PDF Technical Systems Manual Claas Mower DISCO - 3 MB
This technical systems manual for Claas DISCO mowers provides in-depth information beyond a standard operator's guide.
It details the setup, adjustment, and diagnosis of the mower's complex systems.
This guide is designed for technicians and advanced users who need to fine-tune performance or troubleshoot issues.
Use this manual to get the absolute best cutting performance from your DISCO mower.
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--- Page 3 ---
2 DISCO 3000 TC, TRC, AS, FG - Hydraulic system
Hydraulic circuit diagram
38306
2 DISCO 3000 TC, TRC, AS, FG - Hydraulic system
Hydraulic circuit diagram
00 0290 120 0 - SYS DISCO - 09/08 11
--- Page 4 ---
4 DISCO 3050 TCAS
Hydraulic circuit diagram
38308
Key to diagram
Pos. Designation Remark
1010 Oil tank -
- - -
2070 Swath spreader pump -
2071 Swath spreader motor -
2072 Lubrication pump -
- - -
3085 Chassis hydraulic cylinder -
3169 Transport / working hydrau- -
lic cylinder
3189 Swath spreader hydraulic -
cylinder
- - -
6041 Shut-off valve -
6085 Swath spreader shut-off is actuated when raising the swath spreader
valve
- - -
7034 Lock-up valve unit -
7072 Volume flow controller 2 - 25 litres/min infinitely variable adjustment of swathing belt speed
- - -
8001 Quick release coupling -
- - -
Y382 Swath spreader flow control- -
ler solenoid coil
- - -
a Lock Transport / working hydraulic cylinder
- - -
EW1 Single-acting Tractor additional control unit.Raise - lower chassis.
EW2 Single-acting Tractor additional control unit. Raise - lower swath spreader.
DA Double-acting Tractor additional control unit. Swing DISCO to working or transport
position.
00 0290 120 0 - SYS DISCO - 09/08 21
--- Page 5 ---
5 DISCO 3100 Contour / 2700C Contour
Hydraulic circuit diagram
38309
Working / transport position hydraulic cylinder (3169)
DW1 DW2
3169 1004
3169
403210
Pos. Designation Remark
1004 Vent opening -
3169 Transport / working hydrau- -
lic cylinder
- - -
DA1 Port Double-acting additional control unit on tractor
DA2 Plate Double-acting additional control unit on tractor
Description of function
The working/transport position hydraulic cylinder (3169) folds the mower unit
from the transport to the working position and vice versa. The combination of
Single- and Double-acting function provides even folding without dead points
and abrupt movements.
Working position on slopes The hydraulic cylinder in the position shown at the top represents the mower
unit in working position and tilted downward (slope).
Volume flow is fed via port DA1 for the turning area position
The complete cylinder travels until the left ram reaches the cylinder bottom.
Volume flow is fed via port DA2 for raising to transport position.
The right ram first extends up to the stop, in this process the mower unit is at
an angle of about 90Β°. At the same time, but with a slight delay because of
orifice plate 4009, the left ram travels up to the stop and the mower unit
reaches a position of around 115Β°.
00 0290 120 0 - SYS DISCO - 09/08 31
--- Page 6 ---
6 DISCO 3100C
Hydraulic circuit diagram
38310
3168 3169
403176 403177
4009 5015
4009
403183 403185
5015 6041
403178 403179
00 0290 120 0 - SYS DISCO - 09/08 41
--- Page 7 ---
7 DISCO 3500C
09 Hydraulic system main group
38311
7060
8001
403184 403180
EW DW
9041
403181 403182
00 0290 120 0 - SYS DISCO - 09/08 51
--- Page 8 ---
8 DISCO 3900
Hydraulic circuit diagram
38312
7060
8001
403184 403180
EW DW
9041
403181 403182
00 0290 120 0 - SYS DISCO - 09/08 61
--- Page 9 ---
11 DISCO 8550 C Plus - Hydraulic system
Hydraulic circuit diagram
38315
11 DISCO 8550 C Plus - Hydraulic system
Hydraulic circuit diagram
402249
00 0290 120 0 - SYS DISCO - 09/08 71
--- Page 10 ---
12 DISCO 8550 C Plus - Electric system
Speed monitor
38316
Malfunction
A sensor is defective (perma- β Speed < 600 rpm: no warning
nent minus at pin 3) β Speed > 600 rpm: Warning light of defective sensor in CCT lights up and
the warning tone sounds.
A sensor is defective (perma- β Speed < 600 rpm: The warning lights of the two intact sensors light up
nent minus at pin 3), or and the warning tone sounds.
connector disconnected, or one β Speed > 600 rpm: no optical and acoustic warning.
sensor is without power supply.
Two sensors without power sup- β Speed < 600 rpm: The warning light of the intact sensor lights up and the
ply, or connector disconnected warning tone sounds.
β Speed > 600 rpm: no optical and acoustic warning.
Three sensors without power β Speed < 600 rpm: no warning
supply, or connector β Speed > 600 rpm: no warning
disconnected
00 0290 120 0 - SYS DISCO - 09/08 81
--- Page 11 ---
13 DISCO 8550 AS - Electric system
Adapting the belt speedsSwath displacers (belt drive)
38318
β Set potentiometers R44 and R45 to the value 1.5. The belts should run at
the lower speed.
T12
R45
R44
401518
When the measured speed is way above 850 rpm or if the speed cannot be
varied around approx. 400 rpm at the potentiometer, the following setting
must be made:
Basic position β Set switch T12 to βONβ
β Open the cover of module A72.
A72
401540
X Y Z
8 9 10
401538
The LED display (Z) shows 3 horizontal bars.
00 0290 120 0 - SYS DISCO - 09/08 91
--- Page 12 ---
14 DISCO 8550 AS - Hydraulic system
Overall circuit diagram
38319
Designations
Pos Component Coordi-
nates
I Left swath displacer hydraulic valve
II Right swath displacer hydraulic valve
109 Oil cooler
110 Oil tank
112 Return filter
256 Right swath displacer hydraulic pump (14.5 cm3/rev.)
257 Left swath displacer hydraulic pump (14.5 cm3/rev.)
258 Left swath displacer hydraulic motor (20 cm3, Danfoss OMM20,
max. 25 ltr/min, n = 1250 rpm)
259 Right swath displacer hydraulic motor (20 cm3, Danfoss OMM20,
max. 25 ltr/min, n = 1250 rpm)
706-1 Left swath displacer pressure relief valve (140 bar)
706-2 Right swath displacer pressure relief valve (140 bar)
787-1 Left swath displacer pressure balance
787-2 Right swath displacer pressure balance
Y258 Left swath displacer flow controller solenoid valve
(Y6.2)
Y259 Right swath displacer flow controller solenoid valve
(Y7.2)
A Gearbox
00 0290 120 0 - SYS DISCO - 09/08 101
--- Page 13 ---
14 DISCO 8550 AS - Hydraulic system
Functions of overall hydraulic system
38319
Emergency functions In case of a fault in the electric system, the function of the swath displacers
can be performed manually. To this end, switch (T12) must be set to βOFFβ.
Danger!
Danger of accident when operating the valves
manually!
β Shut down the mower unit drive!
β Keep a sufficient distance from moving
parts!
To supply the swath displacer hydraulic motors (258, 259) with volume flow,
the PTO shaft of the tractor must be engaged.
The corresponding valves can be actuated by turning them in.
Y258 Y259
(Y6.2) (Y7.2)
402306
Left swath displacer flow controller solenoid valve (Y258) and right swath dis-
placer flow controller solenoid valve (Y259): Turning in β The belt gets faster
Turning out - The belt gets slower
00 0290 120 0 - SYS DISCO - 09/08 111
--- Page 15 ---
15 DISCO 8500 C-6 = 695SL, 8500 C-8 = 820-880, JAGUAR 8500 C - Hydraulic system
Overall circuit diagram
38321
When working, the working pressures of all cylinders are supported by accu-
mulators 88, 98 and 102. Below 80 bar, the lock-up valve units are open at
switch 94. When the pressure rises above 85 bar, the lock-up valve units are
closed and the mower units remain in their position. The ground pressure of
the mower units can be read on the pressure gauges 87, 97 and 101.
00 0290 120 0 - SYS DISCO - 09/08 121
--- Page 16 ---
16 DISCO 8500 C-6, 8500 C-8, JAGUAR 8500 C - Electric system
Central terminal compartment
38324
16 DISCO 8500 C-6, 8500 C-8, JAGUAR 8500 C - Electric system
Central terminal compartment
Graphics
402277
Key to diagram
Pos. Designation Remark
7 Connector Central terminal compartment
12 Relay for lock-up valve unit 89 and 99
13 Relay for 4/3-way solenoid valve (item 50A)
14 Relay for 4/3-way solenoid valve (item 50B)
15 Relay for lock-up valve unit item 109
17 Terminal strip, plus in the central terminal compartment (located above the relays)
19 Terminal strip, left -
19a Terminal strip, right -
- - -
d Diodes -
K1 Raise/lower right side- Solenoid valve item 74
mounted mower unit
K2 Raise/lower left side- Solenoid valve item 73
mounted mower unit
K3 Front mower unit Solenoid valve item 72
K4 Right mower unit lock-up Solenoid valve item 89
valve unit
K5 Left mower unit lock-up valve Solenoid valve 99
unit
00 0290 120 0 - SYS DISCO - 09/08 131
--- Page 17 ---
17 JAGUAR 8700/8500, DISCO 8700 Plus - Hydraulic system
Overall circuit diagram
38329
17 JAGUAR
Overall circuit
8700/8500,
diagram DISCO 8700 Plus - Hydraulic system
Key to diagram
Pos. Designation Remark
10 Quick release coupling -
11 Quick release coupling Tank connection
12 Mower units pressure gauge L=left R=right M=centre
13 Accumulator 0.16 ltr. 80 bar
14 3 accumulators 0.75 ltr. 35 bar
15 3 accumulators 0.75 ltr. 35 bar
16 3 accumulators 0.75 ltr. 35 bar
17 Non-return valves -
18 Non-return valves -
19a Left mower unit cylinder raise/lower
19b Right mower unit cylinder raise/lower
20a Centre mower unit cylinder raise/lower
20b Centre mower unit cylinder raise/lower
21 Pressure relief valve (210 bar) Starting protection of left mower unit
22 Pressure relief valve (210 bar) Starting protection of right mower unit
23 Pressure relief valve (180 bar) Front attachment cylinder ram ring surface
24a Fold left mower unit cylinder and cylinder starting protection
in/out
24b Right mower unit cylinder and cylinder starting protection
DS1 Pressure switch (85/110 bar) Raise front attachment
DS2 Pressure switch (140 bar) Close left accumulator
DS3 Pressure switch (140 bar) Close right accumulator
DS4 Pressure switch (150 bar) Fold in mower units
DS5 Pressure switch (150 bar) Fold out mower units
M1 Solenoid valve Swing out mower units
M2 Solenoid valve Swing in mower units
M3 Solenoid valve Raise/lower left mower unit
M4 Solenoid valve Raise/lower centre mower unit
M5 Solenoid valve Raise/lower right mower unit
M6 Solenoid valve Left accumulator shut-off valve
M7 Solenoid valve Front accumulator shut-off valve
M8 Solenoid valve Right accumulator shut-off valve
M9 Solenoid valve Raise/lower left load relief valve
M10 Solenoid valve Raise/lower front load relief valve
00 0290 120 0 - SYS DISCO - 09/08 141
--- Page 18 ---
18 JAGUAR 8700/8500, DISCO 8700 Plus - Electric system
Overall circuit diagram from serial no. 492 00 513
38332
18 JAGUAR 8700/8500, DISCO 8700 Plus - Electric system
Overall circuit diagram from serial no. 492 00 513
00 0290 120 0 - SYS DISCO - 09/08 151
--- Page 19 ---
19 DISCO 8700 Plus, DISCO 8550 C-8 for JAGUAR 880-820 (491) - Electric system
Overall circuit diagram
38335
19 DISCO
Overall circuit
8700diagram
Plus, DISCO 8550 C-8 for JAGUAR 880-820 (491) - Electric system
Key to diagram
Pos. Designation Remark
A33 Control box for JAGUAR Types 491 and 492
CCT CLAAS Control Terminal -
CT Connector Connection to CLAAS Control Terminal (CCT)
DS1 Pressure switch 85/110 bar, NO contact, raise front attachment
DS2 Pressure switch 140 bar, NO contact, left mower unit (close accumulator)
pressure switch
DS3 Pressure switch 140 bar, NO contact, right mower unit (close accumulator)
DS4 Pressure switch 150 bar, NO contact, fold side-mounted mower units in/out
DS5 Pressure switch 150 bar, NO contact, lower front mower unit, fold out mower units
DZWL Speed monitor DA60 (supplier: Walterscheid), left mower unit
DZWM Speed monitor DA60 (supplier: Walterscheid), front mower unit
DZWR Speed monitor DA60 (supplier: Walterscheid), right mower unit
H Connector beneath the cab
M Connector in the central terminal compartment (only on JAGUAR Type 492)
MFG Multifunction handle -
M1 Swing out mower units sole- -
noid valve
M2 Swing in mower units sole- -
noid valve
M3 Raise/lower left mower unit -
solenoid valve
M4 Raise/lower centre mower -
unit solenoid valve
M5 Raise/lower right mower unit -
solenoid valve
M6 Left accumulator shut-off -
valve solenoid valve
M7 Front accumulator shut-off -
valve solenoid valve
M8 Right accumulator shut-off -
valve solenoid valve
M9 Raise/lower left load relief -
valve solenoid valve
M10 Raise/lower front load relief -
valve solenoid valve
M11 Raise/lower right load relief -
valve solenoid valve
M12 Lower overall pressure load -
relief valve solenoid valve
00 0290 120 0 - SYS DISCO - 09/08 161
--- Page 20 ---
20 DISCO 8700 Plus, DISCO 8550 C-8 for JAGUAR 880-820 (491) - Hydraulic system
Overall circuit diagram
38336
20 DISCO 8700 Plus, DISCO 8550 C-8
for JAGUAR 880-820 (491) - Hydraulic system
Overall circuit diagram
00 0290 120 0 - SYS DISCO - 09/08 171
--- Page 21 ---
21 DISCO 9100 - 8400
10 Electric system main group
38339
21 DISCO 9100 - 8400
10 Electric system main group
00 0290 120 0 - SYS DISCO - 09/08 181
--- Page 22 ---
21 DISCO 9100 - 8400
Mower unit control module (A068) - Connector pin assignment
38340
Module A068 - Connector X2
Module A068, Connector X2
16 9 6 4
8 1 3 1
8 1 X2 X1 3 1
16 9 6 4
400873
402640
Pin Function CCN Component Circuit Meas- Direc-
dia- ured tion
gram variable
2/1 Power plus +30 Power plus 1 12 V Input
2/2 Right mower unit height Y415 Solenoid coil 1 12 V Output
block valve
2/3 Individual right mower unit Y413 Solenoid coil 1 12 V Output
lifting
2/4 Left mower unit height Y414 Solenoid coil 1 12 V Output
block valve
2/5 Individual left mower unit Y412 Solenoid coil 1 12 V Output
lifting
2/6 Right mower unit load Y408 Solenoid coil 1 12 V Output
relief
2/7 Left mower unit load relief Y407 Solenoid coil 1 12 V Output
2/8 Power earth -31 Power earth 1 Ground Input
2/9 - - - - - -
2/10 Mower unit pressure B296 Sensor 1 0.25 - Input
sensor 4.75 V
2/11 - - - - - -
2/12 - - - - - -
2/13 - - - - - -
2/14 - - - - - -
2/15 - - - - - -
2/16 - - - - - -
00 0290 120 0 - SYS DISCO - 09/08 191
--- Page 23 ---
22 DISCO 9300C - 8600C with push operation
09 Hydraulic system main group
38342
Designations
Pos Component Coordinates
Pos Component Coordinates 7173 Tank shut-off valve The piston is opened by the return pressure against the com-
pression spring (0.4bar) in the ring space.
3016 Safety frame hydraulic cylinder Pressure build-up in the piston top space = transport position
- - -
Pressure build-up in the rod space = working position
9001 Working hydraulics measuring Corn picker connection
3132 Left mower unit hydraulic cylinder Pressure build-up in the piston top space = raise left mower
point
unit. Neutral circulation pressure (no consumer is actuated): about
15 bar at an oil temperature of around 40Β°C
3133 Right mower unit hydraulic Pressure build-up in the piston top space = raise right mower
cylinder unit. 9041 Ground pressure gauge
3148 Front mower unit hydraulic Pressure build-up in the piston top space = raise front mower - - -
cylinder unit.
B278 Front mower unit pressure sensor -
3195 Left mower unit load relief hydrau- Pressure build-up in the piston top space = increase load