CLAAS Forage Harvesters JAGUAR 900-830 Profistar (Type 493) Hydraulic Technical Systems Manual

JAGUAR 900-830 Profistar (Type 493) JAGUAR 900-830 Speedstar (Type 493)

Technical Systems Hydraulic System

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Contens 1 Overall hydraulic system Tier 2 diesel engine / without cooling circuit pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Working hydraulics pre-pressurization relief screw valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Tier 3 diesel engine / with cooling circuit pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Working hydraulics pre-pressurization relief screw valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2 Steering hydraulics Steering without Autopilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Steering without Autopilot circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Steering with Autopilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Steering with Autopilot circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Autopilot valve block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Function diagram, neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Function diagram, actuated by steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Testing and measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Testing the steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3 Working hydraulics Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Working hydraulics circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Main valve: Circulation shut-off valve, front attachment raise/lower solenoid valve . . . . . . . 51 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Upper discharge chute valve combination / discharge flap with pressure accumulator . . . . 57 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Hitch solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

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Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Sharpening, additional control unit 1, additional control unit 2 solenoid valve . . . . . . . . . . . 65 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Corn cracker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Adjusting and venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Upper discharge chute rotation drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Front attachment load switch-over valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Pressure accumulator volume switch-over valve (Direct Disc option) . . . . . . . . . . . . . . . . . . 81 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Pitching dampening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Testing and measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Measuring pre-conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Set values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

4 Low-pressure hydraulic system Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Low-pressure hydraulic system circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 All-wheel drive, servo gearshift, cover, reverse front attachment, front attachment clutch valve block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Fig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Main drive valve block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Fig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Fig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Shifter rail locking hydraulic cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

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Fig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Suction arm drive flow control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Fig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Suction arm drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Fig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Line header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Fig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Knife support valve cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Fig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Testing and measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Fig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Measuring pre-condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

5 Feeder hydraulics Hydraulic feeder drive, components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Fig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Main drive, decelerated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Fig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Main drive ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Fig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Fig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Discription of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Feeder OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Fig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Discription of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

5

3248

Fig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Quick stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Fig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

6 Ground drive hydraulics Overall circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Ground drive hydraulics circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Ground drive control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Variable-displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Fig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Variable-displacement motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Fig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 High-pressure sensor (B97, B98) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Fig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Testing and measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Pressure testing with the high-pressure sensors (B97, B98), pressure display in the CIS terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Fig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 High-pressure sensors measured value table (B97, B98) . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

7 Compressed-air system Trailer brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Engine restrictor / Compressed-air coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

8 Location of components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Individual components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

6

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

1 Overall hydraulic system Tier 2 diesel engine / without cooling circuit pump 3249

1 Overall hydraulic system Tier 2 diesel engine / without cooling circuit pump

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

7

1 Overall hydraulic system Tier 2 diesel engine / without cooling circuit pump 3249

Hydraulic circuit diagram R

A2

L

R

P

734

734

A

A1

B2 Y5

L

Y1 725

A

P

Y10

Y9

351 302 B

A

351

609

801

501

Y4

617

Y86

353

728

726

Service

B2

734

734

Y60

734 B1

Y30

Y29

405

732

Y2

Y3 P

Y88 A

511

T

909

303

405 734

A

A

352

206

Y6

T

P1

B5

P C2

340

P

ZS

729

910

ZB

SP

406

T

734

P

304

734 C1

406 T

Y8

Y7 612 T

442

P1

P1

1

359

2

Y59

A2

317

109-1

109-2 614

Y94

Y93

441

341

Y26

A1

228 T

Z52

P1

790

P

743 Y87

707

Z46

703

P1

Y62

Y61

Y85

T

807

R

L

A

732 Z53

Y77

801

734

332

P

413

901

F

801

P2

796-1

Y73

Y72

333

796-2

102-1 B97 L

T

102-2

P1

Ms

520

S (P)

P1

926 B

211

254

714 19

B

L

205 E

11

218

Y257

T

P1

31

255

A

706

732

T

713

313

412 L1

794-2

716

P (S)

719

791 Y144

Mp

521

B98 U

792

721

793

758 210

925

355

Y256 P1

794-1

A

738

408

908 T

907

B

P2

B123-2

Y255

Y141 110 Y143

A

253

B123-1 Y142

T

112

P2

Z19

jag05-h-01a

8

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

1 Overall hydraulic system Tier 2 diesel engine / without cooling circuit pump 3250 1 Overall Tier 2 diesel hydraulic enginesystem / without cooling circuit pump

Key to diagram Item

Designation

Remark

B2

Ground pressure oil pressure sensor

-

B5

Working hydraulics oil pressure sensor

-

B97

Drive hydraulics forward high-pressure sensor

-

B98

Drive hydraulics backward high-pressure sensor

-

B123

Hydraulic oil temperature sensor

-

-

-

-

F

Filling connection

for initial commissioning

-

-

-

Y1

4-Trac (all-wheel drive) solenoid coil

-

Y2

Discharge flap close solenoid coil

-

Y3

Discharge flap far solenoid coil

-

Y4

Upper discharge chute slow/fast rotation solenoid coil

-

Y5

Upper discharge chute left rotation solenoid coil

-

Y6

Upper discharge chute right rotation solenoid coil

-

Y7

Upper discharge chute raise solenoid coil

-

Y8

Upper discharge chute lower solenoid coil

-

Y9

AUTOPILOT left solenoid coil

-

Y10

AUTOPILOT right solenoid coil

-

Y26

Main drive solenoid coil

PWM-controlled

Y29

Raise hitch solenoid coil

-

Y30

Lower hitch solenoid coil

-

Y59

Servo circuit solenoid coil

-

Y60

Cover solenoid coil

-

Y61

Sharpening stone left movement solenoid coil

-

Y62

Sharpening stone right movement solenoid coil

-

Y72

Additional control valve 1 – A solenoid coil

-

Y73

Additional control valve 1 – B solenoid coil

-

Y77

Working hydraulics circulation shut-off valve solenoid coil

-

Y85

Raise front attachment solenoid coil

PWM-controlled

Y86

Reverse front attachment solenoid coil

-

Y87

Lower front attachment solenoid coil

PWM-controlled

Y88

Front attachment clutch solenoid coil

-

Y93

Additional control valve 2 – A solenoid coil

-

Y94

Additional control valve 2 – B solenoid coil

-

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

9

1 Overall hydraulic system Tier 2 diesel engine / without cooling circuit pump 3250

Item

Designation

Remark

Y141

Ground drive forward

PWM-controlled

Y142

Ground drive reverse

PWM-controlled

Y143

Ground drive/cut-off valve

-

Y144

Ground drive variable-displacement motor

PWM-controlled

Y255

Feeder drive pump adjustment solenoid valve

PWM-controlled

Y256

Main drive brake valve solenoid valve

-

Y257

Feeder quick stop solenoid valve

-

-

-

-

Z19

Hydraulic oil level switch (min.)

-

Z46

Low-pressure hydraulics/ground drive oil pressure actual value function switch

-

Z52

Sharpening stone left movement oil pressure actual value function switch

-

Z53

Sharpening stone right movement oil pressure actual value function switch

-

-

-

-

102

Pressure filter

-

109

Hydraulic system oil cooler

-

110

Oil tank

-

112

Return flow filter

-

-

-

-

205

Working hydraulics pump

-

206

Upper discharge chute rotation drive motor

-

210

Ground drive variable displacement motor

-

211

Ground drive variable displacement pump

-

218

Steering hydraulics pump

-

228

Suction arm drive motor

-

253

Feeder drive variable-displacement pump

-

254

Feeder drive motor

-

255

Ground drive / feeder feed pump

-

-

-

-

302

All-wheel drive clutch hydraulic cylinder

-

303

Discharge flap hydraulic cylinder

-

304

Upper discharge chute hydraulic cylinder

-

313

Ground drive servo control pump hydraulic cylinder

-

317

Main drive clutch hydraulic cylinder

-

323

Steering hydraulics cylinder

-

10

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

1 Overall hydraulic system Tier 2 diesel engine / without cooling circuit pump 3250

Item

Designation

Remark

332

Pick-up crop guard lift hydraulic cylinder

-

333

Pick-up auger lift hydraulic cylinder

-

340

Cover hydraulic cylinder

-

341

Sharpening stone movement hydraulic cylinder

-

351

Front attachment raise/lower hydraulic cylinder

-

352

Front attachment clutch hydraulic cylinder

-

353

Front attachment reverse hydraulic cylinder

-

355

Ground drive servo control motor hydraulic cylinder

-

359

Shifter rail locking hydraulic cylinder

-

-

-

-

405

Orifice plate Ø 0.6 mm

-

406

Orifice plate Ø 0.8 mm

-

408

Orifice plate Ø 1.2 mm

-

412

Orifice plate Ø 2.0 mm

-

413

Orifice plate Ø 2.2 mm

-

441

Rotary coupling

-

442

Venturi meter

-

-

-

-

501

Working hydraulics pre-pressurization accumulator

120 bar

511

Front attachment relief accumulator

40 bar

520

Feed pressure accumulator

10 bar

521

Quick stop accumulator

60 bar

-

-

-

609

Orbitrol steering unit rotary disc valve

-

612

Front attachment load switch-over valve

-

614

Front attachment lower flow control valve

-

617

Working hydraulics pre-pressurization relief screw valve

-

703

Working hydraulics pressure relief valve

180+10 bar

706

Pressure relief valve

3 bar

707

Pressure holding valve (non-return valve)

-

713

Ground drive multifunction valve backward valve

Δp=420 bar

714

Ground drive multifunction valve forward valve

Δp=420 bar

716

Ground drive feed pressure relief valve

24 bar

719

Ground drive tap pressure control valve

-

721

Ground drive oil tapping shuttle valve

-

725

Steering double shock valve

200 bar

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

11

1 Overall hydraulic system Tier 2 diesel engine / without cooling circuit pump 3250

Item

Designation

Remark

726

Steering pressure relief valve

150 bar

728

Anti-cavitation valve (non-return valve)

-

729

Low-pressure hydraulics pressure relief valve

21+1 bar

732

Non-return valve

-

734

Lock-up valve unit (non-return valve)

-

738

Ground drive servo control forward/backward valve

-

743

Pilot-controlled one way valve

-

758

Ground drive servo control restrictor valve

-

790

Suction arm drive flow control valve

-

791

Feeder quick stop valve

-

792

Multifunction valve, forward

-

793

Multifunction valve, reverse

-

794

Shut-off valve

-

796

Bypass valve filter

Δp=2 bar

-

-

-

801

Quick release coupling

-

-

-

-

901

Working hydraulics measuring point

-

907

Ground drive hydraulics control pressure reverse measuring point

-

908

Ground drive hydraulics control pressure forward measuring point

-

909

Steering hydraulics measuring point

-

910

Low-pressure hydraulics measuring point

-

925

Feeder drive measuring point

-

926

Feeder drive reverse measuring point

-

12

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

1 Overall hydraulic system Tier 2 diesel engine / without cooling circuit pump 3250

Working hydraulics pre-pressurization relief screw valve

617

401492

Important!

Service

401490

– The hydraulic circuit (P1) remains pressurised even when the engine is stopped.

– Before opening the pressurised working hydraulics (P1), relieve the pressure of the hydraulic circuit using this screw.

– Deactivation of the main drive brake valve (Y256 / 794-1) prior to performing service work on the cutting cylinder also requires that the pressurised working hydraulics (P1) be relieved.

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

13

1 Overall hydraulic system Tier 2 diesel engine / without cooling circuit pump 3250

14

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

1 Overall hydraulic system Tier 3 diesel engine / with cooling circuit pump 3251

1 Overall hydraulic system

Tier 3 diesel engine / with cooling circuit pump

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

15

1 Overall hydraulic system Tier 3 diesel engine / with cooling circuit pump 3251

Hydraulic circuit diagram A2

323

B R

P

L

734

A

302

Y1

R

Y10

Y9

725 801

Y5

351

A

Service

B

B2

609 A

734

734

734

734 B1

405

352

511

732

Y88

Y2

Y3

Y30

Y29

B5

A P

340

303

405

728

726

A

501

Y4

617

Y60

206

Y6

351

Y86

421

P

L

A

353

A1

B2

734

P

T

909

ZB

ZS

729

910

P C2

T

P1

SP

T

406 734

P

304

734 C1

406 T

Y8

Y7 612 T

B123-1

1

359

2

Y59

A2

317

P1

614

Y94

Y93

441

341

Y26

A1

228 T

Z52

P1

790

P

743

707

Z46

P1

R

732

Y87

703

Y62

Y61

Y85

T

807

L

A

Z53

Y77

801

734

332

P

413

901

F

801

P2

796-1

333

Y73

Y72

796-2

102-1 B97 L

T

102-2

P

P1

Ms

S (P)

P1

520

926 B

254

714

211

109 19

B

L

205 E

31

P1

14 A

255 246 706

732

T

713

313

412 794-2

716

P (S)

L1

11

218

Y257

T

719

791 Y144

Mp

521

P

U

798

792

B98

721

793

758 210

355

925 Y256 P1

794-1

A

738 907

408

908

L

T

B

T

A

P2

B123-2 Y142

Y255

Y141 110 Y143

112

253 P2

Z19

jag05-h-01b

16

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

1 Overall hydraulic system Tier 3 diesel engine / with cooling circuit pump (246) 3252 1Tier Overall 3 diesel hydraulic enginesystem / with cooling circuit pump (246)

Designations Item

Designation

Remark

B2

Ground pressure oil pressure sensor

-

B5

Working hydraulics oil pressure sensor

-

B97

Drive hydraulics forward high-pressure sensor

-

B98

Drive hydraulics backward high-pressure sensor

-

B123

Hydraulic oil temperature sensor

-

-

-

-

F

Filling connection

for initial commissioning

-

-

-

Y1

4-Trac (all-wheel drive) solenoid coil

-

Y2

Discharge flap close solenoid coil

-

Y3

Discharge flap far solenoid coil

-

Y4

Upper discharge chute slow/fast rotation solenoid coil

-

Y5

Upper discharge chute left rotation solenoid coil

-

Y6

Upper discharge chute right rotation solenoid coil

-

Y7

Upper discharge chute raise solenoid coil

-

Y8

Upper discharge chute lower solenoid coil

-

Y9

AUTOPILOT left solenoid coil

-

Y10

AUTOPILOT right solenoid coil

-

Y26

Main drive solenoid coil

PWM-controlled

Y29

Raise hitch solenoid coil

-

Y30

Lower hitch solenoid coil

-

Y59

Servo circuit solenoid coil

-

Y60

Cover solenoid coil

-

Y61

Sharpening stone left movement solenoid coil

-

Y62

Sharpening stone right movement solenoid coil

-

Y72

Additional control valve 1 – A solenoid coil

-

Y73

Additional control valve 1 – B solenoid coil

-

Y77

Working hydraulics circulation shut-off valve solenoid coil

-

Y85

Raise front attachment solenoid coil

PWM-controlled

Y86

Reverse front attachment solenoid coil

-

Y87

Lower front attachment solenoid coil

PWM-controlled

Y88

Front attachment clutch solenoid coil

-

Y93

Additional control valve 2 – A solenoid coil

-

Y94

Additional control valve 2 – B solenoid coil

-

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

17

1 Overall hydraulic system Tier 3 diesel engine / with cooling circuit pump (246) 3252

Item

Designation

Remark

Y141

Ground drive forward

PWM-controlled

Y142

Ground drive reverse

PWM-controlled

Y143

Ground drive/cut-off valve

-

Y144

Ground drive variable-displacement motor

PWM-controlled

Y255

Feeder drive pump adjustment solenoid valve

PWM-controlled

Y256

Main drive brake valve solenoid valve

-

Y257

Feeder quick stop solenoid valve

-

-

-

-

Z19

Hydraulic oil level switch (min.)

-

Z46

Low-pressure hydraulics/ground drive oil pressure actual value function switch

-

Z52

Sharpening stone left movement oil pressure actual value function switch

-

Z53

Sharpening stone right movement oil pressure actual value function switch

-

-

-

-

102

Pressure filter

-

109

Hydraulic system oil cooler

-

110

Oil tank

-

112

Return flow filter

-

-

-

-

205

Working hydraulics pump

-

206

Upper discharge chute rotation drive motor

-

210

Ground drive variable displacement motor

-

211

Ground drive variable displacement pump

-

218

Steering hydraulics pump

-

228

Suction arm drive motor

-

246

Cooling circuit pump

-

253

Feeder drive variable-displacement pump

-

254

Feeder drive motor

-

255

Ground drive / feeder feed pump

-

-

-

-

302

All-wheel drive clutch hydraulic cylinder

-

303

Discharge flap hydraulic cylinder

-

304

Upper discharge chute hydraulic cylinder

-

313

Ground drive servo control pump hydraulic cylinder

-

317

Main drive clutch hydraulic cylinder

-

18

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

1 Overall hydraulic system Tier 3 diesel engine / with cooling circuit pump (246) 3252

Item

Designation

Remark

323

Steering hydraulics cylinder

-

332

Pick-up crop guard lift hydraulic cylinder

-

333

Pick-up auger lift hydraulic cylinder

-

340

Cover hydraulic cylinder

-

341

Sharpening stone movement hydraulic cylinder

-

351

Front attachment raise/lower hydraulic cylinder

-

352

Front attachment clutch hydraulic cylinder

-

353

Front attachment reverse hydraulic cylinder

-

355

Ground drive servo control motor hydraulic cylinder

-

359

Shifter rail locking hydraulic cylinder

-

-

-

-

405

Orifice plate Ø 0.6 mm

-

406

Orifice plate Ø 0.8 mm

-

408

Orifice plate Ø 1.2 mm

-

412

Orifice plate Ø 2.0 mm

-

413

Orifice plate Ø 2.2 mm

-

421

Restrictor A

(option for maize headers)

441

Rotary coupling

-

-

-

-

501

Working hydraulics pre-pressurization accumulator

120 bar

511

Front attachment relief accumulator

40 bar

520

Feed pressure accumulator

10 bar

521

Quick stop accumulator

60 bar

-

-

-

609

Orbitrol steering unit rotary disc valve

-

612

Front attachment load switch-over valve

-

614

Front attachment lower flow control valve

-

617

Working hydraulics pre-pressurization relief screw valve

-

703

Working hydraulics pressure relief valve

180+10 bar

706

Pressure relief valve

3 bar

707

Pressure holding valve (non-return valve)

-

713

Ground drive multifunction valve backward valve

420 bar DP

714

Ground drive multifunction valve forward valve

420 bar DP

716

Ground drive feed pressure relief valve

24 bar

719

Ground drive tap pressure control valve

-

721

Ground drive oil tapping shuttle valve

-

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

19

1 Overall hydraulic system Tier 3 diesel engine / with cooling circuit pump (246) 3252

Item

Designation

Remark

725

Steering double shock valve

200 bar

726

Steering pressure relief valve

150 bar

728

Anti-cavitation valve (non-return valve)

-

729

Low-pressure hydraulics pressure relief valve

21+1 bar

732

Non-return valve

-

734

Lock-up valve unit (non-return valve)

-

738

Ground drive servo control forward/backward valve

-

743

Pilot-controlled one way valve

-

758

Ground drive servo control restrictor valve

-

790

Suction arm drive flow control valve

-

791

Feeder quick stop valve

-

792

Multifunction valve, forward

-

793

Multifunction valve, reverse

-

794

Shut-off valve

-

796

Bypass valve filter

Δp=2 bar

798

Feed pressure relief valve

25 bar

-

-

-

801

Quick release coupling

-

-

-

-

907

Ground drive hydraulics control pressure reverse measuring point

-

908

Ground drive hydraulics control pressure forward measuring point

-

909

Steering hydraulics measuring point

-

910

Low-pressure hydraulics measuring point

-

925

Feeder drive measuring point

-

926

Feeder drive reverse measuring point

-

20

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

1 Overall hydraulic system Tier 3 diesel engine / with cooling circuit pump (246) 3252

Working hydraulics pre-pressurization relief screw valve

617

401492

Important!

Service

401490

– The hydraulic circuit (P1) remains pressurised even when the engine is stopped.

– Before opening the pressurised working hydraulics (P1), relieve the pressure of the hydraulic circuit using this screw.

– Deactivation of the main drive brake valve (Y256 / 794-1) prior to performing service work on the cutting cylinder also requires that the pressurised working hydraulics (P1) be relieved.

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

21

1 Overall hydraulic system Tier 3 diesel engine / with cooling circuit pump (246) 3252

22

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

2 Steering hydraulics Steering without Autopilot 3253

2 Steering hydraulics Steering without Autopilot

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

23

2 Steering hydraulics Steering without Autopilot 3253

Steering without Autopilot circuit diagram

24

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

2 Steering hydraulics Steering without Autopilot 3253

Key to diagram Item

Designation

Remark

109

Hydraulic system oil cooler

-

110

Oil tank

-

-

-

-

205

Working hydraulics pump

-

218

Steering hydraulics pump

-

246

Cooling circuit pump

-

255

Ground drive / feeder feed pump

-

-

-

-

323

Steering hydraulics cylinder

-

-

-

-

609

Orbitrol steering unit rotary disc valve

-

-

-

-

706

Pressure relief valve

3 bar

725

Steering double shock valve

200 bar

726

Steering pressure relief valve

150 bar

728

Anti-cavitation valve (non-return valve)

-

732

Non-return valve

-

798

Feed pressure relief valve

25 bar

-

-

-

909

Steering hydraulics measuring point

-

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

25

2 Steering hydraulics Steering without Autopilot 3253

26

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

2 Steering hydraulics Steering with Autopilot 3253

Steering with Autopilot

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

27

2 Steering hydraulics Steering with Autopilot 3253

Steering with Autopilot circuit diagram

28

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

2 Steering hydraulics Steering with Autopilot 3253

Key to diagram Item

Designation

Remark

109

Hydraulic system oil cooler

-

110

Oil tank

-

112

Return flow filter

-

-

-

-

205

Working hydraulics pump

-

218

Steering hydraulics pump

-

246

Cooling circuit pump

-

255

Ground drive / feeder feed pump

-

-

-

-

323

Steering hydraulics cylinder

-

-

-

-

405

Orifice plate Ø 0.6 mm

-

406

Orifice plate Ø 0.8 mm

-

-

-

-

501

Working hydraulics pre-pressurization accumulator

120 bar

-

-

-

609

Orbitrol steering unit rotary disc valve

-

614

Front attachment lower flow control valve

-

617

Working hydraulics pre-pressurization relief screw valve

-

-

-

-

703

Working hydraulics pressure relief valve

180+10 bar

706

Pressure relief valve

3 bar

707

Pressure holding valve (non-return valve)

-

725

Steering double shock valve

200 bar

726

Steering pressure relief valve

150 bar

728

Anti-cavitation valve (non-return valve)

-

732

Non-return valve

-

734

Lock-up valve unit (non-return valve)

-

743

Pilot-controlled one way valve

-

798

Feed pressure relief valve

25 bar

-

-

-

909

Steering hydraulics measuring point

-

Y2

Discharge flap close solenoid coil

-

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

29

2 Steering hydraulics Steering with Autopilot 3253

Item

Designation

Remark

Y3

Discharge flap far solenoid coil

-

Y4

Upper discharge chute slow/fast rotation solenoid coil

-

Y5

Upper discharge chute left rotation solenoid coil

-

Y6

Upper discharge chute right rotation solenoid coil

-

Y7

Upper discharge chute raise solenoid coil

-

Y8

Upper discharge chute lower solenoid coil

-

Y9

AUTOPILOT left solenoid coil

-

Y10

AUTOPILOT right solenoid coil

-

Y77

Working hydraulics circulation shut-off valve solenoid coil

-

Y85

Raise front attachment solenoid coil

PWM-controlled

Y87

Lower front attachment solenoid coil

PWM-controlled

30

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

2 Steering hydraulics Autopilot valve block 3253

Autopilot valve block

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

31

2 Steering hydraulics Autopilot valve block 3253

Graphics

Y9

Y10

T

P1

A

B

734

K

734

401981

32

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

2 Steering hydraulics Autopilot valve block 3253

Key to diagram Item

Designation

Remark

734

Lock-up valve unit (non-return valve)

-

Y9

AUTOPILOT left solenoid coil

-

Y10

AUTOPILOT right solenoid coil

-

K

Piston

-

Description of function Oil pressure supply

The oil pressure required for performing the function is taken from the preloaded working hydraulics system.

Autopilot – steering to the left

The solenoid coil (Y9) is energised and opens the ball via the pilot spool. Oil flows from P1 to the lock-up valve unit via the ball. The non-return valve (port A) is opened by the oil flow against the spring force and oil flows to the steering cylinder. Before this, the pressure built up pushes the piston (K) towards port (B) and opens the non-return valve (port B). The oil coming from the cylinder return side flows via the open right non-return valve. The return flow lifts the pilot spool of the solenoid coil (Y10) and thus returns to the tank.

Autopilot – steering to the right

The solenoid coil (Y10) is energised and opens the ball via the pilot spool. Oil flows from P1 to the lock-up valve unit via the ball. The non-return valve (port B) is opened by the oil flow against the spring force and oil flows to the steering cylinder. Before this, the pressure built up pushes the piston (K) towards port (A) and opens the non-return valve of port (A). The oil coming from the cylinder return side flows via the open left non-return valve. The return flow lifts the pilot spool of the solenoid coil (Y9) and thus returns to the tank.

Note:

The sealing ring beneath the valve inserts must be replaced upon each assembly as otherwise leaks may occur.

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

33

2 Steering hydraulics Autopilot valve block 3253

34

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

2 Steering hydraulics Function diagram, neutral 3253

Function diagram, neutral

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

35

2 Steering hydraulics Function diagram, neutral 3253

Graphics

229

909

x

609

725

732

728

726

218

112

229 323

609

401977

36

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

2 Steering hydraulics Function diagram, neutral 3253

Key to diagram Item

Designation

Remark

112

Return flow filter

-

-

-

-

218

Steering hydraulics pump

-

229

Steering hydraulics proportioning pump

-

-

-

-

323

Steering hydraulics cylinder

-

-

-

-

609

Orbitrol steering unit rotary disc valve

-

-

-

-

725

Steering double shock valve

200 bar

726

Steering pressure relief valve

150 bar

728

Anti-cavitation valve (non-return valve)

-

732

Non-return valve

-

-

-

-

909

Steering hydraulics measuring point

-

Description of function Steering system

Open center = when the steering is in neutral position, there is a connection between pump and tank.

Non reaction = when the steering is in neutral position, a force acting on the steered wheels does not cause any reaction on the steering wheel.

Key to diagram:

O. Orbitrol S. Steering P. Pump C. Type 200. Oil displacement in cm³/rev.

V. Valve block 20. Pressure setting of shock valves x10

Pressure measurement:

Circulation pressure = 17+8 bar System pressure = 150+15 bar Shock valve = 200±15 bar

Measuring pre-conditions:

Pressure measurements are carried out at: – maximum volume flow (maximum motor speed), – an oil temperature of 45 – 50 °C

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

37

2 Steering hydraulics Function diagram, neutral 3253

Design of valve unit:

The steering valve consists of a rotor set (proportioning pump) (229) and a rotating distributor with inner and outer rotary disc (609). The steering gear shaft actuates the rotary disc (609), the continued rotary movement driving the rotor (229) by means of a socket-type shaft.

Neutral function

In the neutral position, the oil is directed back to the tank through the nonreturn valve (732) and the rotary disc (609) (open center). The circulation pressure must not exceed 20 bar. Both sides of the steering cylinder (323) are shut off by the rotary disc (609). Pressure peaks due to external forces on the steered axle are relieved to the tank via the shock valves (725) (non reaction).

38

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

2 Steering hydraulics Function diagram, neutral 3253

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

39

2 Steering hydraulics Function diagram, neutral 3253

40

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

2 Steering hydraulics Function diagram, actuated by steering 3253

Function diagram, actuated by steering

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

41

2 Steering hydraulics Function diagram, actuated by steering 3253

Graphics

229

323 909 x

609

725

732

218

728 726

229

112

229

609

609

401978

42

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

2 Steering hydraulics Function diagram, actuated by steering 3253

Key to diagram Item

Designation

Remark

112

Return flow filter

-

-

-

-

218

Steering hydraulics pump

-

229

Steering hydraulics proportioning pump

-

-

-

-

323

Steering hydraulics cylinder

-

-

-

-

609

Orbitrol steering unit rotary disc valve

-

-

-

-

725

Steering double shock valve

200 bar

726

Steering pressure relief valve

150 bar

728

Anti-cavitation valve (non-return valve)

-

732

Non-return valve

-

-

-

-

909

Steering hydraulics measuring point

-

Description of function Steering actuation

When actuating the steering in one direction, the inner rotary disc (609) is twisted against the outer rotary disc (609) by up to 8°. During this process, the return line from the pump (218) to the tank is closed and the connection to the proportioning pump (229) is released. Via the rotor (229) and the rotary disc (609), the volume flow is released to the actuated piston face end of the steering cylinder (323) as a function of sense of rotation, path and speed.The displacing area of the steering cylinder (323) here is connected with the tank return line via the rotary disc (609). As soon as steering movements are stopped, leaf springs set the inner and outer rotary disc (609) back to the neutral position. Now both sides of the steering cylinder are shut off again and the connection from the pump (218) to the tank is re-established.

Emergency steering function

When the steering system is not supplied any more externally by pump (218), the non-return valve (732) closes and thus ensures that no oil will escape from the steering system. When actuating the steering in one direction, the inner and outer rotary disc (609) are twisted against each other correspondingly. Now the oil can be conveyed from one side of the steering cylinder (323) to the other side through human power by driving the rotor (229). Oil is sucked in via the non-return valve (728) when steering cylinders with different volumes (left and right) are used.

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

43

2 Steering hydraulics Testing and measurements 3253

Testing and measurements

401979

909

401980

44

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

2 Steering hydraulics Testing and measurements 3253

Description of function Steering hydraulics measuring point

909 Steering hydraulics measuring point

Measuring pre-conditions:

Pressure measurements are carried out at: – maximum volume flow (maximum motor speed), – an oil temperature of 45 – 50 °C

Pressure measurement:

Circulation pressure = 17+8 bar System pressure = 150+15 bar Shock valve = 200±15 bar

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

45

2 Steering hydraulics Testing the steering system 3253

Testing the steering system Description of function Checking the steering gear shaft

Steering gear shaft height play = 0.1 to 0.3 mm. Clearance from bottom inside rotary valve = 3 mm.

Return

When the steering wheel is actuated with the diesel engine shut off, the leaf springs in the rotary disc must bring the steering wheel back to its neutral position.

Reaction

If steering reaction is insufficient, internal leaks in the steering system must be checked. To do this, disconnect the lines from the steering cylinder and plug them tightly with plugs. With the oil at operating temperature and at max. no-load speed of the diesel engine, the steering wheel must not allow more than 4 turns in both directions when using a force of approx. 25 Nm. When the actual number of turns is more than 4, check the steering valve for leaks.

When the actual number of turns is less than 4, check the steering cylinder and the optional autopilot valve for leaks.

Steering force

In case of insufficient power in the steering, check tyre size, tyre pressure and machine ballast, condition of the connecting rod and smooth action of stub axles. A pressure test at the steering hydraulics measuring port must show the value 150+15 bar.

Setting of pressure relief valve

Adjusting the pressure relief valve on the machine in built-in condition is not possible.

Venting the steering system

Any installation work on the steering hydraulics must be followed by venting the system on both hydraulic lines of the steering cylinder with the diesel engine running.

46

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

3 Working hydraulics Hydraulic circuit diagram 3254

3 Working hydraulics Hydraulic circuit diagram

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

47

3 Working hydraulics Hydraulic circuit diagram 3254

Working hydraulics circuit diagram

A2

P

A1

B2 Y5

P

351

351

501

Y4

617

206

Y6

Service

B2

303

405 734

734

734

734 B1

405 Y2

Y3

Y30

Y29

511 B5

P C2

T

P1

ZB

ZS

SP

T

406 734

P2

304

734 C1

406 Y7

Y8

612 T

P1

B123-1

614

Y93

Y94 341 Z52

P1

743 Y87

P1

Y61

Y85

T

707

R

L

A

732

703

Y62

Z53

Y77

801

734

332

P

801 Y72

T

19

205

11

218

31

Y73

333

P1

14

255 246 706

798

110

112

Z19 jag05-h-07a

48

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3 Working hydraulics Hydraulic circuit diagram 3254

Key to diagram Item

Designation

Remark

B2

Ground pressure oil pressure sensor

Sensor

B5

Working hydraulics oil pressure sensor

Sensor

B123-1

Sensor

Overtemperature warning

Hydraulic oil temperature Y2

Discharge flap close solenoid coil

3/2 way solenoid valve

Y3

Discharge flap far solenoid coil

3/2 way solenoid valve

Y4

Upper discharge chute slow/ fast rotation solenoid coil

2-step restrictor

Y5

Upper discharge chute left rotation solenoid coil

3/2 way solenoid valve

Y6

Upper discharge chute right rotation solenoid coil

3/2 way solenoid valve

Y7

Upper discharge chute raise solenoid coil

3/2 way solenoid valve

Y8

Upper discharge chute lower solenoid coil

3/2 way solenoid valve

Y29

Raise hitch solenoid coil

3/2 way solenoid valve

Y30

Lower hitch solenoid coil

3/2 way solenoid valve

Y61

Sharpening stone left movement solenoid coil

3/2 way solenoid valve

Y62

Sharpening stone right movement solenoid coil

3/2 way solenoid valve

Y72

Additional control valve 1 – A solenoid coil

3/2 way solenoid valve

Y73

Additional control valve 1 – B solenoid coil

3/2 way solenoid valve

Y77

Working hydraulics circulation shut-off valve solenoid coil

2/2 way solenoid valve

Y85

Raise front attachment solenoid coil

2/3 way solenoid valve (PWM)

Y87

Lower front attachment solenoid coil

3/3 way solenoid valve (PWM)

Y93

Additional control valve 2 – A solenoid coil

3/2 way solenoid valve

Y94

Additional control valve 2 – B solenoid coil

3/2 way solenoid valve

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49

3 Working hydraulics Hydraulic circuit diagram 3254

Item

Designation

Remark

-

-

-

Z19

Hydraulic oil level switch (min.)

Oil level OK, switch open

Z52

Sharpening stone left movement oil pressure actual value function switch

Sharpening stone in parking position, switch open

Z53

Sharpening stone right movement oil pressure actual value function switch

Sharpening stone in parking position, switch closed

-

-

-

110

Oil tank

-

112

Return flow filter

Sieve filter

205

Working hydraulics pump

19 cm3/U

206

Upper discharge chute rotation drive motor

160 cm3/U

218

Steering hydraulics pump

11 cm3/U

246

Cooling circuit pump

14 cm3/U

255

Ground drive / feeder feed pump

31 cm3/U

-

-

-

303

Discharge flap hydraulic cylinder

-

304

Upper discharge chute hydraulic cylinder

-

332

Pick-up crop guard lift hydraulic cylinder

-

333

Pick-up auger lift hydraulic cylinder

-

341

Sharpening stone movement hydraulic cylinder

-

351

Front attachment raise/lower hydraulic cylinder

-

-

-

-

405

Orifice plate Ø 0.6 mm

-

406

Orifice plate Ø 0.8 mm

-

-

-

-

501

Working hydraulics pre-pressurization accumulator

120 bar

511

Front attachment relief accumulator

40 bar

-

-

-

50

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3 Working hydraulics Hydraulic circuit diagram 3254

Item

Designation

Remark

612

Front attachment load switch-over valve

mechanically actuated

614

Front attachment lower flow control valve

mechanically actuated

617

Working hydraulics pre-pressurization relief screw valve

mechanically actuated

-

-

-

703

Working hydraulics pressure relief valve

180+10 bar

732

Non-return valve

-

707

Pressure holding valve (nonreturn valve)

hydraulically actuated

734

Lock-up valve unit (nonreturn valve)

hydraulically actuated_

743

Pilot-controlled one way valve

2/2 way, hydraulically actuated

-

-

-

801

Quick release coupling

-

-

-

-

901

Working hydraulics measuring point

-

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3 Working hydraulics Hydraulic circuit diagram 3254

52

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3 Working hydraulics Main valve: Circulation shut-off valve, front attachment raise/lower solenoid valve 3254

Main valve: Circulation shut-off valve, front attachment raise/lower solenoid valve

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3 Working hydraulics Main valve: Circulation shut-off valve, front attachment raise/lower solenoid valve 3254

Graphics

E

F V

Y85

Y87

Y77 U

K

614

T

R

743

H

703

A

707

G

P1

901

P 614

Y77

614

Y85 743

A

Y87

732

Y87

Y85

T

901

707

P1

703

Y77

P 401975

901 401982

54

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3 Working hydraulics Main valve: Circulation shut-off valve, front attachment raise/lower solenoid valve 3254

Key to diagram Item

Designation

Remark

A

Output

to front attachment load switch-over valve (612)

T

Tank port

-

P

Pump port

-

P1

Parallel connection

to pre-loaded working hydraulics

G

Non-return valve (inlet valve)

-

E

Pilot spool

-

F

Compressed spring

-

H

Front attachment raise spool

-

K

Piston

-

R

Control spool

5 – 50 l/min

U

Circulation shut-off valve control spool

-

V

Pilot valve

-

-

-

-

Y77

Circulation shut-off valve solenoid coil

-

Y85

Raise front attachment solenoid coil

-

Y87

Lower front attachment solenoid coil

-

-

-

-

614

Flow control valve

Lower front attachment 5 – 50 l/min

703

Working hydraulics pressure relief valve

180+10 bar

901

Working hydraulics measuring port

-

743

Front attachment lower valve

-

707

Pressure holding valve

(non-return valve)

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3 Working hydraulics Main valve: Circulation shut-off valve, front attachment raise/lower solenoid valve 3254

Description of function Pressure relief valve

The spring in the pressure relief valve (703) is pre-stressed for a system pressure of 180+10 bar. The pressure setting may be modified by removing or adding shims.

– A Ø0.5 mm shim corresponds to approx. 10 bar – A Ø1.2 mm shim corresponds to approx. 23 bar The above values refer to a rated pressure of 180 bar and may deviate, depending on the actual system. Each time the setting has been modified, the system pressure must be checked.

Basic setting

To ensure the position of spool (H) for the function "Raise front attachment slow", the dimension from the top edge of the spool (H) to the body must be 4.3 mm with the coil core (Y 85) removed.

The position may be corrected by removing or adding shims above the compressed spring in the spool pot (H).

A weaker compressed spring – as compared to the spool (H) - is located below the spool of the circulation shut-off valve (U).

The drop rate of the front attachment is set to a drop time of 5-6 seconds over the entire stroke range on the Front attachment lower flow control valve (614) (depending on the corresponding setting of the front attachment load switchover valve (612)).

Master valve

The master valve (Y77) blocks the circulating volume flow from P to T of the open hydraulic system when being energised while raising the front attachment or charging the pre-loaded working hydraulics. Single-acting functions are an exception to this when the consumer is relieved to the tank or when oil pressure is taken from a possibly existing working hydraulics pre-pressurization accumulator (501).

In neutral position, the circulation shut-off valve (Y 77) is not actuated, making the oil flow back to the tank via the ring channels on the spool (U).

Due to the large channel cross-section, the circulation pressure is very low.

If pressure must be built up for raising the front attachment or if the working hydraulics pre-load is not sufficient, the master valve (Y77) is energised. Now spool (U) closes the connection from P to T, and the top ring channel is closed first in order to achieve smooth switching-over. The pressure relief valve (703) opens at a maximum system pressure of 180+10 bar and relieves the pressure to the tank.

Front attachment raise - slowly

When the "Raise - slow" function is used, the directional control valve (Y 85) is actuated with a pulsed voltage of 80 Hz and approx. 50% PWM (pulse width modulation).

At the same time, the circulation shut-off valve (Y 77) is actuated with 12 V DC. This pulse circuit makes the spool (H) move only to such an extent that the oil must flow via the restrictor pocket inside the spool and the bottom ring channel. This restricted volume flow is directed to the consumer port (A) via the non-return valve (G) and slowly raises the front attachment. The residual oil quantity flows back into the tank via the pressure relief valve (703).

Front attachment raise - quickly

When the "Raise - fast" function is used, the directional control valve (Y 85) and the circulation shut-off valve (Y 77) are actuated with 12 V DC. The spool (H) is moved to its end position, making oil flow via both ring channels on the spool (H).

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3 Working hydraulics Main valve: Circulation shut-off valve, front attachment raise/lower solenoid valve 3254

The full volume flow is directed to the consumer port (A) via the non-return valve (G) and quickly raises the front attachment.

Pulse width modulation (PWM) A PWM signal is a rectangular signal with a variable ON time. The signal frequency remains constant, but the ON time is varied.

12V

Effektiv

50%

6V

0V

50% 80 Hz

401731

Front attachment lower - slowly

When the "Lower - slow" function is used, only the directional control valve (Y 87) is actuated with a pulsed voltage of 80 Hz and approx. 40% PWM (pulse width modulation) by the Contour module A11.

This pulsed circuit is sufficient to open the spherical seat in the pilot valve (V), however, the force is too low to overcome the spring force (F). Spool (E) therefore cannot close the ring channel to the return line. The load caused by the front attachment displaces the oil via the spherical seat and the bores of spool (E) into the return channel to the tank.

The small cross-section at the spherical seat now restricts the volume flow, making the front attachment lower slowly.

Front attachment lower - quickly

For the "lower quickly" function, only the directional control valve (Y87) is energised with a 12V direct voltage.

The spherical seat in pilot valve (V) is opened and the spring force (F) is overcome through the force of the solenoid. The spool (E) closes the ring channel to the return line, making the load pressure of the front attachment act on the piston plates (K); the load pressure now opens outlet valve (743) due to the surface difference.

The oil is now displaced by the front attachment via the outlet valve (743) and the control spool (R) into the return line to the tank. The drop rate of the front attachment here mainly depends on the setting of the flow control valve (614).

Flow control valve

When the "Lower front attachment – fast" function is used, the oil displaced via port A flows to the tank through the restrictor in the control spool of the flow control valve (614).

This creates a ram pressure ahead of the control spool, making the latter move against the control spring and restrict the return channel to the tank as a function of the load pressure.

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3 Working hydraulics Main valve: Circulation shut-off valve, front attachment raise/lower solenoid valve 3254

When the load pressure at port A changes, both the oil flow through the restrictor and the load pressure against the control spool change, too, and consequently also the return channel cross-section.

This control function keeps the effective oil flow through the restrictor in the control spool and through the cross-section in the return channel constant, regardless of the load pressure.

The front attachment drop rate is adjusted merely by the pre-stress of the control spring at the handwheel. This reduces the effective oil flow by relieving the control spring, since even a low load pressure will restrict the return channel cross-section.

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3 Working hydraulics Upper discharge chute valve combination / discharge flap with pressure accumulator 3254

Upper discharge chute valve combination / discharge flap with pressure accumulator

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59

3 Working hydraulics Upper discharge chute valve combination / discharge flap with pressure accumulator 3254

Graphics

A2

A1

Y5

Y6

Y4

617

501

B1

C1

405

Y2

405

Y3

Y8

T

P1

406

Y7 C2

B2

406

B5 401986

60

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3 Working hydraulics Upper discharge chute valve combination / discharge flap with pressure accumulator 3254

Key to diagram Item

Designation

Remark

A1

Port

Rotate upper discharge chute to the right

A2

Port

Rotate upper discharge chute to the left

B1

Port

Discharge flap close

B2

Port

Discharge flap far

B5

Working hydraulics oil pressure sensor

-

C1

Port

Lower upper discharge chute

C2

Port

Raise upper discharge chute

P1

Port

Pressure supply under pressure by non-return valve (707)

T

Port

Return line to tank

-

-

-

Y2

Discharge flap close solenoid coil

3/2 way solenoid valve

Y3

Discharge flap far solenoid coil

3/2 way solenoid valve

Y4

Upper discharge chute slow/ fast rotation solenoid coil

2-step restrictor

Y5

Upper discharge chute left rotation solenoid coil

3/2 way solenoid valve

Y6

Upper discharge chute right rotation solenoid coil

3/2 way solenoid valve

Y7

Upper discharge chute raise solenoid coil

3/2 way solenoid valve

Y8

Upper discharge chute lower solenoid coil

3/2 way solenoid valve

-

-

-

405

Orifice plate Ø 0.6 mm

-

406

Orifice plate Ø 0.8 mm

-

-

-

-

501

Working hydraulics pre-pressurization accumulator

0.75 l, pre-loaded to 120 bar

-

-

-

617

Working hydraulics pre-pressurization relief screw valve

To relieve the load on the pre-loaded working hydraulics (P1).

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3 Working hydraulics Upper discharge chute valve combination / discharge flap with pressure accumulator 3254

Description of function Pre-loaded working hydraulics system

The pressurised oil from port P1 is under pressure due to non-return valve (707) (see overall circuit diagram).

All working hydraulics functions except for the Raise front attachment function receive their oil pressure from the pre-loaded working hydraulics system. This system is equipped with the working hydraulics pre-load accumulator (501). When the accumulator pre-load drops to approx. 170 bar, the working hydraulics / Autopilot oil pressure sensor (B5) actuates the master valve (Y77) under time control via the Contour module (A11) and the Intake controller module (A14).

Danger!

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

Death or serious injury.

– Relieve the oil pressure before starting service work.To do this, slacken off the balance screw (617).

617

401975

62

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3 Working hydraulics Hitch solenoid valve 3254

Hitch solenoid valve

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63

3 Working hydraulics Hitch solenoid valve 3254

Graphics

Y30

Y29

T

P1

A

B

734

734

K

B

734

A

Y29

P1

734

Y30

T

401987

64

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3 Working hydraulics Hitch solenoid valve 3254

Key to diagram Item

Designation

Remark

A

Consumer port (see overall circuit diagram)

-

B

Consumer port (see overall circuit diagram)

-

K

Piston

-

P1

Port

Pressure supply under pressure by non-return valve (707)

T

Tank port

-

-

-

-

Y29

Raise hitch solenoid coil

-

Y30

Lower hitch solenoid coil

-

-

-

-

734

Lock-up valve unit (nonreturn valve)

-

Description of function Neutral

The solenoid coils are not energised. Both sides of the hydraulic cylinder are blocked tightly by the non-return valves (734) in the consumer ports A and B.

Pre-loaded working hydraulics system

The pressurised oil from port P1 is under pressure due to non-return valve (707) (see overall circuit diagram).

All working hydraulics functions except for the Raise front attachment function receive their oil pressure from the pre-loaded working hydraulics system. This system is equipped with the working hydraulics pre-load accumulator (501). When the accumulator pre-load drops to approx. 170 bar, the working hydraulics / Autopilot oil pressure sensor (B5) actuates the master valve (Y77) under time control via the Contour module (A11) and the Intake controller module (A14).

Working position

According to the necessary direction of movement, one of the solenoid valves is energised. The corresponding pilot spool opens the ball in the valve insert and closes the return line to the tank.

The pressure which consequently rises builds up against piston (K) and opens the non-return valve (734) at port A or B. The return line of the hydraulic cylinder is thus released to the tank via the valve insert of the unactuated solenoid valve. The pressure rising further now opens the non-return valve (734) at the opposite port and the hydraulic cylinders are retracted or extended.

Note:

The sealing ring beneath the valve inserts must be replaced upon each assembly as otherwise leaks may occur.

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3 Working hydraulics Hitch solenoid valve 3254

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3 Working hydraulics Sharpening, additional control unit 1, additional control unit 2 solenoid valve 3254

Sharpening, additional control unit 1, additional control unit 2 solenoid valve

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3 Working hydraulics Sharpening, additional control unit 1, additional control unit 2 solenoid valve 3254

Graphics

Y93 Y61 Y72 12V DC

Y94 Y62 Y73 60%

12V DC

60%

T

B

A P1

401988

68

Y93

Y94

Y61

Y62

Y72

Y73

T

P1

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3 Working hydraulics Sharpening, additional control unit 1, additional control unit 2 solenoid valve 3254

Key to diagram Item

Designation

Remark

A

Consumer port (see overall circuit diagram)

-

B

Consumer port (see overall circuit diagram)

-

P5

Pump via circulation shut-off valve port

-

T

Tank port

-

-

-

-

Y61

Sharpening stone left movement solenoid coil

-

Y62

Sharpening stone right movement solenoid coil

-

Y72

Additional control valve 1 – A solenoid coil

-

Y73

Additional control valve 1 – B solenoid coil

-

Y93

Additional control valve 2 – A solenoid coil

-

Y94

Additional control valve 2 – B solenoid coil

-

Description of function Pre-loaded working hydraulics system

The pressurised oil from port P1 is under pressure due to non-return valve (707) (see overall circuit diagram).

All working hydraulics functions except for the Raise front attachment function receive their oil pressure from the pre-loaded working hydraulics system. This system is equipped with the working hydraulics pre-load accumulator (501). When the accumulator pre-load drops to approx. 170 bar, the working hydraulics / Autopilot oil pressure sensor (B5) actuates the master valve (Y77) under time control via the Contour module (A11) and the Intake controller module (A14).

Sharpening neutral position

None of the solenoid coils (Y61 / Y62) is energised. Ports (A) and (B) are connected to the tank (T).

Sharpening stone to the left

Solenoid coil (Y61) is energised. The pilot spool of solenoid coil (Y61) opens the ball against the pressure in port (P1).

Volume flow flows from port (P1) via the ball to port (A) and continues to the left connecting rod end of the sharpening stone movement hydraulic cylinder (341).

The volume flow displaced during this process from the right-hand connecting rod end of the sharpening stone movement hydraulic cylinder (341) lifts the pilot spool of the solenoid coil (Y62) and thus returns to the tank.

See overall circuit diagram.

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3 Working hydraulics Sharpening, additional control unit 1, additional control unit 2 solenoid valve 3254

Sharpening stone to the right

Solenoid coil (Y62) is energised. The pilot spool of solenoid coil (Y62) opens the ball against the pressure in port (P1).

Volume flow flows from port (P1) via the ball to port (B) and continues to the right connecting rod end of the sharpening stone movement hydraulic cylinder (341).

The return flow coming from the left-hand connecting rod end of the sharpening stone cylinder (341) lifts the pilot spool of the solenoid valve (Y61) and thus returns to the tank.

See overall circuit diagram.

Sharpening pressure limitation

The pressure limitation for sharpening is set to approx. 120 bar.

Setting is carried out by using a special valve insert with a relatively large cross-section at the conical seat.

The hydraulic force acts on the conical seat of the valve insert and consequently against the electromagnetic force.

At a pressure of 120 bar, the conical seat of the valve insert opens because the electromagnetic force is not sufficient any more. The oil pressure is relieved to the tank.

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3 Working hydraulics Corn cracker 3254

Corn cracker

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3 Working hydraulics Corn cracker 3254

Graphics

230

c

A

230 d b

356R

a

e

e

356L

c

B

230 d b

356R

e

a e

356L

401990

72

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3 Working hydraulics Corn cracker 3254

Key to diagram Item

Designation

Remark

A

Figure

Cracker adjusting range (26 mm piston stroke)

B

Figure

Venting range (piston on double pump overall length 231 mm)

a

Port

to left adjusting cylinder

b

Port

to right adjusting cylinder

c

Port

Filling port

d

Piston

is turned in or out for cracker gap adjustment

e

Port

for venting the cracker gap adjustment

-

-

-

230

Corn cracker adjustment pump

Serves as a proportioning pump for cracker adjusting cylinder

-

-

-

356 R

Cylinder

Cracker gap adjustment, right

356 L

Cylinder

Cracker gap adjustment, left

Adjusting and venting Adjusting the minimum Corn cracker gap

Adjust minimum corn cracker gap at the corn cracker adjustment (double pump 230).

Check the gap dimension between the corn cracker rollers at the largest diameter (when rollers are worn), set value = 0.5 mm. Adjustments are carried out on the stop bolts (S).

230 C e

401125

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

S

356L

73

3 Working hydraulics Corn cracker 3254

Venting

– Remove adjusting device at the corn cracker adjustment pump (230) so that the hexagon socket of piston (d) can be accessed.

– Connect minimess hose to the low-pressure hydraulics measuring point (910) and to filling port (c).

– Place vent hoses on vent ports (e) of both adjusting cylinders (356) on the right-hand and left-hand side. Direct the vent hoses into a collecting container.

– Adjust the corn cracker adjustment pump (230) to 231 mm, see item B. Start the engine.

– Vent cylinders (356 L) and (356 R) until the oil comes out without bubbles.

– Stop the engine and remove the minimess hose first from the filling port (c) and then from the low-pressure hydraulics measuring point (910).

– Turn in the piston (d) up to the dimension 222 mm, see figure A. – Slightly open the vent ports (e) on the right-hand and left-hand side and relieve the oil pressure, thus re-establishing the mechanical basic position.

– Close the vent ports (e) again.

– Turn in the piston (d) until the roller gap is 2 mm.

– Check if the clearance of the cracker rollers is parallel. A tolerance of 0.3 mm is allowed. If the clearance is not parallel, repeat the venting process.

– Remove vent hoses. Re-fit adjusting device to the corn cracker adjustment pump (230).

In case of mechanical cracker adjustment, adjust the scale value (2 mm) on the scale. In case of electrical cracker adjustment, program the gap clearance of 2 mm in the CIS. (See Operator's Manual) Attention!

During operation, the clearance of the cracker rollers must absolutely not fall below the minimum clearance of 1 mm, Material machine damage (corn cracker) may occur.

– Make the adjustments correctly.

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3 Working hydraulics Upper discharge chute rotation drive motor 3254

Upper discharge chute rotation drive motor

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3 Working hydraulics Upper discharge chute rotation drive motor 3254

Graphics

206

OMP

A2 A1

Y5

P

501

Y4

617

206

Y6

Service

B2

405 734

303

734 B1

405 Y2

Y3 B5

P C2

406 734

304

734 C1

406 Y7

401991

76

T

Y8

P1

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3 Working hydraulics Upper discharge chute rotation drive motor 3254

Key to diagram Item

Designation

Remark

1

Body

-

2

Output shaft / distributor valve

-

3

Cardan shaft

-

4

Ring gear

-

5

Gear

-

-

-

-

206

Upper discharge chute rotation drive motor

160 cm³/rev.

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3 Working hydraulics Upper discharge chute rotation drive motor 3254

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3 Working hydraulics Front attachment load switch-over valve 3254

Front attachment load switch-over valve

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3 Working hydraulics Front attachment load switch-over valve 3254

Graphics

A 351

B 351

511 511 612

R

P2

612

R

K T

P2

X

K T

X

X

X

C 351 P

B2

511 351

351

612

R

P2

511

ZS

T

ZB

K

SP

T

X

P2

612

X

401992

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3 Working hydraulics Front attachment load switch-over valve 3254

Key to diagram Item

Designation

Remark

B2

Ground pressure oil pressure sensor

-

K

Face end of cylinders

Ø75 µm

R

Rod end of cylinders

Face end Ø 75 mm - Connecting rod area Ø 50 mm

P2

Pressurised oil

from front attachment raise/lower main valve

T

Tank connection

Return line

X

Locking pin

to avoid switching over under load, resulting in unwanted lowering of the front attachment.

351

Front attachment raise/lower hydraulic cylinder

-

511

Front attachment relief accumulator

40 bar

612

Front attachment load switch-over valve

-

Description of function Task

When lifting lightweight and heavy front attachments, the hydraulic pressure in the Front attachment raise/lower cylinders (351) is kept at the same level.

Benefit: Improved response of Contour system and of ground pressure control with an accumulator.

This is made possible by the Front attachment load switch-over valve (612) switching over to different pressure surfaces in the hydraulic cylinders (351).

Figure A

This position is selected for lightweight front attachments such as pick-up and 4-row maize header.

Effective hydraulic pressure area in the Raise/lower front attachment hydraulic cylinders (351): Face end minus rod end = Connecting rod area Ø 50 mm.

Figure B

Switching position to allow actuating the Front attachment load switch-over valve (612).

To do this, the front attachment must be lowered and the hydraulic pressure at port P6 must be completely relieved. (pressure display in CIS shows no pressure.)

The spring (see X) pushes the safety pin in and the change-over lever of the Front attachment load switch-over valve (612) can be set to the other position.

Figure C

This position is used for heavy front attachments such as maize headers, 6row and 8-row RU maize headers and cutterbars.

The rod end of the hydraulic cylinders is connected with the tank. The effective hydraulic pressure surface in the Front attachment raise/lower hydraulic cylinders (351) is the face end Ø 75 mm.

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81

3 Working hydraulics Front attachment load switch-over valve 3254

82

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3 Working hydraulics Pressure accumulator volume switch-over valve (Direct Disc option) 3254

Pressure accumulator volume switch-over valve (Direct Disc option)

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83

3 Working hydraulics Pressure accumulator volume switch-over valve (Direct Disc option) 3254

Graphics

511-2

X

511-2 655

655 T

P2

X

P2

655 401993

84

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3 Working hydraulics Pressure accumulator volume switch-over valve (Direct Disc option) 3254

Key to diagram Item

Designation

Remark

B2

Downward force oil pressure sensor

-

P

Pressurised oil

-

P2

Pressurised oil from Front attachment raise/lower main valve

-

T

Tank port

-

-

-

-

351

Front attachment raise/lower hydraulic cylinder

-

-

-

-

511

Front attachment relief accumulator

-

-

-

-

612

Front attachment load switch-over valve

-

655

Pressure accumulator volume switch-over valve

-

Description of function The switch-over valve (655) allows increasing the volume of accumulator (511). This is required for better adaptation of the ground pressure control (Contour) when using front attachments of different weights (alternative to Direct Disc mower, as an option).

Operation of accumulator circuit

To operate the accumulator volume switching-over (655), the front attachment must be lowered and the hydraulic pressure at port P2 must be completely relieved. (pressure display in CIS shows no pressure.) The spring (see X) pushes the safety pin in and the lever of the accumulator volume switch-over valve (655) can be set to the other position.

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3 Working hydraulics Pitching dampening 3254

Pitching dampening Task

401740

Pitching may occur during transport travel with heavy front attachments mounted. This applies particularly when travelling at high speeds on uneven roads.

This – considerably reduces the driving comfort, – reduces the driving safety – and causes high dynamic loads on mechanical components.

The pitching modifies the pressure in the front attachment hydraulic cylinders.

These pressure changes are detected by a pressure sensor, transmitted into the CONTOUR module as a signal and evaluated there. The CONTOUR module actuates the solenoid valves for raising or lowering the front attachment as a function of these signals.

Pitching is counteracted by slightly raising or lowering the front attachment.

Pitching dampening offers the following benefits: – high driving comfort – safe vehicle handling – lower mechanical loads

86

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3 Working hydraulics Pitching dampening 3254

Operation

S52 S25

401741

Learning the centre pitching axis

1 2 3 4

Switch off the main drive switch (S25).

Set switch (S52) to road travel position.

Raise the front attachment to a height of approx. 400 mm.

Keep the CAC switch (S38) "Cutting height control/Automatic ground pressure control" pressed for approx. 5 seconds until a threefold warning tone is heard.

The position of the centre pitching axis has now been learned.

In this front attachment position, – sensor (B2) "Ground pressure oil pressure" detects the pressure in the hydraulic cylinders "Raise/lower front attachment".

– sensor (B35) "Feed rake conveyor position" detects the front attachment position.

Both signals are transmitted to the CONTOUR module (A11).

The learned "centre pitching axis" is permanently saved in the CONTOUR module (A11). It will not be deleted by switching the ignition OFF and ON. The existing value can only be overwritten by another learning procedure.

Activating pitching dampening

S38

401971

1 2 3 4

Switch off the main drive switch (S25).

Switch on road travel switch (S52).

Raise the front attachment to an arbitrary height.

Press CAC switch (S38) "Cutting height control/Automatic ground pressure control".

The front attachment is now moved to the "centre pitching axis" position.

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3 Working hydraulics Pitching dampening 3254

401743

The activated pitching dampening is identified by the letters "A" (see arrows) in the display.

The left-hand bar graph shows the ground pressure and the right-hand bar chart the position of the front attachment.

Pitching is deactivated by manually raising or lowering the front attachment.

Sensors

B2 B35

401974

Ground pressure oil pressure sensor (B2)

The "Ground pressure oil pressure" sensor (B2) is mounted at the front right on the feed rake conveyor. It detects the pressure in the "Raise/lower front attachment" hydraulic cylinders and transmits the signal to the CONTOUR module (A11).

Feed rake conveyor position sensor (B35)

The "Feed rake conveyor position" sensor (B35) is mounted at the front right on the feed rake conveyor. It detects the front attachment position and transmits the signal to the CONTOUR module (A11).

88

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3 Working hydraulics Pitching dampening 3254

Description of function a b 120 bar 100 bar 80 bar

400032

Example:

When pitching dampening is activated, the front attachment is in the centre pitching axis.Here the pressure in the "Raise/lower front attachment" hydraulic cylinder is approx. 100 bar.

This pressure is detected by the Ground pressure oil pressure sensor (B2) and transmitted to the CONTOUR module (A11). This module has stored a pressure tolerance range of +/- 20 bar around the „centre pitching axis“.

While travelling, the front attachment pitches, resulting in pressure peaks (curve a). When these are outside of the stored pressure tolerance range, the CONTOUR module (A11) energises the solenoid valves that raise or lower the front attachment.

Slightly raising or lowering the front attachment counteracts the pitching to such an extent that the pressure remains within the stored pressure tolerance range of +/- 20 bar (curve b).

When the pressure is within the stored pressure tolerance range of +/- 20 bar, but the front attachment moves too far away from the centre pitching axis during the compensating movements, the Feed rake conveyor position sensor (B35) takes it back to the set position (centre pitching axis).

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3 Working hydraulics Testing and measuring 3254

Testing and measuring Graphics

901

401975

901 Working hydraulics measuring point

Measuring pre-conditions Pressure measurements are carried out at: – maximum volume flow (maximum motor speed), – an oil temperature of 45 – 50 °C.

Set values – Circulation pressure 2.5+6 bar – Maximum pressure 180+10 bar.

90

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4 Low-pressure hydraulic system Hydraulic circuit diagram 3255

4 Low-pressure hydraulic system Hydraulic circuit diagram

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4 Low-pressure hydraulic system Hydraulic circuit diagram 3255

Low-pressure hydraulic system circuit diagram

302

Y1 A

353

801

Y86 A

Y60

421 A

352

Y88 A

340

P

729

910 T

1

359

2

Y59

A2

317

441 Y26

A1

228 T

790

P

807

Z46

413 F

796-1

796-2

102-1 B97 102-2

P

Ms

520

714 19

205

11

218

31

14

255 246 706

713 716 Mp P

798

B98

110 jag05-h-08a

92

Z19

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4 Low-pressure hydraulic system Hydraulic circuit diagram 3255

Designations Item

Designation

Remark

B97

Drive hydraulics forward high-pressure sensor

-

B98

Drive hydraulics backward high-pressure sensor

-

-

-

-

F

Filling connection

for initial commissioning

-

-

-

Y1

4-Trac (all-wheel drive) solenoid coil

-

Y26

Main drive solenoid coil

PWM-controlled

Y59

Servo circuit solenoid coil

-

Y60

Cover solenoid coil

-

Y86

Reverse front attachment solenoid coil

-

Y88

Front attachment clutch solenoid coil

-

-

-

-

Z19

Hydraulic oil level switch (min.)

-

Z46

Low-pressure hydraulics/ground drive oil pressure actual value function switch

-

-

-

-

102

Pressure filter

-

110

Oil tank

-

-

-

-

205

Working hydraulics pump

-

218

Steering hydraulics pump

-

228

Suction arm drive motor

-

246

Cooling circuit pump

-

255

Ground drive / feeder feed pump

-

-

-

-

302

All-wheel drive clutch hydraulic cylinder

-

317

Main drive clutch hydraulic cylinder

-

340

Cover hydraulic cylinder

-

352

Front attachment clutch hydraulic cylinder

-

353

Front attachment reverse hydraulic cylinder

-

359

Shifter rail locking hydraulic cylinder

-

-

-

-

413

Orifice plate Ø 2.2 mm

-

421

Restrictor A

(option for maize headers)

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4 Low-pressure hydraulic system Hydraulic circuit diagram 3255

Item

Designation

Remark

441

Rotary coupling

-

-

-

-

520

Feed pressure accumulator

10 bar

-

-

-

706

Pressure relief valve

3 bar

713

Ground drive multifunction valve backward valve

420 bar DP

714

Ground drive multifunction valve forward valve

420 bar DP

716

Ground drive feed pressure relief valve

24 bar

729

Low-pressure hydraulics pressure relief valve

21+1 bar

790

Suction arm drive flow control valve

-

796

Bypass valve filter

Δp=2 bar

798

Feed pressure relief valve

25 bar

-

-

-

801

Quick release coupling

-

807

Line header

-

-

-

-

910

Low-pressure hydraulics measuring point

-

94

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4 Low-pressure hydraulic system All-wheel drive, servo gearshift, cover, reverse front attachment, front attachment clutch valve block 3255

All-wheel drive, servo gearshift, cover, reverse front attachment, front attachment clutch valve block

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4 Low-pressure hydraulic system All-wheel drive, servo gearshift, cover, reverse front attachment, front attachment clutch valve block 3255

Fig.

S

S

1 2

Y1 Y59 Y60 Y86 Y88

Y1 Y59 Y60 Y86 Y88

A

Y86

T

V

P Y1

A

T

Y60

V

P

Y88 T

Y1

302 A

353

801

Y86 A

Y60

421 A

S

352

Y88

P

A

340

401883

P

729

910 T

Y26 Y59 T P

1

359

Y59

2 A2

317

441 Y26

A1

228 T

790

P P

T

401960

401997

96

P

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4 Low-pressure hydraulic system All-wheel drive, servo gearshift, cover, reverse front attachment, front attachment clutch valve block 3255

Designations Item

Designation

Remark

A

Consumer port

-

P

Low-pressure port

-

S

Emergency operation screw

-

T

Tank port

-

V

Valve insert

-

-

-

-

Y1

4-Trac (all-wheel drive) solenoid coil

-

Y26

Main drive solenoid coil

PWM-controlled

Y59

Servo circuit solenoid coil

-

Y60

Cover solenoid coil

-

Y86

Reverse front attachment solenoid coil

-

Y88

Front attachment clutch solenoid coil

-

-

-

-

228

Suction arm drive motor

-

-

-

-

302

All-wheel drive clutch hydraulic cylinder

-

317

Main drive clutch hydraulic cylinder

-

340

Cover hydraulic cylinder

-

352

Front attachment clutch hydraulic cylinder

-

353

Front attachment reverse hydraulic cylinder

-

359

Shifter rail locking hydraulic cylinder

-

-

-

-

441

Rotary coupling

-

-

-

-

729

Low-pressure hydraulics pressure relief valve

21+1 bar

790

Suction arm drive flow control valve

-

-

-

-

801

Quick release coupling

-

-

-

-

910

Low-pressure hydraulics measuring point

-

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4 Low-pressure hydraulic system All-wheel drive, servo gearshift, cover, reverse front attachment, front attachment clutch valve block 3255

Description of function With the solenoid coil de-energised, a connection is provided from the consumer port (A) to the return line into the tank (T) via the conical seat in the valve insert (V). Here the low pressure (P) applied is blocked by the spherical seat in the valve insert (V). When the corresponding solenoid coil for a given function is actuated, the plunger opens the ball in the valve insert (V) and closes the conical seat to the return line (T). The low pressure (P) is thus applied to the hydraulic cylinder via the consumer port (A).

Note:

98

In case of emergency operation, screw (S) must be screwed in up to the stop to make the conical seat in the valve insert (V) close the return line to the tank (T) tightly.

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4 Low-pressure hydraulic system Main drive valve block 3255

Main drive valve block

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4 Low-pressure hydraulic system Main drive valve block 3255

Fig.

S

S

Y26

Y26

A1

A1

T

V

P

T

V

P

Y26 Y26 T P 1

359

2

Y59

A2

401960

317

441

Y26

A1

228 T

790

P P

T

401998

100

P

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4 Low-pressure hydraulic system Main drive valve block 3255

Designations Item

Designation

Remark

A1

Consumer port

-

P

Low-pressure port

-

S

Emergency operation screw

-

T

Tank port

-

V

Valve insert

-

-

-

-

Y26

Main drive solenoid coil

PWM-controlled

Y59

Servo circuit solenoid coil

-

-

-

-

228

Suction arm drive motor

-

-

-

-

317

Main drive clutch hydraulic cylinder

-

359

Shifter rail locking hydraulic cylinder

-

-

-

-

441

Rotary coupling

-

-

-

-

790

Suction arm drive flow control valve

-

Description of function With the main drive solenoid valve (Y26) de-energised, a connection is provided from port (A) to the tank (T) via the conical seat in the valve insert.

Here the low pressure (P) applied is blocked by the spherical seat in the valve insert. When energising the main drive solenoid valve (Y26) proportionally, the ram opens the ball in the valve insert.The oil pressure (P) now acts against the valve insert cone against the magnetic force. The proportionally rising magnetic force pushes the ram further down and closes the return line (T) with the conical seat. This produces a controlled pressure build-up in the main drive clutch hydraulic cylinder (317) and consequently smooth starting of the main drive.

When the clutch process is complete, the low pressure (P) is applied to the main drive clutch hydraulic cylinder (317) via the consumer port (A1) whereas the return line to the tank (T) is blocked.

Note

The main drive solenoid valve (Y26) is different from the solenoid valves of the remaining low-pressure hydraulic system.The valve insert and the solenoid coil have a different design. Actuation is PWM-controlled (proportional).

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4 Low-pressure hydraulic system Main drive valve block 3255

102

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4 Low-pressure hydraulic system Pressure relief valve 3255

Pressure relief valve

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103

4 Low-pressure hydraulic system Pressure relief valve 3255

Fig.

729

T

P

302

Y1 A

729 T

353

Y86

801

A

Y60

421 A

352

Y88

P 401883

A

340

P

729

910 P

T

402001

104

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4 Low-pressure hydraulic system Pressure relief valve 3255

Designations Item

Designation

Remark

Y1

4-Trac (all-wheel drive) solenoid coil

-

Y60

Cover solenoid coil

-

Y86

Reverse front attachment solenoid coil

-

Y88

Front attachment clutch solenoid coil

-

-

-

-

Z19

Hydraulic oil level switch (min.)

-

Z46

Low-pressure hydraulics/ground drive oil pressure actual value function switch

-

-

-

-

302

All-wheel drive clutch hydraulic cylinder

-

340

Cover hydraulic cylinder

-

352

Front attachment clutch hydraulic cylinder

-

353

Front attachment reverse hydraulic cylinder

-

-

-

-

421

Restrictor A

(option for maize headers)

-

-

-

729

Low-pressure hydraulics pressure relief valve

21+1 bar

-

-

-

801

Quick release coupling

-

-

-

-

910

Low-pressure hydraulics measuring point

-

Description of function Pressure relief valve

The pressure relief valve (729) limits the pressure in the low-pressure hydraulic system and thus protects the connected mechanical components against damage from excessive forces.

The spring in the pressure relief valve (729) is pre-stressed for a system pressure of 21+1 bar.

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4 Low-pressure hydraulic system Pressure relief valve 3255

106

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4 Low-pressure hydraulic system Shifter rail locking hydraulic cylinder 3255

Shifter rail locking hydraulic cylinder

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4 Low-pressure hydraulic system Shifter rail locking hydraulic cylinder 3255

Fig. 1 2

359 e d c b a

1

359

2

Y59

A2

317

441 Y26

A1

228 T

790

P P

T

359 P

f

624

402002

108

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4 Low-pressure hydraulic system Shifter rail locking hydraulic cylinder 3255

Designations Item

Designation

Remark

a

Shifter rail

-

b

Ball

-

c

Compressed spring

-

d

Piston

-

e

Compressed spring

-

f

Port

-

-

-

-

Y26

Main drive solenoid coil

PWM-controlled

Y59

Servo circuit solenoid coil

-

-

-

-

228

Suction arm drive motor

-

-

-

-

317

Main drive clutch hydraulic cylinder

-

359

Shifter rail locking hydraulic cylinder

-

-

-

-

441

Rotary coupling

-

-

-

-

624

Venting valve

-

-

-

-

790

Suction arm drive flow control valve

-

Description of function Shifter rail is locked

No pressurised oil is applied to port (f). The compression spring (e) pushes the ram (d) onto the ball (b) which locks the shifter rail (a).

Shifter rail is unlocked

The solenoid valve (Y59) has switched so that now pressurised oil flows beneath ram (d) via port (f). Ram (d) is moved upwards against the compression spring (e). The ball (b) is now loaded by the compression spring (c) only.

The shifter rail (a) can be actuated against this spring force.

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4 Low-pressure hydraulic system Shifter rail locking hydraulic cylinder 3255

Venting The actuation circuit must be vented: – after the actuation circuit has been opened, – when shifting a gear is possible only after extended actuation of button (K) on the gear shift lever.

401730

Carrying out venting

Note:

110

– – – – – –

Set ground speed control lever to N position.

Block the machine by applying the service brake and the parking brake.

Start diesel engine and let it run at idle speed.

Press button (K) on the gearshift lever.

Another person opens the vent valve (624).

Continue venting until oil comes out without bubbles. Collect any escaping oil.

– Close vent valve (624).

Check oil level in hydraulic oil tank and add some oil if necessary.

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4 Low-pressure hydraulic system Suction arm drive flow control valve 3255

Suction arm drive flow control valve

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4 Low-pressure hydraulic system Suction arm drive flow control valve 3255

Fig.

A

790 C

D E

F

790

B

228

790 P

T

402005

112

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4 Low-pressure hydraulic system Suction arm drive flow control valve 3255

Designations Item

Designation

Remark

A

Low pressure

-

B

To suction arm drive hydraulic motor

-

C

Insert

-

D

Measuring orifice

-

E

Spool

-

F

Spring

-

-

-

-

228

Suction arm drive motor

-

-

-

-

790

Suction arm drive flow control valve

-

Description of function – Ensuring constant speed of suction arm – Avoiding a pressure drop in the low-pressure hydraulics, especially on the main drive clutch.

There is a measuring orifice (D) inside the 2-way flow controller which is part of the moving ram. The diameter determines the volume flow. When the feed flow increases, the ram moves towards the spring (F) and restricts the drain cross-section, keeping the pressure difference at the measuring orifice constant.

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4 Low-pressure hydraulic system Suction arm drive flow control valve 3255

114

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4 Low-pressure hydraulic system Suction arm drive motor 3255

Suction arm drive motor

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4 Low-pressure hydraulic system Suction arm drive motor 3255

Fig.

228

2

3

4 5

228

228

790 P

402006

116

T

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4 Low-pressure hydraulic system Suction arm drive motor 3255

Designations Item

Designation

Remark

1

Body

-

2

Drive shaft

-

3

Cardan shaft

-

4

Stator

-

5

Rotor

-

-

-

-

228

Suction arm drive motor

-

-

-

-

790

Suction arm drive flow control valve

-

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4 Low-pressure hydraulic system Suction arm drive motor 3255

118

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4 Low-pressure hydraulic system Line header 3255

Line header

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119

4 Low-pressure hydraulic system Line header 3255

Fig.

807

807

413

807 Z46

807

Z46

413 401910

402007

120

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4 Low-pressure hydraulic system Line header 3255

Designations Item

Designation

Remark

413

Orifice plate Ø 2.2 mm

-

807

Line header

-

Z46

Low-pressure hydraulics/ground drive oil pressure actual value function switch

-

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121

4 Low-pressure hydraulic system Line header 3255

122

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4 Low-pressure hydraulic system Knife support valve cylinder 3255

Knife support valve cylinder

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4 Low-pressure hydraulic system Knife support valve cylinder 3255

Fig.

Y240

T

P

3031

Y240 Y26

3031 Y26 3031 Y26

402008

124

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4 Low-pressure hydraulic system Knife support valve cylinder 3255

Designations Item

Designation

Remark

3031

Knife support hydraulic cylinder

-

-

-

-

729

Low-pressure hydraulics pressure relief valve

21+1 bar

-

-

-

807

Line header

-

-

-

-

910

Low-pressure hydraulics measuring point

-

-

-

-

Y240

Knife support solenoid coil on/off

-

Description of function Extending the knife support

When solenoid coil (Y240) is energised, pressurised oil is applied to the ram face and the ring face of hydraulic cylinder (3031). The different faces (ring face < ram face) make the ram rod of hydraulic cylinder (3031) extend.

Retracting the knife support

When solenoid coil (Y240) is not energised, the ram face of hydraulic cylinder (3031) is relieved to the tank. The pressurised oil applied to the ring face makes (3031) retract.

Note

The existing set screw only serves as a plug.

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4 Low-pressure hydraulic system Knife support valve cylinder 3255

126

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4 Low-pressure hydraulic system Testing and measurements 3255

Testing and measurements

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4 Low-pressure hydraulic system Testing and measurements 3255

Fig.

910

302

Y1 A

353

801

Y86 A

Y60

421 A

352

T

Y88 A

340

P

729

910 T

910

1

359

2

P 401883

Y59

A2

317

441 Y26

A1

228 T

790

P P

T

402009

128

P

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

4 Low-pressure hydraulic system Testing and measurements 3255

Designations Item

Designation

Remark

Y1

4-Trac (all-wheel drive) solenoid coil

-

Y26

Main drive solenoid coil

PWM-controlled

Y59

Servo circuit solenoid coil

-

Y60

Cover solenoid coil

-

Y86

Reverse front attachment solenoid coil

-

Y88

Front attachment clutch solenoid coil

-

-

-

-

228

Suction arm drive motor

-

-

-

-

302

All-wheel drive clutch hydraulic cylinder

-

317

Main drive clutch hydraulic cylinder

-

340

Cover hydraulic cylinder

-

352

Front attachment clutch hydraulic cylinder

-

353

Front attachment reverse hydraulic cylinder

-

359

Shifter rail locking hydraulic cylinder

-

-

-

-

441

Rotary coupling

-

-

-

-

729

Low-pressure hydraulics pressure relief valve

21+1 bar

790

Suction arm drive flow control valve

-

-

-

-

801

Quick release coupling

-

-

-

-

910

Low-pressure hydraulics measuring point

-

Measuring pre-condition Pressure measurements are carried out at: – maximum volume flow (maximum motor speed), – an oil temperature of 45 – 50 °C. Set value:

21+1 bar

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129

4 Low-pressure hydraulic system Testing and measurements 3255

130

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5 Feeder hydraulics Hydraulic feeder drive, components 3256

5 Feeder hydraulics Hydraulic feeder drive, components

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131

5 Feeder hydraulics Hydraulic feeder drive, components 3256

Fig.

792 253 791 925 Y256

Y255 794-2 B123-2

793 Y257

926

521

254

401983

132

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5 Feeder hydraulics Hydraulic feeder drive, components 3256

Designations Item

Explanation

253

Feeder drive variable-displacement pump

254

Feeder drive motor

-

-

521

Quick stop accumulator

-

-

791

Feeder quick stop valve

792

Multifunction valve, forward

793

Multifunction valve, reverse

794-2

Shut-off valve

-

-

925

Feeder drive measuring point

926

Feeder drive reverse measuring point

-

-

B1232

Hydraulic oil temperature sensor (overtemperature warning)

-

-

Y255

Feeder drive pump adjustment solenoid valve

Y256

Main drive brake valve solenoid valve

Y257

Feeder quick stop solenoid valve

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133

5 Feeder hydraulics Hydraulic feeder drive, components 3256

134

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5 Feeder hydraulics Main drive, decelerated 3256

Main drive, decelerated

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135

5 Feeder hydraulics Main drive, decelerated 3256

Circuit diagram P2

P1 T

926 B

254

Y257

T

P1 A

732

T

412 794-2 791 521 792

793

925 Y256 P1

794-1 408 T

B

T

A

P2

B123-2 Y255

253 P2

jag05-h-02a-1

136

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5 Feeder hydraulics Main drive, decelerated 3256

Fig.

792 253 791 925 Y256

Y255 794-2 B123-2

401985

793 Y257

926

521

254

Designations Item

Explanation

253

Feeder drive variable-displacement pump

254

Feeder drive motor

-

-

408

Orifice plate Ø 1.2 mm

412

Orifice plate Ø 2.0 mm

-

-

521

Quick stop accumulator

-

-

732

Non-return valve

791

Feeder quick stop valve

792

Multifunction valve, forward

793

Multifunction valve, reverse

794-1

Shut-off valve

794-2

Shut-off valve

-

-

925

Feeder drive measuring point

926

Feeder drive reverse measuring point

-

-

B1232

Hydraulic oil temperature sensor (overtemperature warning)

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137

5 Feeder hydraulics Main drive, decelerated 3256

Item

Explanation

-

-

P1

Working hydraulics oil pressure (also pre-loaded while diesel engine is OFF)

P2

Feed pressure

-

-

T

Return line to tank

-

-

Y255

Feeder drive pump adjustment solenoid valve

Y256

Main drive brake valve solenoid valve

Y257

Feeder quick stop solenoid valve

Description of function Braked main drive

When the main drive is shut down, solenoid coil (Y256) is not energized. The shut-off valve (794-1) is switched to its shut-off position by the oil pressure P1. Solenoid coil (Y255) is not energized, which makes the feed drive variable-displacement pump (253) swing to maximum displacement. The main drive is braked by the drive of this variable-displacement pump.

Pressurised working hydraulics

The working hydraulics circuit P1 remains pressurised even when the diesel engine is stopped. This pressure of this circuit may be relieved for service work. See circuit diagram and information provided in the "Overall hydraulic system" chapter.

138

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5 Feeder hydraulics Main drive ON 3256

Main drive ON

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139

5 Feeder hydraulics Main drive ON 3256

Circuit diagram P2

P1 T

926 B

254

Y257

T

P1 A

732

T

412 794-2 791 521 792

793

925 Y256 P1

794-1 408 T

B

T

A

P2

B123-2 Y255

253 P2

jag05-h-02a-2

140

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5 Feeder hydraulics Main drive ON 3256

Fig.

792 253 791 925 Y256

Y255 794-2 B123-2

401985

793 Y257

926

521

254

Designations Item

Explanation

253

Feeder drive variable-displacement pump

254

Feeder drive motor

-

-

408

Orifice plate Ø 1.2 mm

412

Orifice plate Ø 2.0 mm

-

-

521

Quick stop accumulator

-

-

732

Non-return valve

791

Feeder quick stop valve

792

Multifunction valve, forward

793

Multifunction valve, reverse

794-1

Shut-off valve

794-2

Shut-off valve

-

-

925

Feeder drive measuring point

926

Feeder drive reverse measuring point

-

-

B1232

Hydraulic oil temperature sensor (overtemperature warning)

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141

5 Feeder hydraulics Main drive ON 3256

Item

Explanation

-

-

P1

Working hydraulics oil pressure (also pre-loaded while diesel engine is OFF)

P2

Feed pressure

-

-

T

Return line to tank

-

-

Y255

Feeder drive pump adjustment solenoid valve

Y256

Main drive brake valve solenoid valve

Y257

Feeder quick stop solenoid valve

Description of function Main drive not braked

When the main drive is ON, solenoid coil (Y256) is energized. The shut-off valve (794-1) is not switched by the oil pressure P1. The blockage is canceled. The main drive is not braked.

Feed / Oil cooling

The feed oil pressure P2 serves for feeding the pump/motor hydraulic circuit via the multi-function valves (792/793). It also serves as variable-displacement oil pressure for variable-displacement pump (253). Oil cooling is achieved by constantly tapping oil into the variable-displacement pump housing via orifice plate (408).

Feed drive pumpapprox. 0displacement

Solenoid coil (Y255) is accordingly energized by 1200mA. This makes the feed drive variable-displacement pump (253) swing to the feeder operating mode, i.e. approx. 0 displacement. The feeder quick stop valve (791) blocks the return line from the feed drive motor (254). The feed drive is now braked.

142

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5 Feeder hydraulics Reversing 3256

Reversing

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143

5 Feeder hydraulics Reversing 3256

Circuit diagram P2

P1 T

926 B

254

Y257

T

P1 A

732

T

412 794-2 791 521 792

793

925 Y256 P1

794-1 408 T

B

T

A

P2

B123-2 Y255

253 P2

jag05-h-02a-3

144

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5 Feeder hydraulics Reversing 3256

Fig.

792 253 791 925 Y256

Y255 794-2 B123-2

401985

793 Y257

926

521

254

Designations Item

Explanation

253

Feeder drive variable-displacement pump

254

Feeder drive motor

-

-

408

Orifice plate Ø 1.2 mm

412

Orifice plate Ø 2.0 mm

-

-

521

Quick stop accumulator

-

-

732

Non-return valve

791

Feeder quick stop valve

792

Multifunction valve, forward

793

Multifunction valve, reverse

794-1

Shut-off valve

794-2

Shut-off valve

-

-

925

Feeder drive measuring point

926

Feeder drive reverse measuring point

-

-

B1232

Hydraulic oil temperature sensor (overtemperature warning)

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145

5 Feeder hydraulics Reversing 3256

Item

Explanation

-

-

P1

Working hydraulics oil pressure (also pre-loaded while diesel engine is OFF)

P2

Feed pressure

-

-

T

Return line to tank

-

-

Y255

Feeder drive pump adjustment solenoid valve

Y256

Main drive brake valve solenoid valve

Y257

Feeder quick stop solenoid valve

Discription of function Main drive not braked

When the main drive is ON, solenoid coil (Y256) is energized. The shut-off valve (794-1) is not switched by the oil pressure P1. The blockage is canceled. The main drive is not braked.

Front attachment drive disengaged Front attachment drive connected with feed drive

When reversing, the front attachment clutch solenoid coil (Y88) is not energized (the front attachment belt drive is disengaged). The front attachment reverse solenoid coil (Y86) is energized. This connects the front attachment drive and the feed drive mechanically with one another.

Feeder quick stop valve 791 in open position

The feeder quick stop solenoid valve (Y257) is energized. The feeder quick stop valve (791-1) is switched to its open position by the oil pressure P1.

Feed drive pump in reversing displacement by approx. 3°

Solenoid coil (Y255) is energized by PWM to the maximum. This makes the feed drive variable-displacement pump (253) swing to the reversing mode, approx. 3° reversing displacement. The feed drive motor (254) turns in reverse direction. The feeder and the front attachment are reversed together.

Multi-function valve (793) restricts the high pressure for the reversing process to 420 bar.

Feed / Oil cooling

The feed oil pressure P2 serves for feeding the pump/motor hydraulic circuit via the multi-function valves (792/793). It also serves as variable-displacement oil pressure for variable-displacement pump (253). Oil cooling is achieved by constantly tapping oil into the variable-displacement pump housing via orifice plate (408).

The tapping outlet from the pump/motor hydraulic circuit is opened by the shut-off valve (794-2).

146

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5 Feeder hydraulics Feeder OFF 3256

Feeder OFF

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147

5 Feeder hydraulics Feeder OFF 3256

Circuit diagram P2

P1 T

926 B

254

Y257

T

P1 A

732

T

412 794-2 791 521 792

793

925 Y256 P1

794-1 408 T

B

T

A

P2

B123-2 Y255

253 P2

jag05-h-02a-4

148

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5 Feeder hydraulics Feeder OFF 3256

Fig.

792 253 791 925 Y256

Y255 794-2 B123-2

401985

793 Y257

926

521

254

Designations Item

Explanation

253

Feeder drive variable-displacement pump

254

Feeder drive motor

-

-

408

Orifice plate Ø 1.2 mm

412

Orifice plate Ø 2.0 mm

-

-

521

Quick stop accumulator

-

-

732

Non-return valve

791

Feeder quick stop valve

792

Multifunction valve, forward

793

Multifunction valve, reverse

794-1

Shut-off valve

794-2

Shut-off valve

-

-

925

Feeder drive measuring point

926

Feeder drive reverse measuring point

-

-

B1232

Hydraulic oil temperature sensor (overtemperature warning)

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149

5 Feeder hydraulics Feeder OFF 3256

Item

Explanation

-

-

P1

Working hydraulics oil pressure (also pre-loaded while diesel engine is OFF)

P2

Feed pressure

-

-

T

Return line to tank

-

-

Y255

Feeder drive pump adjustment solenoid valve

Y256

Main drive brake valve solenoid valve

Y257

Feeder quick stop solenoid valve

Discription of function Main drive not braked

When the main drive is ON, solenoid coil (Y256) is energized. The shut-off valve (794-1) is not switched by the oil pressure P1. The blockage is canceled. The main drive is not braked.

Feed drive pumpapprox. 0displacement

Solenoid coil (Y255) is accordingly energized by 1200mA. This makes the feed drive variable-displacement pump (253) swing to the feeder operating mode, i.e. approx. 0 displacement. After a short delay time, the feeder quick stop solenoid valve (Y257) is de-energized. The feeder quick stop valve (791) now blocks the return line from the feed drive motor (254). The feed drive is now braked. The small oil flow that may still exist from the feed drive variabledisplacement pump is short-circuited (feed and return lines are connectedvia valve (791)).

Feed / Oil cooling

The feed oil pressure P2 serves for feeding the pump/motor hydraulic circuit via the multi-function valves (792/793). It also serves as variable-displacement oil pressure for variable-displacement pump (253). Oil cooling is achieved by constantly tapping oil into the variable-displacement pump housing via orifice plate (408).

150

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5 Feeder hydraulics Feeding 3256

Feeding

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151

5 Feeder hydraulics Feeding 3256

Circuit diagram P2

P1 T

926 B

254

Y257

T

P1 A

732

T

412 794-2 791 521 792

793

925 Y256 P1

794-1 408 T

B

T

A

P2

B123-2 Y255

253 P2

jag05-h-02a-5

152

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

5 Feeder hydraulics Feeding 3256

Fig.

792 253 791 925 Y256

Y255 794-2 B123-2

401985

793 Y257

926

521

254

Designations Item

Explanation

253

Feeder drive variable-displacement pump

254

Feeder drive motor

-

-

408

Orifice plate Ø 1.2 mm

412

Orifice plate Ø 2.0 mm

-

-

521

Quick stop accumulator

-

-

732

Non-return valve

791

Feeder quick stop valve

792

Multifunction valve, forward

793

Multifunction valve, reverse

794-1

Shut-off valve

794-2

Shut-off valve

-

-

925

Feeder drive measuring point

926

Feeder drive reverse measuring point

-

-

B1232

Hydraulic oil temperature sensor (overtemperature warning)

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153

5 Feeder hydraulics Feeding 3256

Item

Explanation

-

-

P1

Working hydraulics oil pressure (also pre-loaded while diesel engine is OFF)

P2

Feed pressure

-

-

T

Return line to tank

-

-

Y255

Feeder drive pump adjustment solenoid valve

Y256

Main drive brake valve solenoid valve

Y257

Feeder quick stop solenoid valve

Description of function Main drive not braked

When the main drive is ON, solenoid coil (Y256) is energized. The shut-off valve (794-1) is not switched by the oil pressure P1. The blockage is canceled. The main drive is not braked.

Feed drive pumpDisplacement according to the cutting length setpoint

Solenoid coil (Y255) is accordingly energized by PWM. This makes the feed drive variable-displacement pump (253) swing to the feeder mode, i.e. a displacement according to the pre-selected cutting length. The feeder quick stop solenoid valve (Y257) is energized. The feeder quick stop valve (791) is in its open position. Multi-function valve (792) restricts the high pressure for the feeding process to 420 bar.

Feed / Oil cooling

The feed oil pressure P2 serves for feeding the pump/motor hydraulic circuit via the multi-function valves (792/793). It also serves as variable-displacement oil pressure for variable-displacement pump (253). Oil cooling is achieved by constantly tapping oil into the variable-displacement pump housing via orifice plate (408).

When feeding, oil is flushed out of the pump / motor hydraulic circuit via the open shut-off valve (794-2).

154

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5 Feeder hydraulics Quick stop 3256

Quick stop

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155

5 Feeder hydraulics Quick stop 3256

Circuit diagram P2

P1 T

926 B

254

Y257

T

P1 A

732

T

412 794-2 791 521 792

793

925 Y256 P1

794-1 408 T

B

T

A

P2

Q0 Y255

B123-2

253 P2

jag05-h-02a-6

156

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

5 Feeder hydraulics Quick stop 3256

Fig.

792 253 791 925 Y256

Y255 794-2 B123-2

401985

793 Y257

926

521

254

Designations Item

Explanation

253

Feeder drive variable-displacement pump

254

Feeder drive motor

-

-

408

Orifice plate Ø 1.2 mm

412

Orifice plate Ø 2.0 mm

-

-

521

Quick stop accumulator

-

-

732

Non-return valve

791

Feeder quick stop valve

792

Multifunction valve, forward

793

Multifunction valve, reverse

794-1

Shut-off valve

794-2

Shut-off valve

-

-

925

Feeder drive measuring point

926

Feeder drive reverse measuring point

-

-

B1232

Hydraulic oil temperature sensor (overtemperature warning)

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157

5 Feeder hydraulics Quick stop 3256

Item

Explanation

-

-

P1

Working hydraulics oil pressure (also pre-loaded while diesel engine is OFF)

P2

Feed pressure

-

-

T

Return line to tank

-

-

Y255

Feeder drive pump adjustment solenoid valve

Y256

Main drive brake valve solenoid valve

Y257

Feeder quick stop solenoid valve

Description of function Main drive not braked

When the main drive is ON, solenoid coil (Y256) is energized. The shut-off valve (794-1) is not switched by the oil pressure P1. The blockage is canceled. The main drive is not braked.

Feeder quick stop

When the feeder quick stop function is triggered, e.g. by the metal or the stone detector, power supply to the feeder quick stop solenoid valve (Y257) is interrupted. The oil pressure of the pressurised working hydraulics sets the feeder quick stop valve (791) to its shut-off position. In this shut-off position, the oil flow from the feeder drive motor (254) is blocked. The oil flow from the feed drive variable-displacement pump is short-circuited (feed and return lines are connected via valve (791)).

Feed drive pumpapprox. 0displacement after a short delay time

After a short delay time, solenoid coil (Y255) is accordingly energized by 1200mA. This makes the feed drive variable-displacement pump (253) swing to the quick stop operating mode, i.e. approx. 0 displacement.

Feed / Oil cooling

The feed oil pressure P2 serves for feeding the pump/motor hydraulic circuit via the multi-function valves (792/793). It also serves as variable-displacement oil pressure for variable-displacement pump (253). Oil cooling is achieved by constantly tapping oil into the variable-displacement pump housing via orifice plate (408).

158

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6 Ground drive hydraulics Overall circuit diagram 3257

6 Ground drive hydraulics Overall circuit diagram

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

159

6 Ground drive hydraulics Overall circuit diagram 3257

Ground drive hydraulics circuit diagram

B123-1

807

Z46

413 F

796-1

796-2

102-1 B97 102-2

P

L

Ms

S (P)

520

714

211

109 19

B

L

205 E

31

14

255 246 706

713

313

716

P (S)

L1

11

218

719 Y144

Mp P

U

798

B98

721 758 210

355

A

738 907

908

L

Y142

Y141 110 Y143

jag05-h-10a

160

Z19

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

6 Ground drive hydraulics Overall circuit diagram 3258 6 Ground Overall circuit drivediagram hydraulics

Designations Item

Designation

Remark

B97

Drive hydraulics forward high-pressure sensor

Permanently transmits the ground drive forward pressure to the ground drive module (A49). This signal controls the motor rpm and the swivel angle of the ground drive variable displacement motor (210).

B98

Drive hydraulics backward high-pressure sensor

Permanently transmits the ground drive backward pressure to the ground drive module (A49). This signal controls the motor rpm and the swivel angle of the ground drive variable displacement motor (210).

B123

Hydraulic oil temperature sensor

Overtemperature warning.

-

-

-

F

Filling connection

for initial commissioning

-

-

-

Y141

Ground drive forward solenoid coil

The solenoid coil is actuated by the ground drive module (A49) in a modulated way.Solenoid coil actuated = modulated control pressure = forward. The magnetic force is opposed to the control pressure.

Y142

Ground drive backward solenoid coil

The solenoid coil is actuated by the ground drive module (A49) in a modulated way. Solenoid coil energised = modulated control pressure = reverse. The magnetic force is opposed to the control pressure.

Y143

Ground drive/cut off valve solenoid coil

The solenoid coil is actuated by the ground drive module (A49). It is permanently energised when the ignition (+15) is ON = the nonreturn valve is closed. In case of a panic braking (brake force > 600 N), Y143 is not energised = the control pressure for servo control is connected to the tank via the open non-return valve = the ground drive variable displacement pump (211) moves to zero displacement.

Y144

Ground drive variable displacement motor solenoid coil

The solenoid coil is actuated by the ground drive module (A49) in a modulated way and changes the swivel angle of the ground drive variable displacement motor (110).

-

-

-

Z19

Hydraulic oil level switch (min.)

Oil level OK = switch open

Z46

Low-pressure hydraulics switch / ground drive oil pressure

Monitors the pressure in the low-pressure hydraulics.Switch open = Oil pressure OK Switch closed = Oil pressure <12bar.

-

-

-

102

Pressure filter

10 µm

109

Hydraulic system oil cooler

-

110

Oil tank

-

205

Working hydraulics pump

-

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

161

6 Ground drive hydraulics Overall circuit diagram 3258

Item

Designation

Remark

210

Ground drive variable displacement motor

-

211

Ground drive variable displacement pump

-

218

Steering hydraulics pump

Volumetric displacement: 11 cm³/rev. Supplies volume flow for the steering system.

246

Cooling circuit pump

-

255

Ground drive / feeder feed pump

-

-

-

-

313

Ground drive servo control pump hydraulic cylinder

Controls the swivel angle of the ground drive variable displacement pump (211).

355

Ground drive servo control motor hydraulic cylinder

Controls the swivel angle of the ground drive variable displacement motor (210).

-

-

-

413

Orifice plate

Ø 2.2 mm, the low-pressure hydraulics and the suction drive motor are supplied via this orifice plate.

-

-

-

520

Feed pressure accumulator

10 bar

-

-

-

706

Pressure relief valve

3 bar

713

Ground drive multi-function valve backward

– Pressure limitation: 420 bar – Feed for recharging into the closed circuit (replacing the leakage losses)

714

Ground drive multi-function valve forward

– Pressure limitation: 420 bar – Feed for recharging into the closed circuit (replacing the leakage losses)

716

Ground drive feed pressure relief valve

Opening pressure 24 bar. Determines the feed pressure.

719

Ground drive tap pressure control valve

Starts opening at p = 10 bar

721

Ground drive oil tapping shuttle valve

Is actuated by the respective high-pressure circuit.

738

Ground drive servo control pilot valve

758

Ground drive restrictor valve

Restricts the pressure drop in the ground drive pump servo control hydraulic cylinder (313) in case of a panic braking.

796

Bypass valve filter

Δp=2 bar

798

Feed pressure relief valve

25 bar

162

– In basic position, 2 compressed springs hold it exactly in centre position.

– Is controlled by the control pressure generated by the solenoid coils (Y141 or Y142).

– Actuates the 4/3 way valve mechanically.

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

6 Ground drive hydraulics Overall circuit diagram 3258

Item

Designation

Remark

-

-

-

807

Line header

-

-

-

-

907

Ground drive hydraulics control pressure reverse measuring point

-

908

Ground drive hydraulics control pressure forward measuring point

-

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

163

6 Ground drive hydraulics Control 3258 Control

Ground drive control Mechanical zero position

As long as the ground drive variable displacement pump (211) is not driven, it is in neutral position due to the mechanical zero position.

The ground drive pump servo control hydraulic cylinder (313) is mechanically positioned in zero position by two pre-stressed compression springs, preventing the ground drive variable displacement pump (211) from providing volumetric displacement during the starting process.

Pre-condition: the ground drive forward (Y141) and backward (Y142) solenoid coils are not energised.

The setting of the mechanical zero position is carried out when installing the ground drive variable displacement pump (211) and cannot be modified from the outside.

Hydraulic zero position

When the ground drive variable displacement pump (211) is driven, it is kept in neutral position by means of hydraulic zero position.

Pre-condition: the ground drive forward (Y141) and backward (Y142) solenoid coils are not energised.

The feed pressure acts on both sides in the ground drive pump servo control hydraulic cylinder (313) via the centre position of the ground drive forward/ reverse servo control valve (738) and the ground drive restrictor valve (758) and centres it in neutral position.

At the same time, the ground drive restrictor valve (758) is switched from the restricted into the unrestricted position.

The setting of the hydraulic zero position is carried out on the Linde test bench.

Control motion

In the initial position, the solenoid coils (Y141, Y142) are not energised.

Solenoid coil (Y143) is energised.

The feed pressure is directed to the 2/2 way valves upstream of the restrictor.

The servo control supply pressure downstream of the restrictor actuates the 2/2-way valves to the through position. Due to this, feed pressure is applied to the non-actuated 4/2 way valves.

At the same time, the ground drive restrictor valve (758) is switched from the restricted into the unrestricted position by the servo control supply pressure.

The ground drive variable-displacement pump (211) is now in its hydraulic zero position.

Example:

E.g. when a current set by the electronic unit flows through the ground drive forward solenoid coil (Y141), a corresponding magnetic force is generated which actuates the 4/2 way solenoid valve proportionally.

A pressure is directed to the ground drive forward servo control valve (738) as a function of this actuation.

The valve moves by a corresponding path. The volume displaced from the opposite side flows into the tank via the 4/2 way solenoid valve (Y142).

Due to the mechanical coupling, the actuation of the ground drive forward/ backward servo control valve (738) results in a corresponding actuation of the 4/3 way valve.

This actuates the ground drive pump servo control hydraulic cylinder (313) which swivels the ground drive variable displacement pump (211) to the corresponding angle.

164

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6 Ground drive hydraulics Control 3258

When the electronic signal at the ground drive forward solenoid coil (Y141) is decreased, the proportional 4/2 way valve reduces the pressure to the ground drive forward/backward servo control valve (738) and the swivel angle of the ground drive variable displacement pump (211) becomes smaller.

Ground drive/cut off valve solenoid coil (Y143)

The ground drive/shut-off valve solenoid coil (Y143) is de-energised in case of a "panic braking" (pedal force >600 N) (see also Technical systems documentation - Electric system).

When the ground drive/cut off valve solenoid coil (Y143) is de-energized, the magnetic needle is retracted. The ball lifts off from its seat and relieves the servo control supply pressure towards the tank.

This switches the 2/2-way valves of solenoid coils (Y141 and 142) to the closed position and thus takes away the supply pressure to the proportional 4/2-way valves, so that these are set back to their initial position.

Since the servo control supply pressure applied at the ground drive forward/ backward servo control valve (738) collapses, the compressed springs move this valve to its neutral position.

The 4/3 way valve is moved to its centre position due to the mechanical link.

Switching off the ground drive/cut off valve solenoid coil (Y143) creates a pressure drop downstream and switches the ground drive restrictor valve (738) from the unrestricted to the restricted position.

This ensures smooth deceleration since the return time of the ground drive pump servo control hydraulic cylinder (313) is longer.

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165

6 Ground drive hydraulics Control 3258

166

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6 Ground drive hydraulics Variable-displacement pumpControl 3258

Variable-displacement pump

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167

6 Ground drive hydraulics Variable-displacement pumpControl 3258

168

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6 Ground drive hydraulics Variable-displacement pumpControl 3258

Fig.

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169

6 Ground drive hydraulics Variable-displacement pumpControl 3258

102-1 714

211 Y142 Y143 Y144

713

401908

807

Z46

413 F

102-1

796-1

B97 P

L

Ms

S (P)

520

714

211

19

205

11

218

31

14

255 246 706

713

313

716

P (S) Mp P

738 907

798

B98

758

908

L

Y141

Y142

110

402011

170

Y143

Z19

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6 Ground drive hydraulics Variable-displacement pumpControl 3258

Designations Item

Designation

Remark

B97

Drive hydraulics forward high-pressure sensor

Permanently transmits the ground drive forward pressure to the ground drive module (A49). This signal controls the motor rpm and the swivel angle of the ground drive variable displacement motor (210).

B98

Drive hydraulics backward high-pressure sensor

Permanently transmits the ground drive backward pressure to the ground drive module (A49). This signal controls the motor rpm and the swivel angle of the ground drive variable displacement motor (210).

-

-

-

F

Filling connection

for initial commissioning

-

-

-

P, S

Outputs to ground drive variable-displacement motor (210)

-

-

-

-

Y141

Ground drive forward solenoid coil

The solenoid coil is actuated by the ground drive module (A49) in a modulated way.Solenoid coil actuated = modulated control pressure = forward. The magnetic force is opposed to the control pressure.

Y142

Ground drive backward solenoid coil

The solenoid coil is actuated by the ground drive module (A49) in a modulated way. Solenoid coil energised = modulated control pressure = reverse. The magnetic force is opposed to the control pressure.

Y143

Ground drive/cut off valve solenoid coil

The solenoid coil is actuated by the ground drive module (A49). It is permanently energised when the ignition (+15) is ON = the nonreturn valve is closed. In case of a panic braking (brake force > 600 N), Y143 is not energised = the control pressure for servo control is connected to the tank via the open non-return valve = the ground drive variable displacement pump (211) moves to zero displacement.

-

-

-

Z19

Hydraulic oil level switch (min.)

Oil level OK = switch open

Z46

Low-pressure hydraulics switch / ground drive oil pressure

Monitors the pressure in the low-pressure hydraulics.Switch open = Oil pressure OK Switch closed = Oil pressure <12bar.

-

-

-

102

Pressure filter

10 µm

110

Oil tank

-

205

Working hydraulics pump

-

211

Ground drive variable displacement pump

-

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6 Ground drive hydraulics Variable-displacement pumpControl 3258

Item

Designation

Remark

218

Steering hydraulics pump

Volumetric displacement: 11 cm³/rev. Supplies volume flow for the steering system.

246

Cooling circuit pump

-

255

Ground drive / feeder feed pump

-

-

-

-

313

Ground drive servo control pump hydraulic cylinder

Controls the swivel angle of the ground drive variable displacement pump (211).

-

-

-

413

Orifice plate

Ø 2.2 mm, the low-pressure hydraulics and the suction drive motor are supplied via this orifice plate.

-

-

-

520

Feed pressure accumulator

10 bar

-

-

-

706

Pressure relief valve

3 bar

713

Ground drive multi-function valve backward

– Pressure limitation: 420 bar – Feed for recharging into the closed circuit (replacing the leakage losses)

714

Ground drive multi-function valve forward

– Pressure limitation: 420 bar – Feed for recharging into the closed circuit (replacing the leakage losses)

716

Ground drive feed pressure relief valve

738

Ground drive servo control pilot valve

758

Ground drive restrictor valve

Restricts the pressure drop in the ground drive pump servo control hydraulic cylinder (313) in case of a panic braking.

796

Bypass valve filter

Δp=2 bar

798

Feed pressure relief valve

25 bar

-

-

-

807

Line header

-

-

-

-

907

Ground drive hydraulics control pressure reverse measuring point

-

908

Ground drive hydraulics control pressure forward measuring point

-

172

Opening pressure 24 bar. Determines the feed pressure.

– In basic position, 2 compressed springs hold it exactly in centre position.

– Is controlled by the control pressure generated by the solenoid coils (Y141 or Y142).

– Actuates the 4/3 way valve mechanically.

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6 Ground drive hydraulics Variable-displacement motorControl 3258

Variable-displacement motor

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173

6 Ground drive hydraulics Variable-displacement motorControl 3258

174

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6 Ground drive hydraulics Variable-displacement motorControl 3258

Fig.

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175

6 Ground drive hydraulics Variable-displacement motorControl 3258

210

401952

210

A B Y144

B

L

E L1

719

U

Y144 721

210

355

A 402012

176

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6 Ground drive hydraulics Variable-displacement motorControl 3258

Designations Item

Designation

Remark

210

Ground drive variable displacement motor

-

-

-

-

355

Ground drive servo control motor hydraulic cylinder

Controls the swivel angle of the ground drive variable displacement motor (210).

-

-

-

719

Ground drive tap pressure control valve

Starts opening at p = 10 bar

721

Ground drive oil tapping shuttle valve

Is actuated by the respective high-pressure circuit.

-

-

-

Y144

Ground drive variable displacement motor solenoid coil

is energised by the ground drive module (A49) and changes the swivel angle of the ground drive variable-displacement motor (210).

-

-

-

A

Port.

Volume flow generates counterclockwise rotation.

B

Port.

Volume flow generates clockwise rotation.

Description of function In its initial position, the ground drive variable displacement motor (210) is always set to maximum input volume and is adjusted continuously towards the minimum input volume. This adjustment is electro-hydraulical and proportional to the actuation current of (Y144).

When the ground drive variable displacement motor solenoid coil (Y144) is not energised, the control pressure, via port (E), acts in the rod space of hydraulic cylinder (355) which positions the ground drive variable displacement motor (210) to maximum input volume. When the ground drive variable displacement motor solenoid coil (Y144) is energised, this current creates a proportional magnetic force which moves the spool and counteracts the spool spring. A control pressure is accordingly directed into the piston top space of hydraulic cylinder (355) which controls the swivel angle of the ground drive variable displacement motor (210) towards minimum input volume.

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6 Ground drive hydraulics High-pressure sensor (B97, B98)Control 3258

High-pressure sensor (B97, B98) Fig.

102

B98

Designations Item

Designation

Remark

B98

Drive hydraulics backward high-pressure sensor

The drive hydraulics forward high-pressure sensor (B97) is installed on the opposite side.

102

Pressure filter

-

Description of function The ground drive hydraulics forward (B97) and backward (B98) highpressure sensors are installed in the pressure outlets of the ground drive variable displacement pump (211).The ground drive hydraulics forward highpressure sensor B97 permanently transmits the ground drive pressure to the ground drive module (A49). This signal controls the motor rpm and the swivel angle of the ground drive variable displacement motor (210).The ground drive hydraulics backward high-pressure sensor B98 permanently transmits the ground drive pressure to the ground drive module (A49). This signal controls the motor rpm and the swivel angle of the ground drive variable displacement motor (210).

178

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6 Ground drive hydraulics Testing and measurementsControl 3258

Testing and measurements Pressure testing with the high-pressure sensors (B97, B98), pressure display in the CIS terminal.

Fig.

B98

B97

401970 B97: Volt display of ground drive hydraulics forward high-pressure sensor (B97) B98: Volt display of ground drive hydraulics reverse high-pressure sensor (B98)

High-pressure sensors measured value table (B97, B98) Pressure (bar)

Voltage (Volt)

0

0.2 – 0.3

20

0.4

30

0.4 – 0.5

40

0.5 – 0.6

100

1.0

200

1.7 – 1.8

300

2.5

400

3.2 – 3.3

420

3.4

440

3.5

450

3.6

460

3.7

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6 Ground drive hydraulics Testing and measurementsControl 3258

Functional check Sensors

With the engine shut off and vehicle brakes applied: – Switch on the ignition – Set cursor in the CIS to the ground speed control lever symbol (see Operator's Manual).

The CIS displays 0.2 – 0.3 Volt on the measuring values displays (B97) and (B98) which corresponds to a sensor display of 0 bar. (see table).

Measuring pre-conditions for pressure tests: Pressure fed into the highpressure circuit

Set cursor in CIS to the ground speed control lever symbol (see Operator's Manual). Pressure measurements are carried out at minimum motor speed and at an oil temperature of 45 – 50 °C. – Ground speed control lever in normal position – Gearbox in neutral position Set value: 20+4 bar. See high-pressure sensors measured value table (B97, B98).

High pressure measurement

– – – – –

Engage 2 nd gear apply parking brake.

Move ground speed control lever slowly forward or backward to half the end position for a maximum of 5 seconds.

Set value: 420 ... 460 bar max.. See high-pressure sensors measured value table (B97, B98).

Note

During the high-pressure measurement, the pump is in limiting mode (maximum pressure control). The Volt display in the CIS varies, the highest value being decisive for the measurement.

Set value: 420 ... 460 bar max..

See high-pressure sensors measured value table (B97, B98).

During this measurement, the value on the corresponding low-pressure side must not fall below 20 bar (see measured value table).

180

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7 Compressed-air system Trailer brake system 3259

7 Compressed-air system Trailer brake system

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181

7 Compressed-air system Trailer brake system 3259

Circuit diagram

9

6

16 7

3a 0

2

1

2

3

1

20 L

2

1

4

2

2

1

1

5

1 42

8

1

4 2

a

13

41

2

17

18

2 1

2 4 6

11 3b

12 1

2

1

2

15 10

14

20 L

b 5 401746

Key to diagram Item

Component

1

Compressor (350 – 380 cm³)

2

Pressure control valve (12.5 bar)

3a

Air accumulator (20 litres)

3b

Air accumulator (20 litres)

4

Frost protection pump

5

Dewatering valve (automatic)

6

Pressure gauge (10 bar) in the cab

7

Pressure relief valve (8 bar)

8

Trailer control valve (2-wire)

9

Accumulator service line hose coupler (red)

10

Brake service line hose coupler (yellow)

11

Safety valve (14 bar)

12

Relief valve (8.5 bar)

13

Relief valve (6 bar)

182

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7 Compressed-air system Trailer brake system 3259

Item

Component

14

Compressed-air coupling

15

Solenoid valve (proportional) Y100-1

16

Pressure gauge (16 bar)

17

Solenoid valve (4/2-way) Y100-2

18

Shuttle valve

-

-

a

Brake pressure input (service brake)

b

Engine brake connection (depending on equipment fitted)

Description of function Compressor (1)

The compressor is permanently driven by the diesel engine and conveys compressed air into the system.

– – – –

Accumulator coupler head (red) (9) Trailer control valve (8) Solenoid valve Y100-1 (15), connection 1 Solenoid valve Y100-2 (17), connection 1

Pressure control valve (2)

Determines the operating pressure in the compressed-air system.

Frost protection pump (4)

Automatic injection of antifreezing agent into the brake system to protect it against freezing of tubes and downstream components.

Dewatering valve (5)

Automatic draining of condensate from the air accumulator.

Pressure gauge (6)

Displays the pressure in the accumulator circuit (target value = 8 bar).

Pressure relief valve (7)

Limits the pressure (output 2) in the accumulator circuit to 8 bar. This pressure is applied to the following components:

Trailer control valve (8)

The trailer control valve is actuated hydraulically by the liquid pressure in the service brake system (ports 41 and 42).

– Actuation starts at 8 bar of liquid pressure in the service brake system.

– Full actuation at 35 bar of liquid pressure in the service brake system.

Depending on the actuation, compressed air (output 2) is transported to solenoid valve (15), input 4, via the shuttle valve (18).

Accumulator coupler head (9)

A pressure of 8 bar is constantly applied here.

Brake coupler head (10)

Connection of brake line between tractor and trailer (8 bar max.)

Safety valve (11)

Safeguards the compressed air system at 14 bar.

Overflow valve (12)

Safeguards the pressure in the air accumulator (3b) at 8.5 bar min.

Overflow valve (13)

Safeguards the pressure in the air accumulator (3a) at 6 bar min.

Compressed-air coupler (14)

Port for external compressed-air consumers (cleaning, tyres, …)

Solenoid valve Y100-1 (15)

Governs the building-up of pressure at the service line hose coupler (10) while braking.It is actuated: 1 pneumatically = by the actuation pressure from the trailer brake valve (8) or by solenoid valve Y100-2 (17) 2 electrically = by the signal generated upon pulling back (decelerating) the ground speed control lever

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183

7 Compressed-air system Trailer brake system 3259

Pressure gauge (16)

Displays the pressure in the air accumulator (target value = 12.5 bar).

Solenoid valve Y100-2 (17)

For braking, this valve passes the applied pressure of 8 bar (port 1) on to solenoid valve (15), port 4.

– No electrical triggering of solenoid valve (17): The passage from port 1 to port 2 is open when: - the ignition is OFF - and/or the parking brake is actuated.

– Electrical triggering of solenoid valve (17): The passage from port 1 to port 2 is closed when: - the ignition is ON - and/or the parking brake is not actuated.

Shuttle valve (18)

Directs the pressure to solenoid valve Y100-1(15), port 4. This is done either – from the trailer control valve (8), connection 2 or – from solenoid valve (17=Y100-2, connection 2).

184

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7 Compressed-air system Trailer brake system 3259

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185

7 Compressed-air system Engine restrictor / Compressed-air coupling 3259

Engine restrictor / Compressed-air coupling Circuit diagram

16

11 3b

0

2

1

2

3

1

2

12 1

2

14

20 L

b 1

4

2

5

401747

Key to diagram Item

Component

1

Compressor (350 – 380 cm³)

2

Pressure control valve (12.5 bar)

3b

Air accumulator (20 litres)

4

Frost protection pump

5

Dewatering valve (automatic)

11

Safety valve (14 bar)

12

Relief valve (8.5 bar)

13

Relief valve (6 bar)

14

Compressed-air coupling

16

Pressure gauge (16 bar)

-

-

b

Engine brake port (depending on equipment fitted)

186

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7 Compressed-air system Engine restrictor / Compressed-air coupling 3259

Description of function Compressor (1)

The compressor is permanently driven by the diesel engine and conveys compressed air into the system.

Pressure control valve (2)

Determines the operating pressure in the compressed-air system.

Frost protection pump (4)

Automatic injection of antifreezing agent into the brake system to protect it against freezing of tubes and downstream components.

Dewatering valve (5)

Automatic draining of condensate from the air accumulator.

Safety valve (11)

Safeguards the compressed air system at 14 bar.

Overflow valve (12)

Safeguards the pressure in the air accumulator (3b) at 8.5 bar min.

Compressed-air coupler (14)

Port for external compressed-air consumers (cleaning, tyres, …)

Pressure gauge (16)

Displays the pressure in the air accumulator (target value = 12.5 bar).

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187

7 Compressed-air system Engine restrictor / Compressed-air coupling 3259

188

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8 Location of components Overview 3260

8 Location of components Overview Individual components

8 r 22

7 o 21

109 102-1

401907

7 r 19

401957

8 r 20

110

401954

6 j 22

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

205

401914

10 h 20

189

8 Location of components Overview 3260

206 210

401945

401952

8 r 21

8 r 20

218 211 401915

401913

7 j 21

8 r 20

228

246

401939

9 d 21

190

401911

9 d 21

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

8 Location of components Overview 3260

253

254 401930

401923

8 r 20

255

401912

10 l 19

3 t 21

303 302 402014

4 i 21

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

401947

8 p 23

191

8 Location of components Overview 3260

317 304

401946

401940

9 e 19

11 d 19

340

352

402015

401942

12 e 23

10 i 22

359 353

402016

402013

8 p 23

192

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

8 Location of components Overview 3260

441

401941

7 l 23

11 i 23

501

511

401893

401950

9 d 21

8 e 21

609

521 401927

11 i 23

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

401944

7 m 23

193

8 Location of components Overview 3260

612 614 401951

401921

7 l 23

7 m 23

703 617

401896

401918

7 m 23

8 r 22

707 P1

713 401920

8 r 22

194

401963

7 o 22

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8 Location of components Overview 3260

714

729 401962

401878

9 d 21

9 d 21

791

401932

792

401931

9 d 21

9 d 21

794-2

793 401926

8 d 25

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

401935

8 r 20

195

8 Location of components Overview 3260

807

801

401938

401909

7 m 23

8 p 24

901 909

401919

401958

7 o 22

9 d 21

925

910 401879

401933

9 d 21

196

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8 Location of components Overview 3260

926 401924

10 g 19

7 l 23

B5

B2 401956

401900

9 r 20

B98

402017

9 r 20

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

9 d 21

197

8 Location of components Overview 3260

B123-1 B123-2 401953

7 o 22

401928

7 l 23

Y2 Y1 401883

7 l 23

401895

7 l 23

Y5

Y3

401898

7 l 23

198

401897

7 l 23

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

8 Location of components Overview 3260

Y6

Y7

401894

401899

8 r 23

8 r 23

Y26

Y59

401960

401959

7 o 22

7 m 23

Y61

Y60 401881

7 m 23

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

401905

7 m 23

199

8 Location of components Overview 3260

Y62 Y72

401903

401906

7 m 23

7 o 23

Y77

Y73

401904

401916

7 o 23

7 o 22

Y85

Y86 401917

7 o 23

200

401882

7 o 22

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8 Location of components Overview 3260

Y88

Y87 401922

7 m 23

401880

7 m 23

Y93

401901

8 r 20

Y94

401902

9 d 21

Y142 Y143 Y255

Y141 401908

9 d 21

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

401929

9 d 21

201

8 Location of components Overview 3260

Y256

Y257 401934

401925

7 r 19

8 r 22

Z46

Z19

401955

401910

8 e 23

8 e 23

Z53 303

Z52 401949

202

401948

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

8 Location of components Overview 3261 8 Location of components

Overview

Figures

a b c d e f g h i j k l m n o p q r s t u v

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

1 2 3 4 5 6 7 8 9 10 11 12 13 14 a b c d e f g h i j k l m n o p q r s t u v

15 16 17 18 19 20 21 22 23 24 25 26 27 401845

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

15 16 17 18 19 20 21 22 23 24 25 26 27 a b c d e f g h i j k l m n o p q r s t u v

203

8 Location of components Overview 3261

204

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

3248

Index A Accumulator 57 Activating pitching dampening 85 Additional control unit 1 65 Additional control unit 2 65 Autopilot 29

B Balance screw 11, 19

C Circuit diagram Ground drive hydraulics 158 Low-pressure hydraulic system 90 Steering with Autopilot 26 Steering without Autopilot 22 Working hydraulics 46 Component grid 201 Compressed-air coupling 184 Corn cracker 69 Adjusting and venting 71

D Diesel engine Tier 2 5 Direct Disc 81 Discharge flap 57

E Emergency steering 41 Engine restrictor 184

F Flow control valve 55 Front attachment Lower - quickly 55 Lower - slowly 55 Raise - quickly 54 Raise - slowly 54 Front attachment load changeover 77

G Ground drive hydraulics Testing and measurements 177

H Hitch 61 Hydraulic cylinder Shifter rail lock 105

K Knife support 121 Extending 123 Retracting 123 Knife support valve cylinder 121

L Learning the centre pitching axis 85

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

205

3248

Line header 117 Load changeover 77 Location of components 187 Low pressure hydraulic system All-wheel drive valve block 93 Cover valve block 93 Front attachment clutch 93 Main drive valve block 97 Reverse front attachment 93 Servo gearshift valve block 93 Low-pressure hydraulic system Pressure relief valve 101

M Main valve 51 Master valve 51, 54 Measurements 42, 125, 177 Measuring point Steering hydraulics 43 Measuring pre-condition 127 Measuring pre-conditions 88

P Pitching dampening 84 Operation 85 Position of components 201 Pressure accumulator volume switch-over 81 Pressure relief valve 54, 101 Pulse width modulation (PWM) 55

R Raise / lower front attachment 51

S Sensor Feed rake conveyor position 86 Ground pressure oil pressure 86 Sensors 86 Sharpening 65 Steering Actuated 41 Emergency steering 41 Function diagram 33 Function diagram, actuated by steering 39 Layout of valve unit 36 Measuring point 43 neutral 36 Non reaction 35 Open centre 35 Pre-conditions for measuring 35, 43 Pressure measurement 35, 43 Reaction 44 Resetting 44 with Autopilot 25 without Autopilot 21 Steering force 44 Steering gear shaft 44 Steering hydraulics Testing and measurements 42

206

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

3248

Suction arm drive 109, 113 Suction arm drive flow control valve 109 Suction arm drive motor 113

T Testing and measurements 42, 125, 177 Testing the steering system 44 Trailer brake system 179

U Upper discharge chute 57 Upper discharge chute rotation drive motor 73

V Valve block All-wheel drive low pressure hydraulic system 93 Autopilot 29 Cover low pressure hydraulic system 93 Front attachment clutch low pressure hydraulic system 93 Main drive low pressure hydraulic system 97 Reverse front attachment low pressure hydraulic system 93 Servo gearshift low pressure hydraulic system 93 Venting 108 Venting the steering system 44

W Working hydraulics 46 11, 19 Measuring pre-conditions 88

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

207

3248

208

000 293 892 1 - SYS-H JAGUAR 493 - 03/06

3262

Following the policy of CLAAS KGaA mbH to improve their products as technical developments continue, CLAAS reserve the right to make alterations which must not necessarily correspond to text and illustrations contained in this publication, and without incurring obligation to alter any machines previously delivered.

Technical data, dimensions and weights are given as an indication only. Responsibility for errors and omissions not accepted.

Reproduction or translation of this publication, in whole or in part, is not permitted without the written consent of 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

000 293 892 1 SYS-H JAGUAR 493 EN - 03/06 Printed in Germany