrangement of the belt pulleys with respect to the conditioner speed is shown in Fig. 31.

64021

31

R

492 CONTROL TERMINAL

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

7.12

Operation Collision protection If an obstruction is encountered, the overload protection feature is actuated and the cutter bar can swing away to the rear (Fig. 32).

Turn off the mower unit and check for damage.

Put the mower unit back in its normal position (working position). or

R

32

Notes:

• If this button is pressed while the mower unit is sitting on the ground, the side mower units will swing once again into the normal position (working position).

• If the mower unit is first raised before this button is pushed, the middle mower unit is raised fully. After that, the side mower units swing into the normal position (working position) and the middle mower unit is lowered again.

Adjusting the collision protection The collision protection can be adjusted by means of knurled screws (1) and (2).

If the collision protection responds frequently, the knurled screws (1) and (2) can be readjusted. For each readjustment, the knurled screw must only be readjusted half a turn at a time.

1

2 Knurled screw (1) = collision protection for the left mower unit

67252

33

Knurled screw (2) = collision protection for the right mower unit (Fig. 33)

R

492 CONTROL TERMINAL

7.13

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

Operation Rotation monitoring Attention!

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

2 1

3

If fault is not cleared, clutches can be damaged!

Danger!

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

CONTROL TERMINAL

34

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

Control lamp (1) for speed sensor (6) Control lamp (2) for speed sensor (5) Control lamp (3) for speed sensor (4) (Fig. 34, 35)

Note!

4

5

6 35

The fault indication for faulty or wrongly-adjusted speed sensors differs between PTO speeds of less than 600 rpm, and speeds greater than 600 rpm.

Display when PTO speed is less than 600 rpm or PTO drive is turned 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.

R

492 CONTROL TERMINAL

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

7.14

Operation Display when PTO shaft speed is greater than 600 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!

When the PTO shaft speed passes through 600 rpm, an audible signal may sound briefly.

This is caused by speed sensor switch tolerances.

Switching off the audible signal : In order to interrupt the audible signal when the speed sensor is faulty, pull out connector (7) on all three speed sensors (Fig. 74). Replace the defective speed sensor.

7

(Fig. 36)

66994

36

R

492 CONTROL TERMINAL

7.15

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

Operation Mowing Note!

1

The accident prevention regulations of the Agricultural Employers' Liability Insurance Association must be observed at all times while operating.

2 Caution!

67671

37

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

• Prior to operation, all protective devices must be put in the protective position. On the side mower units, remove the safety guards (2) and swing the protective guards (1) downwards (Fig. 37).

• Take the prop stand (3) out of the hole and stow it in the harvester (Fig. 38).

• Before turning on the drive, lower the mower unit

3

to the ground outside the forage area.

66584

38

• Turn on the main drive (chopper drum drive).

Caution!

The main drive must only ever be turned on or off at the lower idle speed of the engine.

70 55 40

• Slowly run the engine up to the permitted speed.

• Only now drive into the forage.

• While mowing, the mower units should slide over

39

the ground with minimum pressure. If this ground pressure is too high, the mower units will have to be relieved – see »Adjusting mower unit relief«, page 7.5.

Check the relief pressure of the mower units (approx. 40 - 70 bar) during mowing by means of the three pressure gauges (4).

(Fig. 39, 40).

• 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).

4

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

65683

40

• It is not possible to mow in reverse with the mower unit. Raise the mower unit when reversing.

• Do not mow on rocky ground!

R

492 CONTROL TERMINAL

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

7.16

Operation • At the headland, raise the mower unit with the main lifting cylinders by pressing button (A) (Fig. 41).

B

R

A

41 Note!

With new versions of the JAGUAR Model 492 it is also possible to raise the mower units at the headland using button (B).

• When driving back into the crop, lower the mower units again with the main lifting cylinders (Fig. 42).

R

42

Caution!

Ear muffs should be worn when mowing with the cab windows or doors open.

Remove the ear muffs when driving on the road.

Danger!

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

For further information, see the Operator's Manual for the forage harvester.

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.

R

492 CONTROL TERMINAL

7.17

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

Operation

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. 43)

69018

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

(Fig. 44, 45)

69019

44

69020

45

R

492 CONTROL TERMINAL

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

7.18

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

(Fig. 46)

69021

46

R

492 CONTROL TERMINAL

7.19

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

Operation Transport position Caution!

Only carry out the changeover when the drive is at a standstill. Wait until the cutting discs and knives are completely motionless!

Caution!

47

Move the guards into the transport position (Fig. 48).

Raise the mower unit slightly with the hydraulics.

R

67261

48

Turn in the latch (1) on the middle mower unit (Fig. 49).

Swing the mower unit into the transport position (Fig. 47).

1 R

63854

or

49 The middle mower unit lifts first. Then the side mower units swing inwards.

Caution!

The side mower units must not be any more than 300 mm above the ground.

Correct the height of the side mower units if necessary.

R

492 CONTROL TERMINAL

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

7.20

Operation Raise left mower unit (Fig. 50). or

R

50 Lower left mower unit (Fig. 51) or

R

+

67234C

51 Raise right mower unit (Fig. 52) or

R

52 Lower right mower unit (Fig. 53) or

R

+

67234C

53

R

492 CONTROL TERMINAL

7.21

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

Operation The middle mower unit must be set down on the side mower units once they have been swung together (Fig. 54).

• Hold these two buttons down simultaneously.

• Set the mower units to the required height using 54

the hydraulics.

R

Caution!

Switch control system off (actuate for approx. 1.5 seconds).

When driving on the roads, hitch the safety chain (2) on to the side mower units. The safety chain (2) serves simultaneously as a restraint for the side mower units (Fig. 55).

2

67675

55

67674

56

R

492 CONTROL TERMINAL

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

7.22

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.

68290

57

The relevant valves can be actuated by pushing in with a pointed implement (see arrow Fig. 57). With older machines that have valves without holes for pushing through, and with valves M6, M7 and M8, a separate power supply (+ve and ground) must be fed to the respective valve in order to switch it manually (Fig. 59).

In order to supply oil to the individual cylinder, the multifunction lever or the buttons on the control terminal must be actuated.

In the event of a failure of all the functions on the multifunction lever / control terminal, open the central electrics unit, disconnect the multifunction lever from the black control unit and connect it in the original position (socket M) on the PCB in the central electrics unit (harvester operation) (see page 6.23).

1

67234

67234C

58

If the multifunction lever has been switched over, actuate button (1) on the lever for the oil supply (Fig. 58).

Note!

The multifunction lever does not need to be switched over if only a cable to the valve is faulty.

Danger!

When manually actuating the valves, turn off the drive!

Maintain an adequate distance from the moving parts!

Note!

Pay attention to the markings on the cables when exchanging cable sets (Fig. 59)!

R

492 CONTROL TERMINAL

7.23

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

Operation DS5

M1 M2 M3 M4 M5 M12 DS1 M8 M7 M6

DZWR

R

DZWL

DZWM L DS3 DS4 DS2

M11 M10 M9

59

Solenoid valve

Function

Solenoid valve

Function

Raise middle mower unit

M1 + M2

Swing in left mower unit

M4 +

Lower middle mower unit

M1 + M2

M4 +

Swing out left mower unit

Raise left mower unit

M1 + M2

Swing in right mower unit

Lower left mower unit

M1 + M2

Swing out right mower unit

M3 +

M3 +

Raise right mower unit M5 +

Lower right mower unit M5 +

R

492 CONTROL TERMINAL

JAGUAR 8700 / 900 / 890 / 870 / 850 / 830

7.24

Operation

Operation Operating the JAGUAR 880 / 860 / 840 / 820 1

3

5

Multifunction lever

2

4

6

7

60

(1)

– Raise left mower unit

(2)

– Lower left mower unit

(5)

– Raise right mower unit

(6)

– Lower right mower unit

(3)

– Raise mower unit (headland)

(4)

– Lower mower unit

(7)

– Lower mower unit (headland)

The following functions must be selected from the operating terminal (– see »Control terminal«, page 7.26): - Switch control system on/off (actuate for approx. 1.5 seconds).

- Swing mower units into working position - lower middle mower unit - Fold mower units together

- Set down middle mower unit on the side units which have been swung together.

- Raise middle mower unit - Adjust mower unit relief.

491 CONTROL TERMINAL

7.25

JAGUAR 880 / 860 / 840 / 820

Operation Control terminal - Switch control system on/off (actuate for approx. 1.5 seconds).

- Swing mower units into working position - lower middle mower unit - Fold mower units together

- Set down middle mower unit on the side units which have been swung together.

- Raise middle mower unit - Raise left mower unit CONTROL TERMINAL

61

- Lower left mower unit

- Raise right mower unit

- Lower right mower unit

- Adjust mower unit relief.

- Reduce mower unit relief - lower all three mower units - Increase mower unit relief - raise all three mower units The check lamp lights up if a universal drive shaft coupling is stalled. A 'beep' sounds. Raise the relevant mower unit immediately and turn the mower units off. Remove blockage.

491 CONTROL TERMINAL

JAGUAR 880 / 860 / 840 / 820

7.26

Operation Working position Caution!

Raise the mower unit before swinging it into the working position!

Switch on control system (hold down for approx. 1.5 seconds).

62

Remove the safety chain (1) and stow it on the holder (2). Hitch hook (4) in the eyelet (3) (Fig. 63, 64).

Raise the mower unit with the hydraulics.

1

2 Swing the mower units apart.

63

3

The middle mower unit lifts first. Then the side mower units swing apart and the middle mower unit swings down.

4

Lower the mower unit with the hydraulics.

2

66535

64

(Fig. 62)

491 CONTROL TERMINAL

7.27

JAGUAR 880 / 860 / 840 / 820

Operation Raise or lower the mower unit with the hydraulics sufficiently that the mounting frame (5) and the swivel support (6) are lying approximately horizontally.

5

(Fig. 65, 66)

Program the preset cutting height control for this position (see JAGUAR operator's manual ).

67673

65

6

67672

66 The cutter bars can be moved both along and transversely to the direction of travel. In normal operation, turn out the latch (7).

(Fig. 67)

7

The latch (7) is only turned in for high cutting.

(Fig. 68) 63855

67

Afterwards, lower the mower units to the ground.

Caution!

Move the guards into the working position – see »Safety devices«, page 6.14.

7

63854

68

491 CONTROL TERMINAL

JAGUAR 880 / 860 / 840 / 820

7.28

Operation Adjusting mower unit relief The basic setting for the mower unit relief is 55 bar.

Depending on the operating conditions and the ground conditions, the relief pressure can be varied in the range from 40 to 70 bar.

70 55 40

(Fig. 69)

69 To adjust the mower unit relief, observe the pressure gauge (1) on the mounting frame.

(Fig. 70)

Adjust the relief on the three mower units by using these buttons on the operating terminal.

1

65683

70 - Increase mower unit relief - raise all three mower units (Fig. 71)

71 - Reduce mower unit relief - lower all three mower units (Fig. 72)

72

491 CONTROL TERMINAL

7.29

JAGUAR 880 / 860 / 840 / 820

Operation The relief on each mower unit can be corrected individually, as required.

Raise left mower unit (Fig. 73)

or

73 Lower left mower unit (Fig. 74)

or

74 Raise right mower unit (Fig. 75)

or

75 Lower right mower unit (Fig. 76)

or

76

491 CONTROL TERMINAL

JAGUAR 880 / 860 / 840 / 820

7.30

Operation Raise middle mower unit (Fig. 77)

77 Lower middle mower unit (Fig. 78)

78

491 CONTROL TERMINAL

7.31

JAGUAR 880 / 860 / 840 / 820

Operation Setting the cutting height The cutting height can be adjusted by altering the angle of tilt (Z) of the cutter bar (Fig. 79).

Middle mower unit High cut: Latch (1) must be turned in for this. The bar can no longer tilt downwards, with the result that a greater cut height is achieved (Fig. 80).

79

2

Shorten the upper link (3) until the desired cut height is attained (Fig. 81).

Low cut: Latch (1) must be turned out for this (Fig. 80). Increase the tension on springs (2). Lengthen the upper link (3) until the desired cut height is attained (Fig. 81).

1

Reduction of the cut height below the default height (40 mm) is not possible. In most applications, however, it is possible to mow with the default cut height.

The latch must then be turned out.

63854

80 Caution!

3

A cut height that is too low causes heavy wear to the cutting discs and mower blades.

Danger!

67262

81

With extremely uneven ground conditions, turn in the latch and reduce the angle of tilt (Z) of the mower unit. This leads to a greater cut height and reduces the risk of throwing out foreign objects (Fig. 79).

491 CONTROL TERMINAL

JAGUAR 880 / 860 / 840 / 820

7.32

Operation Side mower units Adjust the cut height as required, using the spindle (4) (Fig. 82).

4 Note!

6 66525

Make the same setting on both sides! There is an adjustment aid (5) located on the side of the spring; using the notches it is possible to read off the setting at the rear edge of the U-bracket (6).

5 82

Caution!

A cut height that is too low causes heavy wear to the cutting discs and mower blades.

Danger!

With extremely uneven ground conditions, reduce the angle of tilt (Z) of the side mower units. This leads to a greater cut height and reduces the risk of throwing out foreign objects (Fig. 79).

491 CONTROL TERMINAL

7.33

JAGUAR 880 / 860 / 840 / 820

Operation Changing the swath width Middle mower unit

1

The width of the swath can be varied by adjusting the swath plates (1). To do this, unfasten the spring clip (2), reposition the swath plate and push the clip back in again.

2

If the swath width is insufficient, remove the swath plate (1).

(Fig. 83) 66524

83 Hitch the expander on to the bracket (3).

(Fig. 84)

3

65861

84

491 CONTROL TERMINAL

JAGUAR 880 / 860 / 840 / 820

7.34

Operation Side mower units The width of the swath can be altered by altering the outer deflectors. To do this, loosen the star knob (4) and move the deflector (Fig. 85).

4 4

Basic settings: The slot in the cover flap (5) aligns with the slot in the deflectors (7) (Fig. 86, 87).

5

67676

On the left-hand side mower unit, the deflectors (6) are fitted in holes with the notch to the left (Fig. 86).

85

On the right-hand side mower unit, the deflectors (6) are fitted in holes with the notch to the right (Fig. 87).

6

67678

7

5

7

86

6

67677

7

5

7

87

491 CONTROL TERMINAL

7.35

JAGUAR 880 / 860 / 840 / 820

Operation Conditioner Baffle plates

1

The baffle plates can be adjusted by lever (1).

If the lever is pulled to the rear, i.e. in the "+" direction, the effect of the conditioner is intensified. In the "-" direction it is diminished.

(Fig. 88)

63860

88 Changing the speed The belt pulleys on the drive can be changed to adjust the speed of the conditioner. First, release the tension from the drive belt and remove the belt guard.

The arrangement of the belt pulleys with respect to the conditioner speed is shown in Fig. 89.

64021

89

491 CONTROL TERMINAL

JAGUAR 880 / 860 / 840 / 820

7.36

Operation Collision protection If an obstruction is encountered, the overload protection feature is actuated and the cutter bar can swing away to the rear (Fig. 90).

Turn off the mower unit and check for damage.

Put the mower unit back in its normal position (working position).

Notes: 90

• If this button is pressed while the mower unit is sitting on the ground, the side mower units will swing once again into the normal position (working position).

• If the mower unit is first raised before this button is pushed, the middle mower unit is raised fully. After that, the side mower units swing into the normal position (working position) and the middle mower unit is lowered again.

Adjusting the collision protection The collision protection can be adjusted by means of knurled screws (1) and (2).

If the collision protection responds frequently, the knurled screws (1) and (2) can be readjusted. For each readjustment, the knurled screw must only be readjusted half a turn at a time.

1

2 Knurled screw (1) = collision protection for the left mower unit

67252

91

Knurled screw (2) = collision protection for the right mower unit (Fig. 91)

491 CONTROL TERMINAL

7.37

JAGUAR 880 / 860 / 840 / 820

Operation Rotation monitoring Attention!

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

2 1

3

If fault is not cleared, clutches can be damaged!

Danger!

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

CONTROL TERMINAL

92

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

Control lamp (1) for speed sensor (6) Control lamp (2) for speed sensor (5) Control lamp (3) for speed sensor (4) (Fig. 92, 93)

Note!

4

5

6 93

The fault indication for faulty or wrongly-adjusted speed sensors differs between PTO speeds of less than 600 rpm, and speeds greater than 600 rpm.

Display when PTO speed is less than 600 rpm or PTO drive is turned 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.

491 CONTROL TERMINAL

JAGUAR 880 / 860 / 840 / 820

7.38

Operation Display when PTO shaft speed is greater than 600 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!

When the PTO shaft speed passes through 600 rpm, an audible signal may sound briefly.

This is caused by speed sensor switch tolerances.

Switching off the audible signal : In order to interrupt the audible signal when the speed sensor is faulty, pull out connector (7) on all three speed sensors (Fig. 74). Replace the defective speed sensor.

7

(Fig. 94)

66994

94

491 CONTROL TERMINAL

7.39

JAGUAR 880 / 860 / 840 / 820

Operation Mowing Note!

1

The accident prevention regulations of the Agricultural Employers' Liability Insurance Association must be observed at all times while operating.

2 Caution!

67671

95

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

• Prior to operation, all protective devices must be put in the protective position. On the side mower units, remove the safety guards (2) and swing the protective guards (1) downwards (Fig. 95).

• Take the prop stand (3) out of the hole and stow it in the harvester (Fig. 96).

• Before turning on the drive, lower the mower unit

3

to the ground outside the forage area.

66584

96

• Turn on the main drive (chopper drum drive).

Caution!

The main drive must only ever be turned on or off at the lower idle speed of the engine.

70 55 40

• Slowly run the engine up to the permitted speed.

• Only now drive into the forage.

• While mowing, the mower units should slide over

97

the ground with minimum pressure. If this ground pressure is too high, the mower units will have to be relieved – see »Adjusting mower unit relief«, page 7.29.

Check the relief pressure of the mower units (approx. 40 - 70 bar) during mowing by means of the three pressure gauges (4).

(Fig. 97, 98).

• 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).

4

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

65683

98

491 CONTROL TERMINAL

JAGUAR 880 / 860 / 840 / 820

7.40

Operation • It is not possible to mow in reverse with the mower unit. Raise the mower unit when reversing.

• Do not mow on rocky ground!

• At the headland, raise the mower units with the main lifting cylinders (Fig. 99).

99

100

• When driving back into the crop, lower the mower units again with the main lifting cylinders (Fig. 100).

Caution!

Ear muffs should be worn when mowing with the cab windows or doors open.

Remove the ear muffs when driving on the road.

Danger!

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

For further information, see the Operator's Manual for the forage harvester.

491 CONTROL TERMINAL

7.41

JAGUAR 880 / 860 / 840 / 820

Operation 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. 101)

69018

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

(Fig. 102, 103)

69019

102

69020

103

491 CONTROL TERMINAL

JAGUAR 880 / 860 / 840 / 820

7.42

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

(Fig. 104)

69021

104

491 CONTROL TERMINAL

7.43

JAGUAR 880 / 860 / 840 / 820

Operation Transport position Caution!

Only carry out the changeover when the drive is at a standstill. Wait until the cutting discs and knives are completely motionless!

Caution!

105

Move the guards into the transport position (Fig. 106).

Raise the mower unit slightly with the hydraulics.

67261

106

Turn in the latch (1) on the middle mower unit (Fig. 107).

Swing the mower unit into the transport position (Fig. 105).

1 The middle mower unit lifts first. Then the side mower units swing inwards.

Caution!

63854

107

The side mower units must not be any more than 300 mm above the ground.

Correct the height of the side mower units if necessary.

491 CONTROL TERMINAL

JAGUAR 880 / 860 / 840 / 820

7.44

Operation Raise left mower unit (Fig. 108)

or

108 Lower left mower unit (Fig. 109)

or

109 Raise right mower unit (Fig. 110)

or

110 Lower right mower unit (Fig. 111)

or

111

491 CONTROL TERMINAL

7.45

JAGUAR 880 / 860 / 840 / 820

Operation The middle mower unit must be set down on the side mower units once they have been swung together (Fig. 112).

• Hold these two buttons down simultaneously.

• Set the mower units to the required height using 112

the hydraulics.

Caution!

Switch control system off (actuate for approx. 1.5 seconds).

2

When driving on the roads, hitch the safety chain (2) on to the side mower units. The safety chain (2) serves simultaneously as a restraint for the side mower units (Fig. 113).

67675

113

67674

114

491 CONTROL TERMINAL

JAGUAR 880 / 860 / 840 / 820

7.46

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.

68290

115

The relevant valves can be actuated by pushing in with a pointed implement (see arrow, Fig. 115). With older machines that have valves without holes for pushing through, and with valves M6, M7 and M8, a separate power supply (+ve and ground) must be fed to the respective valve in order to switch it manually (Fig. 117).

In order to supply oil to the individual cylinder, the multifunction lever or the buttons on the control terminal must be actuated.

In the event of a failure of all the functions on the multifunction lever / operating terminal, open the central electrics unit, unplug the connector from the black control unit and plug it into cable link (B) (original position).

Disconnect the cable extension (93) at the valve block for the roll-type crop guard and plug in the old connectors (K) again – see »Reinstating the hydraulic control«, page 6.25. Actuate button 16 on the switch console for the oil supply to the valves (Fig. 116).

116 Danger!

When manually actuating the valves, turn off the drive!

Maintain an adequate distance from the moving parts!

Note!

Pay attention to the markings on the cables when exchanging cable sets (Fig. 117)!

491 CONTROL TERMINAL

7.47

JAGUAR 880 / 860 / 840 / 820

Operation DS5

M1 M2 M3 M4 M5 M12 DS1 M8 M7 M6

DZWR

R

DZWL

DZWM L DS3 DS4 DS2

M11 M10 M9

117

Solenoid valve

Function

Solenoid valve

Function

M4 + 16 (Fig. 116, 117)

Raise middle mower unit

M1 + M2

Swing in left mower unit

M4 + 16 (Fig. 116, 117)

Lower middle mower unit

M1 + M2

Swing out left mower unit

M3 + 16 (Fig. 116, 117)

Raise left mower unit

M1 + M2

Swing in right mower unit

M3 + 16 (Fig. 116, 117)

Lower left mower unit

M1 + M2

Swing out right mower unit

M5 + 16 (Fig. 116, 117)

Raise right mower unit

M5 + 16 (Fig. 116, 117)

Lower right mower unit

491 CONTROL TERMINAL

JAGUAR 880 / 860 / 840 / 820

7.48

Operation

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. 118).

64867

118

Order number 0934 152.0

Push-on runners (C03 0030) 2 If skids are exposed to heavy wear, additional runners (2) may be bolted onto them (Fig. 119).

Order number 0934 154.0

66363

7.49

119

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Maintenance

Maintenance

8 Maintenance IMPORTANT MAINTENANCE INSTRUCTIONS

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!

Danger!

As a matter of principle, repair, servicing and cleaning work, and the repair of functional faults on the mower units should only be carried out with the drive turned off, the harvester engine stopped and the battery isolation switch switched off.

– Remove the ignition key!

Danger!

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.

Energy accumulators

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

Danger!

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

– Use suitable stands!

– Close the hydraulic cocks!

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

Note!

Welding work on the mower unit mounting frame may only be carried out after consultation with CLAAS Customer Service. The mounting frame is made of high-strength fine-grained steel and can therefore only be welded under certain conditions.

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 Check all bolts for tightness and retighten if necessary.

Hydraulic system

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

Danger!

Lubrication

When working on the hydraulic system always release the hydraulic pressure and lower the mounting frame and mower units if they are swung up!

Observe the prescribed oil change intervals and oil types in the gearboxes and gear casings. 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.

– Close all shut-off valves!

Danger!

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

Make sure that all pressure gauges read zero with the electronics switched on; only then turn off the ignition!

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

8.1

Maintenance

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.

8.2

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Maintenance

Maintenance DRIVES Danger!

Only undertake work on the v-belt with the mower units turned off and secured against starting up again.

After putting the mower units into service for the first time, check the belt tension after the first 5 operating hours.

Re-tension the belt if necessary.

After that, carry out checks at regular intervals.

Tensioning the drive belts (main gearbox) The drive belts for the main gearbox are tensioned with the jockey pulley (1).

1

To re-tension, loosen the lock nut (2) and turn the threaded tube (3) accordingly.

2

Tighten the lock nut (2) again.

The adjustment aid (4) must be flush on the inside with the bracket (5) (see arrow).

(Fig. 1, 2) 66560

1 4

5

2

3

67341

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

2

8.3

Maintenance Tensioning the drive belt (Conditioner)

1

Middle mower unit To re-tension the belt, turn in the adjusting screw (1).

2

Caution!

Do not overstretch the belt!

3

67260

3

The belts are correctly tensioned when the washer on the tensioning spring (2) is flush with the angle plate (3). Check the belt tension regularly.

(Fig. 3)

Side mower units To re-tension the belt, turn in the spindle (4). The notch (5) on the adjustment aid (6) must sit flush with the cover plate (7).

7 6

5

Default spring length = 200 mm (Fig. 4)

4 Caution!

66534

8.4

4

If a v-belt is worn or broken, replace the whole v-belt set.

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Maintenance GEARBOX Use only Hypoid Gear Oil SAE 90 conforming to (MIL-L-2105 B) API-GL-5-90 for lubricating the gearbox.

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.

Drive diagram

A

B

C

B

E

A

D 5

Mounting frame

1

2

Main gearbox (C): Oil filling quantity: 4.0 litres (1) = Oil filling plug C

(2) = Oil level checking plug (The oil level checking plug is located at the rear of the gearbox) (3) = Oil drain plug (Fig. 5, 6)

3 65687

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

6

8.5

Maintenance Middle mower unit Gearbox (E):

1

Check the oil level daily and correct if necessary. To check the oil level, lower the mower units horizontally on to level ground.

E

Note!

The oil bubble must be visible in the centre of the star in the oil sight glass (2) (Fig. 7).

2 3

66931

7 Oil filling quantity: 2.0 litres (1) = Oil filling plug and checking plug (dismantle right-hand universal drive shaft) (2) = Oil sight glass (3) = Oil drain plug (dismantle right-hand universal drive shaft) (Fig. 5, 7)

Reduction gearbox (D): 4

Check the oil level daily and correct if necessary. To check the oil level, lower the mower units horizontally on to level ground.

D Oil filling quantity: 1.0 litre 5

(4) = Oil filling plug

6

(5) = Oil level check plug (6) = Oil drain plug

63925

8.6

8

(Fig. 5, 8)

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Maintenance Side mower units Gearbox (B):

1

Oil filling quantity: 0.8 litres B

(1) = Oil filling plug (2) = Checking plug (3) = Oil drain plug 2 (Fig. 9 = left side mower unit)

3 65692

9

(Fig. 10 = right side mower unit)

Caution!

1

To check the oil level, always remove the checking plug (2) below the centre of the gearbox.

B

(Fig. 5, 9, 10) 2 3 65691

10 Reduction gearbox (A): A

Oil filling quantity: 1.0 litre (4) = Oil filler plug and checking plug

4

(5) = Oil drain plug (Fig. 5, 11)

5 65689

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

11

8.7

Maintenance Mower head Danger!

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

– Do not touch the bar!

– Wear safety gloves!

Note!

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

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

Oil filling quantity: 4.5 litres

1

(1) = Oil filling and oil level check plug (Fig. 12) (2) = Oil drain plug (Fig. 13)

63847

12

2

63098

8.8

13

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Maintenance Checking the oil level:

• Allow the machine to warm up and park on level ground.

• Raise the cutter bar and support on the right-hand side e.g. with a timber prop X = 100 mm.

• Let the bar down, so that it rests on the ground at the left-hand side, and on the prop at the right-hand side.

• By means of the upper link, set the tilt on the bar to 0°, i.e. horizontal (Fig. 14).

73354 73354

14

• Check the oil level through the check opening (1) with a dipstick. To do this, insert the dipstick vertically into the bar until it touches the bottom.

• Depth of oil: Y = 4 - 6 mm.

1

(Fig. 14, 15) If during a check the oil level in the bar cannot be precisely determined, all the oil must be drained and fresh oil filled to the prescribed quantity.

Y X

1

47163 74163

2 Oil change: 15

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.

Draining oil: Raise the cutter bar and allow to warm up for approx.

8 - 10 minutes.

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

Clean the magnetic plug before reinstalling it.

2

(Fig. 13)

63098

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

16

8.9

Maintenance UNIVERSAL DRIVE SHAFT Danger!

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

– Remove the ignition key!

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

Observe the safety instructions of the manufacturer!

Operate the universal drive shaft only in good condition.

General information concerning the universal drive shafts Danger!

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

– Mounting shaft guard and protective tube.

– Secure the guard against rotation.

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

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

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

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

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

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

8.10

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Maintenance CLUTCHES Maintenance of the plate 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. 17)

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

(Fig. 18)

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

Note!

Replace worn friction discs in good time.

18 Note!

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

(Fig. 19)

19

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

8.11

Maintenance Torques The setting of the clutches must not be modified since otherwise considerable damage may be caused to the universal drive shaft, gearbox etc.

Left-hand universal drive shaft for middle mower unit, cutter bar drive:

3

Friction clutch (3) with 4 friction plates = 1200 Nm (Fig. 20)

66935

20 Side unit universal drive shafts, conditioner drive: 4

Torque setting for the friction and overrunning clutch (4)= 1200 Nm. (Fig. 21)

66927C

21 Side unit universal drive shafts, cutter bar drive: Torque setting of the cam-type cut-out clutch (5)= 1600 Nm.

5

(Fig. 22)

67232

8.12

22

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

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 harvester!

– 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 175.2 - BA DISCO 8700 C Plus / 8700 C

8.13

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

2

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

(Fig. 23)

1 5 67668

23 (3) = Stowage space for mower blades 0952 043.0 (4) = Stowage space for mower blades 0952 042.0

2

(Fig. 24, 25)

4

3 67667 67832

24

3

9368731

4

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

(Fig. 26) 2

67669

8.14

26

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

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. 27)

10 mm

B 68777

27 – 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. 28)

Procedure for changing mower blades: – see »Mower blade quick-change system«, page 8.16 or »Bolted mower blades«, page 8.21.

Ln 61623

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

28

8.15

Maintenance Mower blade quick-change system DISCO 8700 C Plus: 6

For changing mower blades:

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

(Fig. 29, 31)

7

68985

29

Note!

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

7

(Fig. 30)

30

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. 31)

8

68987

31

• Take out mower blade (10).

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

(Fig. 32)

10

68979

8.16

32

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Maintenance

Note!

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

The arrow on the mower blade (10) must correspond to the direction of rotation of the particular mower disc.

10

(Fig. 33) 33

• 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. 34)

10

68980

34

• 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

35 (Fig. 35, 36) 6

11 68984

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

36

8.17

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

(Fig. 37)

7

68982

37

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. 38) 38

68983

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. 39) 12

66615F

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

7

(Fig. 40) 13

67151

8.18

40

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

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. 41)

X X

YY 69049

41 – 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!

42

– Check weld beads before each commissioning!

(Fig. 42)

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

8.19

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

(Fig. 43)

11 69051

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

(Fig. 44)

11 69052

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

VV

Wear limit: (Fig. 45)

11

69053

V = 13 mm

45 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. 46)

46

8.20

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Maintenance Bolted mower blades DISCO 8700 C: 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

47

(Fig. 47)

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. 48) 48

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.

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

8.21

Maintenance

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. 49) 49 – If the bolt shaft is worn from Dn = 18 mm to D = 15 mm.

(Fig. 50)

50 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. 51)

51

8.22

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Maintenance 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. 52) 52 The cutting discs are fastened to one flange each.

2

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

1

Tightening torques: Bolts (1) = 80 Nm Nut (2) = 350 Nm (Fig. 53)

69058

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

53

8.23

Maintenance Mower disc cap The mower discs with caps (4) must always be furnished with plastic covers (3).

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

5

– Renew missing or damaged lids immediately.

54

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. 54)

The front safety guard (6) can be folded up for maintenance work on the cutter bar.

(Fig. 55) 6

6

55

8.24

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Maintenance Fitting pinion units The following notes apply to mower units up to serial no. 654 0 1057: Six pinion units are fitted in the cutter bar next to the collector module (E). These pinion units are subdivided into four A versions and two B versions. The B versions have a red marking on their underside. The configuration of the pinion units is shown in Fig. 56.

B

A

A

A

E

B

A

Middle mower unit

B

A

A

A

E

B

A

Side mower unit - left-hand

B

A

E

A

B

A

B

Side mower unit - right-hand 56 Pinion unit A:

A

B

X

The notch (K) on the pinion shaft (2), the centre of the tooth (Z) and the centre of the flange hole (X) must align.

X 30o

Z K

1

1

Z K

Pinion unit B: The notch (K) on the pinion shaft (2), the centre of the tooth (Z) and the centre line between two flange holes (X) must align.

2

2 57

66930R02

Caution!

The flange hole (X) must thus be offset by exactly 30o (not 22.5o) from the notch (K).

1

(Fig. 57, 58)

2

67638

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

58

8.25

Maintenance The following notes apply to mower units from serial no. 654 0 1058: Seven pinion units A are fitted in the cutter bar.

(Fig. 59) A B

A A

AA

A A

A B

A E

A A

59 Notch (K) on pinion shaft (2) must point precisely at centre of marking countersink (X).

(Fig. 60, 61)

2

74250

A

60

X K

2

75305

8.26

61

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Maintenance SPRING ADJUSTMENT Ground contour following (middle mower unit) The springs controlling the tracking of ground contours lengthwise must be tensioned so that the distance X between the washer and the end of the thread is 40 mm.

X

(Fig. 62)

63880

62

CONDITIONER TINES Fitting/removing tines The accessory kit contains a bolt (1) with which the roll pin (2) can be driven in or out.

Caution!

Fit the tines in accordance with the fitting diagram.

(Fig. 63) c d

c d

c d

c d

c d

c d

c d

24

11

63622F

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

22

63

8.27

Maintenance ELECTRICAL SYSTEM Setting the rotation sensors

M

First set height of sensor (1).

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

1

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

4 mm

(Fig. 64)

W 66992

64 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. 65)

2-4 mm 66992

8.28

65

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

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!

66

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 "1Q2006" signifies manufacture in the first quarter of 2006.

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

67 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. 67)

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

8.29

Maintenance Pressure accumulators Neither welding nor soldering nor any kind of mechanical work may be carried out on the pressure accumulator (1).

(Fig. 68) 1

66592

If a hydraulic line or hose is reconnected, it will have to be bled.

68

Repair work to the hydraulic system with pressure accumulator may only be carried out after releasing the fluid pressure.

Danger!

Make sure that all pressure gauges (2) read zero with the electronics switched on; only then turn off the ignition!

2

65683

8.30

(Fig. 69)

69

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Maintenance Adjusting the safety pressure limiting valve The safety pressure limiting valve (3) is factory-set to 180 bar.

The setting can be tested by raising the side units fully using these two buttons. Hold down the buttons until the pressure gauges indicate 180 bar.

3

65683

Raise the mower units with the main cylinders.

The pressure gauges must indicate 180 bar.

70

R

or

To adjust, depressurise the hydraulic system.

Caution!

At each adjustment, only move the knurled screw by 1/4 turn!

(Fig. 70)

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

8.31

Maintenance SAFETY DEVICES Fold-away guard frames 1

2 Danger!

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

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

71

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

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

(Fig. 71)

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

The winding drum (4) must in the dead centre of the sleeve protector (3). An even gap (X) must be set between sleeve protector and winding drum.

3

(Fig. 72, 73) 4 72

3 X

4

73

8.32

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Maintenance The holder (6) is used for setting. In order to do this, proceed as follows:

• slacken bolts (5), • move sleeve protector (3) as necessary; • retighten bolts (5).

5 3

6 5

(Fig. 74)

5

74 Gap size (X) = 8 – 10 mm (Fig. 75) 3 X

4 75

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

8.33

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

(Fig. 76)

1

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

Then check at regular intervals.

76

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

If necessary, replace the connecting elements by new ones.

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

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

3. Grease all the lubrication points thoroughly until the grease exudes from the bearings – see »Lubrication chart«, page 9.1.

Let the mower unit run for a short time.

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

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

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

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

8. Set down the mower unit.

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

8.34

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Maintenance MALFUNCTIONS Problem Vibration

Cause – Plastic cover missing.

Remedy

• Immediately replace cap on cutting disc and plastic lid – see »Mower disc cap«, page 8.24

Poor adaptation to ground contours

Safety cut-out responding too often

– Feeder drum dirty.

• Clean the feeder drum.

– Wrongly adjusted frame.

• – see »Suspension springs«, page 6.15.

– Joints on mower head seized.

• Clean the links and lubricate

– Insufficient tension in the rubber spring

• Increase spring load – see »Collision protection«, page 7.13.

• Correct the relief pressure with

Ground pressure too high

the safety pressure limiting valve.

- Correct the mower unit relief with these buttons.

Wrong tilting angle of the mower head

– Upper link length wrongly adjusted.

• Turn the upper link out or in.

• Correct the side units with the spindle.

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

– Tilt of mower head not enough.

• Increase tilt of mower head

– Ground speed too high.

• Reduce ground speed.

• Replace mower blades – see

– Blunt or damaged mower blades.

Stubble too high

– Wrongly adjusted tilt of the mower head.

– see »Setting the cutting height«, page 7.8.

»Mower blades«, page 8.13.

• Change tilt of the mower head by adjusting the upper link – see »Setting the cutting height«, page 7.8.

• Correct the side units with the spindle.

Formation of stripes at transition between front and side mower units

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

– Spring relief set too strong

• Reduce spring relief.

– Beam inclined too much to the front

• Change tilt of the side mower

– Ground speed too slow.

• Reduce ground speed.

unit by adjusting the upper link.

8.35

Maintenance Problem

Cause

Remedy

– Build-up of dirt between the runners.

• Clean mower unit.

– Blunt mower blades.

• Change mower blades.

• Correct the speed.

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

Fodder pushed forwards before being cut (creating stripes)

– Swirling effect of the mower blades in light crops.

• Reduce p.t.o. speed and

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

increase ground speed.

»Setting the cutting height«, page 7.8.

• 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 6.15.

• Fit wear or high cut slide runners.

• Increase mower unit relief – see »Suspension springs«, page 6.15.

Increased wear on runners

– Stony, sandy ground

• Screw wear slide runners in position

• Increase mower unit relief – see »Suspension springs«, page 6.15.

Build up of piles in the swathe

– Runners not lying parallel to the ground.

• Adjust the runners flat to the

– Light and wet crops.

• Mount an additional conveyer

– Sloping ground

ground (in the case of extreme high cut point wear of the runner)

hat.

• Reduce ground speed.

Plugs on the swathe plate

– Strong crops

• Swing swathe plate outwards.

– Wrong mounting of the swathe plate.

8.36

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Maintenance Problem Wrapping on the outer conveyer drum

Cause – Strong and flattened crops.

Remedy

• Check rotational speed, increase if necessary.

• Check friction clutch.

Conditioner wrapping

– Sharp drop in harvester rotational speed.

– Strong and flattened crops.

• Increase belt tension.

• Check rotational speed, increase if necessary.

• Reduce ground speed.

• Open the chicane further.

• Swing swathe plate outwards.

• Test accumulator bladders at

Relief no longer constant; pressure gauges no longer return to the preset position at the headland.

– Accumulator bladder faulty.

Pressure gauge falls below zero when system depressurised.

– Pressure gauge faulty.

• Replace pressure gauge.

Side mower units drop too quickly when being lowered.

– Oil pressure collapsing due to too rapid an outflow.

• Turn the drop rate restrictor

35 bar and replace if necessary.

back further.

• Test the 85 bar pressure switch.

Constant note from speed monitor.

– Mower unit blocked.

– Positions of the speed sensors not correct.

– Speed sensors defective.

• Remove blockage.

• Check positions of speed sensors.

• Test speed sensors. Temporarily disconnect all speed sensors.

Side units swing up too slowly at the headland.

– Valve inserts in the pressure accumulators faulty.

Mower units drop down again after actuating the RAISE/LOWER button on the multifunction lever.

– Pressure switch faulty.

Jerky lifting of the mower units in the transport position.

– Oil has not reached operating temperature.

switch.

– Valve is opening when mower units are raised.

Side units swing unevenly.

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

• Test the 85/110 bar pressure

– Restrictors in the flow and return lines of the swivel-out cylinders (valve side) are different or missing.

• Adjust the relief on the mower units in the transport position before raising to 70 to 80 bar.

• Check the restrictors.

8.37

Lubrication chart

Lubrication chart

9 Lubrication chart SAFETY RULES Danger!

As a matter of principle, only lubricate the mower units when the engine is not running.

– Remove the ignition key!

LUBRICANTS Branded 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”

Branded 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.

9.1

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Lubrication chart

Lubrication chart

3 1

2

4

65959

1 65960

2

66543

3 67265

4

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

9.2

Lubrication chart

5 7

8

6

66557

5 66554

6

66589

7 66588

8

9.3

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Lubrication chart

11 9

10

12

66548

9 66556

10

66546

11 66554

12

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

9.4

Lubrication chart

13

15

16

14

66537

13 66555

14

67683

15 67684

16

9.5

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Lubrication chart

20

18

17 19

21

66988

17 66550

18

66551

19 66549

20 66552

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

21

9.6

Lubrication chart

22 23 26

24 25 27

27

66539

22 66539

23

66540

24 66540

25

66560

26 67685

27

9.7

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Lubrication chart

29

66586

30

28 65971

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

28

29 65970

30

9.8

Lubrication chart

32

31 33

34

65968

31 65967

32

65961

33 65962

34

9.9

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

Lubrication chart

36

66586

37

35 65971

0294 175.2 - BA DISCO 8700 C Plus / 8700 C

35

36 65970

37

9.10

Lubrication chart

39

38 40

42

65968

38 65967

39

65961

40 65962

41

9.11

BA DISCO 8700 C Plus / 8700 C - 0294 175.2

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 175.2 BA DISCO 8700 C Plus / 8700 C EN - 08.06 Printed in Germany