Claas Disco 3500 Swathers Tedders Mowers Units

SWATHERS
LIN
ER
350
S
TEDDERS
MOWER UNITS
Repair and Adjust-

ment Instructions
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Introduction
Introduction
1 Introduction INTRODUCTION
This manual contains general instructions on the repair
of CLAAS forage harvesting equipment. It also con-
tains information on the repair of:
– LINER reduction gear
– CLAAS rotary gear
– DISCO mower head
– CORTO direct-cut drive
Please read this manual thoroughly before starting
work! Pay particular attention to the “General
Information” section.
The required spare parts can be found in the parts list
of your forage harvesting equipment.
Your CLAAS Service Department
299 605.1 - RHB Futtererntemaschinen 1.1

Contents
Contents
2 Contents
1. Introduction Repeat assembly .............................................................. 3.14
Introduction ............................................................................... 1.1 Leaky profile ring connection ............................................ 3.14
Conical nipple retaining screws on hydraulic
2. Contents system hoses ................................................................... 3.14
Assembly .......................................................................... 3.14
3. General Information Welding ................................................................................... 3.14
Of special importance ............................................................... 3.1 Fuel and lubricants ................................................................ 3.15
Identification of warnings and dangers ............................... 3.2 Fill amounts ...................................................................... 3.15
Designated use ................................................................... 3.2
Explanation of symbols ............................................................. 3.3 4. Drive systems
Tightening torques .................................................................... 3.4 LINER reduction gear ............................................................... 4.1
General repair instructions ........................................................ 3.6 General assembly and maintenance instructions ............... 4.1
General ............................................................................... 3.6 Bearings ............................................................................. 4.1
Test run ............................................................................... 3.6 Screw connections ............................................................. 4.1
Screw connections .................................................................... 3.6 Radial shaft seals ............................................................... 4.1
General ............................................................................... 3.6 Gearbox in oil bath ............................................................. 4.1
Special shaft nuts ............................................................... 3.6 Reduction gear
Self-locking screws “LINER 680 / 680 L / 680 Profil / 650 Twin / 350 S / 350 T”
(with micro-encapsulated glue) ........................................... 3.6 – version “9.792.100.40” and “9.792.101.40” ..................... 4.2
Liquid screw lock ................................................................ 3.7 List of parts ......................................................................... 4.2
Correct use ......................................................................... 3.7 Dimensions ......................................................................... 4.3
Gaskets ..................................................................................... 3.7 Disassembly ....................................................................... 4.4
Liquid gaskets ..................................................................... 3.7 Assembly ............................................................................ 4.7
Flat gaskets ........................................................................ 3.7 Reduction gear
Finished gaskets ................................................................. 3.7 “LINER 680 / 680 L / 680 Profil / 650 Twin / 350 S / 350 T”
Radial shaft seals ............................................................... 3.8 – version “9.792.116.20” .................................................. 4.12
Bearings .................................................................................... 3.8 List of parts ....................................................................... 4.12
Assembly of clamping ring bearings ................................... 3.8 Dimensions ....................................................................... 4.13
Assembly of adapter sleeve bearings ................................. 3.8 Disassembly ..................................................................... 4.14
Loosening ........................................................................... 3.8 Assembly .......................................................................... 4.17
Tightening ........................................................................... 3.8 Reduction gear
Assembly of roller bearings ................................................ 3.9 “LINER 680 / 680 L / 680 Profil / 650 Twin / 350 S / 350 T”
General ............................................................................... 3.9 – general assembly instructions ....................................... 4.22
Adjustment of roller bearings .............................................. 3.9 Contact pattern ................................................................. 4.22
Shaft-hub connections ........................................................ 3.9 Backlash ........................................................................... 4.22
DRIVE SYSTEMS ..................................................................... 3.9 Lubricants ......................................................................... 4.22
General ............................................................................... 3.9 “CLAAS” reduction gear
Gears ................................................................................ 3.10 – General assembly instructions ...................................... 4.23
Spur gears ........................................................................ 3.10 Installation of curved track ................................................ 4.23
Bevel gears ....................................................................... 3.10 Lubricants ......................................................................... 4.23
Adjustment of spur gears .................................................. 3.10 “CLAAS” rotary gearbox ......................................................... 4.24
Adjustment of cyclopalloid gears ...................................... 3.10 General assembly instructions ......................................... 4.24
Tensioning steel roller chains ........................................... 3.12 Assembly of the angle drive ............................................. 4.24
Tapered ring connections ................................................. 3.13 Lubricants ......................................................................... 4.24
Disassembly ..................................................................... 3.13 DISCO cutter bar .................................................................... 4.25
Assembly .......................................................................... 3.13 Cutter bar with 6 cutting discs “COMER FR-566A” .......... 4.25
Hydraulic system ..................................................................... 3.13 Parts list “cutter bar with 6 cutting discs” .......................... 4.25
Ferrule retaining screws on hydraulic system hoses ........ 3.13 Cutter bar with 7 cutting discs “COMER FR-567A” .......... 4.25
Assembly .......................................................................... 3.13 Parts list “cutter bar with 7 cutting discs” .......................... 4.26
Final assembly .................................................................. 3.13 Parts description ............................................................... 4.26
Repeat assembly .............................................................. 3.13 Dimensions “cutter bar with 6 cutting discs” ..................... 4.27
Leaking ferrule connection ................................................ 3.13 Dimensions “cutter bar with 7 cutting discs” ..................... 4.28
Progressive ring retaining screws on Disassembly ..................................................................... 4.29
hydraulic system hoses .................................................... 3.13 Assembly .......................................................................... 4.31
Assembly .......................................................................... 3.13 Assembling rotors ............................................................. 4.32
Final assembly .................................................................. 3.14 Assembling inlet rotor ....................................................... 4.33
2.1 RHB Futtererntemaschinen - 299 605.1

Contents
Replacing intermediate gear wheel – bearing .................. 4.34

Assembling cutter bars ..................................................... 4.36
Installing rotor ................................................................... 4.37
Leak test ........................................................................... 4.38
Installing slide ................................................................... 4.38
Installing cutting disc and drum ........................................ 4.39
Drum – inlet side ............................................................... 4.39
“COMER” cutter bar
– General assembly instructions ...................................... 4.40
Lubricants ......................................................................... 4.40
“CORTO” direct-cut attachments ............................................ 4.41
Installing direct-cut attachment ......................................... 4.41
Lubricants ......................................................................... 4.41

General Information
General Information
3 General OF SPECIAL IMPORTANCE

Persons who operate, service, repair or check
Information this machine/attachment must read and observe
the information in this manual so they can work
safely. Pay particular attention to the “General
Information” section in the operator's manual
and observe the accident prevention regulations
in force in your jurisdiction.
Before starting work make sure that you have all
the required tools and equipment.
See the parts list for the relevant machine or the
parts overview for the specifications of parts,
e.g. screws and bolts.
Parts are identified with numbers (item num-
bers) for better orientation in the assembly
descriptions. The numbers correspond to the
item numbers in the parts overview.
Text and pictures are kept as neutral as possi-
ble. Text notes call attention to differences in
the specific types.
Technical specifications, dimensions and
weights are understood with the usual toler-
ances.
IMPORTANT: Front, rear, right and left refer to
the direction of forward travel.

General Information
Identification of warnings and dangers Designated use

All parts of this manual having to do with your safety The use of spare parts, accessories and addi-
or the safe operation of the machine are marked tional equipment which is not originally manu-
with the following signs. Please supply all safety factured, and not checked and released by
instructions to any other user. CLAAS can have its negative effect on specific
design features of the CLAAS machine or on its
operability, thereby impair active and/or passive
Danger! operating safety, as well as safety at work (acci-
Failure to observe the instructions identi- dent prevention).
fied by this symbol results in danger for life CLAAS will in no way be liable for damage or
and limb of the user or other persons. personal injury caused by the use of other than
– Measures for avoiding danger. original CLAAS parts, accessories and addi-
tional equipment.
Caution!
Sign to indicate instructions which must be

observed. Failure to do so could result in
damage to the machine.
– Measures for avoiding danger to the
machine.
Note!
This symbol identifies instructions that make

it easier to use the machine effectively and
economically.
Important!
This symbol identifies information that must

be observed during disassembly and assem-
bly.
Environment!
Failure to observe the instructions identified by this
symbol results in damage to the environment.
The environment is in danger if environmentally
hazardous material (e.g. waste oil) is not subject to
correct use and/or disposal.
The warning and instruction signs placed on the

combine provide recommendations for safe opera-
tion. These instructions involve your safety –
observe them at all times!

General Information
General Information
EXPLANATION OF SYMBOLS The user will quickly learn the meanings of these sym-
bols. They are intended to assist in quick recognition of
This CLAAS REPAIR MANUAL uses certain symbols frequently repeated procedures and illustrated instruc-
from the “Symbols–Overview DIN 30600” published by tions.
the German Institute for Standardisation.
Disassembly Prevention of material

Grease
Removal damage
Dismantle Oil Use of special tools
Drain
Assembly Set-up
drainage hole
Install Filling
Visual, monitor inspect
Attach Filler opening
Mark Unlock, lock Overflow
Balance Hold fluid, glue seal Bleeding
Support
Re-usable Dispose of parts cor-
Prop
to a limited extent rectly
Catch
Replace on every Observe installation

Retain parts for re-use
assembly direction

General Information
TIGHTENING TORQUES
Tightening torques (in Nm) for hexagon head bolts, cheese-head screws and hexagonal nuts
Nuts and bolts carbonised, phosphatised or galvanised

Strength class 8.8 10.9 12.9
Dimensions Metric coarse-pitch thread
M4 2.7 3.8 4.6
M5 5.5 8.0 9.5
M6 10.0 14.0 16.0
M8 23.0 33.0 40.0
Hexagon head bolts
M 10 45.0 63.0 75.0
DIN 931
DIN 933 M 12 78.0 110.0 130.0
M 14 122.0 175.0 210.0
Cheese-head screws M 16 195.0 270.0 325.0
DIN 912
M 18 260.0 370.0 440.0
M 20 370.0 525.0 630.0
hexagonal nuts
M 22 510.0 720.0 870.0
DIN 934
M 24 640.0 900.0 1080.0
M 27 980.0 1400.0 1650.0
M 30 1260.0 1800.0 2160.0
Dimensions Metric fine-pitch thread

M8x1 25 35 42
M 10 x 1.25 48 67 80
M 12 x 1.25 88 125 150
M 12 x 1.5 82 113 140
Hexagon head bolts M 14 x 1.5 135 190 225
DIN 960
M 16 x 1.5 210 290 345
DIN 961
M 18 x 1.5 300 415 505
M 20 x 1.5 415 585 700
M 22 x 1.5 560 785 945
Hexagonal nuts
DIN 934 M 24 x 2 720 1000 1200
M 27 x 2 1050 1500 1800
M 30 x 2 1450 2050 2500
CAUTION! Cadmium-plated or copper-plated nuts and bolts must be tightened with torques
25% lower than the specified values.

General Information
Tightening torques for hydraulic system retainers with o-rings in accordance with ISO 6149
Dimensions Tightening torque in accordance with ISO 6149

M8x1 7+2 Nm
M 10 x 1 11+4 Nm
M 12 x 1.5 16+5 Nm
M 14 x 1.5 23+8 Nm
M 16 x 1.5 29+10 Nm
M 18 x 1.5 38+13 Nm
M 20 x 1.5 46+15 Nm
M 22 x 1.5 67+22 Nm
M 24 x 1.5 86+29 Nm
M 26 x 1.5 103+34 Nm
M 27 x 2 103+34 Nm
M 30 x 2 170+57 Nm
M 33 x 2 200+67 Nm
M 36 x 2 245+82 Nm
M 38 x 2 245+82 Nm
M 39 x 2 310+103 Nm
M 42 x 2 380+127 Nm
M 45 x 2 440+147 Nm
Tightening torques for screw plugs
Dimensions Tightening torque

M 16 x 1.5 conical 30 Nm
M 18 x 1.5 conical 50 Nm
M 16 x 1.5 cylindrical 30 Nm
M 18 x 1.5 cylindrical 50 Nm

General Information
GENERAL REPAIR INSTRUCTIONS SCREW CONNECTIONS
General General
1. Find cause of damage, limit damage and secure All nuts and bolts must be checked against the parts
machine. list for strength class, length and correct standard
before assembly.
2. Use original CLAAS parts and appropriate CLAAS
special tools. When tightening the screws and bolts ensure that they
are tightened crosswise starting in the centre, unless
3. Repairs can be carried out quickly and correctly
otherwise specified. Then all threaded connections
when the following are observed:
must be tightened again.
• Mark machine parts before removing them to
The threaded connections are tightened and retight-
ensure that they are correctly re-installed and
ened with a torque spanner.
correctly balanced after replacement.
Nuts must be no more than one strength class below
• Expansion pins must always be positioned with
the bolts used.
the slot to the loaded side. If they are displaced
by 90°, they will loosen, fall out or shear. All screws and bolts must be tightened as specified in
the Tightening torques on page 3.4 table, unless other-
• Replace split pins, wire locks, metal-plate locks,
wise specified.
lock washers and spring washers during repairs.
• Grease lubricated ball bearings and roller bear-
ings with good-quality grease. Special shaft nuts
• Align sprockets and v-belt pulleys with each Special shaft nuts are generally specially manufac-
other. tured and have a turned collar. Unlike the standardised
shaft nuts tab washers are not required. They are
• Observe cleanliness when working on hydraulic
locked by the turned collar being locked or tapped into
systems.
a groove or a profile gap, unless otherwise specified.
• Do not mix different oil types. The turned collar must not be deformed by locking or
tapping to the extent that they are cracked through.
• Rotate or operate machine or machine assem-
blies slowly after repair. If the external diameter of the shaft nut is used as a
seal, the thread of the shaft nut and the shaft is locked
4. Inform the machine owner of the cause, type and
with locking fluid, unless otherwise specified
scope of repairs!
– see Liquid screw lock, page 3.7.
Test run
Self-locking screws
5. Always prepare and conduct a test run after (with micro-encapsulated glue)
repairs.
Replace self-locking screws, e.g. Verbus Plus /
• Correctly screw in and tighten all screws! Imbus–Plus etc., at every assembly. They can be
• Clear up all tools used! re-used up to three times in exceptional cases. Always
tighten at the specified torque.
• Touch up paint at points where welding, drilling
and grinding work was carried out. Always tighten self-locking screws with micro-encap-
sulated glue quickly to the specified torque. Unscrew
• Replace all safety features so they operate cor- these screws quickly to remove them completely. The
rectly! self-locking screws must not come into contact with
• Check electrical connections! sealing compound (e.g. “Epple 33” etc.).
• Check settings on the machine! Instead of self-locking screws, screws locked with liq-
uid locking material must only be used where the
• Lubricate all required grease points! screw connections can be heated up to about 200°C to
• Check all oil levels! loosen them. Note also the specified quality class of
the screws (8.8/10.9 etc.).
• Conduct test run!
Self-locking screws with micro-encapsulated glue can
only be used where the operating temperature does
not exceed max. +90 °C.

General Information
Screws of this type reach their full load capacity after GASKETS
24 hours at +20 °C. The hardening period can be
reduced by heating (e.g. at +70 °C for 15 minutes). Liquid gaskets
Liquid gaskets are used to seal:
Liquid screw lock – Housing sections
(e.g. Delo–ML 187 / Loctite 242 etc.) – Flanges
Only use liquid screw lock when recommended by the – Covers

manufacturer. – Threads
Correct use
Metallic connections that are to be locked with liquid The sealed parts must smooth and undamaged and
thread-lock must be absolutely free from grease. also free from oil and grease on the gasket contact
Clean them with the “activator” included in the work- surfaces. The sealing compound must be spread
shop pack. evenly on the surfaces without breaks and in the
The metal surfaces must be completely free of activa- amount required to seal the special part. Ensure that
tor before applying the liquid thread lock. In particular, drilled holes and threads are covered with sealing
blind holes must not have any activator residue (use compound on the sides that require sealing.
cleaner). The sealing compound must be ventilated to ensure a
With threaded connections apply the liquid thread lock proper seal in accordance with the manufacturer's
to the internal thread (nut) in as small a quantity (drop specifications for joining the parts. Threads on bolts
by drop) as possible. Apply approximately 1d are sealed by applying the sealing compound to the
(d = rated –∅ of the bolt) to the base of the thread only outer thread in the specified quantity.
in blind holes. Proceed in the same way with all over-
length screw-in threads.
Flat gaskets
Note! Flat gaskets are used to seal covers, screw heads,
screw plugs, ventilation components etc.
If the liquid thread lock is applied to the thread of
These gaskets can be paper, rubber, cork, copper or
the bolt or at the start of the inserted end, the liq-
special materials. The gaskets must be undamaged,
uid will be distributed over the entire length of
otherwise the effectiveness of the seal may be
the thread when screwing it in and the breaking
affected.
torque will be too high when attempting to
unscrew the bolt later and the bolt may break. The sealing surfaces of the sealed parts must be
undamaged.
Screw connections that are locked with liquid thread Observe the special regulations for special require-
lock can be loosened easily by heating them to about ments.
200°C.
Finished gaskets
Finished gaskets are used for static and dynamic
seals. This includes o-rings, quad-rings and seals.
The sealed components must be undamaged and free
from roughness and cavities on the seal surfaces.
Visually inspect the seal components before assem-
bly.
The gaskets must be used with oil, grease or a special
lubricant. Use special tools as specified.
During assembly it is particularly important to prevent
crushing or any other damage to the sealing elements.

General Information
Radial shaft seals Assembly of adapter sleeve bearings

Radial shaft seals must be installed as specified by the Adapter sleeve bearings do not require a specially
drawings. Pay particular attention to installation direc- machined bearing seat. They can be installed on any
tion, squareness and installation parity. drawn or turned shaft. This has the advantage that the
shaft can be slid axially as desired and so can be eas-
The seal parts (shaft and bore) must be inspected for
ily aligned.
damage and repaired if necessary.
Always install adapter sleeve bearings to match the
Visually inspect the radial shaft seals before assembly.
conical inner race. Clean the expansion pin and shaft
The lip of the seal must also be covered with oil.
before installation and check that the expansion pin
During assembly of radial shaft seals protective nut moves easily to prevent the expansion pin from
bushes must be slid over the shafts to protect them rotating on the shaft during tightening.
from damage by the sharp edges of safety grooves,
Loosening
keyways etc. If possible, use drive bushes with
attached protective bushes. If protective bushes are First loosen the released expansion pin nut by a few
not available, at least cover the sharp edges, threads revolutions only (thread must still grip fully). Loosen
etc. with adhesive tape. expansion pin with a stroke pipe and a firm tap.
When using radial shaft seals with a metal sheath, the Tightening
sheath region and the corresponding bore section
First tighten expansion pin nut until the expansion pin
must be degreased and covered with the specified
is free of play and has a light tension. Now tighten the
sealing compound for sealing.
nut approximately 90° and then continue to turn until
If the assembly procedure for two-section cases the next groove has passed the locking tab. Lock the
requires the radial shaft seals to be installed before the expansion pin nut with the locking tab.
two halves of the case are joined, ensure that the case
halves are positioned centrally to each other to prevent
crushing in the area of the case separation at the man-
tle of the radial shaft seals.
BEARINGS
Assembly of clamping ring bearings

Clamping ring bearings are fixed on the shaft by rota-
tion of the eccentric ring over the bearing inner race.
Before positioning them grease the inner race and the
shaft with semi-fluid lubricant (e.g. Shell Retinax G or
similar) to make it easier to remove the bearing during
a subsequent disassembly.
Always gently tap the eccentric ring in the direction of
rotation of the shaft and fix it with a setscrew. To
loosen the bearing tap the eccentric ring against the
direction of rotation of the shaft.

General Information
Assembly on shaft Assembly in drilled hole Assembly on shaft and assembly

in drilled hole
71195
1
Assembly of roller bearings Shaft-hub connections
General When assembling wheels and flanges it is very impor-
tant that the workpieces are only heated to the
When assembling roller bearings on shafts ensure that
required joining temperature.
the temperature is raised only as far as required for
easy assembly. Make sure that the bearing installation When using keys or profiles ensure that no burs are
surfaces are absolutely free from burs to provide a formed while joining.
clean surface for the roller bearing.
Any burs found must be removed before final assem-
Bearings must be installed on shafts or in drilled holes bly.
with the specified installation bushes only so only the
outer or inner races or both are loaded (Fig. 1).
Never press on the rollers, balls or cages during
DRIVE SYSTEMS
assembly. General
Adjustment of roller bearings
Roller bearings must always be adjusted. Set the Environment!
specified bearing play or the required pretension as
Dispose of oil and grease according to regulations!
specified. If there are no specifications for adjusting
the roller bearings, they are adjusted free of play.
They are adjusted with the adjusting nuts, by adding When disassembling gearboxes first drain the oil and
shims or by calibration of the bearing covers or then disassemble the gearbox. Separate internally
flanges. connected parts with a soft metal or plastic hammer.

General Information
Initial adjustment required correction Correct adjustment

1
71249
2
Gears Adjustment of spur gears
Spur gears The position of the contact patterns and the required
correction for spur gears are shown in figure 2.
Spur gears must be assembled axially as specified in
the drawing and adjusted as required. To ensure that Example 1 – contact pattern nearer the tooth tip
spur gears run correctly, the tooth flanks must not be
Required correction:
damaged. They must also have the required backlash.
• Adjust pinion further away from crown wheel and
Check that tooth flanks connect correctly by rotating
the spur gears. • crown wheel nearer to pinion.
Bevel gears Example 2 – contact pattern nearer to foot of tooth
Bevel gears must be adjusted to achieve optimum Required correction:
contact pattern of the tooth flanks. The required back-
• Adjust pinion nearer crown wheel and
lash must be retained.
• crown wheel away from pinion.
The position of the contact patterns and of the tooth
flank play is adjusted by changing the installation
dimensions of the pinion shaft and/or crown wheel.
Adjustment of cyclopalloid gears
They are adjusted with the adjusting nuts, by adding
shims or by calibration of the bearing covers or The position of the contact patterns and the required
flanges. correction for cyclopalloid gears are shown in
figures 3 and 4.

General Information
71250
3
Height adjustment of the contact pattern
Example 3 – contact pattern centred but too near
the tooth tip
• crown wheel nearer to pinion.
Example 4 – contact pattern centred but too near

to foot of tooth
• Adjust pinion nearer crown wheel and
• crown wheel away from pinion.
(Fig. 3)

General Information
71251
4
Longitudinal adjustment of the contact pattern
Example 5 – contact pattern too far left or right but
in the centre of the tooth flanks
• crown wheel nearer to pinion.
Example 6 – contact pattern too far right or left but

in the centre of the tooth flanks
Required correction: 5
• Adjust pinion nearer crown wheel and Tensioning steel roller chains
• crown wheel away from pinion. Steel roller chains are correctly tensioned when the
slack side can be pressed approximately 2% from the
(Fig. 4) axle distance in the centre between the sprockets with
low load on the tight span. Check the tension more fre-
quently with new chains.
Example: Axle distance 500 mm = pressure distance
at slack side ca. 10 mm.

General Information
Tapered ring connections Press the pipe against the stop in the connectors and
tighten the union nut until the ferrule grips the pipe
Tapered ring connections are a secure connection for (pipe must no turn). This point can be detected by the
transfer of high forces from the drive element to the increase in force required.
shaft and reverse when correctly preloaded.
Tighten union nut half a turn past the pressure point.
Disassembly
Check the indent in the edge: a visible collar must
After loosening the axial clamp release the tapered occupy the space before the ferrule face. The ferrule
ring connections with a stroke pipe and a firm tap with can be rotated but must not be movable axially.
a hammer.
Final assembly
Important! Position the assembled pipe in the well lubricated

retainer support, tighten the union nut until the force
The internal diameter of the stroke pipe must be increases and then half a turn further.
sufficient to grip over the tapered ring.
Repeat assembly
Whenever the ferrule retaining screw is loosened, the
Assembly union nut must be retightened without increased force.
For assembly it is important to clean the shaft, hub, Leaking ferrule connection
key and tapered rings thoroughly, grease them with
semi-fluid lubricant (e.g. Shell Retinax G or similar) If a connection leaks, the union nut must first be loos-
and tighten them with the specified torque in the cor- ened until oil comes out and then tightened as speci-
rect assembly sequence. fied.
Important! Progressive ring retaining screws on

Do not assemble parts with viscous grease. hydraulic system hoses
All assemblies and factory-assembled profile ring
retaining screws are installed in the matching,
well-lubricated retaining supports with half a turn of the
HYDRAULIC SYSTEM union nut past the point where the force required sig-
nificantly increases.
Ferrule retaining screws on hydraulic system
Assembly
hoses
Saw off the pipe at a right angle.
All assemblies and factory-assembled ferrule retaining
screws are installed in the matching, well-oiled retain-
ing supports with half a turn of the union nut past the Note!
point where the force required significantly increases.
Do not use a pipe cutter! It will cut the pipe wall
Assembly at an angle and will leave burs inside and out-
Saw off the pipe at a right angle. side.
Note! Lightly debur the end of the pipe inside and outside (do
not grind!) and clean it.
Do not use a pipe cutter! It will cut the pipe wall
at an angle and will leave burs inside and out- With elbows the distance from the straight end of the
side. pipe to the beginning of the curve must be at least
twice the height of the union nut.
Slide union nut and profile ring onto the pipe.
Lightly debur the end of the pipe inside and outside (do
not grind!) and clean it. Press the pipe against the stop in the connectors and
tighten the union nut until the profile ring grips the pipe
With elbows the distance from the straight end of the (pipe must not turn). This point can be detected by the
pipe to the beginning of the curve must be at least increase in force required.
twice the height of the union nut.
Tighten union nut half a turn past the pressure point.
Slide union nut and ferrule onto the pipe.

General Information
Check the indent in the edge: a visible collar must Conical nipple retaining screws on hydraulic
occupy the space before the profile ring face. The pro- system hoses
file ring can be rotated but must not be movable axi-
ally. Assembly
Final assembly Oil o-ring on the conical nipple. Tighten the union nut
one third of a turn past the point of significantly
Position the assembled pipe in the well lubricated increased force.
retainer support, tighten the union nut until the force
increases and then half a turn further.
Important!
Important! Hold the retaining supports in place with a span-

ner!
Hold the retaining supports in place with a span-
ner!
Note!
Deviating inlet paths reduce the rated pressure

Repeat assembly
and the life of the retaining screw. This will result
Every time the profile ring retaining screw is loosened in leakage and displacement of the retaining
the union nut must be tightened until the force screws.
increases and then half a turn more.
Important!
WELDING
Hold the retaining supports in place with a span-
ner!
Important!
Proceed as follows for all electrical welding on

the machine:
Leaky profile ring connection
• Switch off the battery master switch!
If a connection leaks, the union nut must first be loos-
ened until oil comes out and then tightened as speci- • Disconnect snap-on connection to monitor.
fied. • Remove the electrical plug-in-type module in the
central electrics.
Note! • Disconnect the electrical snap-on connections
between the engine and main wiring harness.
Deviating inlet paths reduce the rated pressure
and the life of the retaining screw. This will result • Always clamp the welder earth as close as pos-
in leakage and displacement of the pipe. sible to the welded section.

General Information
FUEL AND LUBRICANTS
Unit/ Specifications/ Season/

Fuel
application SAE class temperature
MIL-L-2105 API-GL-4
Gear oil
SAE 90
Gearbox All-year
DIN 51502 - G 00 F
Semi-fluid grease
Retinax G
DIN 51825 - K2K
Grease nipple Multipurpose grease All-year
Retinax EP2
Battery clamps Anti-acid grease All-year
Important!
Observe the lubrication instructions in the

machine operator's manuals!
Fill amounts
See the operator's manual for the fill amounts. The
specified fill amounts are approximate values; always
check the oil level for the exact amount required.

Drive systems
Drive systems
4 Drive systems
LINER REDUCTION GEAR
General assembly and maintenance instruc-

tions
Bearings
Never press on the rollers, balls or cages during
assembly.
Screw connections
Screw connections must be tightened with torque
wrenches.
Tighten screws and bolts with tightening torques,
– see Tightening torques, page 3.4.
Radial shaft seals

When installing radial shaft seals the contact surfaces
between the seal and shaft must be lubricated before-
hand.
Do not allow the seals of radial shaft seals to contact
sharp objects (edges, etc.) during assembly, otherwise
they may be damaged.
Gearbox in oil bath

First oil change after the first 50 hours of operation
and/or at least once a year.

Drive systems
Drive systems
1 2 3 4 5 6 7 8 9 8 10 12 18 13 14 16 15 16 14 13 17
15
10
36
7 22
21 23
37 19 11
20
25 24
25 24 26 35 34
38
32
31
36 5 12 30 29 8 28 27 33 26 20
71187
1
Reduction gear 16 Internal snap ring 80 UNI7437
“LINER 680 / 680 L / 680 Profil / 650 Twin / 17 Nut M40X1.5
350 S / 350 T” – version “9.792.100.40” and 18 Pinion
“9.792.101.40” 19 Flat washer 79.9
20 Flat washer 35.2x43.8x1
COMER K-792B 21 Oil plug 3/8“ GAS
Comer no.: 9.792.100.40; 9.792.101.40 22 Oil plug 1/2“ GAS
23 Oil plug 1/2“ GAS
CLAAS no.: 110 236.2; 110 237.2 24 Lever
25 Radial shaft seal 35X45X7
26 Spacer washer
List of parts 27 Radial shaft seal 55X72X10
Item Description Remarks 28 Spacer washer
29 Shaft
1 Ring gear Z82 M3.75 30 Radial shaft seal 50X72X8
2 Cover 31 Roller bearing 6310
3 Internal hex bolt M10x22 8.8 32 Oil drain plug 3/8“ GAS
4 Roller bearing 6310 Z 33 Cam
5 Internal snap ring 110UNI7437 34 Hexagon head bolt M10x30 8.8
6 Identification plate 35 Cover
7 Key B 10X8X50 36 O-ring 101.27X2.62
8 Flat washer 70.3 37 Housing
9 External snap ring 50 UNI7436 38 Seal 17X22X1.5
10 Flat washer 50.3x2.5
11 Grease
12 Cover (Fig. 1)
13 Bearing seal ring 30208 AV
14 Roller bearing 30208
15 Grease nipple 45G.M10X1

Drive systems
Dimensions
238.5 70
162 59
N.3xM12 18 35
14
Ø26E8 P
15
3˚
Oil plugs
193
OELEINFUELLSTOPFEN
1" 3/8
Z6
137
534.5
119
Oil drain plug

ABLASSCHRAUBE
341.5
Oil level plug
OELSTANDSCHRAUBE
222.5
208
Ø23
50x2x24 h9
P DIN 5480
160
120 N.4xØ16.5
= =
Direction of travel
= =
120
FAHRTRICHTUNG
80
Grease
SCHMIERFETT
NL GI2
131
Inlet
EINGANG
145
540 U/min.
M10x28
131
290
370
80
75
57
N.2Ø13H12
22
Ø35h8
71188
2

Drive systems
Drive systems
Disassembly
Remove snap ring (9) and shims (10) and (8).
(Fig. 3)
Remove cover (2) with a pulling tool.
Environment!
Dispose of old grease correctly!
Clean grease from cover (2).

Remove key (7) and shim (8).
(Fig. 4)
Unscrew bolts (3).

Clean grease from ring gear (1).
Disassemble ring gear (1) with a pulling tool.
(Fig. 5)
Drain oil from the gearbox as follows:
Environment!
Dispose of drained oil correctly!
Place oil container under the gearbox and remove

plug (32), seal (38) and plug (21).
(Fig. 6)

Drive systems
Remove grease nipple (15).
Note!
The flange nut (17) is caulked with the pinion

shaft.
Loosen caulking and remove the flange nut (17) from

the pinion (18).
(Fig. 7)
Tap pinion (18) off with light taps of the hammer in the
direction of the inside of the cover.
Use a pulling tool to remove the shim (18), the bearing
seal ring (13) and the bearing inner race (14) from the
pinion (18).
Note!
The inside bearing seal ring (13) may need to

be replaced.
8 (Fig. 8)
Remove the outside bearing seal ring (13) and outside

bearing inner race (14).
Remove the outside outer race (14) from the cover (2)
with a pulling tool.
Remove snap ring (16).
Remove shim (19).
Remove the inside outer race (14) from the cover (2)
9 (Fig. 9)
Remove snap ring (5) and bolts (34).

Remove cover (35).
Remove shim (8) and spacer (28).
(Fig. 10)
10

Drive systems
Remove shaft (29) with bearing (4), shim (10) and

cover (12) with o-ring (36) upwards.
Remove bearing (4), shim (10) and cover (12) with
o-ring (36) from the shaft (29).
Remove radial shaft seal (27) from the cover (12).
Remove key (7) from the shaft (29).
(Fig. 11)
11
Remove cam plate (33) from the housing (37).

(Fig. 12)
12
Remove lever (24) from the housing (37).

Remove shims (20) and spacers (26) from the
levers (24).
Remove radial shaft seals (25) from the housing (37).
(Fig. 13)
13
Remove snap ring (5) from the cover (35).

Remove cover (12) and bearing (31).
Remove o-ring (36) and radial shaft seal (30) from
cover (12).
Remove plug (22) and (23).
(Fig. 14)
14

Drive systems
Assembly
Note!
Always use new o-rings and radial shaft seals!
Assemble lever (24) with spacer (26) and shim (20).

Install the assembled levers in the housing (37).
Caution!
15
The seal of the radial shaft seal (25) may be
damaged during assembly!
– Cover the holes in the levers (24) with
adhesive tape before assembly of the
radial shaft seal.
Install radial shaft seals (25).

Remove tape.
(Fig. 15)
Position key (7) in the shaft (29) and install cam

plate (33) on the shaft (29).
Install assembled shaft (29) in the housing (37) and
insert the levers (24) in the cam plate (33) at the same
time.
(Fig. 16)
16
Apply silicone strips on the centring of the cover (35).

Assemble cover (35) and housing (37) with the
bolts (34).
Remove excess silicone.
(Fig. 17)
17

Drive systems
Assemble cover (12) with o-ring (36) and radial shaft

seal (27).
Caution!
Do not damage the seal of the radial shaft

seal (27)!
– Before assembly of the cover (12) and the
bearing (4), fasten shaft (29) from the
opposite side.
18 Install assembled cover (12) in the housing.

Grease shaft and bearing seat in housing.
Slide key (10) on the shaft (29).
Fill bearing (4) with grease.
Install bearing (4), snap ring (5) and shim (8).
(Fig. 18)

seal (30).
Slide spacer (28) and shim (8) on the shaft (29).
Install bearing (31) and assembled cover (12) in the
cover (35).
Install snap ring (5).
(Fig. 19)
19
Install oil drain plug (32) with seal (38).

Install plug (21) with Loctite 270.
(Fig. 20)
20

Drive systems
Install ring gear (1) with bolts (3).

Position key (7).
Grease ring gear (1).
(Fig. 21)
21
Assemble pinion (18) with shim, bearing seal ring (13)

and bearing inner race (14).
(Fig. 22)
22
Install inside outer ring (14), shim (19) and inside snap
ring (16).
Install outside snap ring (16) and outside outer
ring (14).
Caution!
The bearing seal ring (13) may be damaged

during assembly of the pinion!
– Install pinion carefully.
23
Insert assembled pinion (18) in cover (2) from the
inside.
(Fig. 23)

Drive systems
Install outside bearing inner race (14) and outside

bearing seal ring (13).
Tighten flange nut (17) with a torque of 79 ÷ 108 Nm.
(Fig. 24)
24
Attach assembled cover (2) to housing (37).

(Fig. 25)
25
Slide keys (8) and (10) on the shaft.

Important!
Ensure that there is no axial play between the

shaft (29) and the cover (2).
(Fig. 26)
26 Check contact pattern and tooth flank play, adjust if

required with shim (8) (Fig. 18) and (19) (Fig. 23)
– see Reduction gear “LINER 680 / 680 L / 680 Profil /
650 Twin / 350 S / 350 T” – general assembly instruc-
tions, page 4.22 and Adjustment of spur gears,
page 3.10.
Remove flange nut (17) and reinstall with Loctite 270.
Caulk flange nut (17) with pinion.
(Fig. 24)

Drive systems
Install grease nipple (15) and fill gearbox with

grease (11).
(Fig. 27)
27
Fill gearbox with oil and install plug (22) and (23) with
Loctite 243.
(Fig. 28)
28

Drive systems
Drive systems
1 2 3 4 5 6 42 9 8 12 18 13 14 16 15 16 14 13 17
15
43
36
7 22
21 23
37 19 11
20
25 24
25 24 26 35 34
38
32
31
36 5 41 30 40 29 39 10 8 28 43 33 27 26 20
71190
29
Reduction gear 17 Nut M40X1.5
“LINER 680 / 680 L / 680 Profil / 650 Twin / 18 Pinion
350 S / 350 T” – version “9.792.116.20” 19 Flat washer 79.9
20 Flat washer 35.2x43.8x1
COMER: K-792B 21 Oil plug 3/8“ GAS
Comer no.: 9.792.116.20 22 Oil plug 1/2“ GAS
23 Oil plug 1/2“ GAS
CLAAS no.: 110 538.0 24 Lever
25 Radial shaft seal 35X45X7
26 Spacer washer
List of parts 27 Radial shaft seal 55X72X10
Item Description Remarks 28 Spacer washer
29 Shaft
1 Ring gear Z82 M3.75 30 Radial shaft seal 65X80X7/8
2 Cover 31 Roller bearing 6310
3 Internal hex bolt M10x22 8.8 32 Oil drain plug 3/8“ GAS
4 Roller bearing 6310 Z 33 Cam
5 Internal snap ring 110UNI7437 34 Hexagon head bolt M10x30 8.8
6 Identification plate 35 Cover
7 Key B 10X8X40 36 O-ring 101.27X2.62
8 Flat washer 70.3 37 Housing
9 Slotted nut M45X1.5 38 Seal 17X22X1.5
10 Flat washer 50.3x2.5 39 O-ring 2-135
11 Grease 40 Bush
12 Cover 41 Cover
13 Bearing seal ring 30208 AV 42 Flat washer 45.3x1.0
14 Roller bearing 30208 43 Spacer washer
15 Grease nipple 45G.M10X1
16 Internal snap ring 80 UNI7437
(Fig. 29)

Drive systems
Dimensions
238.5 70
162 +0.08
+0.03
59
N.3xM12 Ø26 18 35
14
P
15
3˚
Oil plugs
198
OELEINFUELLSTOPFEN
1" 3/8
Z6
137
425
119
Oil drain plug

ABLASSCHRAUBE
227
Oil level plug
OELSTANDSCHRAUBE
108
100
+0.08
Ø26 +0.03 23
14
2.15
50x2x24 g9
P DIN 5480
160
-0.3
120 N.4xØ16.5
0
= =
6.6
Ø47h12
= =
120
80
Direction of travel
FAHRTRICHTUNG
Grease
SCHMIERFETT
NL GI2
131
Inlet
EINGANG
145
540 U/min.
M10x28
131
290
370
80
75
57
N.2Ø13H12
22
Ø35h8
71189
30

Drive systems
Drive systems
Disassembly
Note!
The flange nut (9) is caulked on the shaft (29).

the shaft (29).
Remove shim (42).
(Fig. 31)
31
Remove cover (2) with a pulling tool.
Environment!
Dispose of old grease correctly!

Remove snap ring (5) and shim (8).
(Fig. 32)
32
Unscrew bolts (3).

Clean grease from ring gear (1).
Disassemble ring gear (1) with a pulling tool.
(Fig. 33)
33
Drain oil from the gearbox as follows:
Environment!
Place oil container under the gearbox and remove

plug (32), seal (38) and plug (21).
(Fig. 34)
34

Drive systems
Remove grease nipple (15).
Note!
The flange nut (17) is caulked with the pinion

shaft.

the pinion (18).
(Fig. 35)
35
Tap pinion (18) off with light taps of the hammer in the
direction of the inside of the cover.
Use a pulling tool to remove the shim (18), the bearing
seal ring (13) and the bearing inner race (14).
Note!
The inside bearing seal ring (13) may need to

be replaced.
(Fig. 36)
36
Remove the outside bearing seal ring (13) and outside

bearing inner race (14).
Remove the outside outer race (14) from the cover (2)
Remove snap ring (16).
Remove shim (19).
Remove the inside outer race (14) from the cover (2)
37 (Fig. 37)
Remove bush (40) with o-ring (39) with a pulling tool.

Unscrew bolts (34) and remove cover (35).
Remove shim (8) and spacer (28).
(Fig. 38)
38

Drive systems
Remove shaft (29) with bearing (4), spacer (43) and

cover (12) with o-ring (36) upwards.
Remove radial shaft seal (27) from the cover (27).
Remove spacer (43) and key (7) from the shaft (29).
(Fig. 39)
39
Remove cam plate (33) from the housing (37).

(Fig. 40)
40
Remove lever (24) from the cover (37).

Remove shims (20) and spacers (26) from the
levers (24).
Remove radial shaft seals (25) from the housing (37).
(Fig. 41)
41
Remove snap ring (5) from the cover (35).

Remove cover (41), shim (10) and bearing (31).
Remove o-ring (36) and radial shaft seal (30) from
cover (41).
Remove plug (22) and (23).
(Fig. 42)
42

Drive systems
Assembly
Note!
Assemble lever (24) with spacer (26) and shim (20).

Install the assembled levers in the housing (37).
Caution!
43
The seal of the radial shaft seal (25) may be
damaged during assembly!
– Cover the holes in the levers (24) with
adhesive tape before assembly of the
radial shaft seal.
Install radial shaft seals (25).

Remove tape.
(Fig. 43)
Install spacer (43), key (7) and cam plate (33) on the
shaft (29).
Install assembled shaft (29) in the housing (37) and
insert the levers (24) in the cam plate (33) at the same
time.
(Fig. 44)
44
Apply silicone strips on the centring of the cover (35).

Assemble cover (35) and housing (37) with the
bolts (34).
Remove excess silicone.
(Fig. 45)
45

Drive systems

seal (27).
Caution!
Do not damage the seal of the radial shaft

seal (27)!
– Before assembly of the cover (12) and the
bearing (4), fasten shaft (29) from the
opposite side.
46 Lightly grease sliding surface.

Install assembled cover (12) in the housing (37).
Fill bearing (4) with grease.
Slide spacer (43) on the shaft (29).
Install bearing (4), snap ring (5) and shim (8).
(Fig. 46)

seal (30).
Slide spacer (28) and shim (8) on the shaft (29).
Install bearing (31), shim (10) and assembled
cover (41) in the cover (35).
Caution!
The o-ring (39) may be damaged during

assembly!
47
– Cover shaft transition with adhesive tape
before assembling the o-ring.
Install o-ring (39) on the shaft (29).

Remove tape.
Install bush (40) on the shaft (29).
(Fig. 47)

Drive systems
Install oil drain plug (32) with seal (38).

Install plug (21) with Loctite 270.
(Fig. 48)
48
Install ring gear (1) with bolts (3).

Grease ring gear (1).
(Fig. 49)
49
Assemble pinion (18) with shim, bearing seal ring (13)

and bearing inner race (14).
(Fig. 50)
50

Drive systems
Install inside outer ring (14), shim (19) and inside snap
ring (16).
Install outside snap ring (16) and outside outer
ring (14).
Caution!
The bearing seal ring (13) may be damaged

during assembly of the pinion!
– Install pinion carefully.
51
Insert assembled pinion (18) in cover (2) from the
inside.
(Fig. 51)
Install outside bearing inner race (14) and outside

bearing seal ring (13).
(Fig. 52)
52
Attach assembled cover (2) to housing (37).
Important!
The serrated tooth on the shaft (29) must match

the indent on the cover (2).
(Fig. 53)
53

Drive systems
Install shim (42) and flange nut (9). Tighten flange

nut with a torque of 196 ÷ 245 Nm.
Check contact pattern and backlash, adjust if required
with shim (8) (Fig. 46) and (19) (Fig. 51) – see Reduc-
tion gear “LINER 680 / 680 L / 680 Profil / 650 Twin /
350 S / 350 T” – general assembly instructions,
page 4.22 and Adjustment of spur gears, page 3.10.
Caulk flange nut (9) with shaft.
(Fig. 54)
54 Remove flange nut (17) and reinstall with Loctite 270.

Caulk flange nut (17) with pinion.
(Fig. 52)
Install grease nipple (15) and fill gearbox with

grease (11).
(Fig. 55)
55
Fill gearbox with oil and install plug (22) and (23) with
Loctite 243.
(Fig. 56)
56

Drive systems
Drive systems
Reduction gear
“LINER 680 / 680 L / 680 Profil / 650 Twin /
350 S / 350 T” – general assembly instructions
Contact pattern
Tooth contact between ring gear and pinion must fol-
low as shown in Figure 57.
(Pressure point without load on ring gear and pinion.)
Use shims to adjust the correct contact pattern for the
tooth contact – see Adjustment of spur gears,
page 3.10.
57
Backlash
The backlash must comply with the following guide-
lines:
(0.03 ÷ 0.08) x m (module)
E. g.: module m = 3.75
Backlash = 0.11 ÷ 0.30 mm
(Fig. 57)
Lubricants
Gearbox is lubricated with oil and grease.
Recommended oil type: SAE 90 EP (ISO VG 320)
Amount: 6.2 litres.
Recommended grease type: NLGI 00 EP
Oil change :
First oil change after the first 50 hours of operation,
then every 500 hours and/or at least once a year.

Drive systems
Drive systems
“CLAAS” reduction gear

– General assembly instructions
Installation of curved track
2 When installing the curved track the installation posi-

tion must be correct to ensure the formation of clean
1
windrows in use.
2
The curved track has marks that must be noted.
1
B A The straight arrow (1) shows the direction of travel.
The curved arrow (2) shows the direction of rotation.
58 The curved track is correctly installed when the

straight arrow (1) points in the direction of travel with
reference to the direction of rotation with the reduction
gear installed.
Mark “A” = anticlockwise rotating
Mark “B” = clockwise rotating
Machine model Direction of rotation of

rotors
LINER 3000 clockwise and anticlockwise
rotating
LINER 1550 TWIN Profil anticlockwise rotating only
LINER 1550 Profil anticlockwise rotating only
LINER 880 Profil clockwise and anticlockwise
rotating
LINER 780 Profil clockwise and anticlockwise
rotating
LINER 470 S / 470 T anticlockwise rotating only
LINER 430 S anticlockwise rotating only
LINER 390 S anticlockwise rotating only
(Fig. 58)
Lubricants
Gearbox is lubricated with grease.
Amount: see operator's manual
Recommended grease type: see operator's manual

Drive systems
Drive systems
A “CLAAS” ROTARY GEARBOX
General assembly instructions

3 Machine model:
VOLTO 870 H / 870 T
A VOLTO 770 H / 770 T
2 1 VOLTO 670 H
Assembly of the angle drive
When installing the angle drive the installation position
of the two gears must be noted. This is necessary to
1
prevent the rotors from contacting each other during
operation and for a clean scatter pattern.
Section A-A
For this purpose the drive gear (1) has a red mark (2)
(countersunk).
3
To install the driven gear (1) rotate the drive gear (3)
so the corner (4) of the internal hex (gap) is pointed
4 perpendicularly down. Install the driven gear (1) so the
1 opposite tooth of the tapped hole contacts the mark (2)
in the gap (4) (Fig. 2).
(Fig. 1, 2)
2
2 Lubricants
Gearbox is lubricated with grease.
Recommended grease type: see operator's manual

Drive systems
Drive systems
A B C D
1 2 3 4 5 6
B B C B B B C B B C B B
1 A B C D 43
43 17
44 18 19 47 21 8 44 2
49 39 40 12 41 8
22 45 45
47 4 4
44 43
32 13 5 5
45
31 23 18 6
42
30 34
2
29 3
28 6
15 11
14 3 9
3
24 2 7
32
26 19 20
31
25 21
20
27 10
46 13 16 15 14 13 11
33 8 10
48 38 37 36 35 9 8 7 20
B-B C-C D-D 8
A-A 10 9 8 7
71191
1
DISCO CUTTER BAR
Cutter bar with 6 cutting discs
“COMER FR-566A”
Comer no.: 9.566.610.10
Parts list “cutter bar with 6 cutting discs”
– see page 4.26, Parts description
Cutter bar with 7 cutting discs
“COMER FR-567A”
Comer no.: 9.567.610.10
(Fig. 1)

Drive systems
A B C D
1 2 3 4 5 6 7
B B C B B C B B B B C B B C B B
A B C D
43 10 1 17 10 43
44 18 19 47 21 8 44 2
49 39 40 12 41 8
22 45 45
43 47 4 4
44
32 13 5 5
45
31 23 18 6
42
30 34
2
29 3
28 6
15 11
14 3 9
3
24 2 7
32
26 19 20
31
25 21
20
27 10 46 13 16 15 14 13 11
33 8 10
48 38 37 36 35 9 8 7 20
B-B C-C D-D 8
A-A 10 9 8 7
71193
2
Parts list “cutter bar with 7 cutting discs” 24 Hexagonal nut
25 Snap ring 85
(Fig. 2)
26 Roller bearing 6209 N/C3
Parts description 27 Intermediate gear wheelZ58 M3.5
28 Internal hex bolt M20x30 12.9 DCRT320
Item Description Remarks
29 Pin
1 Expansion pin 10X12 D1481 30 Spacer washer
2 Skid 31 Oil plug 3/8 GAS
3 Bolt M10X30 DCRT320 32 Spring washer 17.16X22X1 CU
4 Roller bearing 6306 2Z/C3 KBC 33 Bolt M10X19 DCRT320
5 Pinion Z18 M3.5 34 Beam housing and cover
6 O-ring OR-3112 35 Bearing sleeve
7 Schnorr spring washer 10.2X22X1.6 36 Roller bearing BAH-0013
8 Hex. nut M10 DCRT320 37 Internal snap ring 72 UNI7437
9 Spacer bushing 38 Drum
10 Countersunk bolt DCRT320 10.9 39 Self-locking nut M24 H21
11 Radial shaft seal 40X60X6 40 Disc spring 50X25.4X3
12 Spacer washer 41 Flange
13 Hexagon head bolt M10x20 42 Pinion Z18 M3.5
14 Disc spring 0.4X40X2.25 43 Countersunk bolt DCRT320 10.9
15 Self-locking nut 20X1,5 H17,3 44 Reinforcement front
16 Drum 45 Hexagon head bolt M10X40 DCRT320
17 Internal hex bolt M10x22 -12.9 DCRT320 46 Cover
18 Bush 47 Roller bearing 6306 DDUC3EEST3H6 NSK
19 Bush 48 Hexagon head bolt M10x30
20 Self-locking nut M10 DIN980 49 Double universal joint
21 Bearing sleeve
22 Cutting disc
(Fig. 1, 2)
23 Reinforcement rear

Drive systems
Dimensions “cutter bar with 6 cutting discs”
320
162.8
52.5 100 100 67.5
76.5
402.2
N.6xØ11
50
5
60
6
425.8
27.5
402.2
2383
Oil plugs 27.5

3
Oil level plug

425.8
60
2
50
402.2
N.6xØ11
76.5
1
162
52.5 100 100 67.5
Inlet 320
Oil drain plug
71192

Drive systems
Dimensions “cutter bar with 7 cutting discs”
320
162.8
52.5 100 100 67.5

7
402.2
76.5
N.6xØ11
6
50
425.8
60
7
5
402.2
27.5
2797
4
425.8
Oil plugs 27.5

Oil level plug
3
402.2
60
2
50
N.6xØ11
414
76.5
1
162
52.5 100 100 67.5
Inlet 320
Oil drain plug
71194

Drive systems
Drive systems
Disassembly
Drain oil as follows:
Environment!
position suitable container under the cutter bar,

open plug (31) and remove seal (32).
(Fig. 5)
Unscrew bolts (17) and remove cover (23).

(Fig. 6)
Unscrew bolts (13) and remove metal cover (46).

Unscrew bolts (48) and remove double universal
joint (49) and spacer (12).
Remove drum (38).
(Fig. 7)
Remove bolts (13).

Remove drum (16) and cutting discs (22).
Unscrew nuts (8) and remove rotors (35) with a pulling
tool.
Turn over cutter bar.
(Fig. 8)

Drive systems
Remove nuts (20) and washers (7).

Remove slide.
Remove perforated strip (44) and bolt (45).
Unscrew all nuts (8) near the edge of the trough and
remove spacer (9).
Note!
The bolts near the bar cover are pressed in!
9 Remove all bolts near the bar cover with a press tool.
(Fig. 9)
Remove hexagonal head bolts (28) while holding the

nut (24) in place.
Remove nuts (24) and pins (29) with a pull tool.
Open cutter bar by removing the cover from the
trough.
Remove intermediate gear wheels (27).
Remove spacers (30).
10 Note!
The roller bearings of the intermediate gear

wheels (27) cannot be disassembled
(Fig. 10)
Note!
The bolts (3) and (45) are pressed in!
Use a press tool:

To remove bolts (3) from the trough.
To remove bolts (45) from the perforated bar (44).
(Fig. 11)
11

Drive systems
Unscrew nut (15) from the mowing disc flange (19).

Remove washer (14).
Use a pull tool:
– Remove mowing disc flange from the pinion (5),
– pinion (5) from the bearing flange (21),
– roller bearing (47) and (4) from the bearing flange.
Remove o-ring (6), bush (18) and radial shaft
seal (11).
(Fig. 12)
12
Unscrew nut (39) from the mowing disc flange/input

rotor (41).
Remove washer (40).
Remove pinion (42) from mowing disc flange (41) with
a pull tool.
Remove circlip (37).
Use a pull tool:
– Remove pinion (42) from the bearing flange (35),
– roller bearing (36) from pinion (42).
13 (Fig. 13)
Assembly
Caution!
Do not damage radial shaft seal and o-rings

during assembly!
– Follow general assembly instructions from
page 3.6.
Note!

Drive systems
Assembling rotors
Install roller bearings (4) in bearing flange (21).
Install assembled bearing flange (21) on pinion (5).
Install o-ring (6) on pinion (5); ensure that the o-ring is
not damaged.
Grease o-ring (6).
Install bush (18).
Caution!
Do not damage radial shaft seal during

14 assembly.
– Use suitable tools.
When installing the radial shaft seal make
sure that there is space between the radial
shaft seal (11) and bearings (47) and (4)!
– Install radial shaft seal (11) about 0.5 mm
lower than the bearing base (47).
Install radial shaft seal (11).
Install roller bearings (47) with the outside race fixed

with LOCTITE 603.
Wipe off excess LOCTITE.
Important!
During installation of the mowing disc flange

note mark/notches on the parts!
Install mowing disc flange on pinion (5).

Install washer (14) and position nut (15) with
LOCTITE 270.
Tighten nut (15) with a torque of 343 Nm.
(Fig. 14)

Drive systems
Assembling inlet rotor

Install roller bearings (36) in bearing flange (35).
Assemble bearing flange (35) with pinion shaft (42).
Install circlip (37).
Install mowing disc flange (41) on pinion shaft (42) in
correct position (see notch on parts).
Install washer (40).
Position nut (39) with LOCTITE 270.
Tighten nut (39) with a torque of 393 Nm.
15
Check resistance torque (rolling resistance) of the pin-
ion/mowing disc flange.
Note!
The resistance torque must not exceed 59 Ncm.
(Fig. 15)

Drive systems
Replacing intermediate gear wheel – bearing

Removing bearing
≈ 700 kN
S 27 Danger!
The bearing cannot be removed without

destroying it! The external ring of the bearing
is destroyed with the press-out tool. This
requires a press force (P) of approximately
700 kN (70 t).
Risk of injury from flying, sharp-edged chips
73556 16 and sharp broken edges!
– Wear protective clothing, eye protection,
25 26 K hearing protection and safety gloves.
– Use a stable support for the intermediate
P gear wheel!
– Do not touch the intermediate gear wheel
while it is being pressed out.
27 – Place a guard (S) around the intermediate
gear wheel (27) during the press-out
process.
– Follow safety instructions for the press-out
A procedure.
73557 17
The bearing (26) is fixed with the snap ring (25) in the
intermediate gear wheel (27).
The position of the groove is marked by the circular
slot (K) on the ring gear.
The bearing (26) is destroyed by being pressed out.
Caution!
If the press tool is incorrectly positioned the

intermediate gear wheel (27) will be
damaged.
– Position press tool on the same side of the
bearing as the slot (K) of the intermediate
gear wheel (Fig. 17).
Proceed as follows to press the bearing out:

– Place a stable support under the hub of the inter-
mediate gear wheel. The best support is a steel
ring (A) with clean contact surfaces.
– Make sure there is sufficient space!
– The slot (K) must point to the press tool!
– Position press tool on the outer ring of the bear-
ing.
– Position guard (S) around the intermediate gear
wheel.

Drive systems
– Start press tool cautiously.

Required pressing force (P): approx. 700 kN (70 t)
Dimensions of steel ring (A): approx. ø120x87x25 mm
(Fig. 16, 17)
Installing bearing
25 T
Important!
26
Note installation position of bearing!
When the bearing is installed flush the groove in
the bearing must be aligned with the groove in
the intermediate gear wheel.
Incorrectly installed bearings cannot be
removed with damaging the hub of the gear.
73558 18
– Install the bearing (26) as far as the groove in the
intermediate gear wheel.
T – Position snap ring (25) SP85 DIN 5417 in the
groove.
– Fix the snap ring (25) in the groove with a
circlip (T) ø85x3 DIN 472 (order no.: 235 189.0).
25
– Install he bearing (26) flush with the hub; the
circlip (T) is pushed to the outside during this
process.
– Make sure that the snap ring is clicked into place
in the groove in the bearing.
19 (Fig. 18, 19)

Drive systems
Assembling cutter bars

Place a continuous silicone cord underneath the bolt
heads (3).
Press in rotor mounting bolts (3) in the cutter bar
cover (34) (except for bolts near edge).
Wipe off excess silicone.
Place a continuous silicone strip in the slot of the
nuts (24).
Place nuts (24) at one level and place the cutter bar
trough (34) on the nuts; align the nuts so they are cen-
tred on the matching drilled holes.
20 Position intermediate gear wheels (27) in the trough
while ensuring that the identification slot are up and
the intermediate gear wheels are centred to the match-
ing drilled holes.
(Fig. 20)
Position spacers (30) on the intermediate gear wheels.

Apply a continuous, unbroken silicone strip to the out-
side edge of the trough.
Important!
Apply the silicone strip carefully, because this

gasket must be absolutely leak-free!
Position cutter bar cover on the trough and fix with the
expansion pins (1).
21
Apply a continuous silicone strip on the two conical
parts of the pin (29) (seal on cover and trough).
Install pins (29) in sequence; this centres the
spacers (30) and the gears (27).
Fix bolts (28) with LOCTITE 270.
Tighten bolts (28) with a torque of 618 ÷ 638 Nm while
holding the nuts stationary.
Check that the intermediate gear wheels run without
problems.
(Fig. 21)

Drive systems
Position all bolts with nuts (8) and if applicable with

spacers (9) on the cutter bar contour.
Important!
Ensure that the correct type of bolt is used

(countersunk or cheese-head screw) and that
the length is correct.
Tighten all bolts or nuts (8) with a torque

of 84 ÷ 98 Nm.
22 Install plug (31) with seal (32).
Tighten plug (31) with a torque of 30 ÷ 35 Nm.
(Fig. 22)
Installing rotor
Apply a continuous silicone strip to the contact area of
the rotors.
Install assembled inlet rotor (42) at the corresponding
position in the cutter bar.
Important!
The drilled holes in the reinforcements are coni-

cal. The bolts are inserted from the narrower
side of the conical drilled hole.
23
Position front perforated bar (44) with bolts (45).

Position rear nuts (8) on the inlet rotor with
LOCTITE 243.
Note!
When the seal has been tested the bolts (45)

must be removed again to install the slide.
Tighten nuts (8) with a torque of 84 ÷ 98 Nm.

Install remaining rotors in the same way as the inlet
rotor in their correct relative positions – see page 4.27,
Dimensions “cutter bar with 6 cutting discs” and
Dimensions “cutter bar with 7 cutting discs” on
page 4.28.
(Fig. 23)

Drive systems
Check cutter bar for free running rotors by turning

rotors by hand.
Leak test
Conduct a leak test as follows
Blow compressed air at 0.35 bar through the plug (31)
into the cutter bar and immerse cutter bar in a water
bath. No bubbles must come out of the bar
or
Connect a pressure gauge with a maximum reading of
0.6 bar to the drilled hole (31) and fill cutter bar with
compressed air at 0.6 bar.
Cut off air feed
24
There must be no loss of pressure over 10 minutes.
Dry cutter bar if required.
Turn bar.
(Fig. 24)
Installing slide
Remove bolts (45) (rotor fastening) and perforated
bar (44) (Fig. 23).
Install slide (2) with toothed washers (7) and nuts (20).
Tighten slide nuts (20) with a torque of 64 ÷ 74 Nm.
Install bolts (45) and perforated bar (44) (Fig. 23).
Position nuts (8) on the inlet rotor with LOCTITE 243.
Tighten nuts (8) on inlet rotor with a torque
of 84 ÷ 98 Nm.
25 Turn bar.
(Fig. 23, 25)

Drive systems
Installing cutting disc and drum

Place cutting discs (22) and drum (16) (opposite inlet
side) on the mowing disc flange.
Position flange bolts (13) and LOCTITE 243; note
number of flange bolts:
Cutting discs (22) = 4 units
Drum (16) = 6 units
Tighten flange screws (13) with a torque
of 69 ÷ 79 Nm.
26 (Fig. 26)
Place cover (23) on cutting discs.

Apply LOCTITE 243 to bolts (17).
Tighten bolts (17) with a torque of 69 ÷ 79 Nm.
(Fig. 27)
Install cover (46) with bolts (13) on the other drum.

(Fig. 28)
27
Drum – inlet side

Assemble drum, spacer and double universal joint with
bolts (48).
(Fig. 28)
28
Fill cutter bar with the specified amount of oil.

Drive systems
“COMER” cutter bar

– General assembly instructions
The rotors must be installed together at the specified
position;
Offset: 90°
Tolerance: L-angle error within 5° for counter-rotating
rotors and within 3° for synchronous rotors.
Lubricants
Gearbox is lubricated with oil and grease.
Recommended oil type: SAE 90 EP (ISO VG 320)
Oil amount:
DISCO 260: 3.5 litres
DISCO 300: 4.0 litres
Recommended grease type: NLGI 2
Oil change :
First oil change after the first 50 hours of operation,
then every 500 hours and/or at least once a year.

Drive systems
Drive systems
“CORTO” DIRECT-CUT ATTACHMENTS

1
2 Machine model:
3 CORTO
Installing direct-cut attachment
4
When installing the direct-cut attachments the drive
shaft (4) must not be struck. The drive shaft (4) must
be installed manually. After tightening the securing
bolts (1) the drive shaft must still slide easily. This is
required to ensure that the mower unit runs more qui-
etly.
73560 1
Proceed as follows to install the direct-cut attach-
ments:
– Coat sealing surfaces with Atmosit. Observe the
general instructions Liquid screw lock on
page 3.7.
– Insert direct-cut attachments into the frame, while
paying attention to the direction of rotation.
– Position securing bolts (1) with bush (3) and
washer (2).
– Tighten securing bolts (1) lightly only.
– Slide in drive shaft (4) manually.
– Align direct-cut attachments.
– Tighten securing bolts (1) to the specified torque.
Torque: 70 Nm
– Check that the drive shaft (4) can still be moved

easily, if necessary adjust alignment of the
direct-cut attachments.
Important!
The max. sliding force must not exceed 150 N.
(Fig. 1)
Lubricants
Recommended gear oil: see operator's manual

Drive systems

Following the policy of CLAAS KGaA mbH of continuous product improvement to keep abreast of technical devel-
opment, we reserve the right to make modifications which must not necessarily correspond to the text and illustra-
tions contained in this operator's manual, and this without assuming the obligation to modify any machines
previously delivered.
Technical specifications, dimensions and weights are understood with the usual tolerances.
Reproduction or translation, in whole or part, only with written authorization by CLAAS KGaA mbH.
All rights under the provision of the Copyright act are reserved.
CLAAS KGaA mbH
33426 Harsewinkel
Germany
CLAAS KGaA mbH
Postfach 1163
33426 Harsewinkel - Germany
Tel.: +49 (0) 5247 12-0
www.claas.com
299 605.1
RHB Futtererntemaschinen
EN - 10.04
Printed in Germany

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SWATHERS

Repair and Adjust-

299 605.1 - RHB Futtererntemaschinen 1.1

2.1 RHB Futtererntemaschinen - 299 605.1

Replacing intermediate gear wheel – bearing .................. 4.34

299 605.1 - RHB Futtererntemaschinen 2.2

3 General OF SPECIAL IMPORTANCE

3.1 RHB Futtererntemaschinen - 299 605.1

Identification of warnings and dangers Designated use

Sign to indicate instructions which must be

This symbol identifies instructions that make

This symbol identifies information that must

The warning and instruction signs placed on the

299 605.1 - RHB Futtererntemaschinen 3.2

Disassembly Prevention of material

Dismantle Oil Use of special tools

Mark Unlock, lock Overflow

Balance Hold fluid, glue seal Bleeding

Replace on every Observe installation

3.3 RHB Futtererntemaschinen - 299 605.1

Nuts and bolts carbonised, phosphatised or galvanised

Dimensions Metric fine-pitch thread

299 605.1 - RHB Futtererntemaschinen 3.4

Dimensions Tightening torque in accordance with ISO 6149

Tightening torques for screw plugs

Dimensions Tightening torque

3.5 RHB Futtererntemaschinen - 299 605.1

GENERAL REPAIR INSTRUCTIONS SCREW CONNECTIONS

299 605.1 - RHB Futtererntemaschinen 3.6

(e.g. Delo–ML 187 / Loctite 242 etc.) – Flanges

Only use liquid screw lock when recommended by the – Covers

3.7 RHB Futtererntemaschinen - 299 605.1

Radial shaft seals Assembly of adapter sleeve bearings

Assembly of clamping ring bearings

299 605.1 - RHB Futtererntemaschinen 3.8

Assembly on shaft Assembly in drilled hole Assembly on shaft and assembly

3.9 RHB Futtererntemaschinen - 299 605.1

Initial adjustment required correction Correct adjustment

299 605.1 - RHB Futtererntemaschinen 3.10

Initial adjustment required correction Correct adjustment

Example 4 – contact pattern centred but too near

3.11 RHB Futtererntemaschinen - 299 605.1

Initial adjustment required correction Correct adjustment

Example 6 – contact pattern too far right or left but

299 605.1 - RHB Futtererntemaschinen 3.12

Important! Position the assembled pipe in the well lubricated

Important! Progressive ring retaining screws on

3.13 RHB Futtererntemaschinen - 299 605.1

Important! Hold the retaining supports in place with a span-

Deviating inlet paths reduce the rated pressure

Proceed as follows for all electrical welding on

299 605.1 - RHB Futtererntemaschinen 3.14

FUEL AND LUBRICANTS

Unit/ Specifications/ Season/

Observe the lubrication instructions in the

3.15 RHB Futtererntemaschinen - 299 605.1

General assembly and maintenance instruc-

Radial shaft seals

Gearbox in oil bath

299 605.1 - RHB Futtererntemaschinen 4.1