CLAAS DISCO 3000 TC / 3000 TC PLUS DISCO 3000 TC FG / 3000 TC FG PLUS DISCO 3000 TRC / 3000 TRC PLUS

DISCO 3000 TC

DISCO 3000 TC / 3000 TC PLUS DISCO 3000 TC FG / 3000 TC FG PLUS DISCO 3000 TRC / 3000 TRC PLUS DISCO 3000 AS / 3000 AS PLUS

Assembly Instructions and Operator´s Manual

Pl ea

se re ad an df ol l ow sa

f et yi

ns

tru

cti

on

s!

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

CLAAS Saulgau GmbH

We

Zeppelinstraße 2

D - 88348 Bad Saulgau

declare under our sole responsibility, that the product

Disc mower - model 650 »DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus«

to which this declaration relates corresponds to the relevant basic safety and health requirements of the Directive 89/392/EEC, and to the requirements of the other relevant Directives:

-/-

For the relevant implementation of the safety and the health requirements mentioned in the Directives, the following standard(s) has (have) been respected:

EN 745 - 1999

Bad Saulgau, 13.02.2004 Technical Management (Geng)

Technical Management (Fetscher)

Technical Management (Switalski)

Basic components of the machine

Basic components of the machine

1

16

15

2

14

13

3

12

11

10

4

9

5

8

3

6

7

68921

1 Basic components of the machine BASIC COMPONENTS OF THE MACHINE Pos.-no. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1.1

Identification plate Drawbar Lighting equipment Carrier frame Drum carrier frame & swath deflector Hydraulic lift Wheel Wheel bracket Cutterbar Angle drive Protective cloth Drive shaft Stand Double gearbox Headstock Universal-joint drive shaft

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Introduction

Introduction

2 Introduction INTRODUCTION This manual provides information on the use, setting and servicing of the CLAAS Disc Mower.

The advice on the care and servicing should be followed in order to obtain maximum performance and long service.

The assembly and the regular inspection of your machine should be performed by your specialist workshop. Neglect in maintenance and service and incorrect use will result in poor machine efficiency and loss of valuable time.

By correct operation and servicing you can make full use of the technical knowledge and experience with which your machine has been designed.

Yours CLAAS Service Department

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

2.1

Contents

Contents

Basic components of the machine ............................................ 1.1

Pull rope DISCO 3000 TC FG ........................................................... 8.8 Storing the machine .................................................................. 8.8 Prior to transport ....................................................................... 8.9 Transport on Public Roads ............................................... 8.10

2. Introduction

9. Operation

Introduction ............................................................................... 2.1

Operation .................................................................................. 9.1 Working position ................................................................. 9.1 Adjusting the working height .............................................. 9.3 Adjusting the lifting height .................................................. 9.4 Adjusting the conditioner .................................................... 9.4 Adjusting the conditioner speed DISCO 3000 TC / TC FG / AS ............................................ 9.4 Adjusting the swath width DISCO 3000 TC / AS ......................................................... 9.5 Adjusting the cross conveyor DISCO 3000 AS ................................................................. 9.5 Adjusting the cross conveyor projection range DISCO 3000 AS ................................................................. 9.6 Adjusting the swath deflectors DISCO 3000 TC FG ........................................................... 9.6 Locking the swath deflectors manually DISCO 3000 TC FG ........................................................... 9.7 Using the mower unit .......................................................... 9.8 Mowing in combination with the cross conveyor DISCO 3000 AS ............................................................... 9.13 Mowing in combination with a cross conveyor and front mounted mower DISCO 3000 AS ............................................................... 9.13 Mowing in combination with the Flapgrouper DISCO 3000 TC FG ......................................................... 9.14 Transport position ............................................................. 9.15 Optional equipment ................................................................ 9.16 High Cut Skids .................................................................. 9.16 Push-on runners ............................................................... 9.17 Extra conditioning plate .................................................... 9.17 Kit for detachable forks ..................................................... 9.17 Hydraulic adapter kit for tractors ...................................... 9.17 Wide Spreading Hood ...................................................... 9.18 Swath plate extension ...................................................... 9.18 Electric lifting system ........................................................ 9.18

3 Contents 1. Basic components of the machine

3. Contents 4. Preface Of special importance ............................................................... 4.1 Identification plate ..................................................................... 4.2

5. Safety Instructions Designated Use ........................................................................ 5.1 Identification of warnings and dangers ..................................... 5.1 General safety and accident prevention instructions ................ 5.1 Attached machines ................................................................... 5.3 Machines as trailors .................................................................. 5.3 PTO operation ........................................................................... 5.3 Hydraulic system ....................................................................... 5.3 Tyres ......................................................................................... 5.4 Maintenance ............................................................................. 5.4 Sound pressure level ................................................................ 5.4 Safety decals with warning symbols ......................................... 5.5

6. Specifications Specifications ............................................................................ 6.1 Noise level ................................................................................ 6.2

7. Assembly Assembly DISCO 3000 TC / TC FG / TRC / AS ........................................ 7.1 Installing the drawbar hydraulics DISCO 3000 TC / TRC / AS ...................................................... 7.6 Installing the drum carrier frame DISCO 3000 TC / TRC / AS ...................................................... 7.8 Installing the Flapgrouper DISCO 3000 TC FG .................................................................. 7.9 Installing the cross conveyor DISCO 3000 AS ...................................................................... 7.17 Final assembly DISCO 3000 TC / TC FG / TRC / AS ...................................... 7.20 Unloading & loading the machine ........................................... 7.21 First attachment to tractor ....................................................... 7.22

8. Before Operation Check and observe the following before putting into operation! 8.1 Attachment to the tractor ........................................................... 8.2 Hitch pin .............................................................................. 8.2 Drive shaft ........................................................................... 8.2 Hydraulic system ................................................................ 8.5 Electric connection .............................................................. 8.6 Water Filling DISCO 3000 TC / TRC ....................................................... 8.6 Prop Stand .......................................................................... 8.7

3.1

10. Maintenance Important maintenance instructions ........................................

Wheels / tyres ...................................................................

Hydraulic System .............................................................

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

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

Safety frame .....................................................................

Gearboxes .............................................................................

Main Gearbox ...................................................................

Angle driv .........................................................................

Cutterbar ..........................................................................

Automatic chain lubrication ..............................................

Drive mechanism ....................................................................

V-belts ..............................................................................

Checking V-belts ..............................................................

Tensioning the conditioner V-belts ...................................

10.1 10.1 10.1 10.1 10.1 10.1 10.2 10.2 10.4 10.5 10.7 10.8 10.8 10.8 10.9

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Contents Tensioning the V-belts of the hydraulic unit ...................... 10.9 Mower blades ........................................................................ 10.10 Changing the cutting blades (quick replacement) Disco 3000 TC Plus / TC FG Plus / TRC Plus / AS Plus : .................................................... 10.12 Blade holder (quick blade replacement) Disco 3000 TC Plus / TC FG Plus / TRC Plus / AS Plus : .................................................... 10.18 Cutting blade securing parts (bolted version) Disco 3000 TC / TC FG / TRC / AS : .............................. 10.20 Cutting discs ......................................................................... 10.21 Replacing cutting discs ................................................... 10.21 Adjusting the conditioner Disco 3000 TRC .................................................................... 10.22 Adjusting the synchronism of the conditioner rollers ...... 10.22 Adjusting the clearance between the rollers ................... 10.22 Adjusting the roller tension ............................................. 10.23 Tensioning the drive chains ............................................ 10.23 Conveyor belt Disco 3000 AS ...................................................................... 10.24 Adjusting the conveyor belt tension ................................ 10.24 Adjusting the float springs ..................................................... 10.25 Drive shaft ............................................................................. 10.25 General information on universal drive shafts ................ 10.25 Clutches ................................................................................ 10.26 Maintenance of the Friction-Type Overrunning Clutch ... 10.26 Hydraulic system ................................................................... 10.27 Topping up hydraulic oil .................................................. 10.27 Hydraulic Hose Lines ...................................................... 10.27 Screw connections ................................................................ 10.28 Connecting elements ............................................................ 10.28 End of season storage .......................................................... 10.28 Problems ............................................................................... 10.29

11. Lubrication Chart Safety instructions ................................................................... 11.1 Lubricants ............................................................................... 11.1 Lubrication .............................................................................. 11.1

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

3.2

Preface

Preface

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

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

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

Please particularly read the sections »Safety Instructions« and »Before Operation«.

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

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

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

IMPORTANT: Front, rear, right and left always refer to as seen in the direction of forward travel.

4.1

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Preface IDENTIFICATION PLATE 1

When ordering spare parts and in any correspondence please state the machine no. (vehicle identification no.) (2) to prevent any supply of wrong parts.

The identification plate (1) with the machine number (vehicle identification no.) (2) is attached on the rear LH side of the carrier frame. (fig. 1-2)

1 1

2

2

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

4.2

Safety Instructions

Safety Instructions

5 Safety Instructions

Caution!

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

Read and follow the operator's manual and the safety instructions before putting the machine into operation!

– Measures for avoiding danger to the machine.

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

Note!

The mower unit is suitable for and foreseen for cutting crops growing out of the ground in natural or seeded fields.

This symbol identifies instructions that make it easier to use the machine effectively and economically.

Use in any other way is considered as contrary to the intended use. The manufacturer does not accept any liability for such use; the user accepts all risk arising from such use.

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 this work and who have been instructed about 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.

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

IDENTIFICATION OF WARNINGS AND DANGERS 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 supply all safety instructions to any other user.

Danger!

Failure to observe the instructions identified by this symbol may result in danger for life and limb of the user or other persons.

– Measures for avoiding danger.

Environment!

Failure to observe the instructions identified by this symbol results in damage to the environment.

The environment is in danger if environmentally hazardous material (e.g. waste oil) is not subject to correct use and/or disposal.

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

GENERAL SAFETY AND ACCIDENT PREVENTION INSTRUCTIONS Basic Rule: Always check the operating and road safety of tractor and machine before starting up!

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

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

Follow the regulations in force as you use public roads!

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

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

5.1

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

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

Check the mower unit every time it will be used 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 at every change of cutting blades according to regulations specified by the manufacturer and replace if necessary!

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

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

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

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

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

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

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

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

Special care is required when working near roads and buildings!

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

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

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

Keep the machine clean to prevent fire! Before starting and before putting it into operation check the area around the machine (children!).

Ensure that you have an adequate view!

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

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

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

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

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

Observe the permissible transport dimensions!

Observe the maximum permissible axle loads and total weights!

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

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

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

Never leave the operator's platform when driving!

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

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

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

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

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

Keep clear of the swivelling range of the operating machine.

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

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

5.2

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

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

ATTACHED MACHINES

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

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

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

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

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

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

Always ensure that no-one is in the danger zone of the machine before switching on the p.t.o. shaft!

A risk of injury due to crushing or shearing exists in the vicinity of the 3-point linkage!

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

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

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

MACHINES AS TRAILORS Secure the machine to prevent it from rolling away!

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

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

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

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

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

5.3

Never engage the PTO shaft while the engine is stopped!

When operating the PTO shaft no-one must ever stand in the vicinity of the rotating PTO stub shaft or universal drive shaft!

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

Danger: rotating masses run on after the PTO has been disengaged! Do not step too close to the machine during this time! You are only allowed to work on the machine when everything has stopped moving.

Cleaning, lubricating or adjustment of the p.t.o. shaft driven machine or universal drive shaft is only permitted with a switched off p.t.o. shaft, switched off engine and the ignition key removed!

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

After uncoupling the universal drive shaft the protective guard must be pushed on to the PTO stub shaft!

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

HYDRAULIC SYSTEM The hydraulic system is under high pressure!

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

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

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

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

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

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

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

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

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

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

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

Fluid escaping under high pressure (hydraulic oil) can penetrate the skin and cause serious injuries. If any fluid is injected into skin, consult a doctor immediately, as– Risk of infections!

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

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

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

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

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

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

MAINTENANCE Repair, service and cleaning work and the elimination of malfunctions should only be performed with the drive and the engine switched off! –Remove the ignition key!

Wait until the cutting discs, knives are completely motionless!

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

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

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

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

Dispose of used oil and grease according to regulations!

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

5.4

Safety Instructions

Safety Instructions SAFETY DECALS WITH WARNING SYMBOLS Safety decals with warning symbols are placed in all danger areas of the machine to help identify risks of injury. The warning symbols in these decals show how to avoid injury and accidents by appropriate behaviour.

The location of the decals on the machine and their wording is shown on the following pages.

The CLAAS spare part number of the decal is quoted before each description.

The figures in brackets refer to the location of the decals shown in the figures.

Immediately replace damaged or illegible safety decals with warning symbols.

When replacing parts with decals affixed to them, make sure you affix new decals again to the new parts.

5.5

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Safety Instructions

1

1

2 Warning symbol 514 946.1 (1) Read and observe the operator's manual and the safety instructions before putting machine into operation!

(Fig. 1, 2)

2

3

4 Warning symbol 514 895.1 (2) Before carrying out maintenance and repair work switch off engine and remove ignition key.

(Fig. 3, 4)

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

5.6

Safety Instructions

A

B

C

5 Warning symbol 936 916.0 (3) Picture (A): Maintain an adequate safe distance from the mower blades when the engine is running.

3

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

Picture (C): Stay clear while engine is running.

(Fig. 5-9) 6

3

7

5.7

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Safety Instructions

3 8

3

9

4

10

4

12 Warning symbol 516 038.0 (4) Keep hands out of hazardous crush or pinch areas as long as parts may move on.

(Fig. 10, 11, 12) 11

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

5.8

Safety Instructions

5

13

14 Warning symbol 516 039.0 (5) Do not attempt to remove guard while the engine is running.

(Fig. 13, 14)

6

15

16 Warning symbol 514 898.1 (6) (DISCO 3000 AS / 3000 AS Plus) Keep clear of the swivelling range of the operating machine.

(Fig. 15, 16)

5.9

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Safety Instructions

7

17

18 Warning symbol 516 052.0 (7) (DISCO 3000 AS / 3000 AS Plus) Never stand on the floor conveyor while the drive system and engine are running.

(Fig. 17, 18)

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

5.10

Specifications

Specifications

6 Specifications SPECIFICATIONS Note!

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

DISCO 3000 TC / DISCO 3000 TC FG

DISCO 3000 TRC

DISCO 3000 AS

KW (PS)

51 (70)

51 (70)

51 (70)

Overall length in transport position

mm

6200

6200

6200

Transport width

mm

3000

3000

3000

Cutting width

mm

3000

3000

3000

PTO Speed

rpm

1000

1000

1000

Speed Mower discs

rpm

3200

3200

3200

Condtioner speed - with Flapgrouper

rpm rpm

900 / 770 1030 / 670

900 -

1030 / 670 -

Infinitelyvariable cutting height

mm

30 - 70

30 - 70

30 - 70

Number of discs

7

7

7

Number of knives

14

14

14

1650 1780

1790 -

1940 -

11,5/80 - 15,3 8PR

11,5/80 - 15,3 8PR

10,0/80 - 12 8PR

Required tractor performance

Weight - with Flapgrouper

kg kg

Tyres Tyre pressure

bar

2,5

2,5

2,5

Tightening torque for wheel bolts

Nm

150

150

150

6.1

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Specifications NOISE LEVEL Microphone location 1

Version of measurement of the sound level according to the measurement procedure specified in the document

Microphone location 2

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

Horizontal level

Machine

M62120-01

The adapted measurement procedure corresponds to Procedure 4 described in this document.

1

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

The tractor used to take the measurements on has a power output of 110 kW (150 PS).

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

A-evaluated equivalent permanent sound pressure levels

DISCO 3000 TC / TRC / AS

Tractor without machine

Cabin window

Tractor with machine

open

closed

open

closed

Microphone location 1 - L(A) eq

dB (A)

77,2

74,8

90,6

78,6

Microphone location 2 - L(A) eq

dB (A)

83,2

80,9

93,5

93,5

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

6.2

Assembly

Assembly

1.

1.

3.

2

= 1

2.

65072F

7 Assembly

1

ASSEMBLY DISCO 3000 TC / TC FG / TRC / AS 1. Fit an appropriate lifting device (400 kg minimum capacity!) to double gearbox (1) and pin (2).

2. Cut the lashing wire which secures the drawbar.

3. Seperate the drawbar from the mower using an appropriate lifting device.

Caution!

Danger of tipping!

– Ensure an equal length of all lifting elements.

(Fig. 1) Danger!

Risk of accident!

– Do not step under suspended loads!

7.1

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Assembly

68929

2 4. Lower the drawbar and double gearbox onto appropriate squared timbers.

Note!

It is possible to use the squared timbers used for shipment.

(Fig. 2) 5. Remove loose parts such aswheels, swath deflectors, pto drive shaft and accessories from the mowing unit.

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

7.2

Assembly

7.

3

4

7.

=

8.

64902F

3 6. Cut the lashing straps of the mower.

7. Fit an appropriate lifting device (3700 kg minimum capacity!) to the lift eyes (3) and (4) of the mower.

Caution!

Danger of tipping!

– Ensure an equal length of all lifting elements.

8. Tilt mower onto cutterbar. Use appropriate squared timbers to prop the cutterbar.

(Fig. 3) Danger!

Risk of accident!

– Do not step under suspended loads!

7.3

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Assembly

!

5

68930

4 9. Fit an appropriate lifting device (400 kg minimum capacity!) to the lift eyes (5).

10. Slowly lift the drawbar to vertical position.

Caution!

Danger of damage to the double gearbox!

– Use a movable support!

(Fig. 4) Danger!

Risk of accident!

– Do not step under suspended loads!

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

7.4

Assembly Fit headstock (6) to the double gearbox using pin (7) and washers (8). Secure using bolts (9) and nuts (10).

(Fig. 5)

7 6

M 10 x 65

10 VM 10

9 30 x 42 x 1,5

8

68931

5 Fit the drawbar to the carrier frame using pin (11).

Drive in both expansion pins (12) and (13), then turn the pin until the ends of both expansion pins are inside groove (14).

11

(Fig. 6, 7) 14

6 12

Install shims (15) as required and fit circlip (16).

13

(Fig. 7)

11 15 16 68933

7 Fit an appropriate lifting device (3700 kg minimum capacity!) to the lift eyes (17). Lift the mower.

(Fig. 8) 17

8

7.5

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Assembly Cut the lashing straps securing the lifting cylinders.

19

Fit hydraulic cylinders with shims (18) to the shafts (19) and secure using expansion pins (20).

20

(Fig. 9 18 24

22 23 21

68936

9 Fit piston rods to the top holes (22) of the wheel brackets using pins (21). Install washers (23) and expansion pins (24).

(Fig. 9, 10)

22

21 10 Fit the right-hand and left-hand wheels to the wheel hubs using the wheel bolts (25).

Tightening torque for the wheelbolts = 150 Nm (Fig. 11)

25 11

INSTALLING THE DRAWBAR HYDRAULICS DISCO 3000 TC / TRC / AS

1 3

Swing drawbar to the outside.

Fit the hydraulic cylinder to the carrier frame using pin (1). Install washers (2) and expansion pins (3) at the top and lower end of the pin.

2

(Fig. 12)

3 12

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

7.6

Assembly

1290

1200

A

1380

B

1525

C

D

68941

13 Fit the hydraulic cylinder to the drawbar using pin (4).

Install washers (5) and expansion pins (6) at the top and lower end of the pin.

4

(Fig. 14)

5

Choose one of the holes (A - D) to match the width of the used tractor.

6

(Fig. 13)

14

7.7

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Assembly

14

10

11

8 13 9

12

17

7

4

16 5

15

1 6

2

68950

3 15

INSTALLING THE DRUM CARRIER FRAME DISCO 3000 TC / TRC / AS

1

Secure the LH and RH side walls (1) to the frame using angle (2), hex. head bolts (M10 x 25) (3), contact washers and securing nuts.

(Fig. 15, 16) 3

16 Secure swath deflector (4) to the LH and RH side walls using cover plates (5), mushroom head screws (M10 x 25) (6), contact washers and securing nuts.

8

Attach swath deflector to slotted holes (9) using mushroom head screw (M12 x 70) (7), washers and toggle nut (8).

(Fig. 15, 17) 4

17

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

7.8

Assembly Bolt hood (10) onto the frame using mushroom head screws (M10 x 20 x 12) (11), contact washers and securing nuts.

13

10

Bolt rear protective cloth (12) with strip (13) onto the hood using mushroom head screws (M8 x 20 x 13) (14), contact washers and securing nuts.

14

(Fig. 15, 18) 12

18 Bolt limit stops (15) with rubber buffers (16) onto the hood using mushroom head screws (M10 x 25) (17), contact washers and securing nuts.

16 15

(Fig. 15, 19)

17

19

INSTALLING THE FLAPGROUPER DISCO 3000 TC FG Swing drawbar to the outside.

Fit the hydraulic cylinder with limit stop (1) to the carrier frame using pin (2). Install washers (3) and expansion pins (4) at the top and lower end of the pin.

2

(Fig. 20) 4

1 3 20 Fit the hydraulic cylinder to the drawbar using pin (5).

Install washers (6) and expansion pins (7) at the top and lower end of the pin.

5

(Fig. 21) 6

Choose one of the holes (A - D) to match the width of the used tractor.

(Fig. 13)

7

21

7.9

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Assembly Route pull rope (8) on drawbar to the front through the ringnuts (9).

(Fig. 22) 9

8 22

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

7.10

Assembly

12

13 14 11

10

68957

23 Bolt side wall (10) onto the LH side of the frame using hex. head bolts (M10 x 25) (11), contact washers and securing nuts.

10

(Fig. 23, 24) 11

24 Bolt side wall (12) onto the RH side of the frame using mushroom head screws (M10 x 25) (13) and (M10 x 55) (14), contact washers and securing nuts.

12

(Fig. 23, 25) 13

14

25

7.11

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Assembly

18

19

17 16

20

15 17

16 16

68951

26 Bolt hood (15) onto frame and side walls using mushroom head screws (M10 x 20 x 12) (16) and (M10 x 25) (17), contact washers and securing nuts.

16

(Fig. 26, 27) 15

27 Bolt limit stops (18) with rubber buffers (19) onto the hood using mushroom head screws (M10 x 25) (20), contact washers and securing nuts.

19 18

(Fig. 26, 28) 20

28

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

7.12

Assembly

22

25 24 21 25

23 22 26 27 31 28 30

29

68956

29 Introduce the LH and RH pins (21) of swath deflector (22) into hole (23) of the hood and secure using washer and expansion pin.

24 25

The rear pin (24) must be located inside guide (25).

(Fig. 29, 30)

21

30 Fit the LH and RH hinges (26) of the supporting plate to the pins (27) of the swath deflector and bolt onto the frame using hex. head bolts (M10 x 25) (28) and (M10 x 60) (29), spacers (30), contact washers and securing nuts.

27

Bolt supporting plate onto the side walls using mushroom head screws (M10 x 25) (31), contact washers and securing nuts.

26

(Fig. 29, 31)

31

7.13

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Assembly

34

38 36 35

42

X Y

32

37

39

41

40

68958

32 Strut (32) has two holes: X and Y. Hole X= Position for light forage Hole Y= Position for heavy forage Slide struts (32) and (34) into each other until the desired holes are in alignment.

Drive securing nut (35) onto the long thread of threaded rod (36). Introduce the threaded rod through the holes of the struts and secure from below using securing nut (37). Secure with locknut and bolt on ball knob (38).

39

33

(Fig. 32) Fit the strut with plastic washers (Rd 50 x 10) (39) and plastic bushes to the pins (40) of the swath deflectors and secure using washers and expansion pins.

Fit hydraulic cylinder (41) to pin (42) and strut (34).

Secure using washers and expansion pins.

42 34

(Fig. 33, 34)

41

34

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

7.14

Assembly

43

A

C

B

D

44

45

35 Install hydraulic hoses (43) along the hood and carrier frame up to steering cylinder (44) and secure using self-locking straps.

45

Connect hoses to lock-up valve unit (45).

A

C

B

D

A-A B-B C-C D-D (Fig. 35, 36) 36

7.15

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Assembly

49

46 47 51 48

50

68961

37 Fit struts (46) of protective cloth with bushes (25 x 4 x 20) (47) to pins (48) and secure using washers and expansion pins.

52 53

Bolt on swath deflector extensions (49) and (50) using mushroom head screws (M10 x 25) (51), contact washers and securing nuts.

(Fig. 37) Fit warning panels (52) to frame cover using mushroom head screws (M10 x 25) (53), contact washers and securing nuts.

55 68966

38

(Fig. 38) Install the wire under the edges (54) of hood and side wall. Secure with self-locking straps. Connect wire to wiring loom (55).

52

(Fig. 38, 39) 54

39

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

7.16

Assembly

5 6 7

2 4 1

3

68968

40

INSTALLING THE CROSS CONVEYOR DISCO 3000 AS Fit stop plate (1) with hydraulic cylinder (2) to frame (3) using pin (4). Secure with washers and expansion pins.

Connect hydraulic hose (5) to hose extension (6) and to hydraulic cylinder (7) and secure to stop plate (1) using pipe clamp (7).

(Fig. 40)

7.17

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Assembly

8 10 12

9

11

15 14

A 13

B B

10

A

68969

41 Fit arm (8) to frame (9) and secure using hex. head bolts (M10 x 6) (10) and washers.

Fit hydraulic cylinder (11) to the arm using pin (12).

Secure with washers and expansion pins.

Connect hydraulic hoses (13).

A-A B-B Fit control lever (14) for automatic cut-out to strap (15) of carrier frame. Secure with washer and split pin.

(Fig. 41)

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

7.18

Assembly

18

A B

16 17 19

68970

42

18

Bolt on conveyor belt (16) with supports (17) using hex. head bolts (M16 x 40) (18), contact washers and securing nuts.

17

(Fig. 42, 43) Connect hydraulic hoses (13) to oil motor (19).

A-A B-B (Fig. 41, 42)

43 Fill hydraulic tank (19) with hydraulic oil.

Mineral oil

Typ HLP DIN 51 524 Typ HM ISO 6763/4 (e.g. HLP 46 - Tellus Oil 46)

19

Tank capacity= 7 litres (Fig. 44)

44

7.19

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Assembly 1

FINAL ASSEMBLY DISCO 3000 TC / TC FG / TRC / AS

1

Hitch mower to tractor and move to working position.

Adjust float springs (1) ( see Adjusting the float springs on page 10.25).

(Fig. 45)

45 Install drive shaft (2). Ensure that all locks are correctly engaged!

Install drive shaft guard (3).

Connect the safety chains (4) to guard and machine.

4 3

(Fig. 46) 2 4 3

46 Installing the blades ( see Mower blades on page 10.10).

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

7.20

Assembly

1

1

68955F

1

UNLOADING & LOADING THE MACHINE Danger!

Always load and transport the machine in accordance with instructions. Danger of accident!

1

– Use only lift eyes (1) of the carrier frame to lift the machine for loading. Lift eyes are marked by decals (2).

2

– Use lifting devices with sufficient capacity and dimensions.Mind the weight of the machine – see Assembly, page 7.1.

2

(Fig. 1-6)

1

2 3

7.21

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Assembly

1 2

4

1 2

5

FIRST ATTACHMENT TO TRACTOR 2

Before the first operation of the mower make sure that the hitch and the PTO shaft suit the tractor.

1. Check the extent of supply (refer to the delivery note).

2. Assemble the machine according to fitting instructions.

3. Adjust the hitch system to match the tractor and attach the machine to the tractor– see Attachment to the tractor, page 8.2.

6

4. Modify the universal drive shaft to match the tractor and install – see Drive shaft, page 8.2.

5. Connect the hydraulic line – see Hydraulic system, page 8.5.

6. Required steps "Check and observe the following before putting into operation!" on page 8.1.

7. Put machine into operation – see Working position, page 9.1.

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

7.22

Before Operation

Before Operation

8 Before Operation Danger!

Switch off the engine before working on the machine.

– Remove the ignition key!

CHECK AND OBSERVE THE FOLLOWING BEFORE PUTTING INTO OPERATION! 1. DISCO 3000 TC / TC FG / TRC: For operation of these mower types the tractor must be fitted with 1 single-acting and 1 double-acting control valves.

DISCO 3000 AS: For operation of this mower type the tractor must be fitted with 2 single-acting and 1 double-acting control valves.

2. Check oil level in gearboxes, oil tanks and cutterbar – see »Drive mechanism«, page 10.8) or »Cutterbar«, page 10.5.

3. Before operation lubricate the machine thoroughly – see »Lubrication Chart«, page 11.1).

4. Check that the mower blades are properly fastened. Messerklingen auf Beschädigungen und Verschleiß prüfen, ggf. austauschen.

– see »Mower blades«, page 10.10).

5. Check bolts for tightness.

6. Check safety devices (such as overload clutches, covers of drive elements etc.) for proper function and tightness.

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

8. Respect the maximum PTO speed and sense of rotation – see »Specifications«, page 6.1)!

9. The mower must only be switched on when in working position.

10. After having fitted the mower to the tractor and connected the universal drive shaft check carefully that the universal drive shaft is freely movable. To do this: • Carefully lift and lower the machine.

11. Only engage the tractor PTO with the engine running at idling speed.

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

13. Do not allow persons in the danger area. If persons approach the danger area, switch off the mower immediately.

8.1

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Before Operation ATTACHMENT TO THE TRACTOR Danger!

Switch off the engine before working on the machine.

– Remove the ignition key!

Before the first operation modify the universal drive shaft to match the tractor – see »Adapting the PTO shaft length«, page 8.2).

Danger!

There is some danger of squashing and shearing in the area of the suspension bracket when lifting and lowering the machine.

– Keep hands out of hazardous crush or pinch areas as long as parts may move on.

Hitch pin Attach the lower links to the hitchpins of hitch bracket (1) and secure.

Note!

The hooks of the lower links must be properly engaged. Use a bolt or pin to secure them if required - see Technical documentation.

A 1 68990

Secure bottom links against lateral movement.

1

Lower the attached mower withthe tractor lower links to X = 735 mm above the ground. (fig. 1)

Drive shaft Adapting the PTO shaft length Pull drive shaft sections apart and connect both sections to the PTO stub shafts. To find the shortest length that the shaft will have to accommodate, hold the two sections alongside each other and mark. (fig. 2)

2

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

8.2

Before Operation Observe the maximum permissible shaft length (LB).

Try to reach the maximum possible overlap for the profile tubes. During field operation, the overlap (PU) of the tubes must never be inferior to 50% of the overlap which is available when the tubes are fully compressed (LZ). In the shortest operating length the tubes must not buttom against each other. A minimum clearance(a) = approx. 40 mm must still be available.

Cut the male and female guardtubes to the correct length.

3

Then cut the same length from the male and female profile tubes.

File the cut area to remove any metalburrs and wipe off any metal fillings.

Grease the sliding surface of the profile tubes. (fig. 3)

1

Mounting universal drive shaft

4

Adjust the universal drive shaft to the tractor before mounting – see »Adapting the PTO shaft length«, page 8.2).

3 2

Fit guard cone (1) to the double gearbox.

Connect the universal drive shaft end with freewheel mechanism and friction clutch to the double gearbox.

Fit pipe clamp (2) with chain (3) to the drive shaft guard tube.

4

Connect the chain to bracket (4) to keep the universal drive shaft clear of the ground when the machine is stored. (fig. 4)

8.3

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Before Operation Attaching the universal drive shaft 5

Danger!

Never remove the guards (5) from the universal drive shaft!

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

6

– Attach the safety chains (6) for the drive shaft guard to the machine and the tractor with the hook.

5

Connect the PTO shaft to the tractor PTO spline.

The overload clutch must be at the machine end.

The stroke length of the universal drive shaft must be checked on the raised and lowered mower unit as well as in the tilted position.

Correct the shaft length as necessary – see »Adapting the PTO shaft length«, page 8.2).

Secure universal drive shaft guard against rotating by securing the chains (6). (fig. 5) Caution!

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

Monitor the maximum p.t.o. speed – see »Specifications«, page 6.1)!

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

Monitor the maximum universal drive shaft bending! – see »Wide angle synchronised joint«, page 8.4)« Wide angle synchronised joint Maximum permitted joint bending: For permanent operation:

25°

For operation over a short period:

45°

When stationary:

90°

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

8.4

Before Operation Hydraulic system Caution!

Risk of soiling of the tractor hydraulics system!

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

DISCO 3000 TC / TC FG / TRC: 1 single-acting control valve - To lift & lower the machine.

1 double-acting control valve - To move the machine to working position.

- To move the machine to transport position.

DISCO 3000 AS: 1 single-acting control valve - To lift & lower the machine.

1 single-acting control valve - To lift & lower the cross conveyor belt.

1 double-acting control valve.

- To move the machine to working position.

- To move the machine to transport position.

Shut-off valves: Danger!

To avoid any unintentional lowering of machine:

A 11

– Close the shut-off taps (11) before any road transport and before disconnecting the hydraulic hoses. (fig. 6 , 7) B 6 Shut-off taps (11) must always be opened during field operation and for lifting and lowering the machine.

A 11

B

8.5

Position (A):

Shut-off valve open

Position (B):

Shut-off valve closed

(fig. 6 , 7)

7

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Before Operation Shut-off valve DISCO 3000 TC FG

B

Caution!

A

To avoid any unintentional operation of the swath deflectors!

12

– Close shut-off tap (12) (fig.) before any road transport and before disconnecting the hydraulic hose. (fig. 8)

8 Shut-off tap (12) must always be opened during field operation and for moving the swath deflectors.

Position (A):

Shut-off valve open

Position (B):

Shut-off valve closed

(fig. 8) Electric connection Connect the 7-pole plug (13) for lighting equipment to the socket provided on the tractor.

13

(fig. 9)

9

Water Filling DISCO 3000 TC / TRC 14

Caution!

The left hand wheel (14) can lift clear of the ground at high forward speed!

– Fill the air tube with liquid to ballast the wheel.

10

Replace the air tube of the left hand wheel by an air tube (11.5/80-15.3) with water filling valve (TR 218). (fig. 10, 11)

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

8.6

Before Operation

Caution!

Danger of detonation!

– Never add water to calcium chloride!

– Add small quantities of calcium chloride to the water and mix thoroughly.

Jack up the machine.

Turn the left hand wheel until the valve is at the top.

25%

Fill the tube to 75% with the water & calcium chloride mixture using a water filling and emptying device (“Hanauer Maus”) (fig. 11).

Water + Calciumchlorid Ballast weight

75%

41 litres 24 kg 65 kg

Inflate the tyre to the prescribed pressure (2.5 bar).

68996

11

Prop Stand After hitching raise the mower slightly with the tractor 3-point linkage. Remove pin (15). (fig. 12)

15

12 Fold up stand (16) and secure to the top hole using locking pin (15).

Secure locking pin (15) by R-clip. (fig. 13)

15

16

13

8.7

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Before Operation Pull rope DISCO 3000 TC FG

17

Pull rope (17) which operates limit stop (18) must be routed towards the tractor and fixed at the operator’s reach.

18

(fig. 14)

14

STORING THE MACHINE Danger!

Switch off the engine before working on the machine.

– Remove the ignition key!

Caution!

Lay out the hydraulic hose so the coupling pin does not get contaminated.

Note!

Only park the mower unit on firm and even ground.

• Shift mower to transport position.

• Withdraw locking pin (1), fold down stand (2) and secure to the lower hole using locking pin (1).

• Secure locking pin (1) by R-clip.

• Lower the machine onto the ground.

1

(fig. 15)

2 15

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

8.8

Before Operation • Close the shut-off taps – see »Hydraulic system«, page 8.5).

3

• Disconnect the hydraulic hoses from the tractor and connect them to the dummy connectors (3).

• Remove the pull rope (DISCO 3000 TC FG) from the cab and store it on the machine clear of dirt. (fig. 16)

16

• Disconnect the lower links.

• Remove the universal drive shaft from the tractor

5

and connect chain (4) to bracket (5) to keep the shaft clear of the ground.

4

(fig. 17)

17

PRIOR TO TRANSPORT Danger!

Switch off the engine before working on the machine.

– Remove the ignition key!

8.9

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Before Operation 1. Hitch mower to tractor – see »Attachment to the tractor«, page 8.2).

2

2. Connect PTO drive shaft and hydraulic hoses – see »Drive shaft«, page 8.2) und »Hydraulic system«, page 8.5.

1

3. Raise prop stand. – see »Prop Stand«, page 8.7).

4. Lift out mower and swivel into transport position – see »Transport position«, page 9.15).

5. Close the shut-off taps – see »Hydraulic system«, page 8.5).

18

6. Fold up the right and left hand guards (1) and secure using supports (2) (fig. 18, 19).

2

Caution!

1

While driving take care that the operating lever of the hydraulic mechanism will not be operated unintentionally.

19

Transport on Public Roads

• When moving the machine on public roads, observe the traffic regulations in force in your country.

• Observe the applicable regulations in your country.

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

• The vehicle ground speed must conform to the traffic and road conditions. Observe national (nation-specific) provisions concerning the maximum permitted vehicle ground speed!

Maximum driving speed 40 km/h.

Reduce speed as appropriate when going around curves.

• Prepare machine for transport – see »Prior to transport«, page 8.9).

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

8.10

Operation

Operation

9 Operation OPERATION Working position Danger!

Switch off the engine before working on the machine.

– Remove the ignition key!

No persons are allowed to stand in the swivelling range of the mower unit.

– Direct all persons away from the danger area!

– Switch off the machine immediately if necessary!

– Only switch on the p.t.o. shaft after fully lowering the mower unit.

A

When lowering the machine from the transport into the working position and vice versa there is clear danger of injury to persons in the swivelling area due to shearing and squashing points.

1

– Never reach into danger zones as long as parts can still move there!

1 Open the shut-off taps (1 -2). (Machine position A). (fig. 1, 2, 3) A 1

2 DISCO 3000 TC FG

A

2

3

9.1

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Operation Drive slowly forward with the tractor and at the same time run drawbar cylinder (3) fully out by operating the double-acting control valve.

The machine moves to working position.

3

(fig. 4)

4 During this operation the swath deflectors (4) of DISCO 3000 TC FG are folded to the right.

4

(fig. 5)

4

5 Run lifting cylinders (5) fully in by operating the single-acting control valve.

5

The machine is lowered into cutting position. (fig. 6)

6 Turn support (6) to the top and fold down the right and left hand guards (7).

6

(fig. 7, 8)

7 7

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

9.2

Operation

6

7

8

Adjusting the working height Danger!

Switch off the engine before working on the machine.

8

– Remove the ignition key!

Risk of injury due to foreign objects being propelled forwards.

– Reduce the tilt angle (Z) of the machine on uneven ground. This produces a greater cutting height and reduces any danger of propelling foreign objects forwards.

9

Caution!

A smaller cutting height produces greater wear on the cutting discs and blades. (fig. 9) Release spring hook (9).

Turn crank (10).

Turn crank cw to increase the cutting height.

Turn crank ccw to reduce the cutting height.

Secure the crank handle by connecting spring hook (9).

10

(fig. 10)

9 10

9.3

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Operation Adjusting the lifting height In the basic setting chains (11) are connected by the 7th link at either side of the machine (up to machine number 650 0 1976 by the 6th link).

Lifting height = 380 mm Release pin (12).

Use pin (12) to connect the chains at either side of the machine by the 6th link (up to machine number 650 0 1976 by the 5th link).

Lifting height = 430 mm

12

11

11

Secure pin (12) by washer and split pin.

Note!

This adjustment will move the cutterbar approx.

25 mm higher. (fig. 11, 12)

11

12 12 Adjusting the conditioner DISCO 3000 TC / TC FG / AS Release spring hook (13).

14

Turn crank (14).

Turn crank cw to reduce conditioning intensity.

Turn crank ccw to increase conditioning intensity.

Secure the crank handle by connecting spring hook (13).

13

(fig. 13) 13 Adjusting the conditioner speed

DISCO 3000 TC / TC FG / AS Conditioner speed can be reduced when operating in particular conditions (e.g. very light crop or low crop density).

15

To do this remove the lower V-belt guard.

Release V-belt (15) – see »Checking V-belts«, page 10.8.

14

Interchange the top and lower V-belt pulleys. When reinstalling the pulleys be sure that shims and locating discs are correctly positioned. (fig. 14, 15)

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

9.4

Operation DISCO 3000 TC: A = 900 rpm B = 770 rpm

DISCO 3000 TC FG / AS: A = 1030 rpm B = 670 rpm (fig. 15) 15 Adjusting the swath width

DISCO 3000 TC / AS Swath width can be varied to match the crop density.

16

Release toggle nuts (16) on right and left.

Move the swath deflectors as required.

Inwards (A) to reduce the swath width; outwards (B) to increase the swath width.

Retighten the toggle nuts (16) firmly. (fig. 16) 16 Adjusting the cross conveyor

DISCO 3000 AS When extremely light crops are handled, the crop flow from the baffle plate to the cross conveyor is no longer ideal. The consequence is that the crop is not fed satisfactorily by the cross conveyor. This problem can be overcome by adjusting the cross conveyor.

Remove the supports (17) on the RH and LH side. (fig. 17)

17 17

When handling long crops: Fit the cross conveyor on the LH side to the front holes (18) and on the RH side to the rear holes (19).

The cross conveyor takes then a slightly oblique position to the travel direction. The crop is fed more rearwards. (fig. 18, 19)

19

9.5

18

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Operation When handling short crops: Fit the cross conveyor on both sides to the front holes (18). (fig. 19)

18 19 Adjusting the cross conveyor projection range

DISCO 3000 AS Turn switch (19) can beused to vary the projection range of the cross conveyor to match the crop density.

Position 0

= minimum projection range

Position 10

= maximum projection range

(fig. 20)

19

20 Adjusting the swath deflectors

DISCO 3000 TC FG Release mushroom head screws (20).

Moving the plate extensions in the slotted holes.

To the rear will reduce the swath width.

To the front will increase the swath width.

20 Note!

Danger of blockage!

21

When crop density is very high, avoid moving the extensions excessively to the rear.

Tighten mushroom head screws (20). (fig. 21)

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

9.6

Operation Locking the swath deflectors manually

DISCO 3000 TC FG Remove strut (21) of the protective cloth.

21

Remove connecting bolt (22) or threaded pin.

Move swath deflectors outward. (fig. 22)

22 22 Close shut-off tap (23) (Position B).

B

The swath deflectors will remain in the selected position. (fig. 23) 23

23

9.7

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Operation Using the mower unit Danger!

Danger due to rotating tools and propelled foreign objects!

– Direct all persons away from the danger area!

– Switch off the machine immediately if necessary!

– The mower unit must be fitted with a safety guard when in use.

– All safety frames must be folded downwards.

– A damaged or worn safety guard must be replaced immediately!

– Never lean on the safety guard or tread on it.

– Keep the area to be mowed free of foreign objects.

Danger!

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

Only conduct work on the mowing blades or their mountings when the drive and cutting discs are stationary!

– Disengage the PTO shaft.

– Switch off engine.

– Remove the ignition key.

– Wear gloves!

Caution!

Before any field operation and after the mowing unit has struck an obstacle: – Check mowing unit for damage and wear and repair as required.

– Check mowing unit for damaged, missing or worn blades and replace blades as required.

– Check cutting blades for correct installation.

– Check blade holder pin for damage and wear and replace as required.

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

9.8

Operation 1. Carry out "Before Operation" steps – see »Check and observe the following before putting into operation!«, page 8.1.

2. Bring machine into working position – see »Working position«, page 9.1.

3. Block three point linkage.

4. When working the hydraulics control lever for the tractor hydraulics connection must be set to »Swimming position (free movement)«.

5. Before passing over the forage switch on the tractor p.t.o. shaft at idling speed and slowly increase to its highest permissible speed (maximum rotational speed – see »Specifications«, page 6.1.

Note!

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

6. Move into the forage.

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

8. 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).

Mowing Danger!

To clear a blockage or remove an obstruction, proceed as follows: – Switch off the PTO. – Stop the tractor engine.

– Wait until the cutting discs are at a complete stop before leaving the tractor cab!

– Remove the ignition key!

– Wear protective gloves!

After a long service time the cutterbar can reach a temperature up to 80°C. – Danger of burning!

– Keep hands clear of the cutterbar.

9.9

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Operation

Attention!

An ear protectionshould be used if the tractor is notfitted with a cab or the cab windows and doors are opened.

Remove ear protection before travelling on public roads.

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

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

• Do not mow on rocky ground!

• Avoid extended and frequent overloads of the PTO driveshaft clutch (24) (fig. 24).

24

24

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

9.10

Operation Environmental protection Using a slightly different mowing technique will help to reduce the loss of animal life.

It will also result in an improved crop quality.

Environment!

Mowing from outside towards the centre will hardly allow animals to escape!

– Always mow from the centre towards the outside of the field!

Go to the field centre and mow towards the outside of the field.

The centre can be mown when sufficient place is available for turning.

This will give animals a chance to escape outwards. (fig. 25)

69018

25 When operating in a long and narrow field, it is recommended to mow first the headland and then lengthwise starting in the centre. (fig. 26, 27)

69019

26

69020

27

9.11

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Operation This mowing technique is ideal in extremely long fields situated close to highways - especially when a front mounted mower is used. (fig. 28)

69021

28

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

9.12

Operation Mowing in combination with the cross conveyor

DISCO 3000 AS

1.

The cross conveyor feeds the mown crop towards the LH side where it is laid onto the previously made swath.

When on an odd number bout (1, 3, 5 …) always mow with the cross conveyor folded up (25). The conveyor belt will stop automatically.

25

Before the 2nd, 4th, 6th … bout fold down the arm of the cross conveyor by operating the single-acting control valve. The conveyor belt stars running automatically.

The 2nd, 4th, 6th … bout has to be mown with the cross conveyor folded down.

2.

(fig. 29)

26

29 Mowing in combination with a cross conveyor and front mounted mower

DISCO 3000 AS The mown crop is laid into one swath in a single operation.

Fold down the arm of the cross conveyor by operating the single-acting control valve. The conveyor belt stars running automatically. (fig. 30)

30

9.13

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Operation Mowing in combination with the Flapgrouper

DISCO 3000 TC FG The Flapgrouper feeds the mown crop towards the LH side where it is laid onto the ground close to the previously made swath.

A

Open shut-off tap (27) (position A).

27

(fig. 31)

31 With mower moved from transport to working position the swath plates of the Flapgrouper are positioned on the RH side.

3.

When on an odd number bout (1, 3, 5 …) always mow with the swath plates of the Flapgrouper on the RH side (28).

Before the 2nd, 4th, 6th … bout drive slowly forward and fold the swath plates and the mowing unit of the Flapgrouper to the LH limit stop using the drawbar hydraulic system.

28

The 2nd, 4th, 6th … bout has to be mown with the swath plates on the LH side (29). (fig. 32)

4.

29

32

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

9.14

Operation Poor conditions Danger!

Be particularly cautious when working in difficult conditions or on uneven ground. To prevent flying objects note the following points: – Make sure no-one is in the area of danger.

– Stop the mower unit immediately if necessary!

– Increase cutting height by extending the upper link – see »Adjusting the working height«, page 9.3.

The mower head should be tilted slightly to the front or at most horizontally.

– Reduce ground speed – Check whether the blades can swing to the rear after colliding with an obstacle.

Transport position Danger!

Switch off the engine before working on the machine.

– Remove the ignition key!

Only swivel the machine into the transport position when the p.t.o. shaft is switched off and the cutting discs and conditioning rollers are stationary.

– Never engage the PTO with the machine in transport position.

When lowering the machine from the transport into the working position and vice versa there is clear danger of injury to persons in the swivelling area due to shearing and squashing points.

– Never reach into danger zones as long as parts can still move there!

9.15

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Operation • Fold up the RH and LH guards (30) and secure using the supports (31). (fig. 33, 34).

• Lift the mowing unit slighly by operating the lifting 31

cylinder

30

• Drive slowly forward with the tractor and at the same time run the drawbar cylinder fully in by operating the double-acting control valve.

The machine moves to transport position.

33

31

30

34

• DISCO 3000 TC FG: Operate pull rope (32) and keep it taut.

Drive slowly forward with the tractor and at the same time run the drawbar cylinder (33) fully in by operating the double-acting control valve.

The machine moves to transport position.

32

33

(fig. 35)

35

OPTIONAL EQUIPMENT High Cut Skids For high cut and for working on abrasive ground the mower can be fitted with 30 mm high cutskids.

1

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

Order no.:

B03 0020

(fig. 36)

36

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

9.16

Operation Push-on runners Additional runners (2) can be screwed on if the slide runners have suffered much wear.

Order no.:

C03 0030

(fig. 37)

2 37 Extra conditioning plate (DISCO 3000 TC / AS up to machine no.: 650 0 2627) To increase conditioning intensity an extra plate (3) can be bolted under the standard conditioning plate.

Order no.:

952 814.0

(fig. 38)

3 38

Kit for detachable forks With the kit for detachable forks for the tractor can be connected to an 8-section PTO shaft (ø=13/8“). This is achieved by exchanging the detachable fork (4) of the universal drive shaft.

Order no.: (fig. 39)

4

67608

974 397.0

39 Hydraulic adapter kit for tractors This adapter kit is provided for tractors whose hydraulic system does not fit the CLAAS connectors.

Order no.:

958 222.0

(fig. 40)

68693

9.17

40

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Operation Wide Spreading Hood 5

DISCO 3000 TC Under good drying conditions or when mowing forage for greensilage the mower can be fitted with a wide spreading hood (1).

Order no.:

934 900.0

(fig. 41)

41 Swath plate extension DISCO 3000 TC If a narrow swath is required, the LH swath deflector can be fitted with an extension (6).

Order no.: (fig. 42)

6

69031

934 767.0

42 Electric lifting system DISCO 3000 AS This adapter kit is provided for tractors equipped with only one single-acting control valve.

The adapter kit can be used to alternate between the functions “lifting the machine” and “lifting the cross conveyor”. There is no need to leave the tractor cab.

Only one single-acting and one double-acting control valve are required.

69029

Order no.: 43

R03 0050

(fig. 43)

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

9.18

Maintenance

Maintenance

10 Maintenance IMPORTANT MAINTENANCE INSTRUCTIONS

After each wheel installation, retighten wheel nuts orbolts after the first 10 operating hours and then check fortightness every 50 operating hours. For the tighteningtorques see specifications).

Always observe the prescribed inflation pressure, see»specifications«.

Danger!

The drive system can suddenly start running while work is carried out on the machine.

Danger of injury!

Hydraulic System Danger!

– Disengage the drive mechanism and stop the engine before any maintenance, servicing or cleaning work and before the elimination of malfunctions.

– Remove the ignition key and disconnect the universal drive shaft.

Hydraulic oil forced out under high pressure can break the skin and cause severe damage to health. In case of injury by hydraulic oil report immediately to a doctor as there is a grave risk of infection!

– Before working on the hydraulic system, it isessential to release pressure from the system and to unfold the rotors.

– Inspect hydraulic hoses regulary and replace damaged or deteriorated hoses by new ones.

Danger!

Components under tension can suddenly be released. Danger of injury!

– Before carrying out any assembly work it is essential to release components under tension such as springs, pressure accumulators etc. according to instructions.

Environment!

Discard used oil and grease according to regulations!

Danger!

When in the raised position the machine can lower inadvertently while repair, service or cleaning work is carried out!

– Use appropriate supports to secure the lifted machine.

Wheels / tyres Danger!

Damaged tyres can suddenly loss their inflation pressure and cause the machine to roll sideways!

– Periodically check tyres for damage and correct inflation pressure.

– Repair work on tyres must only be carried out by skilled workers and with suitable tools.

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

Bolts Check all bolts for tightness and retighten if necessary.

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

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

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

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

Occasionally lubricate all joints with oil or grease.

Environment!

Discard used oil and grease according to regulations!

Danger!

Avoid an excessive inflation pressure.

Danger of bursting!

– Stand clear of the tyre when inflating.

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

– Periodically check the inflation pressure.

10.1

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Maintenance

Maintenance GEARBOXES Danger!

Switch off the engine before working on the machine.

– Remove the ignition key!

Main Gearbox For the lubrication of the main gearbox only transmission oil SAE 85W-90 conforming to (MIL-L-2105 B) API-GL-5-90 must be used. Check oil level daily and correct as required.

1

Oil filling capacity: 2 x 2,0 litre

Top gearbox: 1

1 = breather valve and oil filling opening 2 = Oil filler and oil level check plug 3 = Oil drain plug Lower gearbox:

2

4 = breather valve and oil filling opening 5 = Oil level check plug

3

4

6 = Oil drain plug (fig. 1, 2) Filling with oil:

5 6

2

Move drawbar to horizontal position. Pour oil through the oil filling opening or the checking opening.

Oil change: After commissioning or after a gearbox overhaul undertake the first oil change after 30 working hours, then every 1000 working hours and, at the latest, after each harvesting season.

Draining oil: Top gearbox: Move drawbar to horizontal position. Drain oil through drain plug (3). (fig. 3)

3

3

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

10.2

Maintenance Lower gearbox: Secure the headstock by an appropriate lifting device.

Remove bolts (7) at either side of the lower gearbox.

Remove the headstock.

Move drawbar to horizontal position. Drain oil through drain plug (6).

Reinstall the headstock and tighten bolts firmly.

7

(fig. 4) 6

4

Note!

The used oil can also be removed by suction. It is however advisable to drain the oil.

Unscrew and clean the breather valves (1) and (4) after the first 10 operating hours. Then periodically check the breather valves for proper function and clean if required.

1

Note!

To service the breather valves of the top gearbox it is necessary to remove the bolts (8) at either side and pull off the top gearbox from the drive shaft.

5

Secure the main gearbox by an appropriate lifting device before starting removal! (fig. 5, 6)

8

4

6

10.3

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Maintenance Angle driv For the lubrication of the main gearbox only transmission oil SAE 85W-90 conforming to (MIL-L-2105 B) API-GL-5-90 must be used. Check oil level daily and correct as required.

Oil filling capacity: 1,5 litres 9 = Breather valve and oil filling opening 10 = Oil level check plug 9

11 = Oil drain plug Filling with oil: Move drawbar to horizontal position. Pour oil through the oil filling opening or the checking opening.

Oil change:

10 7

After commissioning or after a gearbox overhaul undertake the first oil change after 30 working hours, then every 1000 working hours and, at the latest, after each harvesting season.

Draining oil: Unscrew cover (12) of the service opening.

Move drawbar to horizontal position. Drain oil through drain plug (11).

Reinstall cover (12) of the service opening. Tighten bolts firmly.

11

(fig. 7, 8)

12

8

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

10.4

Maintenance Cutterbar Danger!

Danger of burns!

After extended operation the mower head can reach temperatures up to around 80° C. – 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.

Danger!

The drive system can suddenly start running while work is carried out on the machine.

Danger of injury!

– Any work on the mower must only be performed with the drive system and engine switched off.

– Disengage the PTO – Stop the engine and do not leave the tractor cab until the cutting discs are at a complete stop.

– Remove the ignition key!

Only use EPSAE90 gear oil to lubricate the cutting disk gearbox. Check the oil level in the gearbox daily and add oil if necessary.

Oil filling capacity:

17

4,5 litres 17 = Oil filler and oil level check plug 18 = Oil drain plug (fig. 9, 10, 11) 9

10.5

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Maintenance

18

10

17

Y

17

X 69041

11 Checking the oil level:

• Lower the mower onto a level area.

• Warm mowing unit up by running it abt. 10 minu-

19

tes.

• Disengage the PTO. • Lift the cutterbar.

• Prop the cutterbar on the RH side using a squared timber. X = 100 mm.

• Lower the RH side of the mower onto the squared timber and the LH side onto the ground.

12

• • • •

Stop the engine.

Remove the ignition key.

Use crank (19) to set mower tilt horizontal.

Check the oil level through the opening of oil filler and level check plug (17) using a dipstick. Introduce the dipstick vertically until it reaches the cutterbar floor.

Prescribed oil level: Y = 4 - 6 mm

• If necessary refill with fresh oil through the opening of oil filler and level check plug (17). (fig. 11, 12)

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

10.6

Maintenance

Note!

If it should not possible to determine the correct oil level, it is necessary to change the oil.

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

Draining oil: 18

• Lower the mower onto a level area. To ensure that all the used oil is drained, the cutterbar must be horizontal or tilted to the LH side.

• Warm mowing unit up by running it abt. 10 minutes.

13

• • • • •

Disengage the PTO. Lift the cutterbar.

Stop the engine.

Remove the ignition key.

Drain the oil through the opening of oil drain plug (18). Clean oil drain plug (18) (magnetic plug) before reinstalling it (fig. 13).

Automatic chain lubrication DISCO 3000 TRC Each time the machine is moved from transport to working position, lubrication pump (14) feeds oil onto the drive chains of the conditioner rollers.

14

Note!

During field operation the control valve for the drawbar hydraulics should be set to floating position.

14

Note!

During a prolonged field work the drawbar cylinder should be pressurized once a hour.

This will ensure a regular lubrication of the drive chains. (fig. 14)

10.7

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Maintenance Before the first operation it is necessary to fill line (15) with oil!

16

Use only clean and biodegradable chain lubricating oil produced on the base of rape.

Caution!

Danger of fire!

– Do not add diesel fuel or other inflammable products.

15 15

Check the oil level in oil tank (16) periodically and refill with fresh oil if required.

Oil filling capacity: 1,0 litre (fig. 15)

DRIVE MECHANISM V-belts Danger!

Switch off the engine before working on the machine.

21

– Remove the ignition key!

20

Checking V-belts

16

When putting the mower initially into service check the V-belt tension after the first 5 operating hours, thereafter check the V-belt tension periodically.

To open the cover release lock (20) using a spanner (size of jaw: 13).

Periodically check the conditioner V-belts (21) for wear, breakage or other damage and replace if required.

Note!

Only replace V-belts as sets! (fig. 16)

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

10.8

Maintenance Tensioning the conditioner V-belts 23

DISCO 3000 TC / AS: Belts are at the correct tension if dimension X = 100 110 mm.

X

To tension the V-belts: Release locknut (22).

22

Turn adjusting spindle (23) until the correct dimension X is obtained. (fig. 17) 17 DISCO 3000 TRC: Belts are at the correct tension if dimension Y = 190 210 mm.

Y

24

To tension the V-belts: Release locknut (24).

Adjust using hex. nut (25) until the correct dimension Y is obtained.

Retighten locknut (24).

25

(fig. 18) 18 Tensioning the V-belts of the hydraulic unit DISCO 3000 AS: Check the belt tension through slot (26) of the cover and retension if required.

28

Release the screws (27).

Tension the belt of the hydraulic unit using screw (28).

Retighten the screws (27).

26

(fig. 19)

27 19

10.9

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Maintenance MOWER BLADES Danger!

The protective guard(1) on the mower unit should only ever be opened when the p.t.o. shaft is switch off and the engine and cutting discs stationary!

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

1 20

– Switch off mower drive.

– Switch off engine.

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

– Remove the ignition key!

– Wear gloves when working on the mower blades! (fig. 20) Caution!

Check the cutting blades before any field operation and after the mowing unit has struck an obstacle!

– Check cutting blades for correct installation!

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

– As a rule, two cutting blades per disc must be installed as otherwise damage to the mowing unit can result due to imbalance.

Only original CLAAS cutting blades must be used!

Order no.: Order no.:

952 042.0 952 043.0

Note!

Use only sharp cutting blades to obtain a good cutting quality.

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.

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

10.10

Maintenance Blade box Blade box (2) on the RH side of the drawbar contains spare cutting blades.

2

3 = Compartment for 952 043.0 cutting blades 4 = Compartment for 952 042.0 cutting blades 3

4

Blade box (2) can be removed from its support by releasing spring (5). (fig. 21, 22)

5 21

3

4

22 When cutting blades have to be replaced it is advisable to remove blade box (2) from its support and to store it next to the cutterbar. (fig. 23)

4 3 2 23

10.11

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Maintenance Changing the cutting blades (quick replacement)

Disco 3000 TC Plus / TC FG Plus / TRC Plus / AS Plus : The cutting blades must be replaced in the following cases: – If the blades are cracked or bent.

Danger!

Cutting blades coming loose from their holder can cause severe personal injury!

– Damaged cutting blades, blade holders and cutting discs must always be replaced. Never try to repair them by welding or straightening!

– If cutting blades are worn.

Width (B) of the cutting blade, measured at a distance of 10 mm from the disc border, must be at least 36 mm. (fig. 24)

24 – If the hole of the cutting blade is widened excessively.

Maximum permissible widening of the hole: from Ln = 18 mm to L = 20 mm. (fig. 25)

25

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

10.12

Maintenance Insert lever (6) between cutting disc (7) and blade holder (8). (fig. 26, 28) 6

7

26

68985

Note!

Align lever (6) parallel to the longitudinal axis of the cutting disc and pull out up to the limit stop!

6 (fig. 27)

27

68986

Clean recess (9) of the skid.

Turn the cutting disc until blade holder (9) is accurately above the recess of the skid.

Push down lever (6).

6

(fig. 28)

8 68987

9

28 Remove cutting blade (10).

Remove crop residues and dirt from the blade holder area. (fig. 29)

10

68979

10.13

29

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Maintenance

Note!

When installing a new cutting blade mind the sense of rotation!

The arrow of the blade must face the sense of rotation of the respective cutting disc. (fig. 30)

30 Install the new cutting blade with the sharp cutting edge down. (fig. 31)

68980

31 Release lever (6).

Danger!

Cutting blades coming loose from their holder can cause severe personal injury!

Be sure the cutting blades and blade holder pins are installed according to instructions.

6 68981

32

– Blade holder pin (11) must rest on the disc (see the arrows) and be seated in a straight position inside hole (12). (fig. 32, 33)

12

11 68984

33

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

10.14

Maintenance Take lever (6) out of the cutting disc. (fig. 34)

6

68982

34

Danger!

Cutting blades coming loose from their holder can cause severe personal injury!

– Be sure the cutting blades and blade holder pins are installed according to instructions.

The cutting blades must be freely movable in both directions.

68983

35 (fig. 35)

10.15

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Maintenance Changing the cutting blades (bolted version))

Disco 3000 TC / TC FG / TRC / AS : The cutting blades must be replaced in the following cases: – If the blades are cracked or bent.

Danger!

Cutting blades coming loose from their holder can cause severe personal injury!

– Damaged cutting blades, blade holders and cutting discs must always be replaced. Never try to repair them by welding or straightening!

– If the blades are worn.

Width (B) of the cutting blade, measured at a distance of 10 mm from the disc border, must be at least 36 mm. (fig. 36)

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

Maximum allowable widening of the drilled hole of Ln = 18 mm to L = 20 mm. (fig. 37)

37

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

10.16

Maintenance 1. To replace blades first clean the seat of the nut (13) and loosen the nut with the socket wrench.

13

2. Mount new blades with edge down.

3. Replace bolt and nut (13).

The cutting blade securing bolt has to be pulled up to 120 Nm torque. (fig. 38)

72187

120 Nm

38

Note!

When installing a new cutting blade mind the sense of rotation!

The arrow of the blade must face the sense of rotation of the respective cutting disc. (fig. 39)

39

Caution!

Apply DELO ML5328 (ET-No. 201 802.1) single component liquid plastics or Loctite (Typ242) (ET-No. 666 285.0) to the nuts each time same have been released.

10.17

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Maintenance Blade holder (quick blade replacement)

Disco 3000 TC Plus / TC FG Plus / TRC Plus / AS Plus : The blade holders must be checked before each field operation.

Danger!

Cutting blades coming loose from their holder can cause severe personal injury!

– Damaged cutting blades, blade holders and cutting discs must always be replaced. Never try to repair them by welding or straightening!

The cutting blades must be replaced in the following cases: – If the pin base is worn.

Max. permissible wear: X = 15 mm Y = 12 mm (fig. 40)

X Y 69049

40 – If the pin is worn in its thickness.

Max. permissible wear: W= 3 mm Z= 4 mm – If the blade holder pin shows visible cracks or if the welded seams (S) are worn. (fig. 41) S Caution!

69050

W

Z

41

Cutting blades coming loose from their holder can cause severe personal injury!

– Check the welded seams before each field operation.

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

10.18

Maintenance – If the blade holder is deformed or the blade holder pin (14) is not seated correctly in the hole of the disc. (fig. 42) 14

69051

42 – If a clearance is visible between blade holder pin (14) and hole (see the arrows). (fig. 43)

14

69052

43 – If the blade holder pin (14) is worn.

Max. permissible wear: V = 13 mm

V

(fig. 44) 14

69053

10.19

44

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Maintenance Cutting blade securing parts (bolted version)

Disco 3000 TC / TC FG / TRC / AS : The securing parts of the cutting blades must be chekked before each field operation.

Caution!

Cutting blades coming loose from their holder can cause severe personal injury!

– Check the securing bolts for correct seat when new installing cutting blades.

The cutting blade securing bolts must be replaced in the following cases: – If they show any visible deformation (e.g. after the cutterbar has struck an obstacle).

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

– If the bolt head is worn down to the knife contact surface. (fig. 45) 45 – If the shank of the bolt is worn from Dn = 18 mm down to D = 15 mm. (fig. 46)

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

– If the contact washer (1) has lost its elasticity or gets loose from the nut.

– If the securing nut is worn.

Max. permissible wear: a = H/2 (fig. 47)

47

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

10.20

Maintenance CUTTING DISCS Danger!

Cutting blades coming loose from their holder can cause severe personal injury!

– Damaged cutting blades, blade holders and cutting discs must always be replaced. Never try to repair them by welding or straightening!

Replacing cutting discs 2 1

Caution!

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. 48) 48 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 torque: Bolts (1) = 80 Nm Nuts (2) = 350 Nm (fig. 49)

69058

49

Caution!

3

Crop or other residues can accumulate inside the cones (4) if the plastic caps (3) are missing or damaged. The result can be a dangerous imbalance causing serious damage to the machine.

– Missing or damaged caps must immediately be replaced.

4

50

10.21

(fig. 50)

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Maintenance Keep outlets (5) open. This will permit water which has entered the disc to drain off (e.g. after the use of a steam cleaner). (fig. 51)

5 51

ADJUSTING THE CONDITIONER DISCO 3000 TRC Adjusting the synchronism of the conditioner rollers The two rollers of the roller conditioner must turn in opposite directions towards each other so that profile can exactly fit into each other. (fig. 52)

69062

52 For adjustment release the bolts (1) on the sprocket of the top roller.

Move the top roller in the slotted holes until the correct position is reached.

1

Retighten bolts (1) firmly. (fig. 53)

53 Adjusting the clearance between the rollers The clearance between the conditioner rollers is adjusted to dimension X = 2 - 3 mm (factory adjustment). (fig. 54)

X 69063

54

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

10.22

Maintenance The clearance between the conditioner rollers can be increased to a maximum dimension of X = 5 mm.

2 3

This will reduce conditioning intensity.

Release the locknuts (2) at either side.

Turn nut (3) until the desired clearance between the conditioner rollers is reached.

Retighten the locknuts (2).

Note!

55

The conditioner rollers must be set to the same clearance at either side! (fig. 55)

Adjusting the roller tension

4

The pressure of the top conditioner roller is created at either side by the springs (4).

The springs are adjusted to dimension Y = 227 mm (factory adjustment).

Y 6

The pressure of the top conditioner roller can be adjusted if required.

5

The higher the tension of the springs, the higher will be the pressure of the top conditioner roller.

56

69065

Increasing the spring tension increases conditioning intensity.

Release the locknuts (5) at either side.

Adjust the spring tension using nut (6).

Retighten the locknuts (5).

Note!

Spring tension must be equal at either side! (fig. 56) Tensioning the drive chains

9

Inner drive chain (7): Release pin (8).

8

Turn screw (9) to adjust the chain tension.

7

Retighten pin (8). (fig. 57)

57

10.23

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Maintenance Outer drive chain (10): Caution!

An excessive chain tension can cause the outer drive chain to break and result in serious damage!

11

– Respect the prescribed deflection of W = 10 mm.

12

58

Release the screws (11) of adjusting plate (12) at either side of the machine.

Chain tension can be adjusted by moving the adjusting plates (12) in the slotted holes.

Retighten the screws (11).

Note!

W

10

The adjusting plates must be moved by the same amount at either side!

11 Check the clearance between the conditioner rollers and adjust if required.

12 69067

59

(fig. 58, 59)

CONVEYOR BELT DISCO 3000 AS Adjusting the conveyor belt tension The pressure springs (1) for the conveyor belt tension must be set to the same tension at either side.

X

X = approx. 45 mm (fig. 60)

1

60

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

10.24

Maintenance ADJUSTING THE FLOAT SPRINGS The relieving of pressure on the mower head by the suspension springs should be set in such a way that the mower head is not pressing too strongly on the ground.

W

The load on the wheels must be high enough to ensure a good lateral stability of the machine.

Basic adjustment of the float springs (1) on the RH and LH side of the machine: X = 200 mm

1 61

Reducing dimension X will increase cutterbar flotation (recommended for soft ground).

Important!

After adjustment the ground following characteristics have to be checked. Correct as necessary by adjusting the float springs. (fig. 61)

DRIVE SHAFT Danger!

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

– Remove the ignition key!

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

Observe the safety instructions of the manufacturer!

General information on universal drive shafts Danger!

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

– Mounting shaft guard and protective tube.

– Fasten them to prevent them rotating!

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

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

10.25

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Maintenance

Protect the universal drive shafts against the weather.

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

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

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

CLUTCHES Maintenance of the Friction-Type Overrunning Clutch Bleeding the clutch is necessary after prolonged idle periods.

1 2

Tighten nut (1) completely.

Turn clutch hub (2) by hand to release the friction discs.

Turn nuts (1) back to the thread end. (fig. 62) 62 New clutch.

The edge of the pressure disc is visible (see the arrow). (fig. 63)

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

Note!

Worn friction discs must be replaced in due course. (fig. 64)

64

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

10.26

Maintenance Friction freewheel mechanism (3).

3

Torque = 1050 Nm (fig. 65)

69073

65

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

Topping up hydraulic oil DISCO 3000 AS Use only mineral oil type HLP DIN 51 524 or type HM ISO 6763/4 (e.g. HLP 46 - Tellus oil 46).

13

Check the oil level periodically and refill with fresh oil if required.

Unscrew the cover with dipstick (13). The oil level must reach the area between the dipstick marks.

Tank capacity: 66

7,0 litres (fig. 66)

Hydraulic Hose Lines Check hydraulic hose lines beforeinitial commissioning of the machine and at least once a year.

In case of damages and aging, replace the hydraulic hose lines!

Note!

Hydraulic hose lines may be used for max. 6 years after manufacture.

67 The date of manufacture (monthand year) can be read on the hydraulic hose line.

Example: "2 Q-02" indicates that the date of manufacture is the 2nd quarter of 2002. (fig. 67)

10.27

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

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

Thereafter check the screws regularly for tightness.

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

Replace connecting elements with new ones where necessary.

END OF SEASON STORAGE 1. Clean all dirt off the machine.

2. Clean off grease and dust from the exterior of all bearings.

3. Perform an oil change on the angle drive, condi-tioner gearbox and mower head.

4. Thoroughly lubricate all lubrication points until the grease flows out of the bearings – see »Lubrication Chart«, page 11.1.

Let the mower unit run for a short time.

5. Check machine for wear and damage and have it repaired.

6. Remove V-belt and store safely in a dry place.

7. Clean rust off and repair paint damage.

8. Store machine in a dry weatherproof space away from synthetic fertiliser.

9. Bring machine into its working position.

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

10.28

Maintenance PROBLEMS Problem

Cause

Vibration

– Plastic cover missing.

Remedy

• Clean the attachment on the cutting disc and the plastic cover immediately.

– Feeder drum dirty.

Poor adaptation to ground contours

– Wrongly adjusted frame.

• Clean the feeder drum.

• – see »Adjusting the float springs«, page 10.25.

– Joints on mower head seized.

• Clean joints and lubricate.

Incorrect tilting angle of the cutterbar

– Cutterbar tilt poorly adjusted.

• Adjust the cutterbar tilt –

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

– Tilt of mower head too large

see »Adjusting the working height«, page 9.3.

• Reduce tilt of the mower head – see »Adjusting the working height«, page 9.3.

– Excessive PTO speed.

• Reduce PTO speed to 900 rpm

– Ground speed too high.

– Blunt or damaged mower blades.

• Reduce ground speed.

• Replace mower blades – see »Mower blades«, page 10.10

• Reduce speed for light forage.

– Wrongly adjusted tilt of the mower head.

• Adjust the cutterbar tilt –

Fodder pushed forwards before being cut (creating stripes)

– Swirling effect of the mower blades in light crops.

• Reduce p.t.o. speed and incre-

Swathe too broad

– Crops growing too thickly.

• Adjust swath deflectors –

Stubble too high

see »Adjusting the working height«, page 9.3.

ase ground speed.

see »Adjusting the swath width DISCO 3000 TC / AS«, page 9.5.

10.29

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Maintenance

Problem Dirt accumulation in the front part of the cutterbar

Cause – Very moist conditions.

– Insufficient flotation.

– Molehills

Remedy

• Increase the cutterbar flotation – see »Adjusting the float springs«, page 10.25

• Increase the cutting height – see »Adjusting the working height«, page 9.3.

• Install wear-resistant skids.

• Raise the mowing unit from time to time if required.

• Clean the mowing unit.

Excessive wear of discs and knives

– Very difficult operating conditions.

• Install wear-resistant skids or highcut skids.

• Increase the cutterbar flotation – see »Adjusting the float springs«, page 10.25.

Increased wear on runners

– Stony, sandy ground.

– Runners not lying parallel to the ground.

• Attach wear runners.

• Increase load relief on mower unit – see »Adjusting the float springs«, page 10.25.

• Set runners flat on the ground (for extreme high cutting wear at certain points on the slide).

Build up of piles in the swathe

– Light and wet crops.

– Hilly terrain

Plugs on the swathe plate

– Strong crops – Wrong mounting of the swathe plate.

Winding of the outer conveyer drum

– Strong and flattened crops.

• Reduce PTO speed and increase forward speed.

• Fold swath deflector outward – see »Adjusting the swath width DISCO 3000 TC / AS«, page 9.5.

• Check V-belt tension, increase if necessary – see »Tensioning the conditioner V-belts«, page 10.9.

• Check rotational speed, increase if necessary.

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

10.30

Maintenance

Problem

Cause

Crop wrapping around conditioner

– Considerable drop of the tractor engine speed.

– High crop density and lodged crop.

Remedy

• Check V-belt tension and increase if required – see »Tensioning the conditioner V-belts«, page 10.9.

• Check PTO speed and increase if required.

• Reduce forward speed.

• Fold swath deflector outward – see »Adjusting the swath width DISCO 3000 TC / AS«, page 9.5.

DISCO 3000 AS: Crop not laid properly onto conveyor belt.

10.31

– Too slow a crop flow speed.

• Close conditioning plate as far as possible.

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Lubrication Chart

Lubrication Chart

11 Lubrication Chart This lubrication chart is applicable to all mowers DISCO 3000 TC / TC FG / TRC / AS from serial no. 650 0 1001.

SAFETY INSTRUCTIONS Danger!

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

– Remove the ignition key!

LUBRICANTS Good quality lubricating grease, e.g.

FINA

»Marson EPL 2«

ARAL

»Aralub HLP 2«

FUCHS

»Rendit TEP 2«

SHELL

»Retinax EP 2« oder »Alvania G3«

DEA

»Glisando EP«

FAG

»Arcanol L 135 V«

SKF

»LGEP2«

Good quality transmission oil SAE90

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.

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

11.1

Lubrication Chart

Lubrication Chart

11.2

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Lubrication Chart

1 2

7

69128

4 5

1

8

3 6

2

DISCO 3000 TC / AS

3 DISCO 3000 TC / AS

4 DISCO 3000 TRC

6

5 DISCO 3000 TRC

7

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

8

11.3

Lubrication Chart

14

11

69128

13

12

9

9 10

10 Unscrew the cover (D) to lubricate.

11.4

11

12

13

14

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Lubrication Chart

17

19

18

20

15

69128

16

15 DISCO 3000 AS

16 DISCO 3000 AS

17

DISCO 3000 TC FG

18

19

DISCO 3000 TC FG

20

293 125.8 - ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus

11.5

Lubrication Chart

11.6

ZBA + BA DISCO 3000 TC / TC Plus / TC FG / TC FG Plus / TRC / TRC Plus / AS / AS Plus - 293 125.8

Following the policy of CLAAS KGaA mbH of continuous product improvement to keep abreast of technical development, we reserve the right to make modifications which must not necessarily correspond to the text and illustrations contained in this operator's manual, and this without assuming the obligation to modify any machines previously delivered.

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

Reproduction or translation, in whole or part, only with written authorization by 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

293 125.8 ZBA+BA DISCO 3000 TC / TC PLUS / TC FG / TC FG PLUS / TRC / TRC PLUS / AS / AS PLUS EN - 11.04 Printed in Germany