Claas DISCO 3900 TC DISCO 3500 TC DISCO 3500 TRC DISCO 3100 TC DISCO 3100 TRC DISCO 3100 TC AS_RU Op

DISCO 3900 TC DISCO 3500 TC DISCO 3500 TRC DISCO 3100 TC DISCO 3100 TRC DISCO 3100 TC AS

Operator’s Manual

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71140 1 Declaration 1.1 Declaratio n ofof conform conformity ity

EC Declaration of Conformity This declaration of conformity is the original declaration of conformity according to the EC Directive 2006/42/EC We

CLAAS Saulgau GmbH Zeppelinstrasse 2, D - 88348 Bad Saulgau

declare under our sole responsibility, that the product disc mower (Type - Machine number - Trade name) F53 - from F5301001 - DISCO 3900 TC F52 - from F5201001 - DISCO 3500 TC / TRC F51 - from F5101001 - DISCO 3100 TC / TRC / TC AS to which this declaration relates meets the relevant basic safety and health requirements of the EC Directive 2006/42/EC Appendix I, For the relevant implementation of the safety and health requirements mentioned in the Directives, the following standard(s) and/or technical specification(s) has (have) been observed: EN ISO 4254-1, EN 745.

The person responsible for documentation in the European Community is: M. Geng, CLAAS Saulgau GmbH, Zeppelinstraße 2, D - 88348 Bad Saulgau

Technical Management

Quality Management

(M. Geng)

(J. Switalski)

Supply Chain Management / Production (A. Fetscher) Bad Saulgau, 07.01.2010

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

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Contents 1 Machine description 1.1 DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.1.1 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.2 DISCO 3100 TC AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.2.1 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2 Introduction 2.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2.1.1 Using the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2.1.2

Validity of manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.2 Identification plates and identification numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2.2.1 Spare parts and technical questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2.2.2

Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3 Safety 3.1 Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 3.1.1 General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 3.1.2

Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.1.3

Reasonable foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.1.4

Directives, statutes and standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.1.5

Technical condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.1.6

Occupational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.1.7

Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.1.8

Safety features on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.1.9

What to do in the event of hazardous situations and accidents . . . . . . . . . . . . . . . . . . . . . . . 22

3.1.10 Decommissioning and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 3.2 Warning and hazard signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 3.2.1 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 3.3 Safety decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 3.3.1 General instructions for warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 3.3.2

Placement on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4 Specifications 4.1 DISCO 3900 TC - Model F53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 4.1.1 Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 4.1.2

Requirements for the tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.1.3

Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.1.4

Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.1.5

Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.2 DISCO 3500 TC / DISCO 3500 TRC - Model F52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 4.2.1 Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4

4.2.2

Requirements for the tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.2.3

Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.2.4

Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.2.5

Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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4.3 DISCO 3100 TC / DISCO 3100 TRC - Model F51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 4.3.1 Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 4.3.2

Requirements for the tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.3.3

Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.3.4

Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.3.5

Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.4 DISCO 3100 TC AS - Model F51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 4.4.1 Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 4.4.2

Requirements for the tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.4.3

Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.4.4

Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.4.5

Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

5 Prior to initial operation 5.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 5.1.1 Checklist for commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 5.2 Adaptation to the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 5.2.1 Universal drive shaft - check length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 5.2.2

Universal drive shaft - adjusting length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.2.3

Mounting universal drive shaft on machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5.2.4

Adjusting the lateral offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5.3 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 5.3.1 Crop spreader (G03 0010) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 5.3.2

Swathing plate extension (G03 0060) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.3.3

High-cut skids (B03 0020) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.3.4

Skid extensions (C03 0030) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.3.5

Hydraulic connection for tractor (R03 0030) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

6 Before putting the machine into operation 6.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 6.1.1 Check list for putting into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

7 Attaching / detaching machine 7.1 Hitching the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 7.1.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 7.1.2

Connecting the hitch bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

7.1.3

Raising the prop stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

7.1.4

Fitting the universal drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

7.1.5

Coupling hydraulic hose lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

7.1.6

Connecting the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

7.1.7

Cross conveyor belt control terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

7.2 Unhitching the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 7.2.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 7.2.2

Lowering the prop stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

7.2.3

Disconnecting the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

7.2.4

Cross conveyor belt control terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

7.2.5

Decoupling hydraulic hose lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

7.2.6

Removing universal drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

7.2.7

Unhitching headstock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

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8 Driving and Transport 8.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 8.1.1 Road travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 8.1.2

Field driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

8.1.3

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

8.2 Transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 8.2.1 Folding down safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 8.2.2

Lifting the mower unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

8.2.3

Swinging to transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

8.2.4

Lowering the cross conveyor belt to working and transport position . . . . . . . . . . . . . . . . . . . . 80

8.3 Loading machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 8.3.1 Loading / unloading machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

9 Setup for work use 9.1 Working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 9.1.1 Folding safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 9.1.2

Adjusting the hitch bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

9.1.3

Adjusting the mower head load relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

9.1.4

Adjusting the cutting height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

9.2 Conditioner of DISCO 3900 TC / 3500 TC / 3100 TC / TC AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 9.2.1 Conditioner speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 9.2.2

Chicane plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

9.2.3

Swathing plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

9.2.4

Crop spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

9.3 DISCO 3500 TRC / 3100 TRC conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 9.3.1 Swathing plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 9.3.2

Mowing without conditioner effect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

9.4 Cross conveyor belt of DISCO 3100 TC AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 9.4.1 Adjusting the discharge flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 9.4.2

Cross conveyor belt – Adjusting the throwing distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

10 Working 10.1 Working in the field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 10.1.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 10.1.2 Swinging into working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 10.1.3 Lowering the mower unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 10.2 Mowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 10.2.1 Putting the machine into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 10.2.2 Mowing methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 10.2.3 Turning area position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 10.2.4 Instructions for mowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 10.2.5 Difficult conditions of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 10.2.6 Recommendation for environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 10.3 Mowing with cross conveyor belt DISCO 3100 TC AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 10.3.1 Putting the machine into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 10.3.2 Lifting / lowering the cross conveyor belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 10.3.3 Starting / stopping the cross conveyor belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 10.3.4 Mowing methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

6

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

71139

11 Maintenance 11.1 General warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 11.1.1 Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 11.1.2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 11.1.3 Wheels / tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 11.1.4 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 11.1.5 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 11.1.6 Protective guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 11.1.7 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 11.1.8 Unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 11.1.9 Cleaning and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 11.1.10 Winter storage recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 11.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 11.2.1 Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 11.3 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 11.3.1 Lubricants chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 11.4 Gearbox / clutch / universal drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 11.4.1 Main gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 11.4.2 Transfer gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 11.4.3 Angle drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 11.4.4 Maintaining universal drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 11.4.5 Friction clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 11.4.6 Venting the friction clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 11.4.7 Replacing the friction discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 11.5 Transport chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 11.5.1 Wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 11.5.2 Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 11.6 Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 11.6.1 Adjusting the hitch bracket pressure springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 11.7 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 11.7.1 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 11.7.2 Hydraulic hose lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 11.7.3 Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 11.7.4 Tensioning the hydraulic pump drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 11.7.5 Replacing the drive belt hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 11.7.6 Cross conveyor belt hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 11.8 Mowing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 11.8.1 Mower head gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 11.8.2 Mower knife box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 11.8.3 Replacing the knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 11.8.4 Knife holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 11.8.5 Maintaining the cutting disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 11.8.6 Replacing the cutting discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 11.8.7 Installing the pinion units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 11.8.8 Adjusting the safety guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 11.8.9 Anti-wrapping guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

7

71139

11.9 Crop processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 11.9.1 Tensioning the conditioner drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 11.9.2 Changing conditioner drive belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 11.9.3 Installing/removing the conditioner tines DISCO 3900 TC / 3500 TC / 3100 TC . . . . . . . . . . 159 11.9.4 DISCO 3500 TRC / 3100 TRC conditioner rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 11.10Crop discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 11.10.1 Adjusting the cross conveyor belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 11.11Attachment parts/machine body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 11.11.1 Adjusting the suspended frame tension springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 11.12Problems and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

12 Lubrication chart 12.1 Lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 12.1.1 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 12.1.2 Lubrication intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 12.1.3 Lubrication points - 8 h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 12.1.4 Lubrication points - 20 h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 12.1.5 Lubrication points - 100 h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 12.1.6 Lubrication points - 250 h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

8

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

1 Machine description 1.1 DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC 71141

1 Machine description 1.1 DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC 71400

1.1.1 Designations

1

2

3

4

5

6

11

16

15

14

13

12

10

9

8

24515

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

7

1

Main gearbox Drawbar Longitudinal frame Main frame Warning plates / lighting Wheel bracket left / right Wheel Conditioner Safety device Mower head Transfer gearbox Excavation cylinder left / right Universal drive shafts, transfer gearbox Stand Hitch bracket Lower arm pin

(Fig. 1)

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

9

1 Machine description 1.1 DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC 71141

17

18

19

27

26

20

18

25

24

23

21

22 24520

15

28

16 17

18 19 29

20

30

3 22602

17 18 19 20 21 22 23 24 25 26 27 28 29 30

2

Drive, conditioner Adjustment of swathing plate, left / right Mower knife box Swing cylinder left / right Control lever, baffle plate, conditioner (TC only) Angle drive Universal drive shaft, angle drive Control lever, cutting height Front safety guard Universal drive shaft, conditioner Adjuster, belt tension Cutting disc Mower knife Cutter bar skid

(Fig. 2, 3)

10

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

1 Machine description 1.2 DISCO 3100 TC AS 71141

1.2 DISCO 3100 TC AS 94584

1.2.1 Designations

1

2

3

18

4

5

6

19

11

16

15

14

13

12

10

9

8

7

17

80200 33169

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

4

Main gearbox Drawbar Longitudinal frame Main frame Warning plates / lighting Wheel bracket left / right Wheel Conditioner Safety device Mower head Transfer gearbox Excavation cylinder left / right Universal drive shafts, transfer gearbox Stand Hitch bracket Lower arm pin Cross conveyor belt Hydraulic oil tank Hydraulic oil pump

(Fig. 4)

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

11

1 Machine description 1.2 DISCO 3100 TC AS 71141

20

21

22

30

29

23

21

28

27

26

24

25 24520

15

31

16 17

18 19 32

20

33

6 22602

20 22 21 23 24 25 26 27 28 29 30 31 32 33

5

Drive, conditioner Adjustment of swathing plate, left / right Mower knife box Swing cylinder left / right Control lever, baffle plate, conditioner (TC only) Angle drive Universal drive shaft, angle drive Control lever, cutting height Front safety guard Universal drive shaft, conditioner Adjuster, belt tension Cutting disc Mower knife Cutterbar skid

(Fig. 5, 6)

12

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

2 Introduction 2.1 General Information 71142

2 Introduction 2.1 General Information 73809

2.1.1 Using the manual This operator's manual is the original operator's manual. In the following texts, it will be referred to simply as the operator's manual.

This operator's manual is intended mainly for the operator and provides information on the use, adjustment, operation and maintenance of the CLAAS harvester.

Please bear in mind that in the chapters below, the CLAAS harvester is also referred to as the machine.

Provided all instructions regarding maintenance and care of your CLAAS harvester are followed, you can count on many years of reliable service from the machine.

Please have your authorised dealer carry out the assembly and the regular inspections of your CLAAS harvester. Failure to perform maintenance or incorrect operation lead to a reduction in performance and a loss of time.

If proper operation and careful maintenance are ensured, your CLAAS harvester, which incorporates the latest harvesting technology, will provide you with excellent service.

Provided all instructions regarding maintenance and care of your CLAAS harvester are followed, you can count on many years of reliable service from the machine.

Texts and figures Pictures and graphics are neutral. Differences are pointed out by notes beneath the figure.

Texts are short and not machine-specific as far as possible. Differences are pointed out by intermediate headings.

Different types of texts can easily be distinguished from one another by their formats. The following formats are distinguished: Formatting

Meaning

Description

Description

Text

Further information on the subject.

Operation

Operations which must be carried out one after the other.

Result

Consequence of operations carried out.

– Instructions Result

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

13

2 Introduction 2.1 General Information 71142

Document structure based on subassemblies As far as the contents permit, the chapters of this manual are structured according to subassemblies. The structure of these subassemblies is the same in all chapters.

Different product groups have different document structures based on subassemblies. CLAAS always takes care to keep these document structures based on subassemblies identical in any documents.

Search and find The wanted subject can easily be found with the recurring subassembly structure, using the table of contents or the header line of this manual.

In addition, the index of this manual is a useful tool for locating a specific subject. The index can be found on the last pages of this manual.

Technical specifications Technical specifications, dimensions, and weights include the usual tolerances.

Directions Text elements such as front, rear, right and left always apply to the direction of travel. In figures, the direction of travel may be indicated by a direction arrow.

Your CLAAS Service Department 71600

2.1.2 Validity of manual This manual applies to the following machines: Designation

Model

Machine number from

to

DISCO 3900 TC mower unit

F53

F5301001

―

DISCO 3500 TC mower unit

F52

F5201001

―

DISCO 3500 TRC mower unit

F52

F5201001

―

DISCO 3100 TC mower unit

F51

F5101001

―

DISCO 3100 TRC mower unit

F51

F5101001

―

DISCO 3100 TC AS mower unit

F51

F5101001

―

14

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

2 Introduction 2.2 Identification plates and identification numbers 71142

2.2 Identification plates and identification numbers 71599

2.2.1 Spare parts and technical questions Please quote the identification number when ordering spare parts or making technical enquiries.

This is necessary to avoid sending incorrect spare parts.

The ID number (Fz-Ident-Nr.) can be found on the identification plate.

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

15

2 Introduction 2.2 Identification plates and identification numbers 71142 71594

2.2.2 Identification plate

2

The identification plate (1) bearing the machine number (Fz-Ident-Nr.) (2) is attached to the right side of the main frame.

1

The machine number (Fz-Ident-Nr.) (2) is also stamped into the body next to the identification plate (1).

(Fig. 1, 2, 3, 4)

1 24555

1 Bezeichnung/Désignation Typ/Type:

Scheibenmähwerk Faucheuse à disques

F53

Fz-Ident.-Nr.:

F5301001

UTyp/Variante ASF

GRP

Baujahr/Annee

2

Reception à la DRIRE

CLAAS SAULGAU GMBH 88348 Bad Saulgau Made in Germany

Zul. Ges. Gewicht

Zul. Stützlast

Zul.Achslast

PTAC

Masse max. admissible attelage

charge max. admissible

2 DISCO 3900 TC

41248

1 Bezeichnung/Désignation Typ/Type:

Scheibenmähwerk Faucheuse à disques

F52

Fz-Ident.-Nr.:

F5201001

UTyp/Variante ASF

GRP

Baujahr/Annee

2

Reception à la DRIRE

CLAAS SAULGAU GMBH 88348 Bad Saulgau Made in Germany

Zul. Ges. Gewicht

Zul. Stützlast

Zul.Achslast

PTAC

Masse max. admissible attelage

charge max. admissible

3 DISCO 3500 TC / 3500 TRC

41249

1 Bezeichnung/Désignation Typ/Type:

Scheibenmähwerk Faucheuse à disques

F51

Fz-Ident.-Nr.:

F5101001

GRP

Baujahr/Annee Reception à la DRIRE

UTyp/Variante

2

CLAAS SAULGAU GMBH 88348 Bad Saulgau Made in Germany

ASF

Zul. Ges. Gewicht

Zul. Stützlast

Zul.Achslast

PTAC

Masse max. admissible attelage

charge max. admissible

4 DISCO 3100 TC / 3100 TRC / 3100 TC AS

16

41250

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

3 Safety 3.1 Basic safety instructions 71143

3 Safety 3.1 Basic safety instructions 13330

3.1.1 General safety information • The operator's manual and the information contained therein must be read and observed to avert hazards to all people who operate, maintain, service or check this machine.

• In particular, read the “Safety” and “Before initial operation” sections.

• Before starting work, familiarise yourself with all the controls and instruments and their functions.

During work or road travel it is too late!

107126

3.1.2 Intended use The CLAAS disc mower is designed exclusively for professional use in line with the recognised regulations of agricultural practices in agricultural harvesting of forage crops.

The disc mower is an agricultural work machine that can be fitted to a tractor/towing mover approved by the manufacturer, which is suitable and intended for cutting forage crops in fields during travel. "Forage crops" are crop stalks such as grass, alfalfa, barley and rye.

The disc mower uses a cutting unit to cut standing or slightly slanting forage crops from the field. The forage crops are deposited behind the disc mower, with or without a conveying unit, for further processing.

When it is driven on public roads, depending on the applicable road vehicle regulations, the disc mower may be coupled to the front or back of a tractor/towing mover approved by the manufacturer, and driven with this vehicle.

The machine may only be used, maintained and serviced by persons who are familiar with the machine and briefed on the hazards that may arise as a result of the machine's functions.

Compliance with the conditions of operation, maintenance and servicing as specified in the operator's manual and by the manufacturer also constitute essential elements for the intended use.

The relevant accident prevention regulations, all other generally recognised regulations on safety and occupational medicine and the road traffic regulations must be observed by users and owners at all times.

Any use other than this is considered "unintended", and the manufacturer is not liable for any resulting damage. All liability in this case is borne by the user.

For specific details, you may request information on intended use in exceptional situations from CLAAS.

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17

3 Safety 3.1 Basic safety instructions 71143 107128

3.1.3 Reasonable foreseeable misuse Machine use outside of the intended use is a use not provided for by the machine manufacturer and therefore constitutes a misuse in the sense of the Machinery Directive. The manufacturer will not be liable for damage resulting from such misuse, but instead the user will be solely responsible.

Such misuse of the CLAAS disc mower includes: • Use of surfaces and spaces which are not described as a workplace or maintenance place in the Operator's Manual.

• Performing adjustment, cleaning and Maintenance work contrary to the information provided in the Operator's Manual.

• Performing troubleshooting and service while drives and/or the diesel engine are running.

• Failure to observe warnings on the machine and in the Operator's Manual.

• Performing service and repairs by personnel that is not trained for such tasks.

• Unauthorised modifications on the machine.

• Fitting of unallowed / non-approved accessories.

• Use of non-original CLAAS spare parts.

• Stationary use.

• Use for mowing / cutting of materials not referred to as forage plants such as hedgerows, bushes, maize stubbles or woody shrubs.

• Use for mowing road edges / lane edges / stony surfaces.

• Use for underfloor work (mowing / cutting).

• Transporting of persons.

• Transporting of goods.

13336

3.1.4 Directives, statutes and standards • In addition to the instructions in this manual, observe the general safety and accident prevention regulations.

• When driving on public streets, observe the applicable regulations and provisions!

• On public streets and roads, the machine must always be in transport position.

• Every time the machine is put into operation, check it and the tractor regarding traffic and operational safety.

18

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3 Safety 3.1 Basic safety instructions 71143 13340

3.1.5 Technical condition • The use of parts, accessories and ancillary equipment that does not originate from CLAAS and is not tested and approved by CLAAS may negatively alter characteristics of the CLAAS machine that are a function of its design or alter its functional performance and thereby affect the active and/or passive driving safety and occupational safety (accident protection).

• CLAAS shall not be held liable for damages that result from using non-CLAAS original parts, accessories and ancillary equipment.

• Also have the assembly of the machine and the regular inspections performed by your specialist workshop. Failure to perform maintenance and incorrect operation result in a reduction of performance and a loss of time.

• If you follow the instructions for correct operation, care and maintenance, the machine will consistently be operational and enjoy a long service life.

26630

3.1.6 Occupational safety • Wear tight-fitting clothing.

• When replacing mowing tools, use suitable tools and wear gloves.

• Avoid fire hazards, keep machine clean.

• Always fit the ballast weights to the points intended for that purpose and in line with regulations.

• Carry out work beneath the jacked-up machine only when a safe support is provided.

• Carry out repair, maintenance and cleaning work and remove malfunctions on the machine always with the drive OFF and the engine OFF. - Remove ignition key.

- No hydraulic line may be under pressure.

- The hydraulic controls of all hydraulic valves and of the tail power lift must be in the neutral position.

• Before starting, check if the machine entrains any loose parts.

• Before moving away and prior to putting the machine into operation, always check the immediate vicinity of the machine (e.g. for children).

Ensure adequate visibility.

• Carrying passengers on the machine during work and transport is not allowed.

• When working with the PTO shaft, no persons are allowed near the rotating PTO shaft or universal drive shaft.

• Even when using the machine in compliance with the intended use, stones and other objects may be thrown off. This is why no persons are allowed in the hazard area.

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3 Safety 3.1 Basic safety instructions 71143

• Particular care must be taken when working near roads and buildings.

• No persons are allowed in the working area and in the hazard area.

• Never stand in the pivot and slewing range of the machine.

• Power-operated parts (e.g. hydraulic system) have pinch and shear points.

• During operation, keep a sufficient safety distance from the cutting tools.

• After shutting down the drive, the mowing tools of the machine may continue to rotate. Approach the machine only after the mowing tools have come to a standstill.

• When hitting an obstacle, shut down the machine immediately and check for damage.

• Control mechanisms (ropes, chains, linkages etc.) of remote-controlled devices must be installed so that in any transport and working positions, no unintended movements are triggered.

• No persons are allowed between the tractor and the machine without the vehicle being secured against rolling away by applying the parking brake and/or by wheel chocks • Do not step between the tractor and the machine when actuating the external control of the threepoint hitch.

• Secure the machine before leaving the tractor!

Lower implements completely! Stop the engine and remove the ignition key.

• When the sound pressure level at the ear of the operator exceeds 85 dB (A), ear protectors must be worn.

20

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3 Safety 3.1 Basic safety instructions 71143 13346

3.1.7 Hydraulics • Male and female couplings should be labelled on hydraulic couplings between tractor and machine in order to prevent incorrect connections. If the connections are reversed, the function will be reversed (e.g. raising / lowering) – danger of an accident.

Danger!

2 33

Fluids under high pressure.

Fluids can penetrate the skin and cause severe injuries.

1 740

– Drain hydraulic pressure from the system before work.

– Work on hydraulic systems must be performed only by authorised specialist workshops.

– Regularly check hose lines.

Search for leaks using a piece of wood or cardboard.

Make sure that the stream of oil is not diverted in the direction of the body.

– Replace damaged hose lines.

– Replace hose lines no later than 6 years after the date of manufacture.

Danger!

Dealing incorrectly with injuries due to hydraulic fluids.

Death or serious injury.

Even a pinhole can result in severe injuries.

– If hydraulic fluid gets in the skin or eyes, have the injury treated by a medical specialist immediately.

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21

3 Safety 3.1 Basic safety instructions 71143 26632

3.1.8 Safety features on the machine • Put the machine into operation only when all guards are fitted and in their protecting position.

• Never put universal drive shaft into operation without a guard.

• Secure the universal drive shaft guard against rotating as well by fastening the chain.

• The safety guards must be checked at regular intervals and worn or damaged safety guards must be replaced.

• The safety devices provided on the machine, e.g. canvas and covers, protect against flying stones and the like and against access to hazardous points. For this reason, they must be moved to their protecting positions before starting work.

• Refit safety devices after carrying out maintenance work.

13352

3.1.9 What to do in the event of hazardous situations and accidents Contact with hazardous substances by: Inhalation – Supply fresh air to affected persons and consult a doctor depending on the symptoms.

– Remove people from the danger zone.

Contact with eyes – Rinse with abundant water for several minutes. If necessary, consult a doctor.

Contact with skin – Always wash with abundant water and soap; immediately remove soiled, drenched articles of clothing, if there is skin irritation (reddening, etc.) consult a doctor.

Swallowing – Do not induce vomiting; see a doctor immediately.

22

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3 Safety 3.1 Basic safety instructions 71143 107360

3.1.10 Decommissioning and disposal When the machine (or its components) reaches the end of its useful life and is surrendered as scrap, the components must be disposed of in the correct manner. The regulations of the local authorities responsible must be observed.

The operating materials in the machine require special disposal and must not be released into the environment. More information on disposal can be obtained from the local authorities responsible, your CLAAS dealer or the CLAAS service department.

– Do not dispose of products marked with the symbol (1) in your domestic waste at the end of their service life.

2 39207

3 7761

– Recycle used materials marked with the symbol (2) in accordance with their labelling.

– Recycle packaging material, do not dispose of it in domestic waste.

– Recycle plastics that are labelled with material information, e.g. PP TV 20, do not dispose of them in domestic waste.

– Used batteries contain hazardous substances and must be taken back by the distributor, disposed of correctly or delivered to a collection point. Do not dispose of used batteries in domestic waste.

– Operating materials, such as oils, hydraulic fluids, brake fluids or fuels, must be treated as hazardous waste and disposed of correctly.

– Have refrigerants disposed of only by specialist companies with experienced personnel and the necessary technical equipment. Refrigerants must never be released into the atmosphere. Have refrigerants disposed of by your CLAAS dealer.

Observe country-specific regulations.

– Follow the regulations of the local authorities responsible.

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23

3 Safety 3.2 Warning and hazard signs 71143

3.2 Warning and hazard signs 13355

3.2.1 Labels All parts of this operator's manual having to do with your safety or the safe operation of the front attachment or the machine are marked with the following signs. Please pass on all safety precautions to any other users of the machine as well.

Danger!

Nature and source of danger Consequences: death or serious injury – Countermeasures Warning!

Nature and source of danger Consequences: injuries – Countermeasures Caution!

Nature and source of danger Consequences: material damage – Countermeasures Note!

Nature and source of information Consequences: enhanced machine economy or easy assembly – Measures Environment!

Nature and source of danger Consequences: damage to the environment – Countermeasures

24

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3 Safety 3.3 Safety decals 71143

3.3 Safety decals 13359

3.3.1 General instructions for warning signs The hazard points on a machine that cannot be remedied by design or protective measures are labelled with safety decals. These safety decals help to alert persons to hazards that can cause personal injury.

The safety decals consist of 2 parts: • The first part shows the hazard inside a warning triangle.

• The second part shows how to avoid injuries and accidents by proper behaviour.

The illustrations on the safety decals consist of generally understandable pictograms. If possible, the safety decals must be placed in the immediate vicinity of the hazard point.

Genuine CLAAS safety decals carry the CLAAS part code and a production date.

The placement and meaning of the safety decals are explained as follows: – Use the 10-digit CLAAS part code in front of each safety decal for ordering.

– The safety decal number shown in ( ) indicates the correct placement of the safety decal in the accompanying illustration.

– There is a text explanation of the safety decal connected with the graphical representation.

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3 Safety 3.3 Safety decals 71143 71517

3.3.2 Placement on the machine Danger!

Hazard points on the machine.

Death or serious injury.

– Replace damaged and illegible safety decals immediately.

– When parts with safety decals on them are replaced, ensure that the relevant safety decals are applied again to the new parts.

00 0515 130 0 (2)

2

4 24521

5 Read and observe the Operator's manual and the safety precautions prior to putting the unit into operation.

(Fig. 4, 5)

26

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3 Safety 3.3 Safety decals 71143

00 0515 134 0 (33)

33

6 24521

7 Stop the engine and remove the key before carrying out maintenance and repair work.

(Fig. 6, 7)

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27

3 Safety 3.3 Safety decals 71143

00 0480 462 0 (1)

1

A

B

C

8 24522

11 Decal (A)

1

Keep a sufficient distance from the cutting units while the engine is running.

Decal (B) Do not touch any moving machine parts. Wait for all parts to come to a complete standstill.

Decal (C) 9

Keep a safe distance while the engine is running.

(Fig. 8, 9, 10, 11)

41251

1

10 24546

28

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3 Safety 3.3 Safety decals 71143

00 0514 899 0 (8)

8

12 24522

8

14 Stay outside the sweep zone when the engine is running.

(Fig. 12, 13, 14) 13 24546

00 0515 380 0 (21)

21

15 24522

17 Never move your hands in the pinch hazard area as long as parts may be moving there.

(Fig. 15, 16, 17)

21

16 24546

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29

3 Safety 3.3 Safety decals 71143

00 0516 039 0 (22)

22

18 24549

19 Do not open or remove the protective devices while the engine is running.

(Fig. 18, 19) 00 0515 139 1 (50)

50

20 24550

21 Accumulators are under gas and oil pressure. Remove and repair such components only as instructed in the technical manual.

(Fig. 20, 21)

30

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3 Safety 3.3 Safety decals 71143

00 0514 799 0 (6)

6

22 DISCO 3100 TC AS

33008

6

24 Never stand in the slewing range of implements.

(Fig. 22, 23, 24)

23 DISCO 3100 TC AS

33009

00 0516 038 0 (21)

21

25 DISCO 3100 TC AS

33264

26 Never move your hands into the pinching hazard area as long as parts may be moving there.

(Fig. 25, 26)

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31

3 Safety 3.3 Safety decals 71143

00 0516 052 0 (25)

25

25 27

DISCO 3100 TC AS

33008

28 Never step on the platform while the drive is engaged and the engine is running.

(Fig. 27, 28) 00 0514 825 0 (32)

32

32 29

DISCO 3100 TC AS

33008

30 Danger from object flung around while engine is running - keep a safe distance.

(Fig. 29, 30)

32

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4 Specifications 4.1 DISCO 3900 TC - Model F53 71144

4 Specifications 4.1 DISCO 3900 TC - Model F53 Technical specifications, dimensions, and weights are understood with the usual tolerances.

94205

4.1.1 Dimensions and weight

D

C

A

B A 76512 24778

1

Working position Width A

4380 mm

Working width B

3800 mm

Swath width

2100 - 2800 mm

Transport position Width C

3820 mm

Length D

8480 mm

Weight DISCO 3900 TC

2405 kg

(Fig. 1)

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

33

4 Specifications 4.1 DISCO 3900 TC - Model F53 71144 94208

4.1.2 Requirements for the tractor Power required for tractor

96 kW / 130 HP

PTO speed

1000 rpm

Hook-up / hitching

Lower link

Category

III

Hydraulic coupling

1 x double-acting, 2 x single-acting 94212

4.1.3 Design Maximum permissible speed

40 km/h

Number of cutting discs per mower unit

9

Number of mower knives

18

Dimensions of knives

115x48x4

Cutting disc speed

3200 rpm

Circumferential speed of knives

84 m/s

Cutting height (horizontal mower head)

40 mm

Cutting height adjusting range

30 - 70 mm

DISCO 3900 TC: Conditioner

Tine conditioner

Conditioner speed

900 rpm

Caution!

The conditioner speed must not exceed 900 rpm.

Risk of machine damage – Do not modify the pulley pair.

94210

4.1.4 Tyres

34

Chassis

340/55-16 12PR

Tyre pressure

2.5 bar

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4 Specifications 4.1 DISCO 3900 TC - Model F53 71144 111576

4.1.5 Noise level A-valuated equivalent permanent sound pressure level DISCO 3900 TC

Cab

Tractor without machine

Tractor with machine

open

closed

open

closed

Microphone arrangement (1)

dB (A)

81,4

75,3

90,9

78,0

Microphone arrangement (2)

dB (A)

88,5

85,4

93,8

92,4

Measuring method 2

1

The measuring method complies with procedure no. 4, “AGRICULTURAL MACHINERY NOISE”, HM Agricultural Inspectorate.

Test conditions compliant with ISO 5131.

The tractor used for the measurement has a power of 180 kW (250 HP).

During the measurement, the machine is standing still on a surface with short grass and runs at an operating speed of 1,000 rpm.

2

76040 23184

(Fig. 2)

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

35

4 Specifications 4.2 DISCO 3500 TC / DISCO 3500 TRC - Model F52 71144

4.2 DISCO 3500 TC / DISCO 3500 TRC Model F52 Technical specifications, dimensions, and weights are understood with the usual tolerances.

71655

4.2.1 Dimensions and weight

D

C

A

B A 76512 24778

3

Working position Width A

3965 mm

Working width B

3400 mm

Swath width

1700 - 2400 mm

Transport position Width C

3400 mm

Length D

8337 mm

Weight DISCO 3500 TC

2290 kg

DISCO 3500 TRC

2390 kg

(Fig. 3)

36

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4 Specifications 4.2 DISCO 3500 TC / DISCO 3500 TRC - Model F52 71144 71657

4.2.2 Requirements for the tractor Power required for tractor

90 kW / 120 hp

PTO speed

1000 rpm

Hook-up / hitching

Lower link

Category

II

Hydraulic coupling

1 x double-acting, 2 x single-acting 71659

4.2.3 Design Maximum permissible speed

40 km/h

Number of cutting discs per mower unit

8

Number of mower knives

16

Dimensions of knives

115 x 48 x 4

Cutting disc speed

3200 rpm

Circumferential speed of mower knives

84 m/s

Cutting height (bar horizontal)

40 mm

Cutting height adjusting range

30 - 70 mm

DISCO 3500 TC: Conditioner

Tine conditioner

Conditioner speed

1080 / 900 rpm

DISCO 3500 TRC: Conditioner

Roller conditioner

Conditioner speed

1030 rpm 94210

4.2.4 Tyres Chassis

340/55-16 12PR

Tyre pressure

2.5 bar

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

37

4 Specifications 4.2 DISCO 3500 TC / DISCO 3500 TRC - Model F52 71144 111580

4.2.5 Noise level A-valuated equivalent permanent sound pressure level DISCO 3500 TC / DISCO 3500 TRC

Cab

Tractor without machine

Tractor with machine

open

closed

open

closed

Microphone arrangement (1)

dB (A)

80,2

76,5

90,4

77,6

Microphone arrangement (2)

dB (A)

84,2

84,0

92,5

93,7

Measuring method 2

1

The measuring method complies with procedure no. 4, “AGRICULTURAL MACHINERY NOISE”, HM Agricultural Inspectorate.

Test conditions compliant with ISO 5131.

The tractor used for the measurement has a power of 103 kW (140 HP).

During the measurement, the machine is standing still on a surface with short grass and runs at an operating speed of 1,000 rpm.

4

76040 23184

38

(Fig. 4)

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

4 Specifications 4.3 DISCO 3100 TC / DISCO 3100 TRC - Model F51 71144

4.3 DISCO 3100 TC / DISCO 3100 TRC Model F51 Technical specifications, dimensions, and weights are understood with the usual tolerances.

71626

4.3.1 Dimensions and weight

D

C

A

B A 76512 24778

5

Working position Width A

3550 mm

Working width B

3000 mm

Swath width

1300 - 2000 mm

Transport position Width C

3000 mm

Length D

7337 mm

Weight DISCO 3100 TC

2220 kg

DISCO 3100 TRC

2320 kg

(Fig. 5)

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39

4 Specifications 4.3 DISCO 3100 TC / DISCO 3100 TRC - Model F51 71144 71632

4.3.2 Requirements for the tractor Power required for tractor

75 kW / 100 hp

PTO speed

1000 rpm

Hook-up / hitching

Lower link

Category

II

Hydraulic coupling

1 x double-acting, 2 x single-acting 71637

4.3.3 Design Maximum permissible speed

40 km/h

Number of cutting discs per mower unit

7

Number of mower knives

14

Dimensions of knives

115 x 48 x 4

Cutting disc speed

3200 rpm

Circumferential speed of mower knives

84 m/s

Cutting height (bar horizontal)

40 mm

Cutting height adjusting range

30 - 70 mm

DISCO 3100 TC: Conditioner

Tine conditioner

Conditioner speed

1080 / 900 rpm

DISCO 3100 TRC: Conditioner

Roller conditioner

Conditioner speed

1030 rpm 94210

4.3.4 Tyres

40

Chassis

340/55-16 12PR

Tyre pressure

2.5 bar

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

4 Specifications 4.3 DISCO 3100 TC / DISCO 3100 TRC - Model F51 71144 111579

4.3.5 Noise level A-valuated equivalent permanent sound pressure level DISCO 3100 TC / DISCO 3100 TRC

Cab

Tractor without machine

Tractor with machine

open

closed

open

closed

Microphone arrangement (1)

dB (A)

81,1

75,3

91,6

77,1

Microphone arrangement (2)

dB (A)

80,1

84,1

92,1

93,9

Measuring method 2

1

The measuring method complies with procedure no. 4, “AGRICULTURAL MACHINERY NOISE”, HM Agricultural Inspectorate.

Test conditions compliant with ISO 5131.

The tractor used for the measurement has a power of 103 kW (140 HP).

During the measurement, the machine is standing still on a surface with short grass and runs at an operating speed of 1,000 rpm.

6

76040 23184

(Fig. 6)

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

41

4 Specifications 4.4 DISCO 3100 TC AS - Model F51 71144

4.4 DISCO 3100 TC AS - Model F51 Technical specifications, dimensions, and weights are understood with the usual tolerances.

94616

4.4.1 Dimensions and weight

C

D

A

B A 80203 33170

7

Working position Width A

3550 mm

Working width B

3000 mm

Swath width

1300 - 2000 mm

Transport position Width C

3000 mm

Length D

8340 mm

Weight DISCO 3100 TC AS

2420 kg

(Fig. 7)

42

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4 Specifications 4.4 DISCO 3100 TC AS - Model F51 71144 94619

4.4.2 Requirements for the tractor Power required for tractor

75 kW / 100 HP

PTO speed

1000 rpm

Hook-up / hitching

Lower link

Category

II

Hydraulic coupling

1 x double-acting, 3 x single-acting 94623

4.4.3 Design Maximum permissible speed

40 km/h

Number of cutting discs per mower unit

7

Number of mower knives

14

Dimensions of knives

115x48x4

Cutting disc speed

3200 rpm

Circumferential speed of knives

84 m/s

Cutting height (horizontal mower head)

40 mm

Cutting height adjusting range

30 – 70 mm

Conditioner speed

860 / 1200 1/min

Cross conveyor belt: Cross conveyor belt

900 x 2200 mm

Oil supply

Hydraulic pump via universal drive shaft / belt drive

Hydraulic pump

25 l/min

Hydraulic oil tank

15 l 94210

4.4.4 Tyres Chassis

340/55-16 12PR

Tyre pressure

2.5 bar

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

43

4 Specifications 4.4 DISCO 3100 TC AS - Model F51 71144 111578

4.4.5 Noise level A-valuated equivalent permanent sound pressure level DISCO 3100 TC AS

Cab

Tractor without machine

Tractor with machine

open

closed

open

closed

Microphone arrangement (1)

dB (A)

80,0

76,8

92,9

78,5

Microphone arrangement (2)

dB (A)

87,4

86,2

95,4

95,3

Measuring method 2

1

The measuring method complies with procedure no. 4, “AGRICULTURAL MACHINERY NOISE”, HM Agricultural Inspectorate.

Test conditions compliant with ISO 5131.

The tractor used for the measurement has a power of 180 kW (250 HP).

During the measurement, the machine is standing still on a surface with short grass and runs at an operating speed of 1,000 rpm.

8

76040 23184

44

(Fig. 8)

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5 Prior to initial operation 5.1 General information 71145

5 Prior to initial operation 5.1 General information 44797

5.1.1 Checklist for commissioning All of the items listed below must be carried out and corrected if necessary.

– Check whether the tractor complies with the requirements of the machine.

– Assemble the machine – see Machine assembly manual.

– Check length of universal drive shaft.

– Lubricate machine.

– Check the lubricant fill levels in all gearboxes.

– Check hydraulic system for leaks.

– Check all nuts and bolts for firm seating.

Observe the prescribed tightening torques.

– Check tire air pressure.

– Check protective guards.

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45

5 Prior to initial operation 5.2 Adaptation to the machine 71145

5.2 Adaptation to the machine 13480

5.2.1 Universal drive shaft - check length Check universal drive shaft length in all operating positions, in order to prevent jamming or insufficient profile covering.

LZ

– Pull apart universal drive shaft halves.

– Fit universal drive shaft halves on tractor and machine sides.

– Hold universal drive shaft halves next to each other.

a PULZ

Universal drive shaft - shortest operating position LZ = universal drive shaft length pushed together 1

69307 13851

PU LZ = profile cover a = 40 mm

LB 1/2

For straight ahead driving, the universal drive shaft halves should engage within each other as far as possible but not bump ends.

1/2

If the universal drive shaft halves bump ends, they must be shortened to the required length. A displacement of a = 40 mm must be present.

(Fig. 1)

PULB

Universal drive shaft - longest operating position 2

69309 21037

LB = maximum universal drive shaft length in operation PU LB = profile cover (Fig. 2) During transport and when the drive is shut down, a profile cover (PU) of at least 100 mm must be present.

46

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5 Prior to initial operation 5.2 Adaptation to the machine 71145 67294

5.2.2 Universal drive shaft - adjusting length Caution!

a

Improperly performed work on the machine or the front attachment can lead to malfunctioning.

C 1

2

Risk of machine damage – Have adjustment and repairs performed only by an authorised specialist workshop.

3

74135 4020

– Pull apart universal drive shaft halves.

– Hold in the shortest operating position of tractor and device.

– From the edge (C) of inner protective tube (1) mark on outer protective tube (2) the dimension (a) 40 mm.

– Remove protective tubes.

– Cut off outer protective tube (2) where marked.

(Fig. 3) – Hold the severed piece (2) against the inner protective tube (1) and cut off the same length on the inner protective tube.

1

(Fig. 4)

2 4 4029

Universal drive shaft without seal on the outer profile tube

2

– Cut outer and inner profile tube at a right angle to the same length as the severed protective tube (2).

– Debur and clean cut ends.

– Grease inner profile.

(Fig. 5)

5 3732

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

47

5 Prior to initial operation 5.2 Adaptation to the machine 71145

1

Universal drive shaft with seal on the outer profile tube

2

– Unscrew screws (1).

– Pull off seal (2).

(Fig. 6) – Cut outer and inner profile tube at a right angle to the same length as the severed protective tube (2).

– Debur and clean cut ends.

6

(Fig. 5)

4021

– Mark hole (I) for seal on the outer profile tube and drill through both walls.

- Distance Y = 7 mm - Drilled hole Ø = 6 mm – Debur profile tube inside and out at the drilled holes.

– Slip on seal (2) and fasten with bolts (1).

– Mount guard.

– Push together universal drive shaft and lubricate.

I

Y

(Fig. 6, 7) 7 4031 71692

5.2.3 Mounting universal drive shaft on machine Danger!

Rotating universal drive shafts.

Death or serious injury.

– Check for secure latching of the locks or locking pins.

– Never operate universal drive shaft without protective guard.

– Replace defective protective guards on the universal drive shaft immediately.

– Observe the recommendations of the drive shaft manufacturer.

– Clean and lubricate PTO shaft.

– To facilitate the coupling operation, the universal drive shaft guard can be pushed back.

Tractor symbol on the protective tube of the universal drive shaft specifies the connection on the tractor side for the universal drive shaft.

Always mount overload and freewheel clutches on the gearbox side.

48

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5 Prior to initial operation 5.2 Adaptation to the machine 71145

Locking pin - lock – Press locking pin (1).

– Push universal drive shaft onto PTO shaft until locking pin engages in the annular groove.

1

Draw lock

2

– Pull back draw sleeve (2).

– Push universal drive shaft onto PTO shaft until catch engages.

QS lock

3 8

74145 6286

– Pull back the towing sleeve (3) until it remains in the open position.

– Push the universal drive shaft onto the PTO shaft until the QS lock automatically engages in the ring groove.

(Fig. 8) – Check if the lock has securely engaged.

– Place the universal drive shaft (1) into the holder (2) on the hitch bracket (3).

3

(Fig. 9)

2

1 9 24569

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

49

5 Prior to initial operation 5.2 Adaptation to the machine 71145 71749

5.2.4 Adjusting the lateral offset

S

S A

A

S

S B

B

C

C

D

D

76513 24781

10

The total working width can only be used if the lateral offset of the machine is matched to the track width of the tractor.

DISCO 3900 TC

50

Track width (S)

Disconnection position

Hydraulic cylinder length (X)

2200 mm

B

747.0 mm

2300 mm

C

760.0 mm

2400 mm

C

755.0 mm

2500 mm

C

751.0 mm

2600 mm

C

747.0 mm

2700 mm

D

760.0 mm

2800 mm

D

755.0 mm

2900 mm

D

751.0 mm

3000 mm

D

747.0 mm

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

5 Prior to initial operation 5.2 Adaptation to the machine 71145

DISCO 3500 TC / TRC Track width (S)

Disconnection position

Hydraulic cylinder length (X)

2200 mm

A

747.0 mm

2300 mm

A

760.0 mm

2400 mm

B

755.0 mm

2500 mm

B

751.0 mm

2600 mm

B

747.0 mm

2700 mm

C

760.0 mm

2800 mm

C

755.0 mm

2900 mm

C

751.0 mm

3000 mm

C

747.0 mm

3100 mm

D

760.0 mm

3200 mm

D

755.0 mm

Track width (S)

Disconnection position

Hydraulic cylinder length (X)

2000 mm

B

747.0 mm

2250 mm

C

751.0 mm

2350 mm

C

747.0 mm

2400 mm

D

760.0 mm

2500 mm

D

755.0 mm

2600 mm

D

751.0 mm

2700 mm

D

747.0 mm

DISCO 3100 TC / TRC / TC AS

(Fig. 10)

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

51

5 Prior to initial operation 5.2 Adaptation to the machine 71145

Adjusting the hydraulic cylinder length

3

Adjust the hydraulic cylinder length (1) on both sides:

1

– Undo the lock nut (2).

– Remove the locking pin (3).

– Adjust the length (X) of the retracted hydraulic cylinder (1) (see tables).

(Fig. 10, 11, 12, 13) 2 11 24792

1

X

12

76514 24793

1 X

13

76515 24794

Hydraulic cylinder alignment position

1

Align the hydraulic cylinder (1) on both sides:

C D

A

B

– Align the hydraulic cylinder (1) in the corresponding holes (A, B, C, D) using the locking pins (3) (see tables).

– Secure the locking pins (3).

– Tighten the lock nut (2).

C D A

(Fig. 10, 11, 14)

B 14 24795

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5 Prior to initial operation 5.3 Accessories 71145

5.3 Accessories 71750

5.3.1 Crop spreader (G03 0010) DISCO 3900 TC

1

Order no.: 00 0483 417 0 DISCO 3500 TC Order no.: 00 0483 417 0 DISCO 3100 TC Order no.: 00 0481 965 0 Under good drying conditions or for wet silaging, the mower unit can be fitted with a crop spreader (1).

15

(Fig. 15)

24598 94561

5.3.2 Swathing plate extension (G03 0060) DISCO 3900 TC 1

Order no.: 00 0480 990 0 Swathing plate extensions for a narrower swath.

The swathing plate extensions (1) are bolted to the existing swathing plates.

(Fig. 16)

16 32957 47125

5.3.3 High-cut skids (B03 0020) Order no.: 00 0482 275 0 1

For high cutting or under harsh ground conditions, 30 mm high-cut skids can be fitted.

The high-cut skids (1) are fitted onto the cutterbar skids on the right and left-hand side.

(Fig. 17)

17 14105

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53

5 Prior to initial operation 5.3 Accessories 71145 71754

5.3.4 Skid extensions (C03 0030) DISCO 3900 TC Order no.: 00 0483 245 0 DISCO 3500 TC / TRC Order no.: 00 0934 558 0 DISCO 3100 TC / TRC / TC AS Order no.: 00 0934 150 0 If the cutterbar skids are exposed to a high level of wear, additional skids (1) can be bolted onto the cutterbar skids.

1 18 9429

(Fig. 18) 71756

5.3.5 Hydraulic connection for tractor (R03 0030) Order no.: 00 0958 222 0 Tractors with a hydraulic port that is not compatible with the CLAAS connection can be converted with this installation kit.

(Fig. 19)

68693

19 4680

54

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

6 Before putting the machine into operation 6.1 General information 71146

6 Before putting the machine into operation 6.1 General information 26605

6.1.1 Check list for putting into operation Danger!

PTO shaft drive and tractor can be placed in gear unintentionally.

Danger of death or injury by drawing in and crushing.

– – – – –

PTO shaft drive OFF. Tractor motor OFF. Set tractor parking brake.

Remove ignition key.

Wait until machine parts come to a full stop.

Carry out the following activities every time before putting the machine into operation: 1 Carry out maintenance work.

2 Check if universal drive shaft moves freely and has the correct length.

3 Secure the universal drive shaft guard against rotating as well by fastening the chains.

4 Check if all safety bars, protective guards and safety blankets are complete and if they are worn or damaged.

5 Fit and lock protective guards completely.

6 Check if safety features (e.g. overload clutches, covers of drive components,...) are complete, perform their function and are seated properly.

7 Check machine for damage. Remove any existing damage before putting the machine into operation.

8 Every time before putting the machine into operation, check if knives are damaged, missing or worn. Replace knives if required.

9 Before driving off, check if the vehicle entrains any loose parts. Parts that may get lost while driving must be fastened or covered up.

10 Do not allow any persons in the hazard area.

When persons approach the hazard area, stop the machine immediately.

11 Observe the maximum PTO speed.

12 Before switching on the PTO shaft, make sure that the selected speed and sense of rotation of the tractor PTO shaft match the permissible speed and sense of direction of the machine.

13 Engage machine only in working position and at idle speed.

14 Never let the machine run while unattended.

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

55

7 Attaching / detaching machine 7.1 Hitching the machine 71147

7 Attaching / detaching machine 7.1 Hitching the machine 67346

7.1.1 General instructions Danger!

PTO shaft drive and tractor can be placed in gear unintentionally.

Danger of death or injury by drawing in and crushing.

– – – – –

PTO shaft drive OFF. Tractor motor OFF. Set tractor parking brake.

Remove ignition key.

Wait until machine parts come to a full stop.

Danger!

Risk of death or injury by pinch points and shears between the tractor and the machine when fitting and removing the machine.

– No persons are allowed between the tractor and the machine.

– Never move your hands in the pinch hazard area as long as parts may be moving there.

– Wait for all machine parts to come to a complete halt.

Caution!

The machine may sink into the ground when stationary.

The machine can then only be reattached with difficulty.

– Put the machine down on solid and level ground.

Attach machine according to specifications and only attach and secure it to the prescribed equipment.

When using a three-point hitch, the hitch categories of the tractor and the machine must absolutely match or be adapted.

Particular care must be taken when hitching or unhitching the machine to or from the tractor.

Before hitching the machine to the three-point hitch, secure the hydraulic control unit of the tractor controlling the rear power lift against unintended raising or lowering.

56

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

7 Attaching / detaching machine 7.1 Hitching the machine 71147 71694

7.1.2 Connecting the hitch bracket – Mount the ball-type profiles (1) on the lower link pins.

1

(Fig. 1)

1 1 24569

Danger!

2

The lower link hooks may open.

Loss of machine - Mortal danger – Never use or transport a machine before both lower link hooks have securely engaged and are locked.

– In particularly difficult conditions of use, secure both lower link hooks against unintended opening.

– To this end, block the hook locking through the safety bore (3) with a bolt and a nut – see also the manufacturer's documentation.

3

1 2 24570

– Adapt the lower link pins (1) to the lower link hooks (2) on the tractor.

– Adjust the lower links (2) to the same height.

– Hook the lower link pins (1) into to the lower link hooks (2) and lock in place.

– Limit the sideways movement of the lower links (2) as much as possible.

(Fig. 2) 71708

7.1.3 Raising the prop stand – Raise the lower link slightly.

– Pull knob (1) and swing stand (2) to the rear until it engages with an audible sound.

2

(Fig. 3)

1 3 24580

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

57

7 Attaching / detaching machine 7.1 Hitching the machine 71147 26838

7.1.4 Fitting the universal drive shaft Danger!

Rotating universal drive shafts.

Risk of death or severe injuries.

– Make sure the locks or locking pins are latched.

– Never operate universal drive shaft without protective guard.

– Replace defective protective guards on the universal drive shaft immediately.

– Use safety chains to prevent the power take-off shaft guards from rotating with the shaft.

Use only universal drive shafts prescribed by the manufacturer.

Protective tube and universal drive shaft guard as well as PTO shaft guard must be installed and be in a properly functioning condition.

Clean and lubricate tractor PTO shaft.

Always make sure the universal drive shaft is correctly assembled and secured!

Tractor symbol on the protective tube of the universal drive shaft specifies the tractor side connection of the universal drive shaft.

Always mount overload and freewheel clutches on the gearbox side.

To facilitate the coupling operation, the universal drive shaft guard can be pushed back.

QS lock – Pull drawing sleeve (3) back until it stops in an open position.

– Slide the universal drive shaft on the PTO shaft until the QS lock engages automatically in the annular groove.

3

(Fig. 4) – Check if the lock has securely engaged.

4

77901 32603

58

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

7 Attaching / detaching machine 7.1 Hitching the machine 71147

– Fasten the chain (1) on the tractor.

(Fig. 5) Note!

Damage and increased wear of drives.

– Let clutch engage slowly so the drives are treated with care.

– Do not exceed the allowed joint angle.

– Observe the information provided by the universal drive shaft manufacturer.

1 5 26594

Engage the PTO shaft only with the machine moved to working position.

Wide angle constant-velocity joint Max. allowed joint angle deviations at: • Continuous operation: 25° • Short-time operation: 45° • Standstill: 80°

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

59

7 Attaching / detaching machine 7.1 Hitching the machine 71147 71704

7.1.5 Coupling hydraulic hose lines Warning!

Do not mix up the hydraulic connections.

Danger of injury from reversed function (e.g. raise/lower).

– Mark the female couplings and connectors of hydraulic connections between the tractor and the machine.

– Connect the hydraulic hoses to the specified connections on the tractor, see operator's manual of tractor.

Caution!

When extending hydraulic hose lines, do not use any straight connectors.

The hydraulic flow may cut through hydraulic hoses.

– Redirect the hydraulic flow using 30° or 45° angles.

Note!

Oil pollution by soiled hydraulic couplers.

– Clean hydraulic couplers before connecting.

Oil loss by leaky hydraulic hoses.

– Watch out for abrasion marks and pinch points.

– Depressurise hydraulic system on the tractor and on the machine.

60

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

7 Attaching / detaching machine 7.1 Hitching the machine 71147

Hydraulic hose lines – Lifting – Attach the hydraulic hose line (1) to a single-acting control valve with float position (floating).

- (1) = blue mark (Fig. 6, 7) 1

6 24582

1 7 24584

Shut-off cock – hydraulic lift: – Open both shut-off cocks (2) to raise and lower the mower unit.

- Position (A): shut-off cocks (2) open. (Fig. 8) - Position (B): shut-off cocks (2) closed. (Fig. 9)

A A

2 8 24612

B

2

B

9 24613

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61

7 Attaching / detaching machine 7.1 Hitching the machine 71147

Hydraulic hoses – swivelling – Attach hydraulic hose line (1, 2) to the connections of a double-acting control valve.

- (1) = green mark - (2) = green mark

2

1

Shut-off cock – swivelling:

10 24582

– Open the shut-off cock (3) to swing the machine into the working position.

- Position (A): shut-off cock (3) open. (Fig. 11) - Position (B): shut-off cock (3) closed. (Fig. 12) The shut-off tap must be closed for road travel.

(Fig. 10, 11, 12)

1

2

B 3

11 24584

1

A

2

3

12 24586

62

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

7 Attaching / detaching machine 7.1 Hitching the machine 71147

Hydraulic hose line – Load relief 2

3 Note!

The hydraulic hose line does not need to be connected during use. However, in that case the load relief of the machine cannot be changed during use.

Connect the hydraulic hose line (3) to adjust / correct the load relief pressure: 13 24583

4

– Pull out the spring clip (2).

– Remove the hydraulic hose line with the shut-off cock from the holder.

- (3) = yellow mark – Connect the hydraulic hose line (3) to a single-acting control valve.

Shut-off cock – load relief: – Open the shut-off cock (4) for adjusting the load relief pressure.

- Position (A): shut-off cock (4) open.

- Position (B): shut-off cock (4) closed.

A B

(Fig. 13, 14) 3

14 24585

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

63

7 Attaching / detaching machine 7.1 Hitching the machine 71147

DISCO 3100 TC AS: Hydraulic hose – cross conveyor belt 1

– Connect hydraulic hoses (1) to the ports of a single-acting control valve.

- (1) = red mark Shut-off tap – cross conveyor belt: – Open shut-off tap (2) for lifting the cross conveyor belt.

- Position (A): Shut-off tap (2) open. (Fig. 16) - Position (B): Shut-off tap (2) closed. (Fig. 17) 15

The shut-off tap must be closed for road travel.

(Fig. 15, 16, 17)

33135

B

2 A

16 33136

B

A 2

17 33137

64

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

7 Attaching / detaching machine 7.1 Hitching the machine 71147 71710

7.1.6 Connecting the power supply Note!

1

Lines that have been worn through can cause a short circuit or other problems in the electrical system.

– Watch for worn or pinched places.

– Note service voltage of the machine.

Power supply for the driving lights: – Insert the 7-pin power supply plug (1) into the socket provided on the tractor.

18 24584

(Fig. 18) 94841

7.1.7 Cross conveyor belt control terminal DISCO 3100 TC AS: – Fasten the cross conveyor belt control terminal (1) in the cab.

– Lay the cable to the drawbar.

– Connect the wiring looms at the connector (2).

1

(Fig. 19)

2 19

75370 33138

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

65

7 Attaching / detaching machine 7.2 Unhitching the machine 71147

7.2 Unhitching the machine 27175

7.2.1 General instructions Danger!

PTO shaft drive and tractor can be placed in gear unintentionally.

Danger of death or injury by drawing in and crushing.

– – – – –

PTO shaft drive OFF. Tractor motor OFF. Set tractor parking brake.

Remove ignition key.

Wait until machine parts come to a full stop.

Warning!

Machine may lower or raise in an uncontrolled manner.

Risk of injury from crushing.

– Lock hydraulics.

– Stay clear of the hazard zone.

– Securely support raised machine.

71758

7.2.2 Lowering the prop stand – Raise the lower link slightly.

– Pull knob (1) and swing stand (2) to the front until it engages with an audible sound.

– Check that the stand is securely locked.

– Slowly lower the hitch bracket and rear power lift onto the stand.

1

(Fig. 20) 2

20 24599

66

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

7 Attaching / detaching machine 7.2 Unhitching the machine 71147 71760

7.2.3 Disconnecting the power supply Power supply for the headlights: – Unplug 7-pin power supply plug (1) from socket on the tractor and stow on the machine.

1

(Fig. 21)

21 24584 94843

7.2.4 Cross conveyor belt control terminal DISCO 3100 TC AS: – Remove cross conveyor belt control terminal (1) from the cab and put it down on the frame.

1

Caution!

Moisture in the control terminal will cause malfunction of the electro-hydraulic machine control system.

Machine damage.

– Protect control terminal against moisture.

2 22

75370

– Remove control terminal (1) from tractor and store it in a moisture-protected place.

33138

In case of frost danger: – Disconnect connecting cable from machine.

– Store the control terminal in a room protected against the weather at room temperature (around 18°C).

(Fig. 22)

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

67

7 Attaching / detaching machine 7.2 Unhitching the machine 71147 71761

7.2.5 Decoupling hydraulic hose lines Hydraulic hose line – Load relief If the current load relief setting is to be preserved for the next operation, proceed as follows before disconnecting the hydraulic hose line (2):

1

– – – –

A B 2

23 24585

If the set load relief is not to be preserved for the next use, proceed as follows before disconnecting the hydraulic hose line (2):

3

1

2 24 24583

3

69774

Close shutoff cock (1), position (B).

Depressurise the hydraulic system on the tractor.

Disconnect the hydraulic hose line (2).

Plug the protective cap on the coupler and the tractor port.

– Put the hydraulic hose with the shut-off tap into the bracket according to figure 2424.

– Secure shut-off tap with spring clip (3).

– Open shut-off tap (1), position (A).

– Set the load relief cylinder hydraulic control unit to float position (floating) or lower (pressureless return).

– Depressurise the hydraulic system on the tractor.

– Disconnect the hydraulic hose line (2).

– Plug the protective cap on the coupler and the tractor port.

– Put the hydraulic hose with the shut-off tap into the bracket according to figure 2424.

– Secure shut-off tap with spring clip (3).

(Fig. 23, 24, 25)

0481 713.0

25

15696

68

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

7 Attaching / detaching machine 7.2 Unhitching the machine 71147

Hydraulic hoses – swivelling 1

– – – –

Close the shut-off cock (3), position (B).

Depressurise the hydraulic system on the tractor.

Disconnect the hydraulic hose lines (1 and 2).

Fit protective caps to couplers and tractor connections.

– Place the hydraulic hoses (1 and 2) in the holder as shown in Figure 27.

2

B 3

(Fig. 26, 27) 26 24584

1

2

27 24582

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

69

7 Attaching / detaching machine 7.2 Unhitching the machine 71147

Hydraulic hose lines – Lifting – – – –

Close the shut-off cocks (2), position (B).

Depressurise the hydraulic system on the tractor.

Disconnect the hydraulic hose line (1).

Fit the protective cap to the coupler and the tractor connection.

– Place the hydraulic hose (1) in the holder as shown in Figure 30.

B

(Fig. 28, 29, 30) 2

B

28 24613

1 29 24584

1

30 24582

70

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

7 Attaching / detaching machine 7.2 Unhitching the machine 71147

DISCO 3100 TC AS: Hydraulic hose – cross conveyor belt B

– – – –

Close the shut-off cock (2), position (B).

Depressurise the hydraulic system on the tractor.

Disconnect the hydraulic hose line (1).

Plug the protective cap on the coupler and the tractor port.

– Put hydraulic hose (1) into the bracket.

A 2

(Fig. 31, 32)

1 31 33137

1

32 33135

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

71

7 Attaching / detaching machine 7.2 Unhitching the machine 71147 71766

7.2.6 Removing universal drive shaft To facilitate the removal operation, the universal drive shaft guard can be pushed back.

Locking pin - lock – Press locking pin (1).

– Pull universal drive shaft from PTO shaft.

Draw lock 1

2

– Pull back draw sleeve (2).

– Pull universal drive shaft from PTO shaft.

QS lock

3 33

74145 6286

– Pull back the pull sleeve (3) until it stops in the open position.

– Pull universal drive shaft off of PTO shaft.

(Fig. 33) – Place the universal drive shaft (1) in the holder (2) on the hitch bracket (3).

– Place protective sleeve on PTO shaft.

3

(Fig. 34)

2

1 34 24569 71767

7.2.7 Unhitching headstock – Unlock the lower link pins (1) in the lower link hooks (2) of the tractor.

– Lower the rear power lift further until lower link hooks (2) are free.

– Carefully drive the tractor away.

2

(Fig. 35)

1 35 24570

72

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8 Driving and Transport 8.1 General information 71148

8 Driving and Transport 8.1 General information 72254

8.1.1 Road travel Danger!

The steering capability of the tractor may be reduced when the machine is mounted. With the machine mounted, the front axle of the tractor must be loaded with at least 20% of the tractor's kerb weight.

Death or serious injury.

– Check if with the machine mounted, the front axle of the tractor is loaded with at least 20% of the tractor's kerb weight.

– Fit ballast if required.

Danger!

Persons are located in the danger zone of the machine.

Death or serious injury.

– Before or while driving the machine, make sure that no people or objects are located in the driving area.

Danger!

The machine can swing to the working position unintendedly.

Death or serious injury.

– Lock the hydraulic control unit of the rear power lift and the lift cylinder during road travel.

When driving on public streets with the machine, observe the prevailing traffic regulations and provisions.

Remove ear protectors during road travel.

Adapt the ground speed to the traffic and road conditions. Reduce your speed when approaching a bend.

Maximum permissible speed on public roads according to the manufacturer: DISCO 3900 TC = 40 km/h DISCO 3500 TC / TRC = 40 km/h DISCO 3100 TC / TRC / TC AS = 40 km/h

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

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8 Driving and Transport 8.1 General information 71148

The provisions of the road traffic regulations (e.g. permitted top speed) applicable in different countries may vary. In case of discrepancies between the instructions provided by the manufacturer and the traffic regulations of the relevant countries, the traffic regulations of the countries concerned apply.

Check and fit transport equipment such as e.g. lighting, warning devices and possibly protective guards.

Observe permissible transport dimensions.

Observe permissible axle loads and total weights.

Bring the machine into the prescribed condition for street transport and secure in accordance with the manufacturer's specifications.

Pinch and shear points result when swinging the machine from transport to working position and vice versa. For this reason, never step between the tractor and the machine.

While the machine is in transport position, always ensure a sufficient lateral lock of the tractor's threepoint implement hitch.

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8 Driving and Transport 8.1 General information 71148

1

1

2

2

3

3

Marking the machine for road travel Road vehicle regulations can vary from country to country. In case of discrepancies between the instructions provided by the manufacturer and the traffic regulations of the relevant countries, the traffic regulations of the countries concerned apply.

The following lighting equipment must be fitted to the machine.

Rear: 1

77537J 24775

4

4

5

5

• Warning plates (1) facing to the rear • Taillights, brake lights and turn indicators (2) • Reflectors (3) Front: • Warning plates (4) facing forwards • Side lights (5) Additionally on DISCO 3100 TC AS: • Additional rear taillight (6) When fitting additional lighting equipment, observe the provisions of the road traffic regulations.

(Fig. 1, 2, 3)

2

77535J 24776

6

3 DISCO 3100 TC AS

33171

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75

8 Driving and Transport 8.1 General information 71148 26853

8.1.2 Field driving Danger!

Persons are located in the danger zone of the machine.

Death or serious injury.

– Before or while driving the machine, make sure that no people or objects are located in the driving area.

Adapt the working speed to the terrain and ground conditions. Avoid sudden turns when driving uphill or downhill or crosswise to the slope.

26854

8.1.3 Handling Danger!

Unexpected machine movements. The driving behaviour and the steering and braking capability are influenced by mounted or trailed machines and ballast.

Death or serious injury.

– Ensure sufficient steering and braking capability.

– Check if with the machine mounted, the front axle of the tractor is loaded with at least 20% of the tractor's kerb weight.

– Fit ballast if required.

– Adapt your driving to the terrain and ground conditions.

– Adapt your driving to the load carried by the tractor.

– Be particularly careful when working on slopes.

– When cornering, consider the wide radius needed and/or the flyweight of the machine.

76

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8 Driving and Transport 8.2 Transport position 71148

8.2 Transport position 71809

8.2.1 Folding down safety devices Danger!

The PTO shaft drive and the tractor can be started unintentionally.

Mortal danger or danger of injury by retracting and pinching.

– – – – –

PTO shaft drive OFF. Tractor engine OFF. Apply tractor parking brake.

Remove ignition key.

Never engage the PTO shaft with the tractor engine stopped.

On both sides:

1

– Fold up the safety frames (1).

(Fig. 4)

4 24605

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

77

8 Driving and Transport 8.2 Transport position 71148 71814

8.2.2 Lifting the mower unit Danger!

When swinging the machine, near the joints there is Mortal danger or danger of injury by pinching or shearing.

– No persons are allowed in the hazard area of the machine.

– Never move your hands in the pinch hazard area as long as parts may be moving there.

– Hitch machine completely to the tractor.

– Actuate the lift cylinder hydraulic control unit until the mower unit has lifted completely into transport position.

– Set the lift cylinder hydraulic control unit to the neutral position.

– Lock the hydraulic control unit of the rear power lift and the lift cylinder during road travel.

(Fig. 5)

5 24605

Danger!

PTO shaft drive and tractor can be placed in gear unintentionally.

B

Danger of death or injury by drawing in and crushing.

2

B

– – – – –

6 24613

PTO shaft drive OFF. Tractor motor OFF. Set tractor parking brake.

Remove ignition key.

Wait until machine parts come to a full stop.

– Close the shut-off cocks (2), position (B).

(Fig. 6)

78

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8 Driving and Transport 8.2 Transport position 71148 71823

8.2.3 Swinging to transport position Danger!

When swinging the machine, near the joints there is Mortal danger or danger of injury by pinching or shearing.

– No persons are allowed in the hazard area of the machine.

– Never move your hands in the pinch hazard area as long as parts may be moving there.

– Open the shut-off cock (1) to swing the machine into the transport position.

- Position (A): shut-off cock (1) open.

(Fig. 7)

1

A

7 24586

– Actuate the hydraulic control unit for the swing cylinder until the mower unit is aligned with the centre of the longitudinal frame.

The red marks (2) on the main frame must be visible on the left and right of the longitudinal frame.

– Set the swing cylinder hydraulic control unit to the neutral position.

1

(Fig. 8)

1

8 24605

– Close the shut-off cock (1) after swinging the machine into the transport position.

- Position (B): shut-off cock (1) closed.

(Fig. 9) B 1

9 24584

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

79

8 Driving and Transport 8.2 Transport position 71148 94848

8.2.4 Lowering the cross conveyor belt to working and transport position DISCO 3100 TC AS: Danger!

B

Lowering the cross conveyor belt involves the following hazards in the joints area: Mortal danger or danger of injury by pinching or shearing.

– No persons are allowed in the hazard area of the machine.

– Never move your hands in the pinch hazard area as long as parts may be moving there.

2 A 1 10

– Open shut-off tap (2) of cross conveyor belt hose (1).

- Position (A): Shut-off tap (2) open.

33136

(Fig. 10) – Lower the cross conveyor belt down to the stop, using a single-acting control unit.

– Set the control unit to neutral position.

(Fig. 11)

11 33169

The shut-off tap must be closed for road travel.

B

– Close the shut-off tap (2) after lowering the cross conveyor belt.

- Position (B): Shut-off tap (2) closed.

(Fig. 12)

A 2

12 33137

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8 Driving and Transport 8.3 Loading machine 71148

8.3 Loading machine 71824

8.3.1 Loading / unloading machine – Securely fit lifting devices at the marked attachment points for lifting (2).

1

Danger!

Mortal danger or danger of injury from improper machine loading and transport.

13 6018

– Suspend machine only at the marked attachment points for lifting.

The attachment points for lifting are marked by decals (1).

– Use sufficiently dimensioned and safe lifting devices.

Observe machine weight.

2 (Fig. 13, 14, 15)

1

14 24609

2

1

1

15 24610

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

81

9 Setup for work use 9.1 Working position 71149

9 Setup for work use 9.1 Working position Danger!

Swinging the machine involves mortal danger or danger of injury by lowering the mower head to the ground.

Death or serious injury.

– No persons are allowed in the hazard area of the machine.

71849

9.1.1 Folding safety devices Danger!

The PTO shaft drive and the tractor can be started unintentionally.

Mortal danger or danger of injury by retracting and pinching.

– – – – –

PTO shaft drive OFF. Tractor engine OFF. Apply tractor parking brake.

Remove ignition key.

Never engage the PTO shaft with the tractor engine stopped.

Before driving into the mowing material, carry out the following on both sides:

1

– Fold down safety frame (1).

(Fig. 1)

1 24605

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9 Setup for work use 9.1 Working position 71149 71845

9.1.2 Adjusting the hitch bracket – Set the height of the hitch bracket (1) above the rear power lift so that the longitudinal frame is horizontal.

– Lock the rear power lift in this position.

(Fig. 2)

1

76507

2 24621 71874

9.1.3 Adjusting the mower head load relief 2

Note!

3

The hydraulic hose line does not need to be connected during use. However, in that case the load relief of the machine cannot be changed during use.

Connecting the hydraulic hose line (3) for adjusting / correcting the load relief pressure:

3 24583

– Pull out the spring clip (2).

– Remove the hydraulic hose line with the shut-off tap from the holder.

– Connect hydraulic hose line (3) to the coupling of a single-acting control valve.

Shut-off tap – Load relief: – Open shut-off tap (4) for adjusting the load relief pressure.

- Position (A): shutoff cock (4) open.

- Position (A): shutoff cock (4) closed.

4

(Fig. 3, 4)

A B 3

4 24585

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

83

9 Setup for work use 9.1 Working position 71149

During fieldwork, the mower head is to glide above the ground at low pressure.

1

The pre-set load relief can be read on the pressure gauge (1). The recommended setting range is marked by recess (A) in the pressure gauge area (2). The tip (S) in the recess marks the basic setting.

Adjusting the load relief: – Actuate the hydraulic load relief cylinder control unit until the desired load relief is displayed.

Adjust the load relief according to ground conditions.

5 24623

A

S

The higher the pressure indicated on the pressure gauge, the: – lower the ground pressure, – more weight of the machine is handled by the tractor, – worse the ground adaptation, – lower the wear, – lower the fuel consumption.

2

The lower the pressure indicated on the pressure gauge, the: 6 24639

– higher the ground pressure, – less weight of the machine is handled by the tractor, – better the ground adaptation, – higher the wear, – higher the fuel consumption.

Recommended load relief 90 – 120 bar Basic adjustment approx. 100 bar (Fig. 5, 6)

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9 Setup for work use 9.1 Working position 71149 71971

9.1.4 Adjusting the cutting height Danger!

PTO shaft drive and tractor can be placed in gear unintentionally.

Danger of death or injury by drawing in and crushing.

– – – – –

PTO shaft drive OFF. Tractor motor OFF. Set tractor parking brake.

Remove ignition key.

Wait until machine parts come to a full stop.

Adjust the cutting height by varying the angle of inclination (Z) of the mower head.

– Use the spindle (1) to set the desired cutting height.

There is an adjustment guide (2) next to the spring.

The setting can be read from the notches.

– In the basic setting, the large notch (K) is flush with the angle plate.

Z

Note!

7

68500 9945

Insufficient cutting height.

Heavy wear on cutting discs and knives.

K

– Adjust cutting height only as low as absolutely necessary.

(Fig. 7, 8)

1

2 8 24798

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

85

9 Setup for work use 9.2 Conditioner of DISCO 3900 TC / 3500 TC / 3100 TC / TC AS 71149

9.2 Conditioner of DISCO 3900 TC / 3500 TC / 3100 TC / TC AS 98827

9.2.1 Conditioner speed DISCO 3900 TC: Caution!

The conditioner speed must not exceed 900 rpm.

Risk of machine damage – Do not modify the pulley pair.

DISCO 3500 TC / 3100 TC / 3100 TC AS: The conditioner speed can be adjusted by replacing the conditioner drive pulleys.

1

9 24549

– Unscrew belt guard.

– Slacken and remove drive belt, see Maintenance – changing drive belt.

– Unscrew pulleys.

– Position pulleys according to the required conditioner speed.

– Fit and tension drive belt.

– Screw on belt guard.

(Fig. 9, 10)

1080

900 76318

10 23455 71982

9.2.2 Chicane plate The effect of the conditioner can be altered by adjusting the chicane plate with the lever (1): – towards "+" = increased conditioner effect – towards "-" = reduced conditioner effect

1

(Fig. 11)

11 24671

86

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9 Setup for work use 9.2 Conditioner of DISCO 3900 TC / 3500 TC / 3100 TC / TC AS 71149 71988

9.2.3 Swathing plates The swath width can be adjusted according to crop conditions and/or on the following machines.

A

Where fodder levels are low, the swath width can be reduced. To do this, swing the swathing plates inwards.

1

– Loosen the star handles (1).

– Adjusting swathing plates - inwards (A) = narrow swath - outwards (B) = wide swath – Tighten the star handles (1).

B

12

(Fig. 12)

24673

Note!

Star handles may come loose due to vibrations.

Loss of star handles, bolts and swathing plates.

– Tighten star handles as tightly as possible so they cannot come loose due to vibrations during operation.

(Fig. 13) 13 24070

If the machine has a crop spreader, the star handle (1) with the baffle plate must be moved inwards on the right-hand side in order to make adjustment (A).

1

(Fig. 14)

A

14 24675

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

87

9 Setup for work use 9.2 Conditioner of DISCO 3900 TC / 3500 TC / 3100 TC / TC AS 71149 71998

9.2.4 Crop spreader To use the crop spreader, move the swath formers (1) as needed.

Adjust the baffle plates (3) as required.

– Loosen the star handles (2).

– Move the baffle plates (3) to the required position.

– Tighten the star handles (2).

1

Note!

Star handles may come loose due to vibrations.

15 24679

Loss of star handles, bolts and swathing plates.

– Tighten star handles as tightly as possible so they cannot come loose due to vibrations during operation.

(Fig. 15, 16, 17)

2

16 24598

3

17 16660

Marks for adjusting the baffle plates: B

Adjust the star handles so that they are level with the marks (A) or (B).

(A) = narrow swath

B

A

A

B

(B) = wide swath (Fig. 18)

A

18 24684

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9 Setup for work use 9.3 DISCO 3500 TRC / 3100 TRC conditioner 71149

9.3 DISCO 3500 TRC / 3100 TRC conditioner 72012

9.3.1 Swathing plates The swath width can be adjusted according to crop conditions and/or on the following machines.

1

Where fodder levels are low, the swath width can be reduced. To do this, swing the swathing plates inwards.

A

– Loosen the star handles (1).

– Adjusting swathing plates - inwards (A) = narrow swath - outwards (B) = wide swath – Tighten the star handles (1).

B

19

(Fig. 19)

23038

Note!

Star handles may come loose due to vibrations.

Loss of star handles, bolts and swathing plates.

– Tighten star handles as tightly as possible so they cannot come loose due to vibrations during operation.

(Fig. 20) 20 24070 68499

9.3.2 Mowing without conditioner effect Danger!

The PTO shaft drive and the tractor can be started unintentionally.

Mortal danger or danger of injury by retracting and pinching.

– – – – –

PTO shaft drive OFF. Tractor engine OFF. Apply tractor parking brake.

Remove ignition key.

Never engage the PTO shaft with the tractor engine stopped.

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

89

9 Setup for work use 9.3 DISCO 3500 TRC / 3100 TRC conditioner 71149

The machine can be used without the effect of the roller conditioner. To do this, fold the top roller up.

1 2

– Remove tension spring (3) on both sides.

- Slacken off nut (2).

- Unscrew bolt (1).

- Remove tension spring (3).

3

(Fig. 21)

21 23472

– Inserting the lever (2) into mounting plate (1) – Fold the top roller up.

(Fig. 22)

1

2 22 23474

– locate in drilled hole (6) with screw (S) (M12x40) on both sides of machine.

Assembly is in the reverse order.

After this, carry out adjustments, see "Maintenance, adjustments and repairs".

(Fig. 23) S

23 23476

90

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

9 Setup for work use 9.4 Cross conveyor belt of DISCO 3100 TC AS 71149

9.4 Cross conveyor belt of DISCO 3100 TC AS 94857

9.4.1 Adjusting the discharge flap DISCO 3100 TC AS: 1

2

Danger!

The PTO shaft drive and the tractor can be started unintentionally.

Mortal danger or danger of injury by retracting and pinching.

1

– – – – –

24 33139

PTO shaft drive OFF. Tractor engine OFF. Apply tractor parking brake.

Remove ignition key.

Never engage the PTO shaft with the tractor engine stopped.

The throwing distance of the conditioner can be adjusted to suit fodder conditions.

– Loosen the star handles (1).

– Adjust the discharge flap (2) so that the crop hits the centre of the cross conveyor belt.

– Tighten the star handles (1).

(Fig. 24) Note!

Star handles may come loose due to vibrations.

Loss of star handles, bolts and swathing plates.

– Tighten star handles as tightly as possible so they cannot come loose due to vibrations during operation.

(Fig. 25) 25 24070

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

91

9 Setup for work use 9.4 Cross conveyor belt of DISCO 3100 TC AS 71149 94860

9.4.2 Cross conveyor belt – Adjusting the throwing distance DISCO 3100 TC AS: The throwing distance, i.e. the speed of the cross conveyor belt can be adapted steplessly to the fodder quantity by means of rotary switch (2) on control terminal (1).

1

Position 0 = shortest throwing distance

2

Position 10 = longest throwing distance Note!

In case of a power failure, the cross conveyor belt switches itself off.

26

(Fig. 26)

33140

92

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10 Working 10.1 Working in the field 71150

10 Working 10.1 Working in the field 26743

10.1.1 General instructions Danger!

The PTO shaft drive and the tractor can be started unintentionally.

Mortal danger or danger of injury by retracting and pinching.

– – – – –

PTO shaft drive OFF. Tractor engine OFF. Apply tractor parking brake.

Remove ignition key.

Never engage the PTO shaft with the tractor engine stopped.

Danger!

While the PTO shaft drive is engaged, there is danger from rotating machine parts.

Mortal danger or danger of injury from rotating machine parts.

– Do not allow any persons inside the hazard area of the machine.

– If necessary, shut down the PTO shaft drive immediately.

– Tractor engine OFF. – Remove ignition key.

Danger!

After disengaging the PTO shaft drive, there is still danger as the flyweight continues to rotate.

Mortal danger or danger of injury from rotating machine parts.

– Wait for all machine parts to come to a complete halt.

Caution!

Improper operation of the PTO shaft causes damage to the PTO shaft drive or to the universal drive shaft.

Risk of machine damage – Do not allow the slip clutch to slip longer than 10 seconds.

– With extreme angles of the universal drive shaft, the PTO should be disengaged beforehand.

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

93

10 Working 10.1 Working in the field 71150

Danger!

Even when using this machine in line with the intended use, there is danger from foreign objects flying away.

Danger of injury from foreign objects flying away.

– Do not allow any persons inside the hazard area of the machine.

– If necessary, stop machine immediately.

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

– Fold all safety frames down and secure them.

– Replace any damaged or worn safety blankets without delay.

– Reduce ground speed.

– Check if the knives can swing back when hitting an obstacle.

– Increase cutting height if required.

Danger!

Danger of injury when working on the knives or their mounting.

Danger of injury from sharp-edged machine parts.

– – – – –

PTO shaft drive OFF. Tractor engine OFF. Apply tractor parking brake.

Remove ignition key.

Wait for all machine parts to come to a complete halt.

– Wear working gloves.

Caution!

Before every use and after hitting an obstacle, check the mower unit for damaged, missing or worn knives.

Machine damage due to unbalance.

– Check proper seat of knives.

– Replace any damaged, missing or worn knives.

– Always fit or replace both knives of each mower disc.

94

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10 Working 10.1 Working in the field 71150 71858

10.1.2 Swinging into working position Danger!

When swinging the machine, near the joints there is Mortal danger or danger of injury by pinching or shearing.

– No persons are allowed in the hazard area of the machine.

– Never move your hands in the pinch hazard area as long as parts may be moving there.

– Open the shut-off cock (1) to swing the machine into the working position.

- Position (A): shut-off cock (1) open.

(Fig. 1)

A

1

1 24586

– Actuate the hydraulic control for the swing cylinder until the mower unit has swung fully left or right.

– Set the swing cylinder hydraulic control unit to the neutral position.

(Fig. 2, 3)

2

76517 24796

3

76516 24797

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

95

10 Working 10.1 Working in the field 71150 71869

10.1.3 Lowering the mower unit Danger!

PTO shaft drive and tractor can be placed in gear unintentionally.

Danger of death or injury by drawing in and crushing.

A A

– – – – –

1 4 24612

PTO shaft drive OFF. Tractor motor OFF. Set tractor parking brake.

Remove ignition key.

Wait until machine parts come to a full stop.

Shut-off cock – hydraulic lift: – Open both shut-off cocks (1) to lower the mower unit.

- Position (A): shut-off cocks (1) open.

(Fig. 4) – Actuate the lift cylinder hydraulic control unit until the mower unit has lowered completely.

– Set the lift cylinder hydraulic control unit to the float position.

(Fig. 5)

5

76508 24622

96

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

10 Working 10.2 Mowing 71150

10.2 Mowing 72027

10.2.1 Putting the machine into operation – Before switching on the PTO shaft, make sure that the selected speed and rotational direction of the tractor PTO shaft match the permissible speed and rotational direction of the tractor.

– Set the height of the hitch bracket (1) above the rear power lift so that the longitudinal frame is horizontal.

– Lock the rear power lift in this position.

– Swing machine to working position.

– Lowering the mower unit.

Set the lift cylinder hydraulic valve to the float position.

– Before driving on the meadow, engage the tractor PTO shaft at idle speed. Slowly increase PTO speed to the rated speed of the machine.

– The whistling sound caused by the high speed of the cutting discs is completely normal and is largely attenuated during mowing work.

– Drive on the meadow.

– Adapt driving and cutting speed to the conditions of use (ground conditions, density, height and condition of plants) so that the clean cut is achieved.

– Check mower head load relief during mowing.

If required, adjust / correct the load relief.

Warning!

When mowing with tractors without a cab or with open cab windows and doors, the operator is fully exposed to the noise from the machine.

Endangering by noise.

– Wear ear protectors.

– Remove ear protectors during road travel.

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

97

10 Working 10.2 Mowing 71150 26773

10.2.2 Mowing methods At the beginning of the work, the machine can be used like an ordinary mower head. According to the conventional mowing method: – Make the first swath in anticlockwise direction.

– Then continue in clockwise direction.

– Observe the recommendations for environmental protection.

(Fig. 6, 7)

6 10173

7 10175

98

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

10 Working 10.2 Mowing 71150 72030

10.2.3 Turning area position Lift to the turning area position: – Actuate the lift cylinder hydraulic control unit until the mower unit has lifted completely.

– Set the lift cylinder hydraulic control unit to the neutral position.

(Fig. 8)

8

76509 24689

Lower from the turning area position: – Set the lift cylinder hydraulic control unit to the float position.

(Fig. 9)

9

76508 24622

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

99

10 Working 10.2 Mowing 71150 72059

10.2.4 Instructions for mowing Warning!

After an extended period of operation, gearboxes may reach a temperature of up to around 110°C and mower heads a temperature of up to around 80°C. Danger of burns due to hot surfaces.

– Never touch the hot gearbox or mower head with your bare hand.

– Wear suitable protecting gloves.

Warning!

Removal of plugging or of foreign object involves Danger of injury from sharp-edged machine parts.

– – – – –

PTO shaft drive OFF. Tractor engine OFF. Apply tractor parking brake.

Remove ignition key.

Wait for all machine parts to come to a complete halt.

– Wear suitable working gloves.

– When mowing dense or down crop and when cornering, the ground speed should be reduced.

– Do not mow on stony ground.

The machine cannot mow in reverse.

– Lift machine when reversing.

When working on slopes for extended periods, especially when mowing crosswise to the slope: – Do not drive in one direction only, but also drive in the opposite direction.

Caution!

When manoeuvring on a slope, there is a risk of the mower unit tipping if it is positioned downhill while turning.

Risk of machine damage – Reduce speed on turns.

– Position the mower unit uphill when turning.

– Drive in as wide a curve as possible.

100

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

10 Working 10.2 Mowing 71150 26682

10.2.5 Difficult conditions of use In case of difficult conditions of use, e.g. stony ground, high number of molehills or dirt and sand accumulations:

Z

10

68500

– Increase the cutting height by turning the spindle (1) so that - the mower head is only slightly tilted to the front.

- Turn the spindle in until the mower head is horizontal.

– Reduce ground speed.

– Check that the knives can swing back if they hit an obstacle.

9945

(Fig. 10, 11)

1 11 24798 26761

10.2.6 Recommendation for environmental protection A simple modification of the usual mowing method helps reduce the stock of game losses.

At the same time, the forage quality is improved.

Environment!

When mowing from the outside to the inside, wild animals have hardly any chance to escape.

Losses of stock of game.

– Mow from the inside to the outside.

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

101

10 Working 10.2 Mowing 71150

– Drive to the middle of the meadow and mow from the inside to the outside.

– Mow the centre after sufficient space for turning is available.

Wild animals thus have the chance to escape to the outside.

(Fig. 12)

12

69018P 10169

On narrow and long meadows: – Mow the turning areas first.

– After that, mow the longitudinal sides towards the outside.

Wild animals thus have the chance to escape to the outside.

(Fig. 13, 14)

13

69019P 10168

14

69020P 10167

On particularly long meadows near roads: – Mow the longitudinal side near the road first.

– After that, mow from the longitudinal side near the road to the opposite longitudinal side.

This method makes sense especially for front mower units.

Wild animals thus have the chance to escape to the outside.

(Fig. 15) 15

69021P 10166

102

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10 Working 10.3 Mowing with cross conveyor belt DISCO 3100 TC AS 71150

10.3 Mowing with cross conveyor belt DISCO 3100 TC AS 94892

10.3.1 Putting the machine into operation – Before switching on the PTO shaft, make sure that the selected speed and rotational direction of the tractor PTO shaft match the permissible speed and rotational direction of the tractor.

– Set the height of the hitch bracket (1) above the rear power lift so that the longitudinal frame is horizontal.

– Lock the rear power lift in this position.

– Swing machine to working position.

– Lowering the mower unit.

Set the lift cylinder hydraulic valve to the float position.

– Lower the cross conveyor belt down to the working position with a single-acting control valve.

– Start the cross conveyor belt.

– Before driving on the meadow, engage the tractor PTO shaft at idle speed. Slowly increase PTO speed to the rated speed of the machine.

– The whistling sound caused by the high speed of the cutting discs is completely normal and is largely attenuated during mowing work.

– Drive on the meadow.

– Adapt driving and cutting speed to the conditions of use (ground conditions, density, height and condition of plants) so that the clean cut is achieved.

– Check mower head load relief during mowing.

If required, adjust / correct the load relief.

Warning!

When mowing with tractors without a cab or with open cab windows and doors, the operator is fully exposed to the noise from the machine.

Endangering by noise.

– Wear ear protectors.

– Remove ear protectors during road travel.

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10 Working 10.3 Mowing with cross conveyor belt DISCO 3100 TC AS 71150 94943

10.3.2 Lifting / lowering the cross conveyor belt DISCO 3100 TC AS: – Lower the cross conveyor belt down to the working position with a single-acting control valve.

(Fig. 16) Note!

When lowering the mower unit to the working position, the cross conveyor belt is automatically tilted.

16

On the turning area, the cross conveyor belt is automatically tilted due to the mower unit lift movement.

33009

– Lift cross conveyor belt with a single-acting control valve.

(Fig. 17)

17 33154 94896

10.3.3 Starting / stopping the cross conveyor belt DISCO 3100 TC AS:

3 4

– Switch the control terminal (1) on/off with switch (4).

1

Indicator light (3) lights up when the control terminal is ON. 2

The throwing distance, i.e. the speed of the cross conveyor belt can be adapted steplessly to the fodder quantity by means of rotary switch (2) on control terminal (1).

Position 0 = shortest throwing distance 18

33140

Position 10 = longest throwing distance Note!

In case of a power failure, the cross conveyor belt switches itself off.

(Fig. 18)

104

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10 Working 10.3 Mowing with cross conveyor belt DISCO 3100 TC AS 71150 94918

10.3.4 Mowing methods DISCO 3100 TC AS: Mowing with cross conveyor belt The cross conveyor belt transports the mowed material to the left on the existing swath.

With the cross conveyor belt lifted, the mowed material is discharged in a swath behind the mower unit.

– Mow the 1st, 3rd, 5th, etc. mowing round with the cross conveyor belt lifted.

The cross conveyor belt is stopped automatically when being lifted.

– Lower the cross conveyor belt down to the working position with the single-acting control valve before starting the 2nd, 4th, 6th, etc. mowing round.

The cross conveyor belt starts automatically as soon as the cross conveyor belt is lowered.

– Mow the 2nd, 4th, 6th, etc. mowing round with the cross conveyor belt lowered down.

Note!

When lowering the mower unit to the working position, the cross conveyor belt is automatically tilted.

1

19 33149

On the turning area, the cross conveyor belt is automatically tilted due to the mower unit lift movement.

– Observe the recommendations for environmental protection.

(Fig. 19)

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105

10 Working 10.3 Mowing with cross conveyor belt DISCO 3100 TC AS 71150

Mowing with cross conveyor belt and front mower unit The cross conveyor belt transports the mowed material to the left on the existing swath.

– Lower the cross conveyor belt down to the working position with the single-acting control valve.

The cross conveyor belt starts automatically as soon as the cross conveyor belt is lowered.

Note!

When lowering the mower unit to the working position, the cross conveyor belt is automatically tilted.

On the turning area, the cross conveyor belt is automatically tilted due to the mower unit lift movement.

1

– Observe the recommendations for environmental protection.

(Fig. 20)

20 33149

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11 Maintenance 11.1 General warning signs 71151

11 Maintenance 11.1 General warning signs In the following sections of this chapter, a procedure instruction refers to the following general warnings.

Danger!

PTO shaft drive and tractor can be placed in gear unintentionally.

Danger of death or injury by drawing in and crushing.

– – – – –

PTO shaft drive OFF. Tractor motor OFF. Set tractor parking brake.

Remove ignition key.

Wait until machine parts come to a full stop.

Warning!

Machine may lower or raise in an uncontrolled manner.

Risk of injury from crushing.

– Lock hydraulics.

– Stay clear of the hazard zone.

– Securely support raised machine.

When carrying out electric welding work on the tractor and on mounted machines, disconnect the cable from the alternator and from the battery.

7468

11.1.1 Bolts – Check all bolts for a tight seat and retighten if necessary (especially all nuts on the chassis and on the steering system).

88014

11.1.2 Lubrication – Observe the specified oil change intervals and oil grades in the hydraulic system and in the gearboxes.

– Use only specified grease for lubricating the machine.

– Before lubricating, remove the dirt on the grease nipples.

– Grease the machine at regular intervals according to the lubrication chart.

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11 Maintenance 11.1 General warning signs 71151

Environment!

Lubricants and fuels end up in the environment.

Environmental pollution.

– Lubricants and fuels must be collected and stored in suitable containers and disposed of in a way that is harmless to the environment and in accordance with existing anti-pollution regulations.

Warning!

Contact with hot liquids or machine parts.

Danger of burns – Wear suitable protective clothing.

– Let liquids or machine parts cool down.

– Comply with instructions.

88017

11.1.3 Wheels / tyres Warning!

Danger of bursting when tyre pressure is too high.

Danger of injury – Do not stand near the tyre while inflating.

– Check tyre pressure regularly.

– The specified tyre pressure must be maintained.

– When a wheel has been fitted, the wheel nuts and/or bolts must be retightened after the first 10 operating hours and then checked for firm seating every 50 operating hours.

– The track adjusting elements must be retightened as specified by the manufacturer.

– Observe the necessary tyre pressure when using ballast.

– Keep oil and grease away from tyres.

– Check tyres for damage regularly on the inside as well.

– Do not clean tyres by applying a steam jet cleaner directly on the tyres.

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11 Maintenance 11.1 General warning signs 71151 11118

11.1.4 Hydraulic system Danger!

Work on the hydraulic system.

Death or serious injury – Relieve the hydraulic pressure before working on the system.

Danger!

Dealing incorrectly with injuries due to hydraulic fluids.

Death or serious injury.

Even a pinhole can result in severe injuries.

– If hydraulic fluid gets in the skin or eyes, have the injury treated by a medical specialist immediately.

Danger!

Pre-loaded energy accumulators (spring, accumulator, hydraulic cylinder).

Death or serious injury.

– Only have authorised and qualified workshops carry out work on energy accumulators.

Danger!

Liquids under high pressure.

Liquids penetrate the skin and cause serious injury.

– Only have authorised and qualified workshops carry out work on the hydraulic system.

– Check hose lines at regular intervals.

Search for leaks using a piece of wood or cardboard.

Ensure that the oil jet will not be directed towards your body.

– Replace any damaged hose lines.

– Replace hose lines 6 years after the date of manufacture at the latest.

13672

11.1.5 Electrical system Caution!

Work on the electrical system.

Risk of machine damage – Before the work, unplug electrical plugs between tractor and machine.

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11 Maintenance 11.1 General warning signs 71151 13674

11.1.6 Protective guards Danger!

Missing or damaged safety devices.

Death or serious injury.

– Fit safety devices before putting the machine into operation.

– Check function of safety devices at regular intervals.

– Replace worn or damaged safety devices by new ones.

13677

11.1.7 Parts Warning!

Use of unauthorised parts.

Risk of injury – Spare parts must at least conform to the technical standards required by the equipment manufacturer!

– It is recommended that CLAAS original parts be used.

26952

11.1.8 Unbalance Caution!

Uneven running of machine parts.

Machine damage and excessive wear.

– Remove dirt accumulations in rotating machine parts regularly and thoroughly.

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11 Maintenance 11.1 General warning signs 71151 87850

11.1.9 Cleaning and care – Observe the general warnings at the beginning of the maintenance chapter.

Caution!

Cleaning of surfaces with decals using highpressure jet cleaners.

The decals are damaged.

– Avoid cleaning with high-pressure cleaners.

– Clean surfaces only if a sufficient distance from the high-pressure jet cleaner is observed.

– Set the water pressure and the water temperature as low as possible.

– Do not subject the decals to mechanical loads during cleaning.

– Replace damaged and illegible decals (hazard warning signs / safety decals / letterings / identification plates) immediately.

• Remove harvesting residues and blade pieces at regular intervals, especially in the open profiled tubes of the arms.

- Danger of damage.

• Do not clean cut-out clutches, bearing, hydraulic system and electric parts with a high-pressure jet cleaner or steam cleaner.

- Danger of damage and corrosion.

• Cleaning at excessive pressure may cause paint damage.

• Before and after cleaning the machine with a highpressure jet cleaner, grease bearings.

After this, carry out a short test run so that the water which has seeped in will be pressed out of the bearings.

• A grease collar should exist at the bearings. This protects the bearings against ingress of dirt, plant juice and water.

• When parking the machine outdoors for an extended period, clean the ram rods of hydraulic cylinders and then apply grease to them.

- Prior to putting the machine into operation, remove the grease from the ram rods hydraulic cylinders.

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11 Maintenance 11.1 General warning signs 71151 70467

11.1.10 Winter storage recommendations – Observe the general warnings at the beginning of the chapter.

1 Remove dirt and stalk parts from the machine.

2 Remove all outside grease and dust from all bearings.

3 Change the oil of angle drives mower head drives.

4 Grease all grease points thoroughly until grease escapes at the bearings.

Let the machine run briefly.

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

6 Clean corroded spots and rework paint damage.

7 Park the machine in a dry and weather-protected space where no artificial fertiliser is stored.

8 Park the machine in working position.

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11 Maintenance 11.2 Maintenance schedule 71151

11.2 Maintenance schedule 72066

11.2.1 Service intervals Note!

The specified maintenance intervals apply to normal conditions of use. When the machine is used in difficult conditions, the maintenance intervals must be shorter.

•

•

– Checking the oil level

•

•

– Oil change

•

– Clean the vent valve and check its function

•

10

50

50

100

200

after the harvest

– Check for leaks

5

every

as needed

daily

after the first time

annually or every 500

Maintenance intervals in operating hours before the harvest

Maintenance operations

Gearbox / Clutch / Universal drive shaft: Main gearbox:

•

•

•

•

Transfer gearbox: – Check for leaks

•

•

– Checking the oil level

•

•

– Oil change

•

– Clean the vent valve and check its function

•

•

•

•

•

Angle drive: – Check for leaks

•

•

– Checking the oil level

•

•

– Oil change

•

– Clean the vent valve and check its function

•

•

– Check that the wheel nuts and bolts are tight, and retighten if necessary.

•

•

– Check tyre pressures and adjust if necessary.

•

•

• •

Chassis: •

•

•

•

Hydraulic system: – Check hydraulic hoses, replace if needed

•

– Check accumulator, adjust if necessary

•

•

• •

DISCO 3100 TC AS: – Tension the hydraulic pump drive belt, replace if necessary

•

– Check hydraulic oil level, top up if required

•

•

– Change hydraulic oil

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• •

• •

•

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11 Maintenance 11.2 Maintenance schedule 71151

•

•

– Checking the oil level

•

•

– Oil change

•

10

50

50

100

200

after the harvest

– Check for leaks

5

every

as needed

daily

after the first time

annually or every 500

Maintenance intervals in operating hours before the harvest

Maintenance operations

Mower unit:

•

•

Knives: – Check mower blades, replace if necessary

•

•

•

•

•

•

Cutting blade holder: – Check the cutting blade holder, renew if necessary Cutting discs: – Check cutting discs, replace if needed Crop processing unit: – Tension drive belt, renew if necessary

•

– Check conditioner tines, renew if necessary

•

•

•

– Check spring tension in conditioner rollers, tension if required

•

•

•

•

•

Crop discharge: DISCO 3100 TC AS: – Adjusting the scraper

•

•

– Tensioning the cross conveyor belt

•

•

Various components, machine body: – Check all bolted joints for a tight fit, retighten if required

•

– Check all fasteners, replace if needed

•

– Clean machine

114

•

•

•

•

• •

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11 Maintenance 11.3 Lubricants 71151

11.3 Lubricants 72083

11.3.1 Lubricants chart Environment!

Lubricants and fuels end up in the environment.

Environmental pollution.

– Lubricants and fuels must be collected and stored in suitable containers and disposed of in a way that is harmless to the environment and in accordance with existing anti-pollution regulations.

Note!

The fill quantities specified are approximate values; the oil level check is always decisive for the correct oil level.

DISCO 3900 TC Component

Fill quantity

Lubricant types / specification

Viscosity /SAE class

Change intervals / checks

Main gearbox Hitch bracket

top: 1.80 litres

Hypoid transmission oil

SAE 90

Observe maintenance schedule

SAE 75W-90

Observe maintenance schedule

SAE 90 EP

Observe maintenance schedule

SAE 90 EP

Observe maintenance schedule

bottom: 2.50 litres Transfer gearbox Mower unit

top: 1.20 litres bottom: 1.70 litres

API-GL-4 (MIL-L-2105 B) 100%-synthetic gear oil Agip ROTRA LSX API-GL-4 + GL-5 (MIL-L-2105 D)

Mower head angle drive

0.80 litres

Mower head

4.50 litres

EP-gear oil ISO VG 150 EP EP-gear oil ISO VG 320

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11 Maintenance 11.3 Lubricants 71151

DISCO 3500 TC / TRC Component

Fill quantity

Lubricant types / specification

Viscosity /SAE class

Change intervals / checks

Main gearbox Hitch bracket

top: 1.80 litres

Hypoid transmission oil

SAE 90

Observe maintenance schedule

SAE 75W-90

Observe maintenance schedule

SAE 90 EP

Observe maintenance schedule

SAE 90 EP

Observe maintenance schedule

bottom: 2.50 litres Transfer gearbox Mower unit

top: 1.20 litres bottom: 1.70 litres

API-GL-4 (MIL-L-2105 B) 100%-synthetic gear oil Agip ROTRA LSX API-GL-4 + GL-5 (MIL-L-2105 D)

Mower head angle drive

0.80 litres

Mower head

4.50 litres

EP-gear oil ISO VG 150 EP EP-gear oil ISO VG 320

DISCO 3100 TC / TRC / TC AS Component

Fill quantity

Lubricant types / specification

Viscosity /SAE class

Change intervals / checks

Main gearbox Hitch bracket

top: 1.80 litres

Hypoid transmission oil

SAE 90

Observe maintenance schedule

SAE 75W-90

Observe maintenance schedule

SAE 90 EP

Observe maintenance schedule

SAE 90 EP

Observe maintenance schedule

HLP 46

Observe maintenance schedule

bottom: 2.50 litres Transfer gearbox Mower unit

top: 1.20 litres bottom: 1.70 litres

API-GL-4 (MIL-L-2105 B) 100%-synthetic gear oil Agip ROTRA LSX API-GL-4 + GL-5 (MIL-L-2105 D)

Mower head angle drive

0.80 litres

Mower head

4.00 litres

EP-gear oil ISO VG 150 EP EP-gear oil ISO VG 320

DISCO 3100 TC AS: Cross conveyor belt hydraulic oil tank

15.00 litres

Mineral oil, type HLP HLP DIN 51524 or HM ISO 6763/4 e.g. HLP 46 – Tellus oil 46

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11 Maintenance 11.3 Lubricants 71151

Grease points Component Grease nipples, bearings, sliding faces .....

Fill quantity

Lubricant types / specification

Viscosity / SAE class

Brand-name multipurpose grease DIN 51 825, K2K

Change intervals / checks See lubrication chart

CLAAS multipurpose grease EP 2 (KP 2 K-30) 400 g cartridge, order no. 00 0147 451 0 Other grease points (once-through lubrication), hinges, linkages ....

Biologically degradable chain lubrication oil CEC-L-33-A-93 > 80%

See lubrication chart

CLAAS Roller chain oil BIO HEES 46 5 litre PE can, order no. 00 0147 457 0

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11 Maintenance 11.4 Gearbox / clutch / universal drive shaft 71151

11.4 Gearbox / clutch / universal drive shaft Follow the prescribed oil types and change times.

Danger!

PTO shaft drive and tractor can be placed in gear unintentionally.

Danger of death or injury by drawing in and crushing.

– – – – –

PTO shaft drive OFF. Tractor motor OFF. Set tractor parking brake.

Remove ignition key.

Wait until machine parts come to a full stop.

Environment!

Lubricants and fuels end up in the environment.

Environmental pollution.

– Lubricants and fuels must be collected and stored in suitable containers and disposed of in a way that is harmless to the environment and in accordance with existing anti-pollution regulations.

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11 Maintenance 11.4 Gearbox / clutch / universal drive shaft 71151 94536

11.4.1 Main gearbox – Observe the general warnings at the beginning of the chapter.

– Park the tractor and attached machine on a level surface.

– Secure the tractor against rolling away.

– Swing machine to working position.

– Set the machine to a horizontal position.

- Horizontal: readjust the lower link if required.

Top gearbox 1 = Breather valve 2 = Filler opening 3 = Oil level plug 4 = Drain plug Lower gearbox 1 = Filler opening and breather valve

76557

3 = Oil level plug 1 25317

4 = Drain plug (Fig. 1, 2)

1 2 3 4 1 3 4

2 32929

Cleaning the breather valve

1

– Unscrew and clean bleed valves (1).

– Check that the breather valves function perfectly and replace them if necessary.

– Screw bleed valves (1) back in and tighten so they are tight.

(Fig. 3)

1

3 32929

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11 Maintenance 11.4 Gearbox / clutch / universal drive shaft 71151

Checking the oil level Top gearbox:

2

– Unscrew the screw plug (3) of the check opening.

3

The oil level must be up to the bottom edge of the check opening (3).

Lower gearbox:

1

– Unscrew the screw plug (3) of the check opening.

3 4 32929

The oil level must be up to the bottom edge of the check opening (3).

Topping up oil Top gearbox: – – – – –

Unscrew the screw plug (2) of the filler opening.

Fill in fresh oil.

Check oil level and top up if necessary.

Remove dirt from the screw plug (2).

Refit the screw plug (2) and tighten so that it forms a seal.

Lower gearbox: – – – – –

Unscrew bleed valve (1) of filler opening.

Fill in fresh oil.

Check oil level and top up if necessary.

Remove dirt from the bleed valve (1).

Refit vent valve (1) and tighten so it is tight.

(Fig. 4)

120

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11 Maintenance 11.4 Gearbox / clutch / universal drive shaft 71151

Draining / changing the oil 2

Environment!

3

Lubricants and fuels end up in the environment.

4

Environmental pollution.

– Lubricants and fuels must be collected and stored in suitable containers and disposed of in a way that is harmless to the environment and in accordance with existing anti-pollution regulations.

1 3 4

5 32929

Drain the oil: – Place a sufficiently large container beneath the drain plugs (4).

– Unscrew drain plugs (4).

– Drain the used oil completely.

– Remove dirt from the drain plugs (4).

– Refit the drain plug (4) and tighten so that it forms a seal.

– Fill in fresh oil at the top and at the bottom.

See topping up oil.

– Check oil level at the top and at the bottom and top up if necessary.

See Checking the oil level.

(Fig. 5)

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11 Maintenance 11.4 Gearbox / clutch / universal drive shaft 71151 72852

11.4.2 Transfer gearbox – Observe the general warnings at the beginning of the chapter.

– Park the tractor and attached machine on a level surface.

– Secure the tractor against rolling away.

– Swing machine to working position.

– Set the machine to a horizontal position.

- Horizontal: readjust the lower link if required.

Top gearbox 1 = Breather valve 2 = Filler opening and oil level screw 3 = Locking screw plug for lower gearbox 6 = Drain plug Lower gearbox 3 = Filler opening 4 = Breather valve 6

76555 25311

5 = Oil level plug 6 = Drain plug

1

(Fig. 6, 7) 2

3

4 6 5 7 25012

Cleaning the breather valve 1

– Unscrew and clean the breather valves (1) and (4).

– Check that the breather valves function perfectly and replace them if necessary.

– Screw the breather valves (1) and (4) back in and tighten firmly to prevent leaks.

4

(Fig. 8)

8 25012

122

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11 Maintenance 11.4 Gearbox / clutch / universal drive shaft 71151

Checking the oil level Note!

2

Do not slacken off or turn out the screw plug stud (3).

3

Top gearbox: – Unscrew the screw plug (2) of the inspection opening.

6 5 9

The oil must come up to the lower edge of the inspection opening (2).

25012

Lower gearbox: – Unscrew the screw plug (5) of the inspection opening.

The oil must come up to the lower edge of the inspection opening (5).

Topping up oil Note!

Do not slacken off or turn out the screw plug stud (3).

Top gearbox: – – – – –

Unscrew the screw plug (2) of the filler opening.

Fill in fresh oil.

Check oil level and top up if necessary.

Remove dirt from the screw plug (2).

Refit the screw plug (2) and tighten so that it forms a seal.

Lower gearbox: – – – – –

Unscrew the screw plug (5) of the filler opening.

Fill in fresh oil.

Check oil level and top up if necessary.

Remove dirt from the screw plug (5).

Refit the screw plug (5) and tighten so that it forms a seal.

(Fig. 9)

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11 Maintenance 11.4 Gearbox / clutch / universal drive shaft 71151

Draining / changing the oil Environment!

2

Lubricants and fuels end up in the environment.

3

Environmental pollution.

– Lubricants and fuels must be collected and stored in suitable containers and disposed of in a way that is harmless to the environment and in accordance with existing anti-pollution regulations.

6 5 10 25012

Note!

The oil in the top gearbox can only be drained together with the oil in the lower gearbox. The locking screw plug (3) must be screwed tight after the lower gearbox has been filled. Only then should you fill the top gearbox via the filler hole (2).

Drain the oil: – Place a sufficiently large container under the drain plug (6).

– Unscrew the drain plugs (6) and locking screw plug (3).

– Drain the used oil completely.

– Clean the drain plugs (6) and locking drain plug (3).

– Refit the drain plug (6) and tighten so that it forms a seal.

(Fig. 10)

124

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Fill the bottom gearbox: – Add new oil via the locking screw plug (3) opening.

2

The oil must come up to the lower edge of the opening (5).

3

– Clean the locking screw plug (3) and the screw plug in the inspection opening (5).

– Screw in the locking screw plug (3) and the screw plug (5) and tighten so that they form a seal.

6 5 11 25012

Fill the top gearbox: – Unscrew the screw plug (2) of the check opening.

– Add new oil via the inspection opening (2).

The oil must come up to the lower edge of the inspection opening (2).

– Remove dirt from the screw plug (2) of the inspection opening.

– Refit the screw plug (2) and tighten so that it forms a seal.

(Fig. 11)

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11 Maintenance 11.4 Gearbox / clutch / universal drive shaft 71151 73912

11.4.3 Angle drive – Observe the general warnings at the beginning of the chapter.

– Park the tractor and attached machine on a level surface.

– Secure the tractor against rolling away.

1 = Filler opening, vent valve and oil level dipstick.

2 = Drain plug (Fig. 12, 13)

12

76556 25319

1

2 13

76541 25027

Checking the oil level – Unscrew the oil level dipstick (1).

– Read the oil level off the dipstick.

1

The oil must come up to the mark on the dipstick.

– Top up oil if required.

– Remove dirt from the dipstick (1).

– Refit the dipstick (1) and tighten.

(Fig. 14) 14

76541 25027

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Topping up oil – – – – –

1

Unscrew the screw plug (1) of the filler opening.

Fill in fresh oil.

Check oil level and top up if necessary.

Remove dirt from the screw plug (1).

Refit the screw plug (1) and tighten so that it forms a seal.

(Fig. 15)

15

76541 25027

Draining / changing the oil Environment!

1

Lubricants and fuels end up in the environment.

Environmental pollution.

– Lubricants and fuels must be collected and stored in suitable containers and disposed of in a way that is harmless to the environment and in accordance with existing anti-pollution regulations.

2 16

76541 25027

– Place a sufficiently large container under the drain plug (2).

– Unscrew the drain plug (2).

– Drain the used oil completely.

– Remove dirt from the drain plug (2).

– Refit drain plug (2) and tighten so that it forms a seal.

– Top up oil.

(Fig. 16) Cleaning the vent valve – Unscrew and clean the vent valve (1).

– Check flawless function of vent valve and replace if required.

– Refit vent valve (1) and tighten so it is tight.

1

(Fig. 17)

17

76541 25027

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127

11 Maintenance 11.4 Gearbox / clutch / universal drive shaft 71151 26957

11.4.4 Maintaining universal drive shaft – Observe the general warnings at the beginning of the maintenance chapter.

Danger!

Rotating universal drive shafts.

Risk of death or severe injuries.

– Check for secure latching of the locks or locking pins.

– Never operate universal drive shaft without protective guard.

– Replace defective protective guards on the universal drive shaft immediately.

General information about universal drive shafts Observe the manufacturer's safety instructions.

The drive shafts must be serviced according to the instructions of the drive shaft manufacturer (see Manufacturer's Operator's Manual).

Damaged or missing guard tubes, guard cones, or safety chains must be replaced immediately.

Protect the universal drive shafts from the effects of weather.

After the work season, always clean and lubricate universal drive shafts in all parts.

In winter operation, the protective tubes must be greased in order to prevent them from freezing up.

After every long period of stoppage, the universal drive shafts must be re-lubricated and their operability checked before restarting.

Vent the clutch before putting the machine into operation for the first time and every time after extended standstill periods.

128

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11 Maintenance 11.4 Gearbox / clutch / universal drive shaft 71151 26958

11.4.5 Friction clutch – Observe the general warnings at the beginning of the maintenance chapter.

Caution!

1

The max. torque of the friction clutch must not be altered.

Machine damage and high wear.

– Work on the friction clutch may only be carried out by authorised specialist workshops.

The friction clutch (1) protects the drive assembly of the machine against overload.

18

66934

Basic adjustment of friction clutch (1):

9582

DISCO 3900 TC Friction clutch (1)

1450 Nm

DISCO 3500 TC / TRC Friction clutch (1)

1200 Nm

DISCO 3100 TC / TRC / TC AS Friction clutch (1)

1200 Nm

(Fig. 18) 26967

11.4.6 Venting the friction clutch Vent the friction clutch after every extended standstill period.

– Observe the general warnings at the beginning of the maintenance chapter.

– Tighten the hex. nuts of the studs completely.

– Loosen the sticking friction discs by turning the clutch hub by hand.

– Turn back the hex. nuts or studs again up to the end of the thread.

(Fig. 19) 19 9573

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129

11 Maintenance 11.4 Gearbox / clutch / universal drive shaft 71151 26968

11.4.7 Replacing the friction discs The figure shows the as-new condition The edge of the thrust disc (arrow) is visible.

(Fig. 20)

20 9574

The friction discs are worn when the edge of the thrust discs (arrow) is not visible any more.

– Replace any worn friction discs in good time.

(Fig. 21)

21 9575

130

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11 Maintenance 11.5 Transport chassis 71151

11.5 Transport chassis 88035

11.5.1 Wheels and tyres – Observe the general warnings at the beginning of the maintenance chapter.

Warning!

Danger of bursting when tyre pressure is too high.

Danger of injury – Do not stand near the tyre while inflating.

– Check tyre pressure regularly.

– The specified tyre pressure must be maintained.

Before carrying out any work on the tyres, care must be taken to ensure that the device is correctly parked and stable and that its wheels are properly chocked to prevent the machine from rolling away (wheel chocks).

Repair work on tyres must only be carried out by professionals and with the proper tools.

Check the air pressure of the tyres regularly.

Keep oil and grease away from tyres.

Check tyres for damage regularly, also on the inner side.

Do not clean tyres by directly pointing a jet cleaner at them.

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11 Maintenance 11.5 Transport chassis 71151 72200

11.5.2 Wheel change – Observe the general warnings at the beginning of the maintenance chapter.

Danger!

2

Jacking up the machine.

Death or serious injury.

– Use jack / jack stand with sufficient capacity.

– Use reliable jack / jack stand.

– Use jack / jack stand on solid and level ground.

– Apply the jack / jack stand at the position of the machine intended for this purpose.

1

22 24767

2 – – – –

Change wheels on a level and solid surface.

Secure machine against rolling away.

Use suitable jacks.

Raise the machine at the jacking points (1). Jacking points (1) are indicated with stickers (2).

– When a wheel has been fitted, the wheel bolts and nuts must be retightened after the first 10 operating hours and then checked for firm seating every 50 operating hours.

23

515 773.0

(Fig. 22, 23)

16176

Check all tightening torques of bolts and nuts at regular intervals and retighten if necessary.

Tightening torque: Wheel nuts (1) A18

300 Nm

(Fig. 24)

1

24 24567

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11 Maintenance 11.6 Hitch 71151

11.6 Hitch 73921

11.6.1 Adjusting the hitch bracket pressure springs (only for DISCO 3100 TC / TRC / TC AS) The pressure springs (1) make the mower unit more stable.

2

2

3

Basic adjustment of pressure springs (1) on the left and right:

3

X

X = 121 mm X Note!

The pressure springs must be tensioned equally on both sides.

1

25 35230

Adjust the pressure springs (1): – Undo the lock nuts (2).

– Tighten the disc (3).

– Fully tighten the lock nut (2).

(Fig. 25)

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11 Maintenance 11.7 Hydraulics 71151

11.7 Hydraulics 26959

11.7.1 Hydraulic system – Observe the general warnings at the beginning of the maintenance chapter.

Danger!

Fluids under high pressure.

Fluids can penetrate the skin and cause severe injuries.

26 740

– Drain hydraulic pressure from the system before work.

– Work on hydraulic systems must be performed only by authorised specialist workshops.

– Regularly check hose lines.

Search for leaks using a piece of wood or cardboard.

Make sure that the stream of oil is not diverted in the direction of the body.

– Replace damaged hose lines.

– Replace hose lines no later than 6 years after the date of manufacture.

Danger!

Dealing incorrectly with injuries due to hydraulic fluids.

Death or serious injury.

Even a pinhole can result in severe injuries.

– If hydraulic fluid gets in the skin or eyes, have the injury treated by a medical specialist immediately.

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

134

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11 Maintenance 11.7 Hydraulics 71151 104985

11.7.2 Hydraulic hose lines – Observe the general warnings at the beginning of the maintenance chapter.

Note!

Before working on the hydraulic system, lower machine, depressurise system and shut down motor.

XXX / 250 bar / 09/07

1

XXX / 250 bar / 09/07 2

Check hydraulic hoses before initial operation, and then at least once a year.

3

Replace damaged and old hydraulic hose lines.

1 XXX / 250 bar / 09/07

Note!

27

91115 40202

Hydraulic hoses must not be used for longer than 6 years after date of manufacture.

The date of manufacture can be identified on the hose fitting (1).

(2) = Year (e.g. 09 = 2009) (3) = Month (e.g. 07 = July) (Fig. 27)

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11 Maintenance 11.7 Hydraulics 71151 72197

11.7.3 Accumulator – Observe the general warnings at the beginning of the chapter.

Danger!

Pre-loaded energy accumulators (spring, accumulator, hydraulic cylinder).

Death or serious injury.

– Only have authorised and qualified workshops carry out work on energy accumulators.

1

Do not carry out any welding or brazing work or machining on the accumulator (1).

28

The accumulator (1) is filled with nitrogen.

26413

DISCO 3900 TC = 65 bar.

DISCO 3500 TC / TRC = 50 bar.

DISCO 3100 TC / TRC / TC AS = 50 bar.

The accumulators lose around 2 - 3% of their pressure per year.

Have the pressure of accumulator (1) checked and corrected if necessary by a specialist workshop every five years.

(Fig. 28) Check pre-loading pressure – – – –

Swing machine to working position.

Load relief pressure to normal position.

Remove load relief pressure - Float position.

Watch the pressure gauge pointer:

The pre-loading pressure is the point where the pointer drops suddenly.

136

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11 Maintenance 11.7 Hydraulics 71151 94733

11.7.4 Tensioning the hydraulic pump drive belt (only for DISCO 3100 TC AS) – Observe the general warnings at the beginning of the chapter.

– Unscrew the cover.

– Undo nuts (1).

– Loosen lock nut (2).

– Turn in bolt (2) until the correct belt tension is achieved.

– Tighten lock nut (2).

– Tighten nuts (1).

– Bolt down the cover.

3 2

1

Check the belt tension regularly.

(Fig. 29) 29 33096 94747

11.7.5 Replacing the drive belt hydraulic pump (only for DISCO 3100 TC AS) – Observe the general warnings at the beginning of the chapter.

– Relieve the tension of drive belt (1).

– Replace the drive belts (1).

– Tension drive belt (1).

Check the belt tension regularly.

(Fig. 30)

1 30 33096

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137

11 Maintenance 11.7 Hydraulics 71151 94752

11.7.6 Cross conveyor belt hydraulic oil (only for DISCO 3100 TC AS) – Observe the general warnings at the beginning of the chapter.

– Park the tractor and attached machine on a level surface.

– Secure the tractor against rolling away.

– Set the machine to a horizontal position.

- Horizontal: readjust the lower link if required.

Checking the oil level 1

The oil level must be between MIN and MAX. Topping up oil – – – – 2 31

Turn out the oil level dipstick (1).

Fill in fresh oil.

Check oil level and top up if necessary.

Remove dirt from oil level dipstick (1) and filler opening.

– Screw the oil level dipstick (1) back in and tighten so it is tight.

Draining / changing the oil

33096

1

32

– Place a sufficiently large container beneath the drain plugs (2).

– Unscrew drain plugs (2).

– Drain the used oil completely.

– Remove dirt from the drain plugs (2).

– Refit drain plug (2) and tighten so it is tight.

– Fill in fresh oil at the top and at the bottom.

See topping up oil.

– Check oil level at the top and at the bottom and top up if necessary.

See Checking the oil level.

33098

(Fig. 31, 32, 33) 1

33 33262

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11 Maintenance 11.8 Mowing unit 71151

11.8 Mowing unit Danger!

Machine can drop in an uncontrolled way Death or serious injury.

– – – – –

PTO shaft drive OFF. Tractor engine OFF. Apply tractor parking brake.

Remove ignition key.

Securely support raised machine.

Warning!

After an extended period of operation, gearboxes may reach a temperature of up to around 110°C and mower heads a temperature of up to around 80°C. Danger of burns due to hot surfaces.

– Never touch the hot gearbox or mower head with your bare hand.

– Wear suitable protecting gloves.

Note!

When the recommended maintenance operations are complied with, there is no reason to worry when strong heat development is detected on the mower unit, provided the cutting discs can be easily rotated by hand with the machine at operating temperature. An operating temperature of around 60° C is to be considered as normal.

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11 Maintenance 11.8 Mowing unit 71151 94542

11.8.1 Mower head gearbox – Observe the general warnings at the beginning of the chapter.

1

2

DISCO 3900 TC

1

2

DISCO 3500 TC / TRC

1

2

80200

DISCO 3100 TC / TRC / TC AS 32937 34 – Park the tractor and attached machine on a level surface.

– Secure the tractor against rolling away.

– Set the mower head to a horizontal position.

- Horizontal: if necessary, use the spindle to adjust the cutting height.

1 = Filler opening, check opening (Fig. 34, 35) 2 = Drain plug

1 35

(Fig. 34, 36) Tightening torque:

24804

Filler opening, check opening (1) 3/8“

35 Nm

Drain plug (2) 3/8"

35 Nm

(Fig. 34, 35, 36)

2 36 17003

140

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11 Maintenance 11.8 Mowing unit 71151

Checking the oil level

1

– Let the mower head run for about 20 minutes until the mower head housing feeds warm to the touch.

– Disengage the PTO shaft.

– Lift the mower head and support it with a square piece of timber (H) on the right side.

– Lower the mower head so that it rests on the ground on the left and on the wooden block on the right.

X

H

(Fig. 37) 37

76558 25321

– Use the spindle to adjust the height so that the mower head is positioned horizontally in the longitudinal direction.

(Fig. 38) DISCO 3900 TC Height of square piece of timber (H) Correct oil level (X)

200 mm 11 mm

DISCO 3500 TC / TRC 38

73354 23685

Height of square piece of timber (H) Correct oil level (X)

200 mm 5 mm

DISCO 3100 TC / TRC / TC AS Height of square piece of timber (H) Correct oil level (X) – – – –

1

150 mm 5 mm

Unscrew the screw plug (1) of the check opening.

Top up oil if required.

Remove dirt from the screw plug (1).

Refit the screw plug (1) and tighten so it is tight.

39 24804

Note!

If it is not possible to determine the oil level in the mower head by performing the check, drain off all of the oil and fill with new oil in the prescribed quantity.

(Fig. 39)

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11 Maintenance 11.8 Mowing unit 71151

Topping up oil – For filling capacity and specification see Lubricants chart.

– Remove dirt from area around the screw plug (1).

– Unscrew the screw plug (1) of the filler opening.

– Remove dirt from the screw plug (1).

– Fill in fresh oil.

– Check oil level and top up if necessary.

– Refit the screw plug (1) and tighten so it is tight.

1

(Fig. 40) 40 24804

Draining / changing the oil – Let the mower head run for approximately 20 minutes until the housing is warm to the touch.

– Disengage the PTO shaft.

– Lift the mower head.

– Stop the tractor engine and remove the ignition key.

Environment!

2 41 17003

Lubricants and fuels end up in the environment.

Environmental pollution.

– Lubricants and fuels must be collected and stored in suitable containers and disposed of in a way that is harmless to the environment and in accordance with existing anti-pollution regulations.

– Place a sufficiently large container beneath the drain plug.

– Unscrew the drain plug (2).

– Drain the used oil completely.

– Remove dirt from the drain plug (2).

– Refit drain plug (2) and tighten so it is tight.

– Top up oil.

(Fig. 41)

142

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11 Maintenance 11.8 Mowing unit 71151 72094

11.8.2 Mower knife box A mower knife box (4) is located on the left side of the main frame.

4

– Keep spare mower knives in the mower knife box (4).

1 = Stowage space for anti-clockwise rotating knives.

2 = Stowage space for clockwise rotating knives.

3

To take off the mower knife box (4):

1

2

– Loosen spring (3).

– Remove the mower knife box (4) from the bracket.

42

(Fig. 42, 43)

24740

To replace mower knives: 1

– Take the filled mower knife box (4) along to the mower head.

2

00 0952 043 0

00 0952 042 0 43 21169

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11 Maintenance 11.8 Mowing unit 71151 72164

11.8.3 Replacing the knives Danger!

Rotating cutting discs and sharp knives.

Danger of death or danger of injury by retracting, pinching and cutting.

– – – – –

PTO shaft drive OFF. Tractor engine OFF. Apply tractor parking brake.

Remove ignition key.

Wait for all machine parts to come to a complete halt.

– Open the safety devices only after all machine parts have come to a complete halt.

– Wear gloves when working on the knives.

Caution!

Damaged, deformed or improperly installed knives may cause damage or unbalance.

Risk of machine damage – Ensure proper seat of knives.

– Replace worn, damaged or deformed knives immediately.

– Always fit or replace both knives of each mower disc.

Check the knives prior to every use and after hitting an obstacle.

Safe machine operation is guaranteed only with properly installed knives.

Replace any missing and damaged knives only in sets as directed by the manufacturer so that no dangerous unbalance can result.

Every time when replacing knives, check the fasteners as specified by the manufacturer and replace them when needed.

Warning!

Use of unallowed spare parts.

Risk of injury – Knives must meet at least the technical requirements specified by CLAAS. – The use of genuine CLAAS spare parts is recommended.

144

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11 Maintenance 11.8 Mowing unit 71151

Note!

– Work only with sharp knives in order to achieve a good cut.

– The use of blunt knives results in increased power consumption and reduces the cutting quality.

– Blunt knives can be turned around and fixed to the same disc again so that mowing is with the second blade of the knife.

– Observe the general warnings at the beginning of the maintenance chapter.

– Swing machine to working position.

Danger!

Damaged, deformed or improperly installed knives may come loose.

Mortal danger or danger of injury from parts flying around.

– Replace any damaged knives, knife holders or cutting discs.

– Do not weld or straighten.

1

2

44 16152

Order no.: Mower knives (1) (anti-clockwise rotating)

00 0952 043 0

Mower knives (2) (clockwise rotating)

00 0952 042 0

The knives must be replaced in the following cases: – When the knives have cracks or are deformed.

Never try to straighten a deformed knife.

– When the knives are worn.

The knife width (B) as measured 10 mm (C) from the edge of the cutting disc is to be at least 36 mm.

C

(Fig. 45) B 45 9419

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11 Maintenance 11.8 Mowing unit 71151

– When the bore of the knife has widened.

Maximum allowed widening of bore from Ln = 18 mm to L = 20 mm.

L

(Fig. 46)

Ln 46

61623 9418

Mower knife quick change system For replacing the knives:

1

– Introduce a tyre-mounting lever (2) between the mower disc (1) and the mower knife holder.

(Fig. 47)

2

47

68985 9417

Note!

Pull the tyre-mounting lever (1) to the outside in parallel to the mower disc up to the stop.

(Fig. 48) 1

48

68986 9416

– Clean the sinking (2) in the skid.

– Place the mower knife holder (3) exactly above the sinking (2) by turning the mower disc.

– Push the tyre-mounting lever (1) downwards.

1

(Fig. 49)

68987

3

2

49 9424

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11 Maintenance 11.8 Mowing unit 71151

– Remove the mower knife (1).

– Remove fodder residues and dirt from the mower knife area.

(Fig. 50)

1

50

68979 9415

DISCO 3900 TC

DISCO 3500 TC / TRC

80200

DISCO 3100 TC / TRC / TC AS 51

32937

Note!

The knives for anticlockwise and clockwise rotating cutting discs are different.

The arrow on the knife must correspond with the sense of rotation of the cutting disc in question.

– Observe the sense of rotation when installing the knives.

(Fig. 51)

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11 Maintenance 11.8 Mowing unit 71151

– Insert new knife (1) with the sharp cutting edge facing down.

– As an alternative, turn the knife around when the other side is still unused and install it with the sharp cutting edge facing down.

(Fig. 52)

1

52

68980 9426

– Relieve the load from the tyre-mounting lever (1).

Danger!

Knives may come loose.

Mortal danger or danger of injury from parts flying around.

– Ensure correct seat of mower knives and knives holding pins.

1 53

68981

The mower knife holding pin (3) must make contact (see arrows) and lay straight in the receiver bore of the mower disc (2).

9427

(Fig. 53, 54)

2

3 54

68984 9428

– Remove the tyre-mounting lever (1) from the mower disc.

(Fig. 55)

1

55

68982 9430

148

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11 Maintenance 11.8 Mowing unit 71151

Danger!

Knives may come loose.

Mortal danger or danger of injury from parts flying around.

– Ensure correct seat of mower knives and knives holding pins.

The mower knife must be freely rotating and must be easy to move in both directions.

56

68983

(Fig. 56)

9431

1

When performing maintenance work on the mower head, the tyre-mounting lever (2) can also be used for arresting the mower discs. To this end:

2

– Place the punch (3) of the tyre-mounting lever (2) into the bore of a skid. The handle of the tyremounting lever (2) must make contact in parallel with the mower head.

– Move the mower disc (1) against the tyre-mounting lever (2) and arrest it in that way.

(Fig. 57)

3 66615F

57 9432

– After use, place the fixing lever (1) in the opening in the drawbar.

1

(Fig. 58)

58 24749

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149

11 Maintenance 11.8 Mowing unit 71151 45511

11.8.4 Knife holder – Observe the general warnings at the beginning of the maintenance chapter.

Danger!

Damaged, deformed or improperly installed knives may come loose.

Mortal danger or danger of injury from parts flying around.

– Replace any damaged knives, knife holders or cutting discs.

– Do not weld or straighten.

– Check the weld seams every time before putting the machine into operation.

Warning!

Use of unallowed spare parts.

Risk of injury – Knife holders must meet at least the technical requirements specified by CLAAS. – The use of genuine CLAAS spare parts is recommended.

– Damaged or worn knife holders must always be replaced.

The knife holders must be replaced in the following cases: • In case of wear of the mower knife holder contour.

Wear limit: X = 15 mm Y = 12 mm (Fig. 59)

X Y 59

69049 9458

• In case of wear of the mower knife holder thickness.

Wear limit: W = 3 mm Z = 4 mm • In case of visible cracks or heavy wear of weld seams (S) on a mower knife holding pin.

S

69050

W

(Fig. 60)

Z

60 9459

150

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11 Maintenance 11.8 Mowing unit 71151

• In case of deformation (bending) of the mower knife holder or when the mower knife holder pin (1) is not straight any more in the receiver bore of the disc.

(Fig. 61)

1 61

69051 9460

• When there is a clearance between the mower knife holder pin (1) and the receiver bore (see arrow) of the disc.

(Fig. 62)

1 62

69052 9461

• In case of wear of the mower knife holder pin (1).

Wear limit: V = 13 mm

V

(Fig. 63) 1

63

69053 9462

The discs must be replaced in the following cases: • In case of widening, wear or damage to the receiver bore in the entire diameter range.

(Fig. 64)

64

66613F 15663

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151

11 Maintenance 11.8 Mowing unit 71151 47835

11.8.5 Maintaining the cutting disc – Observe the general warnings at the beginning of the maintenance chapter.

Danger!

Damaged, deformed or improperly installed knives may come loose.

Mortal danger or danger of injury from parts flying around.

– Replace any damaged knives, knife holders or cutting discs.

– Do not weld or straighten.

– Check the weld seams every time before putting the machine into operation.

– Replace any worn or damaged cutting discs immediately.

See Replacing the cutting discs.

Caution!

1

The extension may be filled with material.

Machine damage due to unbalance.

2

– Replace a missing or damaged lid (1) immediately.

3 Cleaning the drain opening Ensure that the drain openings (2) at the bottom of the feed cylinders are always clear.

65 9581

– Clean drain openings if required.

Thus water inside the component (e.g. from high-pressure jet cleaning) can be drained.

Checking the wear bars – Check the bolt-on wear bars (3) for abrasion.

– Replace in case of excessive wear.

(Fig. 65)

152

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11 Maintenance 11.8 Mowing unit 71151 45524

11.8.6 Replacing the cutting discs – Observe the general warnings at the beginning of the maintenance chapter.

90°

Caution!

Knives may collide.

Risk of machine damage – Arrange cutting discs so that their longer dimension is at a right angle with the neighbouring disc.

66

61628

(Fig. 66)

9578

– Tighten the bolts (1) for fastening the cutting discs with a torque wrench.

– Use liquid locking compound.

- Type Loctite 243

1

Order no.: Loctite Type 243 (50 ml)

00 0666 285 1

(Fig. 67) 67

75630 9904

Check all tightening torques of bolts and nuts at regular intervals and retighten if necessary.

1

Tightening torque:

2

Flange-type cutting discs Bolts (1)

80 Nm

Pinion shaft Nuts (2) 68

75630

380 Nm

(Fig. 68)

9904

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11 Maintenance 11.8 Mowing unit 71151 45525

11.8.7 Installing the pinion units – Tighten the nut (1) for fastening the cutting disc flange with a torque wrench.

– Use liquid locking compound.

- Type Loctite 2701

1

Order no.: Loctite Typ 2701 - 50 ml

00 0213 827 0

(Fig. 69) 69505

69 9613

The notch (K) of the pinion shaft (3) must point exactly to the centre of the marking punch point (X).

X

(Fig. 70) K

2

70

75305 9614

1

Check all tightening torques of bolts and nuts at regular intervals and retighten if necessary.

2

Tightening torque: Pinion unit Nut M24x2 (1)

360 Nm

Nuts M12 (2)

120 Nm

(Fig. 71) 69505

71 9613

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11 Maintenance 11.8 Mowing unit 71151 72130

11.8.8 Adjusting the safety guard Front safety guard holder

1

Pre-load the spring washers (2) of the front safety guard holder (1) sufficiently.

– Tighten the hex. nut (3) and the jam nut (4) with a torque wrench.

The movable safety guard holders must be folding heavily and remain in place in any position.

When mounting the movable safety guard holders, observe the arrangement of the spring washers (2).

72

(Fig. 72, 74)

24565

Safety guard holder, left /right

1

Ensure that the conical spring washers (2) of the lateral safety guard holders (1) are sufficiently pretensioned.

– Tighten the hex. nut (3) and the jam nut (4) with a torque wrench.

The movable safety guard holders must be folding heavily and remain in place in any position.

73

When mounting the movable safety guard holders, observe the arrangement of the spring washers (2).

(Fig. 73, 74)

24563

Check all tightening torques of bolts and nuts at regular intervals and retighten if necessary.

Tightening torque: Left/right/front protective cover holder

4

3

2

6 x hex. nut (3) M12

25 – 30 Nm

6 x lock nuts (4) M12

85 Nm

(Fig. 72, 73, 74) 74 22612

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155

11 Maintenance 11.8 Mowing unit 71151 72151

11.8.9 Anti-wrapping guard Following repair work on the mower head drive, the position of the anti-wrapping guard (1) must be checked and adjusted if required.

The position of the anti-wrapping guard (1) must be concentric with the feed cylinder (2). The anti-wrap guard (1) and feed drum (2) must be adjusted so that there is a uniform gap (X) between them.

1 X

(Fig. 75) 2

75 24752

This adjustment is done on the holder (2), to this end:

2

– Slacken off bolts (1).

– Relocate the anti-wrapping guard (3) accordingly.

– Tighten bolts (1) again.

1 1

(Fig. 76)

3 76 24753

Clearance (X) = 8-10 mm (Fig. 77)

X

77 23758

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11 Maintenance 11.9 Crop processing 71151

11.9 Crop processing Danger!

PTO shaft drive and tractor can be placed in gear unintentionally.

Danger of death or injury by drawing in and crushing.

– – – – –

PTO shaft drive OFF. Tractor motor OFF. Set tractor parking brake.

Remove ignition key.

Wait until machine parts come to a full stop.

72204

11.9.1 Tensioning the conditioner drive belt 1

– Loosen lock nut (1).

– Screw in the tensioning nut (2).

2

The end of the pressure spring (3) should be aligned with the end of the setting guide (4) – Fully tighten the lock nut (1).

– Check the belt tension regularly.

(Fig. 78) 4

3 78 23560 72358

11.9.2 Changing conditioner drive belts – Unscrew the belt guard (1).

1

(Fig. 79)

79 23561

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11 Maintenance 11.9 Crop processing 71151

– Insert the fixing lever (1) into the strap (2).

(Fig. 80, 81)

1 2 3 80 24805

– Raise the jockey pulley arm (3) using the fixing lever (1).

– Peg the idler pulley arm (3) with a bolt (4).

– Replace the drive belts (5).

1

Note!

3

If a drive belt is worn or broken, always replace the entire drive belt kit.

5

(Fig. 80, 81, 82)

4

Reassemble in the reverse order.

81 23562

Check the belt tension.

3

4

82 23767

158

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11 Maintenance 11.9 Crop processing 71151 72202

11.9.3 Installing/removing the conditioner tines DISCO 3900 TC / 3500 TC / 3100 TC c d

c d

c d c d

c d

c d

c d

76312 23563

83

Mount the tines according to the fitting diagram.

The machine accessories include a locking pin (1).

This pin (1) can be used for driving the expansion pin (2) in or out.

(Fig. 83)

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159

11 Maintenance 11.9 Crop processing 71151 72122

11.9.4 DISCO 3500 TRC / 3100 TRC conditioner rollers Adjusting the tension springs The pressure force of the top roller conditioner roller is produced by the tension springs (3).

Basic setting of tension springs on left and right: X = 65 mm

2

Note!

The tension springs (3) must be equally tensioned on both sides!

1

The tension springs (3) can be adjusted as required.

3

Tensioning: – Loosen lock nut (1).

– Tighten bolt (2).

– Tighten the lock nut (1).

Detensioning: – Loosen lock nut (1).

– Loosen bolt (2).

– Tighten the lock nut (1).

(Fig. 84, 85) 84 23564

X

85 23565

Adjusting synchronous running Turn the rollers of the roller conditioner so towards each other that their sections intermesh precisely.

(Fig. 86)

X

86 64904F

160

14235

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11 Maintenance 11.9 Crop processing 71151

Adjusting the roller clearance

1

Adjusting the minimum clearance (X) between the rollers: – Slacken off bolt (2).

– Adjusting the minimum clearance (X) with bolt (1): - X = 3 - 5 mm – Tighten bolt (2).

Note!

87

The conditioner rollers must be adjusted with the same clearance on both sides.

23566

(Fig. 86, 87)

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161

11 Maintenance 11.10 Crop discharge 71151

11.10 Crop discharge 94775

11.10.1 Adjusting the cross conveyor belt (only for DISCO 3100 TC AS) – Observe the general warnings at the beginning of the chapter.

Removing the conveyor belt – – – – –

1

4

5 2

4 88 33139

Remove rear panel (1).

Unscrew baffle plate (2).

Remove angle (3).

Remove anti-wrapping guard (4).

Relieve the tension of conveyor belt (5) on both sides of the drive shaft: - Loosen bolts (6).

- Loosen lock nut (7).

Attention! Do not slacken off lock nut (8).

- Relieve the tension of conveyor belt (5) at bolts (9).

– Remove conveyor belt (5).

(Fig. 88, 89, 90)

4

5

3

4

89 33245

5

4

6

9

8

7

6

90 33248

162

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11 Maintenance 11.10 Crop discharge 71151

Adjusting the scraper Before installing a new conveyor belt or after repairs on the cross conveyor belt, adjust the scraper on the guide roller.

5

1 4

3

2

91 33250

5 X

– Slacken off nut (1) on both sides of the guide roller.

– Undo the lock nuts (2).

Attention! Do not slacken off lock nuts (3).

– Turn bolts (3) in or out until a clearance X = 0.5 0.8 mm is provided across the entire width of scraper (5). Adjust the clearance with a feeler gauge.

– Tighten nuts (1) on both sides of the guide roller to 60 Nm. – Tighten the lock nuts (2).

– Check clearance of scraper.

With the nut (1) tightened, the clearance X must be 0.3 - 0.5 mm across the entire width of scraper (5).

(Fig. 91, 92)

X

92 33263

Adjusting the guide roller 5

4

2

3

Before installing a new conveyor belt or after repairs on the cross conveyor belt, adjust the guide roller.

1

– Loosen bolts (2).

– Undo the lock nuts (3).

Attention! Do not slacken off lock nuts (4).

– Adjusting the guide roller (1) on both sides: - Adjust guide roller (1) at bolts (5) until the component edge is above the mark (arrow).

– Tighten bolts (2).

– Tighten lock nuts (3).

2

93

Rear right

2

1

2 Front right

(Fig. 93, 94)

33252

3

4

5

94

33253

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11 Maintenance 11.10 Crop discharge 71151

Tensioning the conveyor belt The description below applies only to new conveyor belts.

1

X1 X2

82309

95 33259

5

4

6

– Place the new conveyor belt (1) in position and align it to the centre.

Ensure that the running direction is correct (see arrows)!

– Apply two marks at the middle of the belt and with a spacing of (X1) = 1000 mm.

– Loosen bolts (6).

– Loosen lock nut (7).

Attention! Do not slacken off lock nut (8)!

– Tensioning the conveyor belt (5) evenly on both sides of the drive shaft at bolts (9): - Tension the conveyor belt (5) evenly until the dimension (X2) = 1006 mm is achieved.

– Tighten bolts (6).

– Tighten lock nut (7).

Check the lateral offset after tensioning the conveyor belt.

9

8

7

6

96 33248

– Lower the cross conveyor belt down to working position.

– Carry out a test run of the conveyor belt at the lowest belt speed (step 1 = around 500 rpm).

– Stop test run immediately in case of lateral offset of conveyor belt.

– Correcting the lateral offset of the conveyor belt if required: - In case of left-side offset – retighten the left side - In case of right-side offset – retighten the right side – Check belt tension and correct it if required.

(Fig. 95, 96)

164

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11 Maintenance 11.10 Crop discharge 71151

Assembling the conveyor belt – Bolt down rear panel (1).

Clearance from the conveyor belt bars (X) = 2.5 - 6.0 mm Clearance between frame and mounting plate (Y) = 138 mm – Bolt down baffle plate (2).

Clearance from the conveyor belt strap (Z) = 2.0 - 4.0 mm – Bolt down angle (3).

– Bolt down anti-wrapping guard (4).

1

4 Z X 2

4 97

(Fig. 97, 98, 99)

33139

Y

4

Y

3

4

98 33245

1

2 Z

82310

X

3

99 33261

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165

11 Maintenance 11.11 Attachment parts/machine body 71151

11.11 Attachment parts/machine body 72360

11.11.1 Adjusting the suspended frame tension springs 3

X

3

Basic adjustments for tension springs (1) on the left and right (top edge of holder to end of eye bolt):

2

X = 30 mm

X

2

Note!

1

1

The springs must be equally tensioned on both sides.

Adjust the tension springs (1):

100 24806

– Undo the lock nuts (2).

– Screw in the tensioning nut (3).

– Fully tighten the lock nut (2).

(Fig. 100)

166

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11 Maintenance 11.12 Problems and remedies 71151

11.12 Problems and remedies Problem

Cause, remedy

Vibrations

Drive input drum dirty.

– Clean drive input drum.

Poor ground adaptation.

Lift cylinder is blocked.

– Set the lift cylinder hydraulic control unit to the float position.

Excessive weight reduction.

– Reduce weight reduction.

Joints at the mower head have seized.

– Clean and grease joints.

Lemon tubes of universal drive shaft seized.

– Grease lemon tubes.

Incorrect inclination of mower head (cutting height).

Incorrect spindle length adjustment.

– Tighten or undo the spindle.

Stubbles are too high.

Mower head inclination improperly adjusted.

Excessive cutting height.

– Change the mower head inclination by adjusting the spindle.

Poor cutting quality in dense / down fodder.

Insufficient PTO speed.

– Increase PTO speed to the maximum permissible speed.

Excessive ground speed.

– Reduce ground speed.

Blunt or damaged knives.

– Replace knives.

Poor cutting quality in lightweight, wet fodder.

Excessive PTO speed, fodder is blown away.

– Reduce PTO speed.

Ground speed too low.

– Increase ground speed.

Blunt or damaged knives.

– Replace knives.

Mowed fodder is pushed forward, especially when travelling downhill (stripes).

Vortex effect caused by knives in light fodder.

– Install additional feed cones.

– Reduce PTO speed and increase ground speed.

Conditioner tines bent – Replace conditioner tines.

Swath too narrow.

Very dense crop.

– Adjust swathing plates.

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11 Maintenance 11.12 Problems and remedies 71151

Problem

Cause, remedy

Swath too wide.

Very dense crop.

– Adjust swathing plates.

Dirt accumulations between the skids.

Very moist conditions of use.

Molehills – Increase cutting height.

– Raise the mower head from time to time as required.

– Clean mower head.

– Fit wear skids.

Insufficient machine weight reduction.

– Increase weight reduction.

Increased wear of cutting discs and knives.

Very difficult conditions of use.

– Increase weight reduction.

– Increase cutting height.

– Fit high-cut skids.

Increased skid wear.

Insufficient weight reduction, machine exerts too much pressure on ground.

– Increase weight reduction.

Stony, sandy soils.

– Fit the wear skids.

Skid does not make parallel contact with the ground.

– Adjust skids so they are flat relative to the ground (extreme high-cutting settings will cause point-shaped skid wear).

Swath forms piles.

Light and wet crops, slopes.

– Install additional feed cones.

– Increase ground speed.

Wrapping of outside feed cylinder.

Heavy and flat crops.

– Check PTO shaft speed, increase to maximum permissible speed.

– Replace wear bars of feed cylinders.

– Check friction clutch.

Clogging on swathing plates.

Heavy and flat crops.

– Adjust swathing plates.

– Replace wear bars of feed cylinders.

Conditioner is winding.

Sudden reduction in tractor speed.

– Check PTO shaft speed, increase to maximum permissible speed.

– Check belt tension.

Heavy and flat crops.

– Reduce ground speed.

– Reduce speed of chicane plate.

– Adjust swathing plates.

168

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11 Maintenance 11.12 Problems and remedies 71151

Problem

Cause, remedy

DISCO 3100 TC AS:

Speed of material flow is too low.

No proper discharge of cut material on the cross conveyor belt.

DISCO 3100 TC AS: Cross conveyor belt stops or cannot be started.

DISCO 3100 TC AS: Cross conveyor belt does not stop in the lifted position.

– Close chicane as far as possible.

Power failure of control terminal.

– Check power supply of control terminal.

– Check V-belt.

– Switch the control terminal on.

Power failure of control terminal.

– Check contact switch.

– Adjust contact switch.

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169

12 Lubrication chart 12.1 Lubrication points 71152

12 Lubrication chart 12.1 Lubrication points 26614

12.1.1 Lubricants For the lubrication of the machine or front attachment, a distinction is made between grease and chain oil.

Grease For the specification, see the Lubricants chart.

Only use proprietary grease.

Order no. CLAAS proprietary grease: 00 0241 736 0 (complies with SKF LGEP2) 00 0147 451 0 multi-purpose grease EP2KP 2K-30

Proprietary grease from other manufacturers: Manufacturer

Designation

FINA

Marson EPL 2

ARAL

Aralub HLP 2

FUCHS

Renolit EP 2

SHELL

Retinax EP 2 or Alvania G 3

DEA

Glisando EP 2

AVIA

Avilup EP special grease

FAG

Arcanol L 135 V

SKF

LGEP 2

Chain oil For the specification, see the Lubricants chart.

Only use biodegradable chain oil.

170

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12 Lubrication chart 12.1 Lubrication points 71152 72366

12.1.2 Lubrication intervals Note!

The specified greasing cycles apply only for normal conditions of use.When the machine is used in difficult conditions, the maintenance intervals must be shorter.

Use only specified grease for lubricating the machine.

Before lubricating, remove the dirt on the grease nipples.

Grease the machine at regular intervals according to the lubrication chart.

Apply oil to all joints when necessary.

Danger!

PTO shaft drive and tractor can be placed in gear unintentionally.

Danger of death or injury by drawing in and crushing.

– – – – –

PTO shaft drive OFF. Tractor motor OFF. Set tractor parking brake.

Remove ignition key.

Wait until machine parts come to a full stop.

Warning!

Machine may lower or raise in an uncontrolled manner.

Risk of injury from crushing.

– Lock hydraulics.

– Stay clear of the hazard zone.

– Securely support raised machine.

Environment!

Lubricants and fuels end up in the environment.

Environmental pollution.

– Lubricants and fuels must be collected and stored in suitable containers and disposed of in a way that is harmless to the environment and in accordance with existing anti-pollution regulations.

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12 Lubrication chart 12.1 Lubrication points 71152

DISCO 3900 TC / 3500 TC / 3100 TC / 3100 TC AS Lubrication point number

Operating hours 8

2, 3

•

20

100

Comments

250

Folding frame bearing, on left/right

5

•

Folding frame bearings

6

•

Double joint slide fit

7

•

Bearing of jockey pulley arm

8

•

Cutting height spindle

9

•

Hitch bracket bearings

10

•

Drawbar / main frame bearings

11, 12, 13

•

Lift rod / connecting link bearings

12, 13

•

Lift cylinder bearing

15, 16

•

Swing cylinder bearings

17

•

Torque bracket

20

•

Main gearbox

18, 19, 21, 22

•

Conditioner drum bearing,

32

•

Tractor universal drive shaft – lemon tube

33

•

Transfer gearbox universal drive shaft – lemon tube

35

•

Mower unit universal drive shaft – lemon tube

34

•

Conditioner universal drive shaft – lemon tube

37 38, 39, 40 41 42

•

Tractor universal drive shaft – universal joints, universal drive shaft guard

•

Transfer gearbox universal drive shaft – universal joint, universal drive shaft guard

•

Conditioner universal drive shaft – universal joints, universal drive shaft guard

•

Mower unit universal drive shaft – universal joints, universal drive shaft guard

DISCO 3100 TC AS: 24

•

Arm bearing, top

25

•

Cross conveyor bearing, bottom

26

•

Lift cylinder bearing

27, 28, 29, 30

•

Cross conveyor belt

172

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

12 Lubrication chart 12.1 Lubrication points 71152

DISCO 3500 TRC / 3100 TRC Lubrication point number

Operating hours 8

2, 3

•

20

100

Comments

250

Folding frame bearing, on left/right

5

•

Folding frame bearings

6

•

Double joint slide fit

7

•

Bearing of jockey pulley arm

8

•

Cutting height spindle

9

•

Hitch bracket bearings

10

•

Drawbar / main frame bearings

11, 12, 13

•

Lift rod / connecting link bearings

12, 13

•

Lift cylinder bearing

15, 16

•

Swing cylinder bearings

17

•

Torque bracket

20

•

Main gearbox

18, 19, 21, 22

•

Conditioner drum bearing,

32

•

Tractor universal drive shaft – lemon tube

33

•

Transfer gearbox universal drive shaft – lemon tube

35

•

Mower unit universal drive shaft – lemon tube

34

•

Conditioner universal drive shaft – lemon tube

37 38, 39, 40 41 42

•

Tractor universal drive shaft – universal joints, universal drive shaft guard

•

Transfer gearbox universal drive shaft – universal joint, universal drive shaft guard

•

Conditioner universal drive shaft – universal joints, universal drive shaft guard

•

Mower unit universal drive shaft – universal joints, universal drive shaft guard

Lubricant symbols in illustrations The following symbols are used in illustrations:

Lubricate lubrication point with grease gun.

Lubricate lubrication point with oil can.

Use grease.

Use chain lube.

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

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12 Lubrication chart 12.1 Lubrication points 71152 69639

12.1.3 Lubrication points - 8 h

3

2

76519

24807

174

24808

2

24549

3

1

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

12 Lubrication chart 12.1 Lubrication points 71152 69640

12.1.4 Lubrication points - 20 h

11

12 13

5 8 7

9

10

6 76519 22601

4

24809

5

24798

8

24812

11

24808

6

24810

9

24813

12

23454

7

24811

10

24814

13

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

175

12 Lubrication chart 12.1 Lubrication points 71152

20

17 18 22

16

19 15

21

76519

176

22601

14

24815

15

3900 TC / 3500 TC / 3100 TC

23773

18

3500 TRC / 3100 TRC

23775

21

24816

16

3900 TC / 3500 TC / 3100 TC

23774

19

3500 TRC / 3100 TRC

23776

22

24817

17

24817

20

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

12 Lubrication chart 12.1 Lubrication points 71152

24

26

25

28 30

27 29 DISCO 3100 TC AS

DISCO 3100 TC AS

33112

24

DISCO 3100 TC AS

33115

27

DISCO 3100 TC AS

33113

25

DISCO 3100 TC AS

33116

28

DISCO 3100 TC AS

33114

26

DISCO 3100 TC AS

33117

29

DISCO 3100 TC AS

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

33172

23

33118

30

177

12 Lubrication chart 12.1 Lubrication points 71152 72367

12.1.5 Lubrication points - 100 h

33 32 34

35

76519

75616

23805

32

22601

31

10299

35

74178

10298

33

10298

34

75616

178

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

12 Lubrication chart 12.1 Lubrication points 71152 72368

12.1.6 Lubrication points - 250 h

40 37

38

39 41

42

76519

75616

23805

37

22601

36

10299

42

74178

10298

40

10298

41

75616

23805

38

23805

39

00 0295 391 2 - DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS - 01/10

179

71139

Index

Cutting discs General ............................................................. 152 Replacement .................................................... 153

A Accessories ............................................................. 53 Accessory Crop spreader .................................................... 53 High-cut skids ..................................................... 53 Hydraulic connection for tractor ......................... 54 Skid extensions .................................................. 54 Swathing plate extension ................................... 53 Accumulator Maintenance ..................................................... 136 Adjusting swathing plates .................................. 87, 89 Adjusting the crop spreader .................................... 88 Adjusting the cross conveyor belt .......................... 162 Adjusting the cutting height ..................................... 85 Adjusting the lateral offset ....................................... 50 Adjusting the tension spring Roller conditioner ............................................. 160 Angle drive ............................................................ 126 Areas where adhesives have been applied Cleaning ........................................................... 111

Decals Cleaning ........................................................... 111 Design ................................................... 34, 37, 40, 43 Dimensions ............................................ 33, 36, 39, 42 Disposal batteries .............................................................. 23 machine .............................................................. 23 operating materials ............................................. 23 packaging material ............................................. 23 refrigerant ........................................................... 23

E Electrical system Maintenance ..................................................... 109 Environmental protection ....................................... 101 Every time before putting into operation Check list ............................................................ 55

F

B Batteries disposal .............................................................. 23 Before commissioning checklist ............................................................. 45 Bolts ...................................................................... 107

C Chain lubrication oil Specification ..................................................... 117 Check list Before putting into operation .............................. 55 Chicane plate .......................................................... 86 Conditioner Changing the drive belts .................................. 157 Conditioner rollers on DISCO 3500 TRC / 3100 TRC ................................160 Installing/removing the conditioner tines .......... 159 Mowing without roller conditioner ....................... 89 Tensioning the drive belt .................................. 157 Conditioner speed ................................................... 86 Crop spreader Accessory ........................................................... 53 Cross conveyor belt Adjusting the discharge flap ............................... 91 Adjusting the guide roller .................................. 163 Adjusting the scraper ....................................... 163 Adjusting the speed .................................... 92, 104 Adjusting the throwing distance ......................... 92 Assembling the conveyor belt .......................... 165 Lifting / lowering ............................................... 104 Removing the conveyor belt ............................. 162 Starting / stopping ............................................ 104 Tensioning the conveyor belt ........................... 164 Cross conveyor belt hydraulic oil ........................... 138 Cross conveyor belt of DISCO 3100 TC AS ............ 91

180

D

Feed cylinder ......................................................... 152 Field driving ............................................................. 76 Fieldwork Difficult conditions of use .................................. 101 Environmental protection .................................. 101 General instructions ........................................... 93 First aid measures ................................................... 22 For Overload clutch see Friction clutch Formatierung von Texten .......................................................... 13 Friction clutch ........................................................ 129 Replacing the friction discs ............................... 130 Venting ............................................................. 129

G Grease Specification ..................................................... 117

H Handling .................................................................. 76 Headstock Unhitching .......................................................... 72 High-cut skids Accessory ........................................................... 53 Hitch bracket Adjusting the height ............................................ 83 Adjusting the pressure springs ......................... 133 Connecting ......................................................... 57 Hydraulic connection for tractor Accessory ........................................................... 54 Hydraulic hose lines Coupling ............................................................. 60 Decoupling ......................................................... 68 maintenance ..................................................... 135

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71139

Hydraulic system Maintenance .....................................................134

I Identification plate ....................................................16 Installing the pinion units ........................................154 Instructions for mowing ............................................93 Intended use ............................................................17

K Knives Holder ...............................................................150 Replacement .....................................................144

L Lifting the mower unit ...............................................78 Load relief Adjustment ..........................................................83 Loading/unloading machine .....................................81 Lowering the mower unit ..........................................96 Lubricants ......................................................115, 170 Lubrication Lubricants chart ................................................115 Lubrication intervals ..........................................171 Lubrication points ..............................................170 Lubrication points - 100 h ..................................178 lubrication points - 20 h .....................................175 Lubrication points - 250 h ..................................179 Lubrication points - 8 h ......................................174

M Machine Cleaning and maintaining .................................111 disposal ...............................................................23 Hitching ...............................................................56 Hitching - General instructions ............................56 Loading/unloading ...............................................81 Unhitching ...........................................................66 Unhitching - General instructions ........................66 Machine description .............................................9, 11 Machine maintenance ............................................111 Main gearbox .........................................................119

Maintenance Accumulator ......................................................136 Adjusting the cross conveyor belt .....................162 Angle drive ........................................................126 Anti-wrapping guard ..........................................156 Cross conveyor belt hydraulic oil ......................138 Cutting discs .....................................................152 Electrical system ...............................................109 Feed cylinder ....................................................152 Friction clutch ....................................................129 Friction discs .....................................................130 hydraulic hose lines ..........................................135 Hydraulic system ...............................................134 Installing the pinion units ...................................154 Knife holder .......................................................150 Knives ...............................................................144 Main gearbox ....................................................119 Mower head gearbox ........................................140 Mower knife box ................................................143 Protective guards ..............................................110 Replacing the cutting discs ...............................153 Safety guard holder ...........................................155 Transfer gearbox ...............................................122 Wheel change ...................................................132 Wheels and tyres ..............................................131 Maintenance instructions Unbalance .........................................................110 Misuse reasonable foreseeable ......................................18 Mower head Adjusting the load relief .......................................83 Mower head gearbox Maintenance .....................................................140 Mowing Difficult conditions of use ..................................101 General instructions for mowing .........................93 Turning area position ..........................................99 Mowing with cross conveyor belt ...........................103

N Noise level ..............................................35, 38, 41, 44

O Operating materials disposal ...............................................................23

P Packaging material disposal ...............................................................23 Parts .......................................................................110 Power supply Connecting ..........................................................65 Disconnecting .....................................................67 Problems Remedies ..........................................................167 Prop stand Lowering .............................................................66 Raising ................................................................57

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Reasonable foreseeable misuse ............................. 18 Refrigerant disposal .............................................................. 23 Replacing the drive belt hydraulic pump ............... 137 Requirements for tractor ........................ 34, 37, 40, 43 Road travel .............................................................. 73 Roller conditioner Adjusting synchronous running ........................ 160 Adjusting the roller clearance ........................... 161 Adjusting the tension spring ............................. 160

Unbalance ............................................................. 110 Universal drive shaft Adjusting length .................................................. 47 Check length ...................................................... 46 Fitting to the tractor ............................................ 58 General ............................................................. 128 Mounting on machine ......................................... 48 Removing ........................................................... 72 Wide angle constant-velocity joint ...................... 59 Use intended use ....................................................... 17 reasonable foreseeable misuse ......................... 18

S Safety Directives, statutes and standards ..................... 18 General information ............................................ 17 Hydraulics .......................................................... 21 intended use ....................................................... 17 Labels ................................................................. 24 Occupational safety ............................................ 19 reasonable foreseeable misuse ......................... 18 Safety features on the machine ......................... 22 Technical condition ............................................ 19 What to do in hazardous situations .................... 22 Safety decals Placement on the machine ................................. 26 Safety devices Safety frame in transport position ...................... 77 Safety frame in working position ........................ 82 Safety guard holder Adjustment ....................................................... 155 Serial number .......................................................... 14 Service intervals .................................................... 113 Skid extensions Accessory ........................................................... 54 Spare parts .............................................................. 15 Specifications DISCO 3100 TC AS ........................................... 42 DISCO 3900 TC ................................................. 33 Permanent sound pressure level ..... 35, 38, 41, 44 Sound pressure level measurement 35, 38, 41, 44 Suspended frame Adjusting tension springs ................................. 166 Swathing plate extension Accessory ........................................................... 53

V Validity of manual ............................................................ 14

W Warning signs General instructions ........................................... 25 Labels ................................................................. 24 Wear bars .............................................................. 152 Weight ................................................... 33, 36, 39, 42 Winter storage ....................................................... 112 Working position Adjusting the hitch bracket ................................. 83 Adjusting the mower head load relief ................. 83 Folding in safety frame ....................................... 82 Swinging into working position ........................... 95

T Technical questions ................................................. 15 Technical specifications .......................................... 14 DISCO 3100 TC / DISCO 3100 TRC ................. 39 DISCO 3500 TC / DISCO 3500 TRC ................. 36 Tensioning the hydraulic pump drive belt .............. 137 Transfer gearbox ................................................... 122 Transport position .................................................... 77 Folding down the safety frame ........................... 77 Lowering the cross conveyor belt ....................... 80 Swinging to transport position ............................ 79 Turning area position ............................................... 99 Tyres ..................................................... 34, 37, 40, 43

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At CLAAS KGaA mbH we are constantly improving our products to reflect the latest technological developments. For this reason, we reserve the right to make changes to diagrams and descriptions in this documentation without incurring any obligation to alter any machines previously delivered.

Technical specifications, dimensions, and weights are understood with the usual tolerances. Responsibility for errors or omissions not accepted.

Reproduction or translation of this publication, in whole or part, is not permitted without the written consent of the CLAAS KGaA mbH. All rights under the provision of the Copyright Act are reserved.

CLAAS KGaA mbH 33426 HARSEWINKEL Germany

Our contribution to the environment: CLAAS have printed this manual on 100 % chlorine free paper.

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

00 0295 391 2 DISCO 3900 TC; 3500 TC / TRC; 3100 TC / TRC / TC AS en - 01/10 Printed in Germany