CLAAS JAGUAR 900 - 830 JAGUAR 900 - 830 PROFISTAR JAGUAR 900 - 830 SPEEDSTAR Hydraulic& Technical

JAGUAR 900 - 830 JAGUAR 900 - 830 PROFISTAR JAGUAR 900 - 830 SPEEDSTAR* (*with Electro-Hydraulic Ground Drive)

Technical Systems Hydraulic System

JAGUAR

TIC

Jag-h

11/04

TIC

JAGUAR

Chapter 1 Overall hydraulic system..................................................... 1-1 2 Steering hydraulics.............................................................. 2-1 3 Working hydraulics.............................................................. 3-1 4 Low-pressure hydraulics..................................................... 4-1 5 Ground drive hydraulics...................................................... 5-1 6 Float position ....................................................................... 6-1 7 Compressed-air system ...................................................... 7-1 Index................................................................................. index-1

11/04

Jag-h

JAGUAR

TIC

Jag-h

11/04

TIC

JAGUAR

1. Overall Hydraulic System

1 Overall hydraulic system

1.1

Hydraulic circuit diagrams......................................... 1-4

1.1.1 1.1.2

JAGUAR 20/25km/h from serial no. 492 01614........ 1-4 JAGUAR 20/25km/h from serial no. 492 00133 – 492 01613 .................. 1-10 JAGUAR 20/25km/h km/h from serial no. 492 00011 – 492 00132 .................. 1-16 JAGUAR SPEEDSTAR/PROFISTAR with electro-hydraulic ground drive (EFA) ...................... 1-22

1.1.3 1.1.4

11/04

1.2

Valve inserts............................................................ 1-26

1.2.1 1.2.2

Overview of valve inserts ........................................ 1-26 Function of valve inserts ......................................... 1-27

Jag-h-Kap01

1-1

1. Overall Hydraulic System

1-2

JAGUAR

Jag-h-Kap01

TIC

11/04

1.1 Hydraulic circuit diagrams 1.1.1 JAGUAR 20/25 km/h - from serial no. 492 01614

1. Overall Hydraulic System 1.1 1.1.1

1-4

JAGUAR

TIC

Hydraulic circuit diagrams JAGUAR 20/25km/h from serial no. 492 01614

Jag-h-Kap01

11/04

TIC

JAGUAR

1. Overall Hydraulic System

Functional changes as compared with JAGUAR 20/25 km/h from serial no. 492 00133 - 492 01613 (see 1.1.2): the suction arm drive motor (228) runs permanently because it is supplied with oil directly from the line header (807). the line header (807) has been added. the front attachment clutch hydraulic cylinder (352) has been modified as from serial no. 1820, this eliminates the optional one-way restrictor valve 422 for RU. Item B2 B5 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10 Y26 Y29 Y30 Y60 Y61 Y62 Y72 Y73 Y77 Y85 Y86 Y87 Y88 Y93 Y94 Z19 Z20 Z46 Z47 Z52 Z53 102 104 107 109 110 112 205 206 209 210

11/04

Designation Ground pressure oil pressure sensor Working hydraulics oil pressure sensor 4-Trac (all-wheel drive) solenoid coil Discharge door close solenoid coil Discharge door far solenoid coil Upper discharge chute slow/fast rotation solenoid coil Upper discharge chute left rotation solenoid coil Upper discharge chute right rotation solenoid coil Upper discharge chute raise solenoid coil Upper discharge chute lower solenoid coil AUTOPILOT left solenoid coil AUTOPILOT right solenoid coil Main drive solenoid coil Raise hitch solenoid coil Lower hitch solenoid coil Cover solenoid coil Sharpening stone left movement solenoid coil Sharpening stone right movement solenoid coil Additional control valve 1 – A solenoid coil Additional control valve 1 – B solenoid coil Working hydraulics circulation shut-off valve solenoid coil Raise front attachment solenoid coil Reverse front attachment solenoid coil Lower front attachment solenoid coil Front attachment clutch solenoid coil Additional control valve 2 – A solenoid coil Additional control valve 2 – B solenoid coil Hydraulic oil level switch (min.)

Hydraulic oil temperature Low-pressure hydraulics/ground drive oil pressure actual value function switch Reverser drive end position actual value function switch Sharpening stone left movement oil pressure actual value function switch Sharpening stone right movement oil pressure actual value function switch Pressure filter Control pressure vent plug Oil drain Hydraulic system oil cooler Oil tank Return flow filter Working hydraulics pump Upper discharge chute rotation drive motor Ground drive feed pump Ground drive variable displacement motor

Jag-h-Kap01

Remark Sensor Sensor 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 2-step restrictor 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 2/2 way solenoid valve 2/3 way solenoid valve (PWM) 3/2 way solenoid valve 3/3 way solenoid valve (PWM) 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve Oil level OK, switch open Normally open contact Oil level OK, switch open Normally open contact Sharpening stone in parking position, switch open Sharpening stone in parking position, switch closed 10 µm

Sieve filter 19 cm³/rev. at n = 2890 rpm 160 cm³/rev.

22.5 cm³/rev. at n = 2890 rpm See ESIS

1-5

1. Overall Hydraulic System

JAGUAR

Item 211 218

Designation Ground drive variable displacement pump Steering hydraulics pump

226 228 233 302 303 304 313 317 323-1 323-3 332 333 340 341 351 352

Front attachment reverser drive motor Suction arm drive motor Silage additive pump All-wheel drive clutch hydraulic cylinder Discharge door hydraulic cylinder Upper discharge chute hydraulic cylinder Ground drive servo control pump hydraulic cylinder Main drive clutch hydraulic cylinder Steering hydraulics cylinder Steering hydraulics cylinder (all-wheel drive) Pick-up crop guard lift hydraulic cylinder Pick-up auger lift hydraulic cylinder Cover hydraulic cylinder Sharpening stone movement hydraulic cylinder Front attachment raise/lower hydraulic cylinder Front attachment clutch hydraulic cylinder

353 355 405 406 411 421 422

Front attachment reverse hydraulic cylinder Ground drive servo control motor hydraulic cylinder Orifice plate ∅ 0.6 mm Orifice plate ∅ 0.8 mm Orifice plate ∅ 1.8 mm Front attachment engage one-way restrictor valve Front attachment engage one-way restrictor valve

441 442 501 504 511 609 612 614 615 616 617 703 707 708 710 713 714 716 718 719 721 725 726 728 729 732 734 737

Rotary coupling Venturi meter Working hydraulics pre-pressurization accumulator Main drive clutch accumulator Front attachment relief accumulator Orbitrol steering unit rotary disc valve Front attachment load switch-over valve Front attachment lower flow control valve Ground drive direction control pressure valve Ground drive speed control pressure valve Working hydraulics pre-pressurization relief screw valve Working hydraulics pressure relief valve Pressure holding valve (non-return valve) Ground drive pressure cut-off valve Ground drive filter bypass valve Ground drive multifunction valve backward valve Ground drive multifunction valve forward valve Ground drive feed pressure relief valve Ground drive feed circuit cold weather starting valve Ground drive tap pressure control valve Ground drive oil tapping shuttle valve Steering double shock valve Steering pressure relief valve Anti-cavitation valve (non-return valve) Low-pressure hydraulics pressure relief valve Non-return valve Lock-up valve unit (non-return valve) Ground drive servo control motor speed valve

1-6

Jag-h-Kap01

TIC Remark See ESIS 8 cm³/rev. at n = 2890 rpm 11 cm³/rev. for JAGUAR with electronic ground drive 470 cm³/rev.

50 cm³/rev. actuated by oil pressure

actuated by oil pressure

new cylinder as from serial no.

1820

option for RU, is dropped as from serial no. 1820 0.75 l, pre-pressurized to 80 bar 0.075 l, pre-pressurized to 6 bar pre-pressurized to 40 bar OSPC 200 mechanically actuated mechanically actuated mechanically actuated mechanically actuated mechanically actuated 175+15 bar, hydraulically actuated hydraulically actuated hydraulically actuated ∆p = 2 bar, hydraulically actuated 420 bar, hydraulically actuated 420 bar, hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated

11/04

TIC

JAGUAR

1. Overall Hydraulic System

Item 738 742 743 790

Designation Ground drive servo control forward/backward valve Steering safety valve Pilot-controlled one way valve Suction arm drive flow control valve

804 807 901 902 903 908

Whole crop harvesting cutterbar quick release coupling Line header Working hydraulics measuring point Ground drive hydraulics high pressure backward measuring point Ground drive hydraulics high pressure forward measuring point Ground drive hydraulics control pressure forward measuring point Steering hydraulics measuring point Low-pressure hydraulics measuring point Minimess port

909 910

11/04

Jag-h-Kap01

Remark hydraulically actuated hydraulically actuated 2/2 way, hydraulically actuated Q = 2 l/min, hydraulically actuated

1-7

1. Overall Hydraulic System

1-8

JAGUAR

Jag-h-Kap01

TIC

11/04

1.1.2 JAGUAR 20/25 km/h - from serial no 492 00133 – 492 01613

1. Overall Hydraulic System 1.1.2

1-10

JAGUAR

TIC

JAGUAR 20/25km/h from serial no 492 00133 – 492 01613

Jag-h-Kap01

11/04

TIC

JAGUAR

1. Overall Hydraulic System

Functional changes as compared with JAGUAR 20/25 km/h from serial no. 492 00011-492 00132 (see 1.1.3): The ground drive control pressure shuttle valve (739) has been dropped.

The line installation in this area was modified accordingly.

Item B2 B5 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10 Y26 Y29 Y30 Y60 Y61 Y62 Y72 Y73 Y77 Y85 Y86 Y87 Y88 Y93 Y94 Z19 Z20 Z46 Z47 Z52 Z53 102 104 107 109 110 112 205 206 209 210

11/04

Designation Ground pressure oil pressure sensor Working hydraulics oil pressure sensor 4-Trac (all-wheel drive) solenoid coil Discharge door close solenoid coil Discharge door far solenoid coil Upper discharge chute slow/fast rotation solenoid coil Upper discharge chute left rotation solenoid coil Upper discharge chute right rotation solenoid coil Upper discharge chute raise solenoid coil Upper discharge chute lower solenoid coil AUTOPILOT left solenoid coil AUTOPILOT right solenoid coil Main drive solenoid coil Raise hitch solenoid coil Lower hitch solenoid coil Cover solenoid coil Sharpening stone left movement solenoid coil Sharpening stone right movement solenoid coil Additional control valve 1 – A solenoid coil Additional control valve 1 – B solenoid coil Working hydraulics circulation shut-off valve solenoid coil Raise front attachment solenoid coil Reverse front attachment solenoid coil Lower front attachment solenoid coil Front attachment clutch solenoid coil Additional control valve 2 – A solenoid coil Additional control valve 2 – B solenoid coil Hydraulic oil level switch (min.)

Hydraulic oil temperature Low-pressure hydraulics/ground drive oil pressure actual value function switch Reverser drive end position actual value function switch Sharpening stone left movement oil pressure actual value function switch Sharpening stone right movement oil pressure actual value function switch Pressure filter Control pressure vent plug Oil drain Hydraulic system oil cooler Oil tank Return flow filter Working hydraulics pump Upper discharge chute rotation drive motor Ground drive feed pump Ground drive variable displacement motor

Jag-h-Kap01

Remark Sensor Sensor 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 2-step restrictor 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 2/2 way solenoid valve 2/3 way solenoid valve (PWM) 3/2 way solenoid valve 3/3 way solenoid valve (PWM) 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve Oil level OK, switch open Normally open contact Oil level OK, switch open Normally open contact Sharpening stone in parking position, switch open Sharpening stone in parking position, switch closed 10 µm

Sieve filter 19 cm³/rev. at n = 2890 rpm 160 cm³/rev.

22.5 cm³/rev. at n = 2890 rpm See ESIS

1-11

1. Overall Hydraulic System

JAGUAR

Item 211 218

Designation Ground drive variable displacement pump Steering hydraulics pump

226 228 233 302 303 304 313 317 323-1 323-2 323-3 332 333 340 341 351 352 353 355 405 406 411 421 422 441 442 501 504 511 609

Front attachment reverser drive motor Suction arm drive motor Silage additive pump All-wheel drive clutch hydraulic cylinder Discharge door hydraulic cylinder Upper discharge chute hydraulic cylinder Ground drive servo control pump hydraulic cylinder Main drive clutch hydraulic cylinder Steering hydraulics cylinder Steering hydraulics cylinder (all-wheel drive) Steering hydraulics cylinder (all-wheel drive) Pick-up crop guard lift hydraulic cylinder Pick-up auger lift hydraulic cylinder Cover hydraulic cylinder Sharpening stone movement hydraulic cylinder Front attachment raise/lower hydraulic cylinder Front attachment clutch hydraulic cylinder Front attachment reverse hydraulic cylinder Ground drive servo control motor hydraulic cylinder Orifice plate ∅ 0.6 mm Orifice plate ∅ 0.8 mm Orifice plate ∅ 1.8 mm Front attachment engage one-way restrictor valve Front attachment engage one-way restrictor valve Rotary coupling Venturi meter Working hydraulics pre-pressurization accumulator Main drive clutch accumulator Front attachment relief accumulator Orbitrol steering unit rotary disc valve

612 614 615 616 617 703 707 708 710 713 714 716 718 719 721 725 726 728 729 732 734 737

Front attachment load switch-over valve Front attachment lower flow control valve Ground drive control pressure direction valve Ground drive control pressure speed valve Working hydraulics pre-pressurization relief screw valve Working hydraulics pressure relief valve Pressure holding valve (non-return valve) Ground drive pressure cut-off valve Ground drive filter bypass valve Ground drive multifunction valve backward valve Ground drive multifunction valve forward valve Ground drive feed pressure relief valve Ground drive feed circuit cold weather starting valve Ground drive tap pressure control valve Ground drive oil tapping shuttle valve Steering double shock valve Steering pressure relief valve Anti-cavitation valve (non-return valve) Low-pressure hydraulics pressure relief valve Non-return valve Lock-up valve unit (non-return valve) Ground drive servo control motor speed valve

1-12

Jag-h-Kap01

TIC Remark See ESIS 8 cm³/rev. at n = 2890 rpm 11 cm³/rev. for JAGUAR with electronic ground drive 470 cm³/rev.

50 cm³/rev. actuated by oil pressure

actuated by oil pressure Up to serial no. 492 01019 From serial no. 492 01020

optional RU 0.75 l, pre-pressurized to 80 bar 0.075 l, pre-pressurized to 6 bar pre-pressurized to 40 bar OSPC 250 up to 492 01019 OSPC 200 from 492 01020 OSPC 200 from 492 00133 USA mechanically actuated mechanically actuated mechanically actuated mechanically actuated mechanically actuated 175+15 bar, hydraulically actuated hydraulically actuated hydraulically actuated ∆p = 2 bar, hydraulically actuated 420 bar, hydraulically actuated 420 bar, hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated

11/04

TIC

JAGUAR

1. Overall Hydraulic System

Item 738 742 743 790

Designation Ground drive servo control forward/backward valve Steering safety valve Pilot-controlled one way valve Suction arm drive flow control valve

804 901 902 903 908

Whole crop harvesting cutterbar quick release coupling Working hydraulics measuring point Ground drive hydraulics high pressure backward measuring point Ground drive hydraulics high pressure forward measuring point Ground drive hydraulics control pressure forward measuring point Steering hydraulics measuring point Low-pressure hydraulics measuring point Minimess port

909 910

11/04

Jag-h-Kap01

Remark hydraulically actuated hydraulically actuated 2/2 way, hydraulically actuated Q = 2 l/min, hydraulically actuated

1-13

1. Overall Hydraulic System

1-14

JAGUAR

Jag-h-Kap01

TIC

11/04

1.1.3 JAGUAR 20/25 km/h - from serial no. 492 00011 – 492 00132

1. Overall Hydraulic System 1.1.3

1-16

JAGUAR

TIC

JAGUAR 20/25km/h km/h from serial no. 492 00011 – 492 00132

Jag-h-Kap01

11/04

TIC Item B2 B5 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10 Y26 Y29 Y30 Y60 Y61 Y62 Y72 Y73 Y77 Y85 Y86 Y87 Y88 Y93 Y94 Z19 Z20 Z46 Z47 Z52 Z53 102 104 107 109 110 112 205 206 209 210

11/04

JAGUAR Designation Ground pressure oil pressure sensor Working hydraulics oil pressure sensor 4-Trac (all-wheel drive) solenoid coil Discharge door close solenoid coil Discharge door far solenoid coil Upper discharge chute slow/fast rotation solenoid coil Upper discharge chute left rotation solenoid coil Upper discharge chute right rotation solenoid coil Upper discharge chute raise solenoid coil Upper discharge chute lower solenoid coil AUTOPILOT left solenoid coil AUTOPILOT right solenoid coil Main drive solenoid coil Raise hitch solenoid coil Lower hitch solenoid coil Cover solenoid coil Sharpening stone left movement solenoid coil Sharpening stone right movement solenoid coil Additional control valve 1 – A solenoid coil Additional control valve 1 – B solenoid coil Working hydraulics circulation shut-off valve solenoid coil Raise front attachment solenoid coil Reverse front attachment solenoid coil Lower front attachment solenoid coil Front attachment clutch solenoid coil Additional control valve 2 – A solenoid coil Additional control valve 2 – B solenoid coil Hydraulic oil level switch (min.)

Hydraulic oil temperature Low-pressure hydraulics/ground drive oil pressure actual value function switch Reverser drive end position actual value function switch Sharpening stone left movement oil pressure actual value function switch Sharpening stone right movement oil pressure actual value function switch Pressure filter Control pressure vent plug Oil drain Hydraulic system oil cooler Oil tank Return flow filter Working hydraulics pump Upper discharge chute rotation drive motor Ground drive feed pump Ground drive variable displacement motor

Jag-h-Kap01

1. Overall Hydraulic System Remark Sensor Sensor 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 2-step restrictor 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 2/2 way solenoid valve 2/3 way solenoid valve (PWM) 3/2 way solenoid valve 3/3 way solenoid valve (PWM) 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve Oil level OK, switch open Normally open contact Oil level OK, switch open Normally open contact Sharpening stone in parking position, switch open Sharpening stone in parking position, switch closed 10 µm

Sieve filter 19 cm³/rev. at n = 2890 rpm 160 cm³/rev.

22.5 cm³/rev. at n = 2890 rpm See ESIS

1-17

1. Overall Hydraulic System Item 211 218 226 228 233 302 303 304 313 317 323-1 323-2 332 333 340 341 351 352 353 355 405 406 411 421 422 441 442 501 504 511 609 612 614 615 616 617 703 707 708 710 713 714 716 718 719 721 725 726 728 729 732 734 737

1-18

JAGUAR

Designation Ground drive variable displacement pump Steering hydraulics pump Front attachment reverser drive motor Suction arm drive motor Silage additive pump All-wheel drive clutch hydraulic cylinder Discharge door hydraulic cylinder Upper discharge chute hydraulic cylinder Ground drive servo control pump hydraulic cylinder Main drive clutch hydraulic cylinder Steering hydraulics cylinder Steering hydraulics cylinder (all-wheel drive) Pick-up crop guard lift hydraulic cylinder Pick-up auger lift hydraulic cylinder Cover hydraulic cylinder Sharpening stone movement hydraulic cylinder Front attachment raise/lower hydraulic cylinder Front attachment clutch hydraulic cylinder Front attachment reverse hydraulic cylinder Ground drive servo control motor hydraulic cylinder Orifice plate ∅ 0.6 mm Orifice plate ∅ 0.8 mm Orifice plate ∅ 1.8 mm Front attachment engage one-way restrictor valve One-way restrictor valve Rotary coupling Venturi meter Working hydraulics pre-pressurization accumulator Main drive clutch accumulator Front attachment relief accumulator Orbitrol steering unit rotary disc valve Front attachment load switch-over valve Front attachment lower flow control valve Ground drive control pressure direction valve Ground drive control pressure speed valve Working hydraulics pre-pressurization relief screw valve Working hydraulics pressure relief valve Pressure holding valve (non-return valve) Ground drive pressure cut-off valve Ground drive filter bypass valve Ground drive multifunction valve backward valve Ground drive multifunction valve forward valve Ground drive feed pressure relief valve Ground drive feed circuit cold weather starting valve Ground drive tap pressure control valve Ground drive oil tapping shuttle valve Steering double shock valve Steering pressure relief valve Anti-cavitation valve (non-return valve) Low-pressure hydraulics pressure relief valve Non-return valve Lock-up valve unit (non-return valve) Ground drive servo control motor speed valve

Jag-h-Kap01

TIC Remark See ESIS 8 cm³/rev. at n = 2890 rpm 470 cm³/rev.

50 cm³/rev. actuated by oil pressure

actuated by oil pressure

optional RU 0.75 l, pre-pressurized to 80 bar 0.075 l, pre-pressurized to 6 bar pre-pressurized to 40 bar OSPC 250 mechanically actuated mechanically actuated mechanically actuated mechanically actuated mechanically actuated 175+15 bar, hydraulically actuated hydraulically actuated hydraulically actuated ∆p = 2 bar, hydraulically actuated 420 bar, hydraulically actuated 420 bar, hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated 21+1 bar hydraulically actuated hydraulically actuated hydraulically actuated

11/04

TIC Item 738 739 742 743 790 804 901 902 903 908 909 910

11/04

JAGUAR Designation Ground drive servo control forward/backward valve Ground drive control pressure shuttle valve Steering safety valve Pilot-controlled one way valve Suction arm drive flow control valve Whole crop harvesting cutterbar quick release coupling Working hydraulics measuring point Ground drive hydraulics high pressure backward measuring point Ground drive hydraulics high pressure forward measuring point Ground drive hydraulics control pressure forward measuring point Steering hydraulics measuring point Low-pressure hydraulics measuring point

Jag-h-Kap01

1. Overall Hydraulic System Remark hydraulically actuated hydraulically actuated 2/2 way, hydraulically actuated Q = 2 l/min, hydraulically actuated

Minimess port

1-19

1. Overall Hydraulic System

1-20

JAGUAR

Jag-h-Kap01

TIC

11/04

1.1.4 JAGUAR - JAGUAR SPEEDSTAR/PROFISTAR with electro-hydraulic ground drive (EFA)

1. Overall Hydraulic System 1.1.4

1-22

JAGUAR

TIC

JAGUAR SPEEDSTAR/PROFISTAR with electro-hydraulic ground drive (EFA)

Jag-h-Kap01

11/04

TIC Item B2 B5 B97 B98 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10 Y26 Y29 Y30 Y59 Y60 Y61 Y62 Y72 Y73 Y77 Y85 Y86 Y87 Y88 Y93 Y94 Y141 Y142 Y143 Y144 Z19 Z20 Z46 Z47 Z52 Z53 102 107 109 110 112 205 206 209 210

11/04

JAGUAR Designation Ground pressure oil pressure sensor Working hydraulics oil pressure sensor Drive hydraulics forward high-pressure sensor Drive hydraulics backward high-pressure sensor 4-Trac (all-wheel drive) solenoid coil Discharge door close solenoid coil Discharge door far solenoid coil Upper discharge chute slow/fast rotation solenoid coil Upper discharge chute left rotation solenoid coil Upper discharge chute right rotation solenoid coil Upper discharge chute raise solenoid coil Upper discharge chute lower solenoid coil AUTOPILOT left solenoid coil AUTOPILOT right solenoid coil Main drive solenoid coil Raise hitch solenoid coil Lower hitch solenoid coil Servo circuit solenoid coil Cover solenoid coil Sharpening stone left movement solenoid coil Sharpening stone right movement solenoid coil Additional control valve 1 – A solenoid coil Additional control valve 1 – B solenoid coil Working hydraulics circulation shut-off valve solenoid coil Raise front attachment solenoid coil Reverse front attachment solenoid coil Lower front attachment solenoid coil Front attachment clutch solenoid coil Additional control valve 2 – A solenoid coil Additional control valve 2 – B solenoid coil Ground drive forward solenoid coil Ground drive backward solenoid coil Ground drive/cut off valve solenoid coil Ground drive variable displacement motor solenoid coil Hydraulic oil level switch (min.)

Hydraulic oil temperature Low-pressure hydraulics/ground drive oil pressure actual value function switch Reverser drive end position actual value function switch Sharpening stone left movement oil pressure actual value function switch Sharpening stone right movement oil pressure actual value function switch Pressure filter Oil drain Hydraulic system oil cooler Oil tank Return flow filter Working hydraulics pump Upper discharge chute rotation drive motor Ground drive feed pump Ground drive variable displacement motor

Jag-h-Kap01

1. Overall Hydraulic System Remark Sensor Sensor 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 2-step restrictor 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 2/2 way solenoid valve 2/3 way solenoid valve (PWM) 3/2 way solenoid valve 3/3 way solenoid valve (PWM) 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve

Oil level OK, switch open Normally open contact Oil level OK, switch open Normally open contact Sharpening stone in parking position, switch open Sharpening stone in parking position, switch closed 10 µm

Sieve filter 19 cm³/rev. at n = 2890 rpm 160 cm³/rev.

22.5 cm³/rev. at n = 2890 rpm See ESIS

1-23

1. Overall Hydraulic System

JAGUAR

Item 211 218

Designation Ground drive variable displacement pump Steering hydraulics pump

226 228 233 302 303 304 313 317 323-1 323-3 332 333 340 341 351 352 353 355 359 405 406 413 421 441 442 501 504 511 609

Front attachment reverser drive motor Suction arm drive motor Silage additive pump All-wheel drive clutch hydraulic cylinder Discharge door hydraulic cylinder Upper discharge chute hydraulic cylinder Ground drive servo control pump hydraulic cylinder Main drive clutch hydraulic cylinder Steering hydraulics cylinder Steering hydraulics cylinder (all-wheel drive) Pick-up crop guard lift hydraulic cylinder Pick-up auger lift hydraulic cylinder Cover hydraulic cylinder Sharpening stone movement hydraulic cylinder Front attachment raise/lower hydraulic cylinder Front attachment clutch hydraulic cylinder Front attachment reverse hydraulic cylinder Ground drive servo control motor hydraulic cylinder Shifter rail locking Orifice plate ∅ 0.6 mm Orifice plate ∅ 0.8 mm Orifice plate ∅ 2.2 mm Front attachment engage one-way restrictor valve Rotary coupling Venturi meter Working hydraulics pre-pressurization accumulator Main drive clutch accumulator Front attachment relief accumulator Orbitrol steering unit rotary disc valve

612 614 617 703

Front attachment load switch-over valve Front attachment lower flow control valve Working hydraulics pre-pressurization relief screw valve Working hydraulics pressure relief valve

707 710

Pressure holding valve (non-return valve) Ground drive filter bypass valve

713 714 716 718 719 721 725 726 728 729 734

Ground drive multifunction valve backward valve Ground drive multifunction valve forward valve Ground drive feed pressure relief valve Ground drive feed circuit cold weather starting valve Ground drive tap pressure control valve Ground drive oil tapping shuttle valve Steering double shock valve Steering pressure relief valve Anti-cavitation valve (non-return valve) Low-pressure hydraulics pressure relief valve Lock-up valve unit (non-return valve)

1-24

Jag-h-Kap01

TIC Remark See ESIS 8 cm³/rev. at n = 2890 rpm 11 cm³/rev. for JAGUAR with electronic ground drive 470 cm³/rev.

50 cm³/rev. actuated by oil pressure

actuated by oil pressure

0.75 l, pre-pressurized to 80 bar 0.075 l, pre-pressurized to 6 bar pre-pressurized to 40 bar OSPC 200, mechanically actuated mechanically actuated mechanically actuated mechanically actuated 175+15 bar, hydraulically actuated hydraulically actuated ∆p = 2 bar, hydraulically actuated 420 bar, hydraulically actuated 420 bar, hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated

11/04

TIC

JAGUAR

Item 738 742 743 757 758 790

Designation Ground drive servo control forward/backward valve Steering safety valve Pilot-controlled one way valve Ground drive additional feed valve Ground drive restrictor valve Suction arm drive flow control valve

804 807 901 909 910 916

Whole crop harvesting cutterbar quick release coupling Line header Working hydraulics measuring point Steering hydraulics measuring point Low-pressure hydraulics measuring point Working hydraulics pump measuring point

11/04

Jag-h-Kap01

1. Overall Hydraulic System Remark hydraulically actuated hydraulically actuated 2/2 way, hydraulically actuated

Q = 2 l/min, hydraulically actuated

Minimess port

1-25

1. Overall Hydraulic System 1.2 1.2.1

JAGUAR

TIC

Valve inserts Overview of valve inserts

Valve inserts in the directional control valves Fig. A B

Item

Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y72 Y73 Y93 Y94

C

Y61 Y62

Designation

Remark

None Discharge door close solenoid 3/2 way coil solenoid valve Discharge door far solenoid coil 3/2 way solenoid valve Upper discharge chute 2-step slow/fast rotation solenoid coil restrictor Upper discharge chute left 3/2 way rotation solenoid coil solenoid valve Upper discharge chute right 3/2 way rotation solenoid coil solenoid valve Upper discharge chute raise 3/2 way solenoid coil solenoid valve Upper discharge chute lower 3/2 way solenoid coil solenoid valve Additional control valve 1 – A 3/2 way solenoid coil solenoid valve Additional control valve 1 – B 3/2 way solenoid coil solenoid valve Additional control valve 2 – A 3/2 way solenoid coil solenoid valve Additional control valve 2 – B 3/2 way solenoid coil solenoid valve Sharpening stone left movement solenoid coil Sharpening stone right movement solenoid coil

Marking at top None None

Marking at Order no. bottom 2 631 442.0 None 631 444.0

None

None

631 444.0

None

None

631 444.0

None

None

631 444.0

None

None

631 444.0

None

None

631 444.0

None

None

631 444.0

None

None

631 444.0

None

None

631 444.0

None

None

631 444.0

None

None

631 444.0

3

631 482.0

3

631 482.0

2 3/2 way solenoid valve 2 3/2 way solenoid valve

D

1

3

631 483.0

E

4

2

631 500.0

F

3

3

631 421.1

G

without shoulder

None

631 525.0

H

None

None

631 524.0

K – Ball V – pilot spool

Note: When disassembling or replacing a valve insert, the copper ring 094 001.0 must be replaced.

Some of the solenoid valve coil cores are equipped with a return spring in which case they are marked with an "F" on the face end. When performing repairs, these coil cores with return spring 213 030.1 may also be used for functions without return spring.

1-26

Jag-h-Kap01

11/04

TIC 1.2.2.

JAGUAR

1. Overall Hydraulic System

Function of valve inserts

Description of function

Some of the valve inserts used are listed below in order to make the differences between these inserts regarding their function on the machine clear.

631 444.0

This valve insert is designed as a spool-type seated valve and therefore closes the return line to the tank before the spherical seat is opened.

A positive overlap avoids both oil losses during the switch-over process and pressure peaks in the tank line which is important when operating accumulators.

In this valve, the stroke is limited by the solenoid which has the biggest force in its end position, thus delaying the switch-off time due to the residual magnetism.

Spherical seat 2.5 mm Spool 2.8 mm

631 482.0 Spherical seat 1.8 mm Conical seat 3.7 mm

11/04

This conical seat valve has a mechanical stop provided by the cone, preventing the solenoid from reaching its end position and ensuring that the valve cuts off very fast as compared to the spool-type seated valves.

In addition, the large conical seat in this valve has a pressure-limiting function.

The small spherical seat here acts as a restrictor and allows the valve to switch against relatively high pressure levels with a small current intensity.

Jag-h-Kap01

1-27

1. Overall Hydraulic System Pressure limitation

1-28

JAGUAR

TIC

The pressure limitation for this conical seat valve (631482.0) is set to approx. 120 bar. Setting is carried out by using a valve insert with a relatively large cross-section at the conical seat.

The hydraulic force acts on the valve insert and consequently also on the electromagnetic force.

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

Jag-h-Kap01

11/04

TIC

JAGUAR

2. Steering Hydraulic System

2 Steering hydraulics

11/04

2.1

Hydraulic circuit diagram..........................................................2-2

2.2

Function diagram of steering hydraulics ..................................2-4

2.2.1 2.2.2

Neutral .....................................................................................2-4 Steering actuation ....................................................................2-6

2.3

Checking the steering ..............................................................2-8

2.4

Autopilot solenoid valve .........................................................2-10

2.5

Testing and measurements ...................................................2-12

Jag-h-Kap02

2-1

2. Steering Hydraulic System 2.1

2-2

JAGUAR

TIC

Hydraulic circuit diagram

Jag-h-Kap02

11/04

TIC

JAGUAR

Item Y9 Y10 Y77 Y85 Y86 Y87 Z19 Z20 102 109 110 112 205 209 211 218

Designation AUTOPILOT left solenoid coil AUTOPILOT right solenoid coil Working hydraulics circulation shut-off valve solenoid coil Raise front attachment solenoid coil Reverse front attachment solenoid coil Lower front attachment solenoid coil Hydraulic oil level switch (min.)

Hydraulic oil temperature switch Pressure filter Hydraulic system oil cooler Oil tank Return flow filter Working hydraulics pump Ground drive feed pump Ground drive variable displacement pump Steering hydraulics pump

323-1 323-2 323-3 442 609

Steering hydraulics cylinder Steering hydraulics cylinder (all-wheel drive) Steering hydraulics cylinder (all-wheel drive) Venturi meter Orbitrol steering unit rotary disc valve

614 703 707 710 718 725 726 728 742 743 901 909

Front attachment lower flow control valve Working hydraulics pressure relief valve Pressure holding valve (non-return valve) Ground drive filter bypass valve Ground drive feed circuit cold weather starting valve Steering double shock valve Steering pressure relief valve Anti-cavitation valve (non-return valve) Steering safety valve Pilot-controlled one way valve Working hydraulics measuring point Steering hydraulics measuring point

Remark:

11/04

2. Steering Hydraulic System Remark 3/2 way solenoid valve 3/2 way solenoid valve 2/2 way solenoid valve 2/3 way solenoid valve (PWM) 3/2 way solenoid valve 3/3 way solenoid valve (PWM) Oil level OK, switch open Normally open contact 10 µm

Sieve filter 19 cm³/rev. at n = 2890 rpm 22.5 cm³/rev. at n = 2890 rpm 105 cm³/rev.

8 cm³/rev. at n = 2890 rpm 11 cm³/rev. for JAGUAR with electronic ground drive Up to serial no. 492 01019 From serial no. 492 01020 OSPC 250 up to 492 01019 OSPC 200 from 492 01020 OSPC 200 from 492 00133 USA mechanically actuated 175 +15 bar, hydraulically actuated hydraulically actuated ∆p = 2 bar, hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated 2/2 way, hydraulically actuated

In drawing H 2593.0, component 757 Ground drive additional feed valve is missing for JAGUAR SPEEDSTAR/PROFISTAR with electronic ground drive.

Jag-h-Kap02

2-3

2. Steering Hydraulic System 2.2 2.2.1

2-4

JAGUAR

TIC

Function diagram of steering hydraulics Neutral

Jag-h-Kap02

11/04

TIC

JAGUAR

Item 112 218 229 323-1 323-2 323-3 609

Designation Return flow filter Steering hydraulics pump Steering hydraulics proportioning pump Steering hydraulics cylinder Steering hydraulics cylinder (all-wheel drive) Steering hydraulics cylinder (all-wheel drive) Orbitrol steering unit rotary disc valve

725 726 728 742

Steering double shock valve Steering pressure relief valve Anti-cavitation valve (non-return valve) Steering safety valve

2. Steering Hydraulic System Remark Sieve filter 8 cm³/rev. at n = 2890 rpm

Up to serial no. 492 01019 From serial no. 492 01020 OSPC 250 up to 492 01019 OSPC 200 from 492 01020 OSPC 200 from 492 00133 USA hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated

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.

Designations:

O S P C 250 200 V 20

Pressure measurement:

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

Measuring preconditions: Steering hydraulics:

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

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).

– Orbit (Orbitrol) – Steering – Pump – Version – Oil displacement in cm³/rev.

– Oil displacement in cm³/rev.

– Valve block – Pressure setting of shock valves x10

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 neutral position, the oil is directed back to the tank through the nonreturn valve (742) 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).

11/04

Jag-h-Kap02

2-5

2. Steering Hydraulic System 2.2.2

2-6

JAGUAR

TIC

Steering actuation

Jag-h-Kap02

11/04

TIC

JAGUAR

2. Steering Hydraulic System

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 as a function of sense of rotation, path and speed to the piston or the piston rod side of the steering cylinder (323). Here, the displacing surface of the steering cylinder (323) is connected with the return line to the tank via the rotary disc (609).

As soon as there is no more steering motion, leaf springs bring the inner and outer rotary discs (609) back to 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 (742) 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) via nonreturn valve (728) to the other side through human power by driving the rotor (229).

11/04

Jag-h-Kap02

2-7

2. Steering Hydraulic System 2.3

JAGUAR

TIC

Checking the steering

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.

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.

Power

A pressure test at the steering hydraulics measuring port must show the value 150+15 bar.

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

Caution:

2-8

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.

Jag-h-Kap02

11/04

TIC

11/04

JAGUAR

Jag-h-Kap02

2. Steering Hydraulic System

2-9

2. Steering Hydraulic System 2.4

2-10

JAGUAR

TIC

Autopilot solenoid valve

Jag-h-Kap02

11/04

TIC Item A B P5 T Y9 Y10 K 734

JAGUAR Designation Port Port Port Port AUTOPILOT left solenoid coil AUTOPILOT left solenoid coil Piston Lock-up valve unit (non-return valve)

2. Steering Hydraulic System

Remark Autopilot left Autopilot right Pressure supply Return line Is activated to make Autopilot steer to the left Is activated to make Autopilot steer to the right Opens non-return valve mechanically

Autopilot – steering to the left

The working hydraulics circulation shut-off valve (Y 77) and the solenoid coil (Y 9) are actuated and open the ball via the pilot spool.

Oil flows from P5 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 (Y 10) and thus returns to the tank.

Autopilot – steering to the right

The working hydraulics circulation shut-off valve (Y 77) and the solenoid coil (Y 10) are actuated and open the ball via the pilot spool.

Oil flows from P5 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 (S) towards port (A) and opens the non-return valve (port A).

The oil coming from the cylinder return side flows via the open left nonreturn valve. The return flow lifts the pilot spool of the solenoid coil (Y 9) and thus returns to the tank.

Note:

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

Dimensions of copper ring: 14 x 8 x 1 mm.

11/04

Jag-h-Kap02

2-11

2. Steering Hydraulic System 2.5

JAGUAR

TIC

Testing and measurements

909 Steering hydraulics measuring point 442 Venturi meter Measuring pre-conditions: Steering hydraulics:

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

Set values:

Circulation pressure = 15+8 bar.

Maximum pressure = 167+15 bar.

2-12

Jag-h-Kap02

11/04

TIC

JAGUAR

3. Working Hydraulics

3 Working hydraulics

11/04

3.1

Hydraulic circuit diagram..........................................................3-4

3.2

Main valve: Circulation shut-off valve, front attachment raise/lower solenoid valve ............................3-8

3.3

Valve combination with accumulator .....................................3-12

3.4

Hitch solenoid valve ...............................................................3-14

3.5

Grinding, additional control unit 1, additional control unit 2 solenoid valve .................................3-16

3.6

Corn cracker adjustment........................................................3-18

3.7

Front attachment reverse solenoid valve (Y 86)....................3-22

3.8

Front attachment reverser drive motor (226).........................3-24

3.9

Upper discharge chute rotation drive motor (206) .................3-26

3.10

Front attachment load switch-over valve (612)......................3-28

3.11

Pressure accumulator volume switch-over valve (Direct Disc option) ................................................................3-30

3.12

Testing and measurements ...................................................3-32

Jag-h-Kap03

3-1

3. Working Hydraulics

3-2

JAGUAR

Jag-h-Kap03

TIC

11/04

3.1 Hydraulic circuit diagram

3. Working Hydraulics 3.1

3-4

JAGUAR

TIC

Hydraulic circuit diagram

Jag-h-Kap03

11/04

TIC Item B2 B5 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10 Y29 Y30 Y61 Y62 Y72 Y73 Y77 Y85 Y86 Y87 Y93 Y94 Z19 Z20 Z47 Z52

JAGUAR

107 110 112 205 206 209 211 218

Designation Ground pressure oil pressure sensor Working hydraulics oil pressure sensor Discharge door close solenoid coil Discharge door far solenoid coil Upper discharge chute slow/fast rotation solenoid coil Upper discharge chute left rotation solenoid coil Upper discharge chute right rotation solenoid coil Upper discharge chute raise solenoid coil Upper discharge chute lower solenoid coil AUTOPILOT left solenoid coil AUTOPILOT right solenoid coil Raise hitch solenoid coil Lower hitch solenoid coil Sharpening stone left movement solenoid coil Sharpening stone right movement solenoid coil Additional control valve 1 – A solenoid coil Additional control valve 1 – B solenoid coil Working hydraulics circulation shut-off valve solenoid coil Raise front attachment solenoid coil Reverse front attachment solenoid coil Lower front attachment solenoid coil Additional control valve 2 – A solenoid coil Additional control valve 2 – B solenoid coil Hydraulic oil level switch (min.)

Hydraulic oil temperature Reverser drive end position actual value function switch Sharpening stone left movement oil pressure actual value function switch Sharpening stone right movement oil pressure actual value function switch Oil drain Oil tank Return flow filter Working hydraulics pump Upper discharge chute rotation drive motor Ground drive feed pump Ground drive variable displacement pump Steering hydraulics pump

226 233 303 304 323 332 333 341 351 353 405 406 501 511 612 614 617

Front attachment reverser drive motor Silage additive pump Discharge door hydraulic cylinder Upper discharge chute hydraulic cylinder Steering hydraulics cylinder Pick-up crop guard lift hydraulic cylinder Pick-up auger lift hydraulic cylinder Sharpening stone movement hydraulic cylinder Front attachment raise/lower hydraulic cylinder Front attachment reverse hydraulic cylinder Orifice plate ∅ 0.6 mm Orifice plate ∅ 0.8 mm Working hydraulics pre-pressurization accumulator Front attachment relief accumulator Front attachment load switch-over valve Front attachment lower flow control valve Working hydraulics pre-pressurization relief screw valve

Z53

11/04

Jag-h-Kap03

3. Working Hydraulics Remark Sensor Sensor 3/2 way solenoid valve 3/2 way solenoid valve 2-step restrictor 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 2/2 way solenoid valve 2/3 way solenoid valve (PWM) 3/2 way solenoid valve 3/3 way solenoid valve (PWM) 3/2 way solenoid valve 3/2 way solenoid valve Oil level OK, switch open Normally open contact Normally open contact Sharpening stone in parking position, switch open Sharpening stone in parking position, switch closed

Sieve filter 19 cm³/rev.

160 cm³/rev.

22.5 cm³/rev.

See ESIS JAGUAR 20/25 km/h = 8 cm³/rev.

JAGUAR 40 km/h = 11 cm³/rev.

470 cm³/rev.

0.75 l. pre-pressurized to 80 bar pre-pressurized to 40 bar mechanically actuated mechanically actuated mechanically actuated

3-5

3. Working Hydraulics Item 703 707 734 743 804 901

3-6

JAGUAR

Designation Working hydraulics pressure relief valve Pressure holding valve (non-return valve) Lock-up valve unit (non-return valve) Pilot-controlled one way valve Whole crop harvesting cutterbar quick release coupling Working hydraulics measuring point

Jag-h-Kap03

TIC Remark 175+15 bar, hydraulically actuated hydraulically actuated hydraulically actuated 2/2 way, hydraulically actuated

11/04

TIC

11/04

JAGUAR

Jag-h-Kap03

3. Working Hydraulics

3-7

3. Working Hydraulics 3.2

3-8

JAGUAR

TIC

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

Jag-h-Kap03

11/04

TIC

JAGUAR

Designations

3. Working Hydraulics

A T P5a P5b G E F H K R U V

Output to front attachment load switch-over valve (612) Tank port Pump port Parallel port to other directional control valves Non-return valve (inlet valve) Pilot spool Compressed spring Front attachment raise spool Piston Control spool .......................................................5 – 50 l/min Circulation shut-off valve control spool Pilot valve

Y 77 Y 85 Y 87

Circulation shut-off valve solenoid coil Raise front attachment solenoid coil Lower front attachment solenoid coil

614

Front attachment lower flow control valve ....................................................... 5 – 50 l/min

703 901 743 707

Pressure relief valve ............................................180+15 bar Working hydraulics measuring port Front attachment lower valve Pressure holding valve (non-return valve)

Function description:

1/3

Pressure relief valve

The spring in the pressure relief valve (703) is pre-stressed for a system pressure of 180±15 bar. The pressure setting may be modified by removing or adding shims.

A 0.5 mm shim corresponds to approx. 10 bar A 1.2 mm shim corresponds to approx. 23 bar

Note:

Basic setting

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.

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 switch-over valve (612)).

11/04

Jag-h-Kap03

3-9

3. Working Hydraulics

JAGUAR

TIC

Function description::

2/3

Function of circulation shut-off valve

The circulation shut-off valve (Y 77) blocks the circulating volume flow from P5a to T of the open hydraulic system when a function has been actuated.

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.

When pressure must be built up for a consumer or if the working hydraulics pre-pressurization is not sufficient (on machines with accumulator 501), the circulation shut-off valve (Y 77) is actuated using the directional control valve of the corresponding function. Now spool (U) closes the connection from P5a 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+15 bar and relieves the pressure to the tank.

Function "Raise front attachment - slow"

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

The residual oil flows back to the tank via the pressure relief valve (703).

Function "Raise front attachment - fast"

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). 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

12V

Effektiv

6V

0V Lex-034

3-10

50%

50% 80Hz

Jag-h-Kap03

11/04

TIC

JAGUAR

3. Working Hydraulics

Function description:

3/3

Function "Lower front attachment - slow"

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.

Function "Lower front attachment - fast"

When the "Lower - fast" function is used, only the directional control valve (Y 87) is actuated with 12 V DC. 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. 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.

11/04

Jag-h-Kap03

3-11

3. Working Hydraulics 3.3

3-12

JAGUAR

TIC

Valve combination with accumulator

Jag-h-Kap03

11/04

TIC

JAGUAR

3. Working Hydraulics

Item A1 A2 B1 B2 B5 C1 C2 P5

Designation Port Port Port Port Working hydraulics oil pressure Port Port Port

T Y2 Y3 Y4

Port Discharge door close solenoid coil Discharge door far solenoid coil Upper discharge chute slow/fast rotation solenoid coil Upper discharge chute left rotation solenoid coil 3/2 way solenoid valve 3/2 way solenoid valve Upper discharge chute right rotation solenoid coil Upper discharge chute raise solenoid coil 3/2 way solenoid valve Upper discharge chute lower solenoid coil 3/2 way solenoid valve Orifice plate Ø 0.6 mm Orifice plate Ø 0.8 mm 0.75 l. pre-pressurized to 80 bar Working hydraulics pre-pressurization accumulator mechanically actuated Working hydraulics pre-pressurization relief screw valve

Y5 Y6 Y7 Y8 405 406 501 617

Function

Caution – Danger of accident

11/04

Remark Rotate upper discharge chute to the right Rotate upper discharge chute to the left Discharge door close Discharge door far Sensor Lower upper discharge chute Raise upper discharge chute Pressure supply under pressure by non-return valve (707) Return line to tank 3/2 way solenoid valve 3/2 way solenoid valve 2-step restrictor

The pressurized oil from port P5 is under pressure due to non-return valve (707) (see overall circuit diagram). Machines with Autopilot are equipped with the accumulator (501).

This accumulator prevents the circulation shut-off valve (Y 77) from being activated too frequently for small oil consumptions in rapid sequence from the pre-pressurized hydraulic circuit P5b (see Main valve) and avoids the resulting oil heat-up.

The applied oil pressure is monitored by the working hydraulics sensor (B 5) and reported to the module A9 "Autopilot".

If the oil pressure falls below 135 bar, module A9 activates the circulation shut-off valve Y 77 and deactivates it at 165 bar.

This pressurized oil is available at all working hydraulics solenoid valves except the front attachment raise and lower solenoid valves.

Prior to performing service work on the working hydraulics, the oil under pressure must be drained by unscrewing the relief screw (617).

For function and tasks of the solenoid coils please refer to the table.

Jag-h-Kap03

3-13

3. Working Hydraulics 3.4

3-14

JAGUAR

TIC

Hitch solenoid valve

Jag-h-Kap03

11/04

TIC

JAGUAR

Designations

3. Working Hydraulics

Y29 Y30 734

Raise hitch solenoid coil Lower hitch solenoid coil Lock-up valve unit (non-return valve)

T P5 A B K

Tank port Pump via circulation shut-off valve port Consumer port (see overall circuit diagram) Consumer port (see overall circuit diagram) Piston

Neutral function

Solenoid coils are not energized.

Both sides of the hydraulic cylinder are blocked tightly by the non-return valves (137) in the consumer ports A and B.

Funktion Arbeitsstellung

Solenoid coils are energized.

According to the required direction of motion, one of the solenoid valves and the working hydraulics circulation shut-off valve (Y 77) are actuated.

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 (137) 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 (137) at the opposite port and the hydraulic cylinders are retracted or extended.

Note:

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

Dimensions of copper ring: 14 x 8 x 1 mm.

11/04

Jag-h-Kap03

3-15

3. Working Hydraulics 3.5

3-16

JAGUAR

TIC

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

Jag-h-Kap03

11/04

TIC

JAGUAR

Designations

3. Working Hydraulics

Y61 Y62 Y72 Y73 Y93 Y94

Sharpening stone left movement solenoid coil Sharpening stone right movement solenoid coil Additional control valve 1 – A solenoid coil Additional control valve 1 – B solenoid coil Additional control valve 2 – A solenoid coil Additional control valve 2 – B solenoid coil

T P5 A B

Tank port Pump via circulation shut-off valve port Consumer port (see overall circuit diagram) Consumer port (see overall circuit diagram)

Explanation of function, using grinding as an example 0 position

None of the solenoid coils (Y 61 / Y 62) is energized. Ports (A) and (B) are connected to the tank (T).

Sharpening stone to the left

The circulation shut-off valve (Y 77) and the solenoid coil (Y 61) are actuated. The pilot spool of the solenoid coil (Y 61) opens the ball against the pressure in port (P5).

Volume flow flows from port (P5) via the ball to port (A) and continues to the left-hand 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 also overall circuit diagram)

Sharpening stone to the right (see also overall circuit diagram)

Pressure limitation

The pressure limitation for sharpening is set to approx. 120 bar. Setting is carried out by using a valve insert with a relatively large cross-section at the conical seat. The hydraulic force acts on the valve insert and consequently also on the electromagnetic force. Starting at a pressure of 120 bar, the conical seat in the valve insert opens because the electromagnetic force is not sufficient any more and the oil pressure is relieved to the tank.

Note:

11/04

The circulation shut-off valve (Y 77) and the solenoid coil (Y 62) are actuated and open the ball via the pilot spool. Oil flows from P5 via the ball to port B, continues to oil pressure switch Z 53 and to the right-hand connecting rod end of the sharpening stone 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.

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

Jag-h-Kap03

3-17

3. Working Hydraulics 3.6

3-18

JAGUAR

TIC

Corn cracker adjustment

Jag-h-Kap03

11/04

TIC Item A B a b c d e 356 R 356 L 230

JAGUAR Designation Figure Figure Port Port Port Piston Port Cylinder Cylinder Corn cracker adjustment pump

Adjusting and venting

Remark Cracker adjusting range (26 mm piston stroke) Venting range (piston on double pump overall length 231 mm) to left adjusting cylinder to right adjusting cylinder Filling port is turned in or out for cracker gap adjustment for venting the cracker gap adjustment Cracker gap adjustment, right Cracker gap adjustment, left Serves as a proportioning pump for cracker adjusting cylinder

Adjust minimum corn cracker gap at the corn cracker adjustment (double pump 230). Check the gap between the corn cracker rollers at the biggest diameter (with worn rollers), set value 0.5 mm.

Adjustment to be carried out at the stop bolts (S).

-

-

-

-

11/04

3. Working Hydraulics

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.

Jag-h-Kap03

3-19

3. Working Hydraulics

JAGUAR

TIC

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) Caution!

3-20

During operation, the clearance of the cracker rollers must absolutely not fall below the minimum clearance of 1 mm, i.e. the corn cracker clearance must not be set to less than 1 mm (manual and/or electrical).

Otherwise, the bolts (S) might get in contact and cause damage to the corn cracker.

Jag-h-Kap03

11/04

TIC

JAGUAR

3. Working Hydraulics

Notes::

11/04

Jag-h-Kap03

3-21

3. Working Hydraulics 3.7

3-22

JAGUAR

TIC

Front attachment reverse solenoid valve (Y 86)

Jag-h-Kap03

11/04

TIC Designations

JAGUAR

3. Working Hydraulics

Y86 Z47 226 353

Reverse front attachment solenoid coil Reverser drive end position Front attachment reverser drive motor Front attachment reverse hydraulic cylinder

T P5 A

Tank port Pump via circulation shut-off valve port Front attachment reverse hydraulic cylinder port

Neutral function

The spring force displaces the oil from the reverser cylinder (353) via the connection from A to T in the solenoid valve (Y 86) to the tank. Port (P5) is shut off.

Reversing function

Just before it reaches its end position is the volume flow totally released to the front attachment reverser drive motor (226) by the front attachment reverse hydraulic cylinder (353).

11/04

Jag-h-Kap03

3-23

3. Working Hydraulics 3.8

3-24

JAGUAR

TIC

Front attachment reverser drive motor (226)

Jag-h-Kap03

11/04

TIC Designations:

11/04

JAGUAR 226

3. Working Hydraulics

Front attachment reverser drive motor....................470 cm³/rev.

Jag-h-Kap03

3-25

3. Working Hydraulics 3.9

3-26

JAGUAR

TIC

Upper discharge chute rotation drive motor (206)

Jag-h-Kap03

11/04

TIC Key to diagram:

11/04

JAGUAR

3. Working Hydraulics

1 2 3 4 5

Housing Output shaft / distributor valve Cardan shaft Ring gear Gear

206

Upper discharge chute rotation drive motor ...........160 cm³/rev.

Jag-h-Kap03

3-27

3. Working Hydraulics 3.10

3-28

JAGUAR

TIC

Front attachment load switch-over valve (612)

Jag-h-Kap03

11/04

TIC Task:

JAGUAR

3. Working Hydraulics

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).

Designations

K R P6 T X

Figure A

Face end of cylinders Ø 75 mm Rod end of cylinders = (face end Ø 75 mm – cylinder rod surface Ø 50 mm) Pressurized oil from Front attachment raise/lower main valve.

Tank port return line Safety pin to avoid switching over under load, resulting in unwanted lowering of the front attachment.

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

Effective hydraulic pressure surface in the Front attachment raise/lower hydraulic cylinders (351): Face end minus rod end = cylinder rod surface Ø 50 mm.

Figure B

Switching position to allow actuating the Front attachment load switchover 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, 6-row 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.

11/04

Jag-h-Kap03

3-29

3. Working Hydraulics 3.11

3-30

JAGUAR

TIC

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

Jag-h-Kap03

11/04

TIC Key to diagram:

JAGUAR

3. Working Hydraulics

351 511 612 655

Raise/lower front attachment hydraulic cylinder Front attachment relief accumulator Front attachment load switch-over valve Pressure accumulator volume switch-over valve

B2 P P6 T

Downward force oil pressure sensor Pressurized oil Pressurized oil from Front attachment raise/lower main valve Tank port

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

11/04

To operate the accumulator volume switching-over (655), 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 lever of the accumulator volume switch-over valve (655) can be set to the other position.

Jag-h-Kap03

3-31

3. Working Hydraulics 3.12

JAGUAR

TIC

Testing and measurements

901 Working hydraulics measuring point

Measuring pre-conditions: Working hydraulics:

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 185+15 bar.

3-32

Jag-h-Kap03

11/04

TIC

JAGUAR

4. Low-pressure hydraulics

4 Low-pressure hydraulics

4.1

Hydraulic circuit diagram......................................................... 4-2

4.1.1 4.1.2

JAGUAR 20/25 km/h from serial no. 492 01614 .................... 4-2 JAGUAR 20/25 km/h from serial no. 492 00011 – 492 01613 ................................. 4-4 JAGUAR SPEEDSTAR/PROFISTAR with electro-hydraulic ground drive (EFA)...................................... 4-6

4.1.3

11/04

4.2

Position of components .......................................................... 4-8

4.3

Solenoid valve (3/2 way)....................................................... 4-12

4.4

Pressure relief valve ............................................................. 4-14

4.5

Front attachment clutch hydraulic cylinder ........................... 4-16

4.6

Shifter rail locking hydraulic cylinder..................................... 4-18

4.7

Suction arm drive flow control valve ..................................... 4-20

4.8

Suction arm drive motor........................................................ 4-22

4.9

Line header ........................................................................... 4-24

4.10

Knife support valve cylinder.................................................. 4-26

4.11

Testing and measurements .................................................. 4-28

Jag-h-Kap04

4-1

4. Low-pressure hydraulics 4.1 4.1.1

4-2

JAGUAR

TIC

Hydraulic circuit diagram JAGUAR 20/25 km/h from serial no. 492 01614

Jag-h-Kap04

11/04

TIC

JAGUAR

4. Low-pressure hydraulics

Functional changes as compared with JAGUAR 20/25 km/h from serial no. 492 00011-492 01613 (see 5.1.2): the suction arm drive motor (228) runs permanently because it is supplied with oil directly from the line header (807). the line header (807) has been added.

Item Y1 Y26 Y60 Y88 Z19 Z20 Z46 102 109 110 205 209 210 211 218 228 302 317 340 352

Designation 4-Trac (all-wheel drive) solenoid coil Main drive solenoid coil Cover solenoid coil Front attachment clutch solenoid coil Hydraulic oil level switch (min.)

Hydraulic oil temperature Low-pressure hydraulics/ground drive oil pressure actual value function switch Pressure filter Hydraulic system oil cooler Oil tank Working hydraulics pump Ground drive feed pump Ground drive variable displacement motor Ground drive variable displacement pump Steering hydraulics pump Suction arm drive motor All-wheel drive clutch hydraulic cylinder Main drive clutch hydraulic cylinder Cover hydraulic cylinder Front attachment clutch hydraulic cylinder

406 411 421 441 442 504 609 710 718 729 790 807 910

Orifice plate ∅ 0.8 mm Orifice plate ∅ 1.8 mm Front attachment engage one-way restrictor valve Rotary coupling Venturi meter Main drive clutch accumulator Orbitrol steering unit rotary disc valve Ground drive filter bypass valve Ground drive feed circuit cold weather starting valve Low-pressure hydraulics pressure relief valve Suction arm drive flow control valve Line header Low-pressure hydraulics measuring point

11/04

Jag-h-Kap04

Remark 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve Oil level OK, switch open Normally open contact Oil level OK, switch open

19 cm³/rev. at n = 2890 rpm 22.5 cm³/rev. at n = 2890 rpm See ESIS 8 cm³/rev. at n = 2890 rpm 50 cm³/rev. actuated by oil pressure actuated by oil pressure new cylinder as from serial no. 1820

0.075 l, pre-pressurized to 6 bar OSPC 200, mechanically actuated ∆p = 2 bar, hydraulically actuated hydraulically actuated hydraulically actuated Q = 2 l/min, hydraulically actuated Minimess port

4-3

4. Low-pressure hydraulics 4.1.2

4-4

JAGUAR

TIC

JAGUAR 20/25 km/h from serial no. 492 00011 - 492 01613

Jag-h-Kap04

11/04

TIC Item Y1 Y26 Y60 Y88 Z19 Z20 Z46

JAGUAR

102 109 110 205 209 210 211 218 228 302 317 340 352 406 411 421 422

Designation 4-Trac (all-wheel drive) solenoid coil Main drive solenoid coil Cover solenoid coil Front attachment clutch solenoid coil Hydraulic oil level switch (min.)

Hydraulic oil temperature Low-pressure hydraulics/ground drive oil pressure actual value function switch Pressure filter Hydraulic system oil cooler Oil tank Working hydraulics pump Ground drive feed pump Ground drive variable displacement motor Ground drive variable displacement pump Steering hydraulics pump Suction arm drive motor All-wheel drive clutch hydraulic cylinder Main drive clutch hydraulic cylinder Cover hydraulic cylinder Front attachment clutch hydraulic cylinder Orifice plate ∅ 0.8 mm Orifice plate ∅ 1.8 mm Front attachment engage one-way restrictor valve Front attachment engage one-way restrictor valve

441 442 504 609

Rotary coupling Venturi meter Main drive clutch accumulator Orbitrol steering unit rotary disc valve

710 718 729 790 910

Ground drive filter bypass valve

11/04

Ground drive feed circuit cold weather starting valve Low-pressure hydraulics pressure relief valve Suction arm drive flow control valve Low-pressure hydraulics measuring point

Jag-h-Kap04

4. Low-pressure hydraulics Remark 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve Oil level OK, switch open Normally open contact Oil level OK, switch open

19 cm³/rev. at n = 2890 rpm 22.5 cm³/rev. at n = 2890 rpm See ESIS 8 cm³/rev. at n = 2890 rpm 50 cm³/rev. actuated by oil pressure actuated by oil pressure

option for RU, is dropped as from serial no. 1820 0,075l. pre-pressurized to 6 bar OSPC 250 up to 492 01019 OSPC 200 from 492 01020 OSPC 200 from 492 00133 USA ∆p = 2 bar, hydraulically actuated hydraulically actuated hydraulically actuated Q = 2 l/min, hydraulically actuated Minimess port

4-5

4. Low-pressure hydraulics 4.1.3

4-6

JAGUAR

TIC

JAGUAR SPEEDSTAR/PROFISTAR with electro-hydraulic ground drive (EFA)

Jag-h-Kap04

11/04

TIC Item Y1 Y26 Y59 Y60 Y88 Z19 Z20 Z46 102 109 110 205 209 210 211 218 228 302 317 340 352 359 406 413 421 441 442 504 609 710 718 729 790 807 910

11/04

JAGUAR Designation 4-Trac (all-wheel drive) solenoid coil Main drive solenoid coil Servo circuit solenoid coil Cover solenoid coil Front attachment clutch solenoid coil Hydraulic oil level switch (min.)

Hydraulic oil temperature Low-pressure hydraulics/ground drive oil pressure actual value function switch Pressure filter Hydraulic system oil cooler Oil tank Working hydraulics pump Ground drive feed pump Ground drive variable displacement motor Ground drive variable displacement pump Steering hydraulics pump Suction arm drive motor All-wheel drive clutch hydraulic cylinder Main drive clutch hydraulic cylinder Cover hydraulic cylinder Front attachment clutch hydraulic cylinder Shifter rail locking Orifice plate ∅ 0.8 mm Orifice plate ∅ 2.2 mm Front attachment engage one-way restrictor valve Rotary coupling Venturi meter Main drive clutch accumulator Orbitrol steering unit rotary disc valve Ground drive filter bypass valve Ground drive feed circuit cold weather starting valve Low-pressure hydraulics pressure relief valve Suction arm drive flow control valve Line header Low-pressure hydraulics measuring point

Jag-h-Kap04

4. Low-pressure hydraulics Remark 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve 3/2 way solenoid valve Oil level OK, switch open Normally open contact Oil level OK, switch open

19 cm³/rev. at n = 2890 rpm 22.5 cm³/rev. at n = 2890 rpm See ESIS 8 cm³/rev. at n = 2890 rpm 50 cm³/rev. actuated by oil pressure actuated by oil pressure

0.075 l, pre-pressurized to 6 bar OSPC 200, mechanically actuated ∆p = 2 bar, hydraulically actuated hydraulically actuated hydraulically actuated Q = 2 l/min, hydraulically actuated Minimess port

4-7

4. Low-pressure hydraulics 4.2

JAGUAR

TIC

Position of components

Tailgate area

Y59 Y26 504

Servo circuit solenoid coil Main drive solenoid coil Main drive clutch accumulator

228 790

Suction arm drive motor Suction arm drive flow control valve

Inside, centre

4-8

Jag-h-Kap04

11/04

TIC

JAGUAR

4. Low-pressure hydraulics

Front, under right-hand front attachment channel cover

421 352

Actuate front attachment one-way restrictor valve Front attachment clutch hydraulic cylinder

441 317

Rotary coupling Main drive clutch hydraulic cylinder

Centre right

11/04

Jag-h-Kap04

4-9

4. Low-pressure hydraulics

JAGUAR

TIC

Inside, right

Y1 Y60 Y88 729 910

4-10

4-Trac (all-wheel drive) solenoid coil Cover solenoid coil Front attachment clutch solenoid coil Low-pressure hydraulics pressure relief valve Low-pressure hydraulics measuring point

Jag-h-Kap04

11/04

TIC

JAGUAR

4. Low-pressure hydraulics

Notes:

11/04

Jag-h-Kap04

4-11

4. Low-pressure hydraulics 4.3

4-12

JAGUAR

TIC

Solenoid valve (3/2 way)

Jag-h-Kap04

11/04

TIC

JAGUAR A P4 S T V

Key to diagram:

4. Low-pressure hydraulics

Consumer port Low-pressure port Emergency operation screw Tank port Valve insert

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 (P4) 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 (P4) is thus applied to the hydraulic cylinder via the consumer port (A).

Note:

11/04

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.

Jag-h-Kap04

4-13

4. Low-pressure hydraulics 4.4

4-14

JAGUAR

TIC

Pressure relief valve

Jag-h-Kap04

11/04

TIC Key to diagram:

11/04

JAGUAR 729

4. Low-pressure hydraulics

Low-pressure hydraulics pressure relief valve............21+4 bar

Jag-h-Kap04

4-15

4. Low-pressure hydraulics 4.5

4-16

JAGUAR

TIC

Front attachment clutch hydraulic cylinder (352)

Jag-h-Kap04

11/04

TIC Key to diagram:::

11/04

JAGUAR

4. Low-pressure hydraulics

352

Front attachment clutch hydraulic cylinder (Figure A: from serial no. 1820 Figure B: up to serial no. 1819)

421

Front attachment engage one-way restrictor valve

422

Front attachment engage one-way restrictor valve (option for RU, is dropped as from serial no. 1820)

Jag-h-Kap04

4-17

4. Low-pressure hydraulics 4.6

4-18

JAGUAR

TIC

Shifter rail locking hydraulic cylinder

Jag-h-Kap04

11/04

TIC

JAGUAR

Keys to diagram:

Function:

4. Low-pressure hydraulics

359 624

Shifter rail locking hydraulic cylinder Venting valve

a b c d e f

Shifter rail Ball Compressed spring Piston Compressed spring Port

Shifter rail is locked No pressurized oil is applied at port (f).

The compressed spring (e) pushes the piston (d) on the ball (b) which locks the shifter rail (a).

Shifter rail is unlocked The solenoid valve (Y104) has been actuated, making pressurized oil flow beneath the piston (d) via port (f).

The piston (d) is actuated to the top against the compressed spring (e).

Now the ball (b) is loaded only by the compressed spring (c). The shifter rail (a) can be actuated against this spring force.

Venting procedure The actuation circuit must be vented: -

when the actuation circuit has been opened, when shifting gears is possible only after extended actuation of button (K) on the gear shift lever.

1. Set ground speed control lever to N position.

2. Block the machine by actuating the service braking system and the parking brake.

3. Start diesel engine and let it run at idle speed.

4. Press button (K) on the ground speed control lever.

5. Another person opens the vent valve (624).

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

7. Close vent valve (624).

Note:

11/04

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

Jag-h-Kap04

4-19

4. Low-pressure hydraulics 4.7

4-20

JAGUAR

TIC

Suction arm drive flow control valve

Jag-h-Kap04

11/04

TIC Bezeichnungen:

JAGUAR

4. Low-pressure hydraulics

790

Suction arm drive flow control valve

A B C D E F

Low pressure To suction arm drive hydraulic motor Insert Measuring orifice Spool Spring

Function: - Ensuring constant speed of suction arm - Avoiding an oil pressure drop in the low-pressure hydraulics, especially on the main drive clutch.

2 way flow controller: The measuring orifice (D) whose diameter determines the volume flow is part of the movable piston.

When the feed flow increases, the piston moves towards the spring (F) and restricts the drain cross-section, keeping the pressure difference at the measuring orifice constant.

11/04

Jag-h-Kap04

4-21

4. Low-pressure hydraulics 4.8

4-22

JAGUAR

TIC

Suction arm drive motor (228)

Jag-h-Kap04

11/04

TIC Designations:

11/04

JAGUAR

4. Low-pressure hydraulics

228

Suction arm drive motor ..........................................50 cm³/rev.

1 2 3 4 5

Body Drive shaft Cardan shaft Ring gear Gear

Jag-h-Kap04

4-23

4. Low-pressure hydraulics 4.9

4-24

JAGUAR

TIC

Line header

Jag-h-Kap04

11/04

TIC

JAGUAR

Item 102 413 807 Z46

Designation Pressure filter Orifice plate Line header Pressure switch

P1 P2 P3 P4

Volume flow input Output Output Output

11/04

4. Low-pressure hydraulics

Remark ∅ 2.2 mm 12 bar NC contact. Monitors the pressure in the low-pressure hydraulics. from pressure filter (102) to the ground drive variable displacement motor (210), input (E). to suction arm drive motor (228) to low-pressure hydraulics

Jag-h-Kap04

4-25

4. Low-pressure hydraulics 4.10

4-26

JAGUAR

TIC

Knife support valve cylinder

Jag-h-Kap04

11/04

TIC

JAGUAR

Key to diagram:

4. Low-pressure hydraulics

729 910 3031

Low-pressure hydraulic system pressure relief valve Low-pressure hydraulics measuring point Knife support hydraulic cylinder

Y240

Knife support solenoid coil on/off

Function: Extending the knife support

When solenoid coil Y240 is actuated, pressurized oil is applied to the ram face and the ring face of hydraulic cylinder 3031.

The difference faces (ring face < ram face) makes the ram rod of hydraulic cylinder 3031 extend.

Retracting the knife support

When solenoid coil Y240 is not actuated, the ram face of hydraulic cylinder 3031 is relieved to the tank.

The pressurized oil applied to the ring face makes the ram rod of hydraulic cylinder 3031 retract.

Note:

11/04

The existing set screw only serves as a plug.

Jag-h-Kap04

4-27

4. Low-pressure hydraulics 4.11

JAGUAR

Testing and measurements

Descriptions:

910

Measuring pre-conditions: Low-pressure hydraulics:

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

4-28

TIC

Low-pressure hydraulics measuring point......

Jag-h-Kap04

19+4 bar

11/04

TIC

JAGUAR

5. Ground drive hydraulics

5 Ground drive hydraulics 5.1

JAGUAR 20/25 km/h from serial no 492 01614 ......................5-4

5.1.1

Ground drive hydraulics circuit diagram ..................................5-4

5.1.2

Diagram: Propulsive power (F) / Ground speed (v).................5-6

5.1.3

Function of ground drive ..........................................................5-8

5.1.4

Testing and measurements ...................................................5-12

5.1.5

Venting the HPV pump / HMV motor control pressure circuit. ......................................5-14

5.2

JAGUAR 20/25 km/h from serial no. 492 00133 up to serial no. 492 01613...........5-16

5.2.1

Ground drive hydraulics circuit diagram ................................5-16

5.3

JAGUAR 20/25 km/h from serial no. 492 00011 up to serial no. 492 00132.....................................................5-16

5.3.1

Ground drive hydraulics circuit diagram ................................5-16

5.4

JAGUAR SPEEDSTAR/PROFISTAR with electrohydraulic actuation (EFA) ......................................................5-20

5.4.1

Ground drive hydraulics circuit diagram ................................5-20

5.4.2

Ground drive control ..............................................................5-24

5.4.3

Components ..........................................................................5-26

5.4.3.1 Ground drive variable displacement pump (211) ..................5-24 5.4.3.2 Solenoid coil: Y141, Y142, Y143..........................................5-28 5.4.3.3 Ground drive variable displacement motor (210) ..................5-30 5.4.3.4 Ground drive additional feed valve (757) .............................5-32 5.4.3.5 Ground drive filter bypass valve (710)...................................5-33 5.4.3.6 Pressure switches B97 and B98 ...........................................5-34 5.4.3.7 Line header (807) ..................................................................5-35 5.4.3.8 Venturi meter .........................................................................5-36

11/04

5.4.4

Diagram: Propulsive power (F) / Ground speed (v) ..............5-37

5.4.5

Testing and measurements ...................................................5-38

Jag-h-Kap05

5-1

5. Ground drive hydraulics

5-2

JAGUAR

Jag-h-Kap05

TIC

11/04

5.1 JAGUAR 20/25 km/h - from serial no 492 01614 5.1.1 Ground drive hydraulics circuit diagram

5. Ground drive hydraulics 5.1 5.1.1

5-4

JAGUAR

TIC

JAGUAR 20/25 km/h from serial no 492 01614 Ground drive hydraulics circuit diagram

Jag-h-Kap05

11/04

TIC Item Z19 Z20 Z46 102 104 107 109 110 205 209 210 211 218 233 313 355 411 442 609 615 616 708 710 713 714 716 718 719 721 725 726 728 729 732 737 738 742 807 902 903 908 909 910

11/04

JAGUAR Designation Hydraulic oil level switch (min.)

Hydraulic oil temperature Low-pressure hydraulics/ground drive oil pressure actual value function switch Pressure filter Control pressure vent plug Oil drain Hydraulic system oil cooler Oil tank Working hydraulics pump Ground drive feed pump Ground drive variable displacement motor Ground drive variable displacement pump Steering hydraulics pump Silage additive pump Ground drive pump servo control hydraulic cylinder Ground drive motor servo control hydraulic cylinder Orifice plate ∅ 1.8 mm Venturi meter Orbitrol steering unit rotary disc valve Ground drive control pressure direction valve Ground drive control pressure speed valve Ground drive pressure cut-off valve Ground drive filter bypass valve Ground drive multifunction valve backward valve Ground drive multifunction valve forward valve Ground drive feed pressure relief valve Ground drive feed circuit cold weather starting valve Ground drive tap pressure control valve Ground drive oil tapping shuttle valve Steering double shock valve Steering pressure relief valve Anti-cavitation valve (non-return valve) Low-pressure hydraulics pressure relief valve Non-return valve Ground drive servo control motor speed valve Ground drive servo control forward/backward valve Steering safety valve Line header Ground drive hydraulics high pressure backward measuring point Ground drive hydraulics high pressure forward measuring point Ground drive hydraulics control pressure forward measuring point Steering hydraulics measuring point Low-pressure hydraulics measuring point

Jag-h-Kap05

5. Ground drive hydraulics Remark Oil level OK, switch open Normally open contact Oil level OK, switch open 10 µm

19 cm³/rev. at n = 2890 rpm 22.5 cm³/rev. at n = 2890 rpm See ESIS 8 cm³/rev. at n = 2890 rpm

OSPC 250, mechanically actuated mechanically actuated mechanically actuated hydraulically actuated ∆p = 2 bar, hydraulically actuated 420 bar, hydraulically actuated 420 bar, hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated

Minimess port

5-5

5. Ground drive hydraulics 5.1.2

JAGUAR

TIC

Diagram: Propulsive power (F) / Ground speed (v)

Curve a

The first forward gear is engaged, the ground speed control lever is moved from its 0 position to the front.

Curve section 1: When starting, the ground drive variable displacement pump HPV 105 swivels from a volumetric displacement of 0 towards 105 cm³/rev.

The ground drive variable displacement motor HMV is set to its maximum input volume of 105 cm³/rev. on Jaguar 850, 830 up to serial no. 492 00135 135 cm³/rev. on Jaguar 900, 890, 870 and 850, 830 from serial no.: 492 00136 Now: - maximum propulsive power is reached; - the max. ground speed is approx. 9 km/h.

Curve section 2: The ground drive variable displacement pump HPV 105 is set to 105 cm³/rev. of volumetric displacement.

The ground drive variable displacement motor HMV swivels from an input volume of 105 cm³/rev. to 85 cm³/rev. for Jaguar 850, 830 up to serial no. 49200135 and from 135 cm³/rev. to 85 cm³/rev. on Jaguar 900, 890, 870 and 850, 830 from serial no. 49200136 Now: - the propulsive power decreases; - the ground speed increases up to approx. 14 km/h.

Curve b

The second forward gear is engaged, the ground speed control lever is moved from its 0 position to the front.

Curve section 3: When starting, the ground drive variable displacement pump HPV 105 swivels from a volumetric displacement of 0 towards 105 cm³/rev.

The ground drive variable displacement motor HMV is set to its maximum input volume of 105 cm³/rev. on Jaguar 850, 830 up to serial no. 49200135 135 cm³/rev. on Jaguar 900, 890, 870 and 850, 830 from serial no. 49200136 Now: - the propulsive force is smaller than in the first gear - the max. ground speed is approx. 19 km/h.

Curve section 4: The ground drive variable displacement pump HPV 105 is set to 105 cm³/rev. of volumetric displacement.

The ground drive variable displacement motor HMV swivels from an input volume of 105 cm³/rev. to 85 cm³/rev. for Jaguar 850, 830 up to serial no. 49200135 and from 135 cm³/rev. to 85 cm³/rev. on Jaguar 900, 890, 870 and 850, 830 from serial no. 49200136 Now: - the propulsive power decreases; - the ground speed increases up to 20 km/h or 25 km/h.

5-6

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TIC

JAGUAR

5. Ground drive hydraulics

Pump HPV 105

HPV = High-pressure pump, variable.

Max. volumetric displacement 105 cm³/rev.

Maximum operating pressure 420 bar Maximum speed 2890 rpm Swivel angle 21° Mechanical – hydraulic swivel and maximum pressure control Feed pump 22.5 cm³/rev.

Pressure filter 10 µm Filter bypass valve ∆p = 2 bar

Motor HMV 105 or 135

HMV = High-pressure motor, adjustable.

Maximum input volume 135 cm³/rev. on Jaguar 900, 890, 870.

Maximum input volume 105 cm³/rev. on Jaguar 850, 830 up to serial no. 492 00135.

Minimum input volume 85 cm³/rev. for all types.

Variable hydraulic swivel

Warning devices

Overtemperature alarm at 104°C Feed pressure < 12 bar Oil level < min.

11/04

Jag-h-Kap05

5-7

5. Ground drive hydraulics 5.1.3

JAGUAR

TIC

Function of ground drive

Linde HPV - HMV ground drive, variable, with maximum propulsive force control Motor started, ground speed control lever in neutral position

- The ground drive feed pump (209) takes in cooled oil and pumps it to the pressure filter (102).

- In case of cold oil, the ground drive feed circuit cold weather starting valve (718) prevents pressure build-up > 28 bar.

- Oil flows through pressure filter (102).

When the filter resistance exceeds a ∆p = 2 bar, the ground drive filter bypass valve (710) is opened and lets the oil continue to flow without filtering.

- The ground drive feed pressure relief valve (716) controls the cooled and filtered oil to a pressure of 22.5 bar which is available as feed pressure at the following points: • Via orifice plate (401) Ø 1.8 mm to the low-pressure hydraulics • to feed the ground drive multi-function valves (713) (714).

• on both sides of the ground drive pump servo control (313) • at the ground drive control pressure speed control valve (616).

The oil pressure controlled to 21 bar by the low-pressure hydraulics pressure relief valve (729) is applied as control pressure to the ground drive motor servo control cylinder (355) via the ground drive servo control motor speed valve (737).

The motor swivels to maximum input volume (= low speed and high propulsive force).

The ground drive servo control direction pump valve (738) is springcentred and in its neutral position. Both cylinder spaces are connected with the tank via the ground drive control pressure direction valve (615).

Motor started, ground speed control lever moved to forward travel

Pump: When moving the ground speed control lever, the ground drive control pressure direction valve (615) and the ground drive control pressure speed control valve (616) are actuated.

This pre-selects the forward direction of travel and a control pressure proportional to the lever movement is built up for the servo control.

At a control pressure of 4 bar and higher, the spring force at the ground drive servo control direction pump valve (738) is overcome. The ground drive servo control direction pump valve (738) now actuates the ground drive pump servo control cylinder (313).

The HPV pump swivels proportionally to the position of the ground speed control lever.

At a control pressure of 9 bar, the pump has reached its maximum position = max. volumetric displacement.

Motor: The control pressure generated by actuating the ground speed control lever is also applied at the servo control motor speed valve (737). When the ground speed control lever is moved so far that a control pressure of > 9 bar is built up, the spring force of this valve is overcome and the ground drive motor servo control cylinder (355) is adjusted proportionally to the position of the ground speed control lever towards low input volume = max. ground speed.

Maximum ground speed is reached: • with motor HMV 105 at 10.5 bar and • with motor HMV 135 at 12 bar control pressure.

The Bowden cable on the pump is mounted in the inner bore of the adjusting lever on ground drives with HMV 135 and in the outer bore with the HMV 105. The pivot position of the Bowden cable must not be modified.

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JAGUAR

5. Ground drive hydraulics

Forward travel.

Feed of cooled and filtered oil into the closed highpressure circuit.

When driving, a pressure is generated in the high-pressure forward line which corresponds to the resistance to vehicular motion.

A lower pressure (feed pressure) is available in the high-pressure backward line.

This pressure difference actuates the ground drive oil tapping shuttle valve (721).

Oil is tapped from the high-pressure backward line via the ground drive tap pressure control valve (719). Since the feed pressure is applied to the ground drive multi-function valves (713) and (714), fresh oil is introduced via the ground drive backward multi-function valve (713).

The forward multi-function valve is closed by the oil pressure (due to the resistance to vehicular motion).

Backward travel.

Feed of cooled and filtered oil into the closed highpressure circuit.

When driving, a pressure is generated in the high-pressure backward line which corresponds to the resistance to vehicular motion.

A lower pressure (feed pressure) is available in the high-pressure forward line.

This pressure difference actuates the ground drive oil tapping shuttle valve (721).

Oil is tapped from the high-pressure forward line via the ground drive tap pressure control valve. Since the feed pressure is applied to the ground drive multi-function valves (713) and (714), fresh oil is introduced via the ground drive forward multi-function valve (714). The backward multi-function valve is closed by the oil pressure (due to the resistance to vehicular motion).

Motor started, ground speed control lever moved to backward travel.

Basically, the "Driving backward" control is the same as for "Driving forward".

The difference is that the control pressure direction valve (615) is actuated in the backward position.

The motor servo control is actuated via the ground drive control pressure shuttle valve (739) only on machines up to serial no. …..

Machines from serial no. …. actuate only the pump when in backward motion.

The motor therefore remains in the large input volume range = large propulsive power. The shuttle valve has been dropped, see circuit diagram.

Maximum propulsive force control.

The forward oil pressure of the high-pressure circuit is applied to the ground drive pressure cut-off valves (708).

When increased resistance to vehicular motion occurs, high pressure of up to 400 bar may build up. This increased oil pressure opens the ground drive pressure cut-off valve (708).

This open valve lets the control pressure of the motor and pump servo control relieve to the tank via the non-return valve (732) set to 4.6 bar.

The ground drive motor servo control valve (355) is set back to its initial position due to the decrease of the control pressure to below 9 bar. The motor now swivels to its maximum input volume = increased propulsive force.

By swivelling to the maximum input volume the forward oil pressure of the high-pressure circuit drops again. The forward ground drive pressure cut-off valve (708) closes again.

The machine now moves at slow speed and maximum propulsive force.

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5. Ground drive hydraulics

JAGUAR

TIC

Maximum pressure control:

The forward or backward oil pressure of the high-pressure circuit is applied to the ground drive pressure cut-off valves 708 and the ground drive multi-function valves 713 or 714. When increased resistance to vehicular motion occurs, high pressure of up to 420 bar may build up.

This increased oil pressure opens the corresponding ground drive pressure cut-off valve 708. This open valve lets the control pressure of the motor and pump servo control relieve to the tank via the non-return valve 732 set to 4.6 bar. The motor swivels to maximum input volume.

However, when the pressure in the high-pressure circuit remains at more than 420 bar, the pump swivels back to minimum volumetric displacement (minimum speed) at 4.6 bar control pressure. As the pump does not swivel fully to the neutral position, a small oil flow is displaced via the ground drive forward or backward multi-function valves 713, 714. This reduces the thermal load when driving in the maximum pressure range.

Oil cooling

The oil tapped into the motor body via the ground drive tap pressure control valve 719 is fed to the oil tank and the Venturi meter 442 via a connecting line. Along with the circulation oil flow of the steering system, a part of this heated oil is fed into oil cooler 109.

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TIC

11/04

JAGUAR

Jag-h-Kap05

5. Ground drive hydraulics

5-11

5. Ground drive hydraulics 5.1.4

JAGUAR

TIC

Testing and measurements

Measuring points

Measuring point (902): Ground drive high-pressure backward Measuring point (903): Ground drive high-pressure forward

Measuring point (908): Control pressure backward

5-12

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TIC

JAGUAR

5. Ground drive hydraulics

Measuring port

Tee union, Claas spare part no. 239039.0 Elbow union, Claas spare part no. 238693.0 Minimess port, Claas spare part no. 683656.0

Measuring adapter

Minimess port M 14 x 1.5 = 238 711.0 with 683 656.1

Measuring preconditions

Pressure measurements are carried out at minimum motor speed and at an oil temperature of 45 – 50 °C.

Pressure fed into the high-pressure circuit

• Ground speed control lever and transmission in neutral position.

Set value: 20 + 4 bar at the measuring points (903) and (902).

• Move ground speed control lever fully and transmission in neutral position.

Set value difference: 0 ... 1 bar at the measuring points (902) and (903).

High pressure measurement

• Engage transmission gear, • engage parking and service 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. at the measuring points (902) and (903).

During this measurement, the value on the corresponding low-pressure side measuring point (903) or (902) must not fall below 14 bar.

Forward control pressure measurement

• Install measuring port (908).

• Switch transmission in neutral position.

• Block the machine by actuating the service braking system and the parking brake.

• Move the ground speed control lever fully to the front.

Set value: 11.5 bar for ground drive with HMV 105.

Set value: 12.5 bar for ground drive with HMV 135.

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Jag-h-Kap05

5-13

5. Ground drive hydraulics 5.1.5

JAGUAR

TIC

Venting the HPV pump / HMV motor control pressure circuit.

Venting valve (104) • • • • •

Switch off engine, remove ignition key.

Switch transmission in neutral position.

Open venting valve 104 for approx. 2 turns.

Start motor and let it run at minimum rpm.

Block the machine by actuating the service braking system and the parking brake.

• Move ground speed control lever fully to the front for approx.

30 seconds.

• Switch off engine, remove ignition key.

• Close venting valve 104 and lock it with the sealing flange nut.

Further filling and venting instructions

5-14

For further filling and venting instructions please refer to the Repair Manual JAGUAR 492.

Jag-h-Kap05

11/04

5.2 JAGUAR 20/25 km/h - from serial no.492 00133 up to serial no. 492 01613 5.2.1 Ground drive hydraulics circuit diagram

5. Ground drive hydraulics 5.2 5.2.1

5-16

JAGUAR

TIC

JAGUAR 20/25 km/h from serial no. 492 00133 up to serial no. 492 01613 Ground drive hydraulics circuit diagram

Jag-h-Kap05

11/04

TIC

JAGUAR

Item Z19 Z20 102 104 107 109 110 205 209 210

Designation Hydraulic oil level switch (min.)

Hydraulic oil temperature switch Pressure filter Control pressure vent plug Oil drain Hydraulic system oil cooler Oil tank Working hydraulics pump Ground drive feed pump Ground drive variable displacement motor

211 218 233 313 355 411 442 609 615 616 708 710 713 714 716 718 719 721 725 726 728 729 732 737 738 742 902

Ground drive variable displacement pump Steering hydraulics pump Silage additive pump Ground drive pump servo control hydraulic cylinder Ground drive motor servo control hydraulic cylinder Orifice plate ∅ 1.8 mm Venturi meter Orbitrol steering unit rotary disc valve Ground drive control pressure direction valve Ground drive control pressure speed valve Ground drive pressure cut-off valve Ground drive filter bypass valve Ground drive multifunction valve backward valve Ground drive multifunction valve forward valve Ground drive feed pressure relief valve Ground drive feed circuit cold weather starting valve Ground drive tap pressure control valve Ground drive oil tapping shuttle valve Steering double shock valve Steering pressure relief valve Anti-cavitation valve (non-return valve) Low-pressure hydraulics pressure relief valve Non-return valve Ground drive servo control motor speed valve Ground drive servo control forward/backward valve Steering safety valve Ground drive hydraulics high pressure backward measuring point Ground drive hydraulics high pressure forward measuring point Ground drive hydraulics control pressure forward measuring point Steering hydraulics measuring point Low-pressure hydraulics measuring point

903 908 909 910

11/04

Jag-h-Kap05

5. Ground drive hydraulics Remark Oil level OK, switch open Normally open contact 10 µm

19 cm³/rev. at n = 2890 rpm 22.5 cm³/rev. at n = 2890 rpm 105 / 85 cm³/rev. for 830, 850 135 / 85 cm³/rev. for 870, 890, 900 105 cm³/rev.

8 cm³/rev. at n = 2890 rpm

OSPC 250, mechanically actuated mechanically actuated mechanically actuated hydraulically actuated ∆p = 2 bar, hydraulically actuated 420 bar, hydraulically actuated 420 bar, hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated 21+1 bar hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated

Minimess port

5-17

5. Ground drive hydraulics

5-18

JAGUAR

Jag-h-Kap05

TIC

11/04

5.3 JAGUAR 20/25 km/h - from serial no. 4920 0011 up to serial no. 4920 0132 5.3.1 Ground drive hydraulics circuit diagram

5. Ground drive hydraulics 5.3 5.3.1

5-16

JAGUAR

TIC

JAGUAR 20/25 km/h from serial no. 4920 0011 up to serial no. 4920 0132 Ground drive hydraulics circuit diagram

Jag-h-Kap05

11/04

TIC Item Z19 Z20 102 104 107 109 110 205 209 210 211 218 233 313 355 411 442 609 615 616 708 710 713 714 716 718 719 721 725 726 728 729 732 737 738 739 742 902 903 908 909 910

11/04

JAGUAR Designation Hydraulic oil level switch (min.)

Hydraulic oil temperature switch Pressure filter Control pressure vent plug Oil drain Hydraulic system oil cooler Oil tank Working hydraulics pump Ground drive feed pump Ground drive variable displacement motor Ground drive variable displacement pump Steering hydraulics pump Silage additive pump Ground drive pump servo control hydraulic cylinder Ground drive motor servo control hydraulic cylinder Orifice plate ∅ 1.8 mm Venturi meter Orbitrol steering unit rotary disc valve Ground drive control pressure direction valve Ground drive control pressure speed valve Ground drive pressure cut-off valve Ground drive filter bypass valve Ground drive multifunction valve backward valve Ground drive multifunction valve forward valve Ground drive feed pressure relief valve Ground drive feed circuit cold weather starting valve Ground drive tap pressure control valve Ground drive oil tapping shuttle valve Steering double shock valve Steering pressure relief valve Anti-cavitation valve (non-return valve) Low-pressure hydraulics pressure relief valve Non-return valve Ground drive servo control motor speed valve Ground drive servo control forward/backward valve Ground drive control pressure shuttle valve Steering safety valve Ground drive hydraulics high pressure backward measuring point Ground drive hydraulics high pressure forward measuring point Ground drive hydraulics control pressure forward measuring point Steering hydraulics measuring point Low-pressure hydraulics measuring point

Jag-h-Kap05

5. Ground drive hydraulics Remark Oil level OK, switch open Normally open contact 10 µm

19 cm³/rev. at n = 2890 rpm 22.5 cm³/rev. at n = 2890 rpm See ESIS 8 cm³/rev. at n = 2890 rpm

OSPC 250, mechanically actuated mechanically actuated mechanically actuated hydraulically actuated ∆p = 2 bar, hydraulically actuated 420 bar, hydraulically actuated 420 bar, hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated 21+1 bar hydraulically actuated hydraulically actuated hydraulically actuated hydraulically actuated

Minimess port

5-17

5. Ground drive hydraulics

5-18

JAGUAR

Jag-h-Kap05

TIC

11/04

5.4 JAGUAR SPEEDSTAR/PROFISTAR - with electro-hydraulic actuation (EFA) 5.4.1 Ground drive hydraulics circuit diagram

5. Ground drive hydraulics 5.4 5.4.1

5-20

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TIC

JAGUAR SPEEDSTAR/PROFISTAR with electro-hydraulic actuation (EFA) Ground drive hydraulics circuit diagram

Jag-h-Kap05

11/04

TIC Item Y141

Y142 Y143

Y144 Z19 Z20 Z46 B97

B98

102 107 109 110 112 205 209 210 211 218 233

313 355 413 442 609

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JAGUAR

5. Ground drive hydraulics

Designation Ground drive forward solenoid coil

Remark 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.

Ground drive backward solenoid The solenoid coil is actuated by the ground drive module (A49) in coil a modulated way.

Solenoid coil actuated = pressure at port (S) = backward Ground drive/cut off valve The solenoid coil is actuated by the ground drive module (A49). solenoid coil It is permanently energized when the ignition (+15) is ON = the non-return valve is closed.

In case of a panic braking (brake force > 55 kg) Y143 is not energized = 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.

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

Hydraulic oil level switch (min.) Oil level OK = switch open Hydraulic oil temperature switch Normally open contact Low-pressure hydraulics Monitors the pressure in the low-pressure hydraulics. switch / ground drive oil Switch open = oil pressure OK pressure Switch closed = oil pressure < 12 bar.

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

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

Pressure filter 10 µm Oil drain Hydraulic system oil cooler Oil tank Return flow filter Working hydraulics pump 19 cm³/rev. = 2890 rpm Ground drive feed pump 22.5 cm³/rev. at n = 2890 rpm Ground drive variable displacement motor See ESIS Ground drive variable displacement pump Steering hydraulics pump Volumetric displacement: 11 cm³/rev. Supplies volume flow for the steering system.

Silage additive pump (option) Is driven by the transfer gearbox. The circuit diagram shows the installation situation when the silage additive pump function is not needed. For information on the use of the silage additive pump, please refer to the corresponding fitting instructions.

Ground drive pump servo Controls the swivel angle of the ground drive variable control hydraulic cylinder displacement pump (211).

Ground drive motor servo Controls the swivel angle of the ground drive variable control hydraulic cylinder displacement motor (210).

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

Venturi meter Feeds a partial volume flow from the steering hydraulics circuit into the cooling circuit.

Orbitrol steering unit rotary disc Is mechanically actuated by the steering wheel valve

Jag-h-Kap05

5-21

5. Ground drive hydraulics Item 710 713

Designation Ground drive filter bypass valve Ground drive multi-function valve backward

714

Ground drive multi-function valve forward

716

Ground drive feed pressure relief valve Ground drive feed circuit cold weather starting valve Ground drive tap pressure control valve Ground drive oil tapping shuttle valve Ground drive servo control restrictor valve

718 719 721 738

757 758

Ground drive additional feed valve Ground drive restrictor valve

807

Line header

5-22

JAGUAR

TIC

Remark Opens at a filter resistance of ∆p = 2 bar - Pressure limitation: 420 bar - Feed for reloading into the closed circuit (replacing the leakage losses) - Pressure limitation: 420 bar - Feed for reloading into the closed circuit (replacing the leakage losses) Opening pressure 24 bar. Determines the feed pressure.

Opens at a pressure of > 30 bar (when oil is cold).

Starts opening at p = 10 bar Is actuated by the respective high-pressure circuit.

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.

Feeds additional volume flow into the feed and the low-pressure circuit when the pressure in port (Z) falls below 19 bar.

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

P1 Volume flow input from pressure filter (102) P2 Output to the ground drive variable displacement motor (210), input (E).

P3 Output to suction arm drive motor (228) P4 Output to low-pressure hydraulics

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JAGUAR

Jag-h-Kap05

5. Ground drive hydraulics

5-23

5. Ground drive hydraulics 5.4.2

JAGUAR

TIC

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 energized. 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 energized.

The feed pressure (p7) acts on both sides in the ground drive pump servo control hydraulic cylinder (313) via the centre position of the ground drive forward/backward 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 energized.

Solenoid coil (Y143) is energized.

The feed pressure (p7) is directed to the 2/2 way valves upstream of the restrictor. The servo control supply pressure (p8) downstream of the restrictor actuates the 2/2 way valves to through position. Due to this, feed pressure (p7) 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 (p8).

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

Example

5-24

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.

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.

Jag-h-Kap05

11/04

TIC Ground drive/cut off valve solenoid coil (Y143)

11/04

JAGUAR

5. Ground drive hydraulics

The Ground drive/cut off valve solenoid coil (Y143) is de-energized in case of a panic braking (pedal force > 600 N) (see also Technical Systems – Electric System).

When the ground drive/cut off valve solenoid coil (Y143) is deenergized, the magnetic needle is retracted. The ball lifts off from its seat and relieves the servo control supply pressure (p8) towards the tank.

This has the following result: The 2/2 way valves of the solenoid coils (Y141 and 142) are switched back to blocked position and therefore take away the supply pressure to the proportional 4/2 way valves.

This makes the latter return to their initial position.

Since the servo control supply pressure (p8) 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 of (p8) and switches the ground drive restrictor valve (738) from the unrestricted to the restricted position.

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

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5-25

5. Ground drive hydraulics 5.4.3

JAGUAR

TIC

Components Ground drive variable displacement pump (211)

211 Ground drive variable displacement pump

5-26

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5. Ground drive hydraulics

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5. Ground drive hydraulics

JAGUAR

TIC

5.4.3.2 Solenoid coil: Y141, Y142, Y143

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.

5-28

Y141

Ground drive forward solenoid coil Solenoid coil actuated = modulated control pressure build-up = forward.

Y142

Ground drive backward solenoid coil Solenoid coil actuated = pressure at port (S) = backward

Y143

The solenoid coil is actuated by the ground drive module (A49).

It is permanently energized when the ignition (+15) is ON = the non-return valve is closed.

In case of a panic braking (brake force > 55 kg), Y143 is not energized (see also "Electric System chapter") = 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.

211 P, S

Ground drive variable displacement pump Outputs to ground drive variable displacement motor (210)

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5. Ground drive hydraulics

5-29

5. Ground drive hydraulics

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TIC

5.4.3.3 Ground drive variable displacement motor (210)

210 Ground drive variable displacement motor Y144 The ground drive variable displacement motor solenoid coil is actuated 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.

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 control motion is electrohydraulical and proportional to the actuation current of Y144.

5-30

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5. Ground drive hydraulics

When the ground drive variable displacement motor solenoid coil (Y144) is not energized, 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 energized, 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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5. Ground drive hydraulics

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TIC

5.4.3.4 Ground drive additional feed valve (757)

205 218 757 916

Working hydraulics pump: 19 cm³, nmax = 2890 rpm Steering hydraulics pump: 11 cm³/rev.

Ground drive additional feed valve Working hydraulics pump measuring point

P5 T Z

Working hydraulics port Tank port Additional feed port into feed pressure circuit and low-pressure hydraulics.

Function

When the pressure at port (Z) falls below 19 bar, the ground drive additional feed valve (757) feeds an additional volume flow into the feed and the low-pressure circuits.

In the initial position (see circuit diagram), the following circuits are supplied: • The high-pressure circuit (port P5) and • The feed pressure circuit and/or the low-pressure circuit (port Z).

5-32

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5. Ground drive hydraulics

When the pressure in port (Z) rises above 19 bar, the valve switches and supplies the working hydraulics exclusively via port (P5).

When the pressure in port (Z) falls below 19 bar, the valve switches to its initial position. Now a partial volume flow flows via port (Z) into the feed pressure circuit and into the low-pressure hydraulics. This condition is maintained until the pressure in port (Z) rises above 19 bar.

5.4.3.5 Ground drive filter bypass valve (710)

710

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Ground drive filter bypass valve

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5. Ground drive hydraulics

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TIC

5.4.3.6 Pressure switches B97 and B98

B98 102 Task

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

Pressure filter

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 high-pressure 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).

5-34

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5. Ground drive hydraulics

5.4.3.7 Line header (807)

Item 102 413 807 Z46

Designation Pressure filter Orifice plate Line header Pressure switch

P1 P2 P3 P4

Volume flow input Output Output Output

11/04

Remark ∅ 2.2mm 12 bar NC contact. Monitors the pressure in the low-pressure hydraulics. from pressure filter (102) to the ground drive variable displacement motor (210), input (E). to suction arm drive motor (228) to low-pressure hydraulics

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5. Ground drive hydraulics

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TIC

5.4.3.8 Venturi meter

Oil cooling

The oil tapped into the motor body via the ground drive tap pressure control valve (719) is fed to the oil tank and the Venturi meter 442 via a connecting line. Along with the circulation oil flow of the steering system, a part of the heated oil is fed into oil cooler 109. a b c

5-36

Input from Orbitrol steering unit rotary disc valve (609) port (T) Output to oil cooler (109) Output to the ground drive variable displacement motor (110), port (E).

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JAGUAR

5. Ground drive hydraulics

Diagram: Propulsive power (F) / Ground speed (v)

Curve a

The first forward gear is engaged, speed control lever is moved from its 0 position to the front.

Curve section 1: When starting, the ground drive variable displacement pump HPV swings from a volumetric displacement of 0 towards maximum displacement.

The ground drive variable displacement motor HMV stands at its maximum input volume.

Now: - maximum propulsive power is reached; - the max. ground speed is approx. 7.5km/h.

Curve section 2: The ground drive variable displacement pump HPV stands at maximum displacement.

The ground drive variable displacement motor HMV swivels from its maximum input volume to approx. 98cm³/rev. of input volume.

Now: - the propulsive power decreases; - the ground speed increases up to approx. 16.5km/h.

Curve b

The second forward gear is engaged, the ground speed control lever is moved from its 0 position to the front.

Curve section 3: When starting, the ground drive variable displacement pump HPV swings from a volumetric displacement of 0 towards maximum displacement.

The ground drive variable displacement motor HMV stands at its maximum input volume.

Now: - the propulsive force is smaller than in the first gear - the max. ground speed is approx. 19 km/h.

Curve section 4: The ground drive variable displacement pump HPV stands at maximum displacement.

The ground drive variable displacement motor HMV swivels from its maximum input volume to approx. 98cm³/rev. of input volume.

Now: - the propulsive power decreases; - the ground speed increases up to approx. 40km/h.

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5. Ground drive hydraulics 5.4.5

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TIC

Testing and measurements

Pressure testing with the high-pressure sensors B97 and B98, using the display of the CIS terminal Note:

Set cursor in CIS to the ground speed control lever symbol (see Operator's Manual).

Volt display:

B97

Volt display:

5-38

B98

Drive hydraulics forward high-pressure sensor

Drive hydraulics backward high-pressure sensor

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TIC Measuring values table of high-pressure sensors B97 and B98

Function testing of sensors:

JAGUAR Pressure 0 bar 20 bar 30 bar 40 bar 100 bar 200 bar 300 bar 400 bar 420 bar 440 bar 450 bar 460 bar

5. Ground drive hydraulics Volt 0.2 – 0.3 Volt 0.4 Volt 0.4 – 0.5 Volt 0.5 – 0.6 Volt 1.0 Volt 1.7 – 1.8 Volt 2.5 Volt 3.2 – 3.3 Volt 3.4 Volt 3.5 Volt 3.6 Volt 3.7 Volt

With the motor shut off and vehicle brakes applied • Switch on the ignition • Set cursor in 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 preconditions for pressure tests:

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.

Pressure fed into the high-pressure circuit

• Ground speed control lever and transmission in neutral position.

Set value: 20+4 bar on the measuring value displays B97 and B98 (see table).

High pressure measurement

• Engage second gear, • apply parking brake.

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

Note:

During this 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 on the measuring value displays B97 and B98 (see table).

During this process, the value on the corresponding low-pressure side measuring value displays B97 or B98 must not fall below 20 bar (see table).

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5-39

5. Ground drive hydraulics

5-40

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6. Float position

6 Float position

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6.1

Working method...................................................................... 6-2

6.2

Operation ................................................................................ 6-3

6.3

Sensors ................................................................................... 6-5

6.4

Function ...................................................................................6-6

Jag-h-Kap06

6-1

6. Float position 6.1

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TIC

Working method

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.

• • • •

6-2

The float position offers the following benefits: high driving comfort safe vehicle handling lower mechanical loads

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6.2

Operation

6.2.1

Learning the centre pitching axis

1.

2.

3.

4.

6. Float position

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.

6.2.2

Activating the float position

1.

2.

3.

4.

11/04

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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6. Float position

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TIC

The activated float position 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.

6-4

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JAGUAR

6. Float position

Sensors

B2 The "Ground pressure oil pressure" sensor is mounted at the front right-hand side 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).

B35 The "Feed rake conveyor position" sensor is mounted at the front right-hand side on the feed rake conveyor.

It detects the front attachment position and transmits the signal to the CONTOUR module (A11).

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6-5

6. Float position 6.4

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TIC

Function

Example:

The following example explains the working method of the float position: After the centre pitching axis has been learned, the pressure in the "Raise/lower front attachment" hydraulic cylinders is 100 bar. This pressure is detected by sensor (B2) "Ground pressure oil pressure".

A pressure tolerance range of +/- 20 bar is stored in the CONTOUR module (A11).

The pressure peaks occurring during road travel (curve a) are outside of the pressure tolerance range.

The CONTOUR module actuates the solenoid valves for raising or lowering the front attachment correspondingly.

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 away too much from the centre pitching axis during its compensating motions, it is returned by the position sensor.

6-6

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7. Compressed-air system

7 Compressed-air system

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7.1

Trailer brake system circuit diagram....................................... 7-2

7.2

Motor restrictor / compressed-air coupling ............................. 7-6

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7-1

7. Compressed-air system 7.1

7-2

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Trailer brake system circuit diagram

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TIC Key to diagram:

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JAGUAR

7. Compressed-air system

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

Compressor ...................................................(350 – 380 cm3) Pressure control valve ...................................(12.5 bar) Air accumulator (20 litres) Air accumulator (20 litres) Frost protection pump Dewatering valve (automatic) Pressure gauge (10 bar) in the cab Pressure relief valve (8 bar) Trailer control valve (2-wire) Accumulator service line hose coupler (red) Brake service line hose coupler (yellow) Safety valve (14 bar) Relief valve (8.5 bar) Relief valve (6 bar) Compressed-air coupling Solenoid valve (proportional) Y100-1 Pressure gauge (16 bar) Solenoid valve (4/2-way) Y100-2 Shuttle valve

a b

Brake pressure input (service brake) Engine brake port (depending on equipment fitted)

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7. Compressed-air system Description of function: 1 Compressor

2 Pressure control valve

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TIC

1/2 The compressor is permanently driven by the diesel engine and conveys compressed air into the system.

Compressor start at p < 11.5 bar Compressor stop at p > 12.5 bar - for controlled compressors.

-Controlled compressor: The pressure control valve controls the compressor and consequently the operating pressure.

-Uncontrolled compressor: The operating pressure is adjusted directly by the pressure control valve.

4 Frost protection pump

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

5 Dewatering valve

Automatic draining of condensate from the air accumulator.

6 Pressure gauge

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

7 Pressure relief valve

Limits the pressure (output 2) in the accumulator circuit to 8 bar.

This pressure is applied to the following components: - Pressure gauge 6 - Accumulator service line hose coupler (red) 9 - Trailer control valve 8, port 1 - Solenoid valve 15 (Y100-1), port 1 - Solenoid valve 17 (Y100-2), port 1

8 Trailer control valve

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).

9 Accumulator service line hose coupler

A pressure of 8 bar is constantly applied here.

10 Brake service line hose coupler

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

11 Safety valve

Safeguards the compressed air system at 14 bar.

7-4

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TIC Description of function:

JAGUAR

7. Compressed-air system

1/2

12 Relief valve

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

13 Relief valve

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

14 Compressed-air coupling

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

15 Solenoid valve (Y100-1)

Governs the building-up of pressure at the service line hose coupler (10) while braking.

The following control modes apply: a) pneumatic = Control pressure from trailer brake valve (8) or from the solenoid valve (17=Y100-2) b) electrical = Signal upon pulling back (deceleration) of ground speed control lever.

16 Pressure gauge

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

17 Solenoid valve (Y100-2)

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.

18 Shuttle valve

11/04

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

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7. Compressed-air system 7.2

7-6

JAGUAR

TIC

Motor restrictor / compressed-air coupling

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TIC Key to diagram:

JAGUAR

7. Compressed-air system

1 2 3b 4 5 11 12 14 16

Compressor (350 – 380 cm3) Pressure control valve (12.5 bar) Air accumulator (20 litres) Frost protection pump Dewatering valve (automatic) Safety valve (14 bar) Relief valve (8.5 bar) Compressed-air coupling Pressure gauge (16 bar)

b

Engine brake port (depending on equipment fitted)

Description of function: 1 Compressor

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

Compressor start at p < 11.5 bar Compressor stop at p > 12.5 bar

2 Pressure control valve

Controlled compressor: The pressure control valve controls the compressor and consequently the operating pressure.

Uncontrolled compressor: The operating pressure is adjusted directly by the pressure control valve.

4 Frost protection pump

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

5 Dewatering valve

The dewatering valve serves for automatically draining the condensate collected in the air accumulator.

11 Safety valve

Safeguards the compressed-air brake system at 14 bar max.

12 Relief valve

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

14 Compressed-air coupling

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

16 Pressure gauge

Displays the pressure in the air accumulator - target value 12.5 bar.

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7-7

7. Compressed-air system

7-8

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Index

JAGUAR Index:

Index-2

TIC

A

Accumulator .....................................................

Accumulator circuit...........................................

Accumulator volume switching-over ................

Additional control unit ......................................

Additional feed ................................................

Autopilot ...........................................................

B

Bypass valve.................................................... 5-37

C

Circuit diagram.................................................

Compressed-air coupling.................................

Compressed-air system .................................

Corn Cracker ..................................................

D

Direct – Disc..................................................... 3-30

E

Emergency steering ......................................... 2-7

F

Filling and venting instructions......................... 5-14 Float position.................................................... 6-1 Flow control valve ........................................... 3-11, 4-20

G

Ground drive control ........................................ 5-28 Ground drive hydraulics................................... 5-1 Ground drive control ........................................ 5-28

H

High-pressure measurement ...........................

High-pressure sensors.....................................

Hitch.................................................................

HMV motor.......................................................

HPV pump........................................................

Hydraulic circuit diagram .................................

K

Knife support.................................................... 4-26

L

Line header ...................................................... 4-24, 5-39 Load switch-over.............................................. 3-28

M

Main valve........................................................

Master valve ....................................................

Measured value table ......................................

Motor restrictor ...............................................

3-8 3-8 5-43 7-8

P

Pressure control...............................................

Pressure limitation ...........................................

Pressure relief valve ......................................

Propulsive power .............................................

Pulse width modulation ...................................

5-10 1-28, 3-17 3-9, 4-14 5-6, 5-41 3-10

R

Raise/lower front attachment ........................... 3-8 Reverse front attachment ................................ 3-22 Reverser drive.................................................. 3-24

Jag-h-in

3-12 3-31 3-30 3-16 5-36 2-10

5-4, 5-16, 5-20, 5-24 7-8 7-1 3-18

5-43 5-43 3-14 5-7 5-7 1-4, 2-2, 3-4, 4-2

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TIC

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JAGUAR S

Sharpening ..............................................................

Shifter rail locking ....................................................

Shut-off valve...........................................................

Steering actuation....................................................

Steering hydraulics ..................................................

Suction arm drive.....................................................

T

Trailer brake system ................................................ 7-3

U

Upper discharge chute ............................................ 3-26

V

Valve combination ...................................................

Valve inserts ...........................................................

Variable displacement motor ...................................

Venting.....................................................................

Venturi nozzle ..........................................................

W

Working hydraulics .................................................. 3-1

Jag-h-in

3-16 4-18 5-29 2-6 2-1 4-22

3-10 1-22 5-34 3-19, 4-19, 5-14 5-40

Index-3

JAGUAR

Index-4

Jag-h-in

TIC

11/04

Following the policy of the 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 or omissions not accepted.

Reproduction or translation of this publication, in whole or part, is not permitted without the written consent of the CLAAS KGaA mbH. All rights under the provision of the Copyright Act 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

0298 712.3 SYS-H JAGUAR 900-830 EN - 03.05 - NF Printed in Germany