CLAAS MEGA 370 - 350 Hydraulic Systems &Technical Service Manual - PDF DOWNLOAD

MEGA 370 – 350 From serial number: 845 00387 835 00361

Technical Systems Hydraulic System

Hydraulic system

MEGA

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Hydraulic system

Table of Contents Chapter 1 Overall hydraulic system ................................................... 1-1 Chapter 2 Steering hydraulics ............................................................ 2-1 Chapter 3 Working hydraulics ............................................................ 3-1 Chapter 4 Low-pressure hydraulic circuit ......................................... 4-1 Chapter 5 Front attachments .............................................................. 5-1 Chapter 6 Ground drive hydraulics .................................................... 6-1 Chapter 7 Rotary chaff screen cleaning ............................................ 7-1 Index .............................................................................................. index-1

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Overall hydraulic system

Chapter 1 Overall hydraulic system

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1.1

Overall hydraulic system circuit diagram ..................................... 1-4

1.2

Oil tank, oil specification, filling quantities, oil change, oil filter, oil pressure..................................................................... 1-8

1.3

Hydraulic pumps ........................................................................ 1-10

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Overall hydraulic system

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1.1 Overall hydraulic system circuit diagram

Overall hydraulic system 1.1

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Overall hydraulic system circuit diagram

TIC Key to diagram:

MEGA I II III IV V

Overall hydraulic system

Main valve block Working hydraulics valve block Low-pressure hydraulics valve block Steering (Orbitrol) valve block Ground drive hydraulics (hydrostatic motor) A - Depending on the equipment fitted to the machine, the pressure relief valves (706-1, 706-2) are integrated either in the hydraulic pump (217) or in hydraulic motor (216).

109 110 112

Oil cooler Oil tank Return filter

205 209 210

216 217 218 226

3 Working hydraulics pump .................................... 11 cm /rev.

Ground drive feed pump ...................................... 22 cm3/rev.

Ground drive fixed displacement motor HMF 75 ................................................................ 75 cm3/rev.

Ground drive variable displacement pump HPV 105 (MEGA 360) ......................................... 105 cm3/rev.

HPV 75 (MEGA 350) ......................................... 75 cm3/rev.

Rotary chaff screen motor ................................... 8.0 cm3/rev.

Rotary chaff screen pump.................................... 5.5 cm3/rev.

Steering hydraulics pump .................................... 5.5 cm3/rev.

Front attachment reverser drive motor

301 305 306 311 312 313 314 315 316 320 321 323 351 352 353

3-D sieve pan hydraulic cylinder AUTOCONTOUR cross levelling right hydraulic cylinder AUTOCONTOUR cross levelling left hydraulic cylinder Threshing drum variable-speed drive hydraulic cylinder Threshing mechanism clutch hydraulic cylinder Ground drive servo control pump hydraulic cylinder Reel raise/lower slave cylinder Reel raise/lower master cylinder Horizontal reel adjustment hydraulic cylinder Swing grain tank unloading tube hydraulic cylinder Grain tank unloading clutch hydraulic cylinder Steering hydraulic cylinder Raise/lower front attachment hydraulic cylinder Front attachment coupling hydraulic cylinder Reverse front attachment hydraulic cylinder

406 408 410 412 441

Orifice plate.......................................................... Ø 0.8 mm Orifice plate.......................................................... Ø 1.2 mm Orifice plate ......................................................... Ø 1.5 mm Orifice plate.......................................................... Ø 2.0 mm Rotary coupling

503 508

AUTOPILOT accumulator Front attachment dampening accumulator

601 604 606 609 614

3D sieve pan pendulum control 4/3 way valve AUTOPILOT balance screw Ground drive servo control 4/3 way valve Orbitrol steering system rotary valve Front attachment lower flow control valve

211

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Overall hydraulic system Key to diagram:

MEGA 703 706-1 706-2 710 713 714 716 718 719 721 725 726 728 729 732 734 740 742 743 759 776

Working hydraulics pressure relief valve ............. 180+10 Pressure relief valve (on pump side) ................... 120 bar Pressure relief valve (on motor side) .................. 100 bar Ground drive filter bypass valve .......................... 2 bar Ground drive multi-function valve, reverse Ground drive multi-function valve, forward Ground drive feed pressure relief valve............... 23-2.5 bar Ground drive feed circuit cold start injector Ground drive flush pressure control valve ........... 10 bar Ground drive flush-out shuttle valve Steering double shock valve................................ 200+20 bar Steering pressure relief valve .............................. 125+5 bar Anti-cavitation valve (non-return valve) Low-pressure hydraulic system pressure relief valve.... 19 bar Non-return valve Lock-up valve unit (non-return valve) AUTOCONTOUR cross levelling flow control valve Steering safety valve Lower front attachment pilot valve One-way restrictor valve, two-sided Reversing connecting valve

801

Quick release coupling

901 902

904 909 910

Working hydraulics measuring point Ground drive hydraulics high pressure backward measuring point Ground drive hydraulics high pressure forward measuring point Ground drive hydraulics feed pressure measuring point Steering hydraulics measuring point Low-pressure hydraulics measuring point

Y9/Y10 Y19/Y20 Y21 Y22/Y23 Y24/Y25 Y33/Y34 Y35 Y67/Y68 Y77 Y85/Y87 Y86 Y88

AUTOPILOT left/right solenoid valve Threshing drum variable-speed drive slow/fast Threshing mechanism clutch engage solenoid valve Reel raise/lower solenoid valve Reel forward/backward solenoid valve Swing grain tank unloading tube in/out solenoid valve Grain tank unloading solenoid valve AUTOPILOT left/right transverse control solenoid valve Working hydraulics master valve solenoid valve Front attachment raise/lower solenoid valve Reverse front attachment solenoid valve Front attachment clutch solenoid valve

Z4

AUTOPILOT oil pressure actual value switch

A B M P P1 P2 P3 P4 R T

Consumer port Consumer port Reverser drive motor port Pump port Working hydraulics port Steering hydraulics port Ground drive hydraulics port Low-pressure hydraulics port Reverser drive motor port Tank port

903

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Overall hydraulic system

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1-7

Overall hydraulic system 1.2

1-8

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Oil tank, oil specification, filling quantities, oil change, oil filter, oil pressure

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TIC Key to diagram:

MEGA

Overall hydraulic system

112

Return flow filter

A B C D E F G H

Ground drive port Working hydraulics suction line Working hydraulics return line port Low-pressure hydraulics return line Steering return line Ground drive port Steering suction line Oil level dipstick

Z19

Hydraulic oil level (min.) actual value switch

Oil specification

Multigrade hydraulic oil HV (ISO VG 46), DIN 51524 part 3

Filling quantities

Total hydraulic system = 25 litres, depending on equipment fitted Oil change = 20 litres

Oil change

Once a year or after 500 operating hours Check oil only with cutterbar cylinders retracted.

Oil filter

Working hydraulics = Filtering screen inside tank (60 µm) Hydrostatic ground drive = Filter cartridge (10 µm) Filter change once a year or after 500 operating hours.

Oil pressure

+10 Working hydraulics = 180 bar +15 Steering = 125 bar Low-pressure hydraulics = 19+2 bar Ground drive high pressure = 420+30 bar Ground drive feed pressure = 18+2 bar Working hydraulics circulation pressure = 15+12 bar Steering hydraulics circulation pressure = 10+10 bar

Note: These values refer to measurements made at a hydraulic oil operating temperature of 45 – 50 °C.

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Overall hydraulic system 1.3

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Hydraulic pumps

TIC Key to diagram:

MEGA 205 217 218

Overall hydraulic system

Working hydraulics pump .................................... 11 cm3/rev.

Rotary chaff screen drive pump........................... 5.5 cm3/rev.

Steering hydraulics pump ................................... 5.5 cm3/rev.

706-1 Pressure relief valve ............................................ 120 bar A - Depending on the equipment fitted to the machine, the pressure relief valves (706-1, 706-2) are integrated either in the hydraulic pump (217) or in hydraulic motor (216).

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Steering hydraulics

Chapter 2 Steering hydraulics

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2.1

Steering hydraulics circuit diagram without AUTOPILOT............ 2-4

2.2

Steering hydraulics circuit diagram with AUTOPILOT................. 2-8

2.3

Steering valve unit ..................................................................... 2-10

2.4

Function of steering – neutral .................................................... 2-12

2.5

Checking the steering ................................................................ 2-16

2.6

AUTOPILOT left/right solenoid valve......................................... 2-18

2.7

Checking the AUTOPILOT System ........................................... 2-20

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Steering hydraulics

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2.1 Steering hydraulics circuit diagram - without AUTOPILOT

Steering hydraulics 2.1

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Steering hydraulics circuit diagram without AUTOPILOT Key to diagram:

Pressure measurement

IV

Steering (Orbitrol) valve block

108 110 112 205 218 323 609 725 726 728 742 909

Emergency steering oil tank ............................... approx. 250 cm3 Oil tank Working hydraulics return flow filter Working hydraulics pump .................................... 12 cm3 Steering hydraulics pump.................................... 6 cm3 Steering hydraulic cylinder Orbitrol steering unit rotary disc valve Steering double shock valve ............................... 200±15 bar Steering pressure relief valve.............................. 125+20 bar Non-return valve Steering safety valve Measuring port

Note:

The machines of the MEGA series are equipped with one steering cylinder (323) only. Therefore, these machines generally have the emergency steering tank (108) in order to compensate the volumetric difference between the piston surface and the piston ring surface.

Circulation pressure = 10+7 bar System pressure = 125+15 bar Shock valve = 200±15 bar Note:

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These values refer to measurements made at the max. noload speed of the diesel engine and a hydraulic oil operating temperature of approx. 60 °C.

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Steering hydraulics

Description of function: Steering

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In the neutral steering position, oil flows freely through the steering control unit = Orbitrol (609).

Turning the steering wheel to one direction causes the discs to rotate relative to each other. At 1.5°, opening the channels towards the chambers starts. At 4°, the neutral position channels are fully closed. At 6°, the channels to the chambers are fully open. The rotation of the discs relative to each other is limited to ± 8°.

A feed of pressurized oil to the rotor set has the following effects: Rotation of rotor Feed of an oil quantity which is proportional to the rotation into the steering cylinder, the rear wheels being influenced.

An internal mechanical return from the rotor to the outside disc so that the channels in the valve are closed when the rotor rotates to the same angle as the steering wheel.

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2.2 Steering hydraulics circuit diagram - with AUTOPILOT

Steering hydraulics 2.2

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Steering hydraulics circuit diagram with AUTOPILOT Key to diagram:

108 110 112 116 205 218 323 410 503 609 703 725 726 728 732 734 742 901 909

Emergency steering oil tank.................................250 cm3 Oil tank Working hydraulics return flow filter Resonance tube Working hydraulics pump.....................................12 cm3 Steering hydraulics pump ....................................6 cm3 Steering hydraulic cylinder Orifice plate ..........................................................Ø 1.5 mm AUTOPILOT accumulator ....................................80 bar Orbitrol steering unit rotary disc valve Working hydraulics pressure relief valve .............180+20 bar Steering double shock valve ................................200±15 bar Steering pressure relief valve ..............................125+20 bar Non-return valve Non-return valve (emergency steering) Lock-up valve unit (non-return valve) Steering safety valve Working hydraulics measuring port Steering hydraulics measuring port

P1 T

Pump port Tank port

Y 9/Y10

AUTOPILOT left/right solenoid valve

Z4

AUTOPILOT oil pressure (NC contact) pressure switch ....................................................135/160 bar

Note:

Pressure measurement

+7 Circulation pressure = 10 bar System pressure = 125+15 bar Shock valve = 200±15 bar

Note:

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The machines of the MEGA series are equipped with one steering cylinder (323) only. Therefore, these machines generally have the emergency steering tank (108) in order to compensate the volumetric difference between the piston surface and the piston ring surface.

These values refer to measurements made at the max. no-load speed of the diesel engine and a hydraulic oil operating temperature of approx. 60 °C.

TIC

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Steering hydraulics

Description of function: Steering

In the neutral steering position, oil flows freely through the steering control unit = Orbitrol (609).

Turning the steering wheel to one direction causes the discs to rotate relative to each other. At 1.5°, opening the channels towards the chambers starts. At 4°, the neutral position channels are fully closed. At 6°, the channels to the chambers are fully open. The rotation of the discs relative to each other is limited to ± 8°.

A feed of pressurized oil to the rotor set has the following effects: Rotation of rotor Feed of an oil quantity which is proportional to the rotation into the steering cylinder, the rear wheels being influenced.

An internal mechanical return from the rotor to the outside disc so that the channels in the valve are closed when the rotor rotates to the same angle as the steering wheel.

Autopilot (see Electric system Diagram 28)

When the road travel circuit is unlocked and the threshing mechanism is engaged, the AUTOPILOT module A 9 is supplied with power by the main switch S 10. Following the start signal by foot switch S 9, the solenoid coil Y9 / Y10 is actuated according to the signals from touch sensor B7 / B8.

The steering position is being checked by rear wheel position indicator B 6.

For safety reasons, the AUTOPILOT function is interrupted immediately by the signal of the overrider switch Z3 when actuating the steering manually. If the driver leaves the seat, the seat contact Z5 will interrupt the autopilot function after approx. 5 s.

The centralizing switch R3 on the switch console enables the machine to drive precisely straight ahead even when driving on a slope.

For quick response of the steering in autopilot mode, the hydraulic system is equipped with a accumulator 503. If the pressure in this accumulator falls below approx. 135 bar, the oil pressure switch Z4 actuates the circulation shut-off valve Y77 until the pressure level reaches approx.

160 bar again.

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Steering hydraulics 2.3

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Steering valve unit

TIC Key to diagram:

Steering system

MEGA 112 218 229 323 609 725 726 728 742 909

Steering hydraulics

Working hydraulics return flow filter Steering hydraulics pump ....................................6 cm3 Steering hydraulics proportioning pump Steering hydraulic cylinder Orbitrol steering unit rotary disc valve Steering double shock valve ................................200±15 bar Steering pressure relief valve ..............................125+20 bar Anti-cavitation valve (non-return valve) Steering safety valve Steering hydraulics measuring point

Open center: with the steering 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.

Valve unit

DANFOSS OSPB 125 with valve block OVP 20 O S P B 250 V 20

Design of valve unit

= Orbit (Orbitrol) = Steering = Pump = Version 3 = Oil displacement in cm /rev = Valve block = Pressure setting of shock valves x10

The steering valve consists of a steering hydraulics proportioning pump (229) and a rotating Orbitrol rotary disc (609).

The steering gear shaft actuates the Orbitrol rotary disc (609), the continued rotary movement driving the steering hydraulics proportioning pump (229) by means of a socket-type shaft.

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Steering hydraulics 2.4

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Function of steering - neutral

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Steering hydraulics

Description of function: Neutral

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In neutral position, the oil is directed back to the tank through the steering safety valve (742) and the Orbitrol rotary disc (609) (open center).

The circulation pressure must not exceed 10+7 bar.

Both sides of the steering hydraulic cylinder (323) are shut off by the Orbitrol rotary disc (609). Pressure peaks due to external forces on the steered axle are relieved to the tank via the steering double shock valves (725) (non reaction).

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Steering actuation

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Steering hydraulics

Description of function: Steering actuation

When actuating the steering to one or another direction, the Orbitrol rotary disc (609) is rotated by up to 8° relative to the outside disc. During this process, the return line from the steering hydraulics pump (218) to the tank is closed and the connection to the steering hydraulics proportioning pump (229) is released.

Via the steering hydraulics proportioning pump (229) and the Orbitrol rotary disc (609), the volume flow is released as a function of the sense of rotation, path and speed to the piston surface or the piston ring surface of the steering hydraulic cylinder (323). Here, the displacing surface of the steering hydraulic cylinder (323) is connected with the return line to the tank via the Orbitrol rotary disc (609).

As soon as there is no more steering motion, leaf springs bring the inner and the Orbitrol rotary discs (609) back to neutral position. Now both sides of the steering cylinder are shut off again and the connection from the steering hydraulics pump (218) to the tank is re-established.

Emergency steering

When the steering system is not supplied any more externally by steering hydraulics pump (218), the steering safety valve (742) closes and thus ensures that no oil will escape from the steering system.

When the steering is actuated, the inner and outer disc of the Orbitrol rotary disc (609) are rotated relative to each other. Now the oil can be conveyed from one side of the steering hydraulic cylinder (323) via the anti-cavitation valve (non-return valve) (728) to the other side through human power by the drive of the steering hydraulics proportioning pump (229).

On machines with one steering hydraulic cylinder (323), a reservoir in the return line to the tank compensates the volumetric difference between the piston surface and piston ring surface.

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Checking the steering

Steering gear shaft

Height play = 0.1 to 0.3 mm Clearance from bottom inside rotary disc = 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/minute in both directions when using a force of approx. 25 Nm. When the actual number of turns is more than 4/minute, check the steering valve for leaks.

When the actual number of turns is below 4/minute, check the steering cylinder for leaks.

Power

In case of steering forces above 25 Nm, check tyre size and pressure, condition of the piston rod and if stub axles move smoothly.

A pressure test at the steering hydraulics measuring port must show the +15 value 125 bar.

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

Important! 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.

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Steering hydraulics

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Steering hydraulics 2.6

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AUTOPILOT left/right solenoid valve

TIC Key to diagram:

MEGA

Steering hydraulics

410 503 604 732 734

Orifice plate ..........................................................Ø 1.5 mm AUTOPILOT accumulator ....................................0.7 l/ 80 bar AUTOPILOT balance screw Non-return valve Lock-up valve unit (non-return valve)

Y9 Y10

AUTOPILOT left solenoid valve AUTOPILOT right solenoid valve

Z4

Autopilot oil pressure actual value switch ............135/160±5 bar

A B P1 T

Steering cylinder port Steering cylinder port Working hydraulics pump via circulation shut-off valve port Working hydraulics return line port

Important! Prior to dismounting items 503, 732, Z4, Y9 or Y10, the accumulator must be relieved at the balance screw (604).

Description of function: If the accumulator pressure falls below 135±5 bar while the engine is running, the oil pressure switch (Z4) actuates the circulation shut-off valve (Y77).

The pressure build-up within the system caused by the circulation shut-off valve pre-loads the accumulator (503) via the non-return valve (732).

When the system pressure and consequently the accumulator pressure reach 160±5 bar, the oil pressure switch (Z4) opens and the circulation shut-off valve (Y77) goes back to neutral position. The non-return valve (732) separates the energy thus stored from the remaining working hydraulics system.

The pressure in this closed system is applied at the balls of the valve inserts of solenoid valves (Y9/Y10).

One of the solenoid valves (Y9/Y10) is actuated by the AUTOPILOT module, depending on the required steering direction.

The corresponding pilot spool opens the ball in the valve insert and closes the return line to the tank. The pressure now rising builds up against the piston and now opens the non-return valve at port A or B. The return line of the steering cylinder is relieved to the tank via the valve insert of the unactuated solenoid valve (Y9/Y10).

The pressure rising further now opens the non-return valve at the opposite port and the steering cylinder is retracted or extended.

When the corresponding steering angle has been reached, the AUTOPILOT module deenergizes the solenoid valve (Y9/Y10).

If the oil pressure inside the accumulator (503) falls below 135±5 bar during the steering procedure, the oil pressure switch (Z4) is closed.

The circulation shut-off valve is actuated again and the accumulator (503) is pre-loaded again (see Electric system – diagram 28).

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Steering hydraulics 2.7

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Checking the AUTOPILOT System When checking the steering at standstill, relieve the load from the rear axle by slightly raising the machine.

Fault: Diagnosis:

With the AUTOPILOT activated, the rear axle does not react. Manual steering and working hydraulics work flawlessly.

When the steering reacts when the corresponding solenoid valve is actuated manually, troubleshooting should start in the electric system.

When the steering reacts to manual actuation only if another working hydraulics function is also actuated, check the oil pressure switch on the valve block.

Fault: Diagnosis:

The hydraulic system is overheated in AUTOPILOT operation.

If overheating is removed by disconnecting the oil pressure switch connector, the following causes are possible: Accumulator defective Oil pressure switch defective Valve insert leaky Inlet valve leaky Pressure relief screw leaky

Fault: Diagnosis:

With the AUTOPILOT shut off, manual steering is heavy on one side.

Check the corresponding non-return valve in the lock-up valve unit.

Fault: Diagnosis:

The machines automatically steers to one or another direction.

Check the corresponding non-return valve in the lock-up valve unit and/or the steering cylinder seals.

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Working hydraulics

Chapter 3 Working hydraulics

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3.1

Working hydraulics circuit diagram.............................................. 3-4

3.2

Main Valve with master valve, pressure relief valve, raise/lower front attachment ........................................................ 3-6

3.3

Threshing Drum Speed Control ................................................. 3-14

3.4

Swing Grain Tank Unloading Tube............................................ 3-18

3.5

Reverse Front Attachment......................................................... 3-22

3.6

Vertical Reel Adjustment ........................................................... 3-26

3.7

Horizontal Reel Adjustment ....................................................... 3-30

3.8

AUTO-CONTOUR cutterbar transverse control ........................ 3-34

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Working hydraulics

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3.1 Working hydraulics circuit diagram

Working hydraulics 3.1

MEGA

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Working hydraulics circuit diagram Key to diagram:

I II

Main valve block Working hydraulics valve block

110 112

Oil tank Return filter

205 218 226

Working hydraulics pump .................................... 12 cm3/rev.

Steering hydraulics pump .................................... 6 cm3/rev.

Front attachment reverser drive motor

305 306 311 314 315 316 320 351 353

AUTOCONTOUR cross levelling right hydraulic cylinder AUTOCONTOUR cross levelling left hydraulic cylinder Threshing drum variable-speed drive hydraulic cylinder Reel raise/lower slave cylinder Reel raise/lower master cylinder Horizontal reel adjustment hydraulic cylinder Swing grain tank unloading tube hydraulic cylinder Raise/lower front attachment hydraulic cylinder Reverse front attachment hydraulic cylinder

406 408 441

Orifice plate F....................................................... Ø 0.8 mm Orifice plate.......................................................... Ø 1.2 mm Rotary coupling

508

Accumulator

614

Front attachment lower flow control valve

703 732 734 740 743 776

Working hydraulics pressure relief valve ............. 175 Non-return valve Lock-up valve unit (non-return valve) AUTOCONTOUR cross levelling flow control valve Lower front attachment pilot valve Reversing connecting valve

801 901

Quick release coupling Working hydraulics measuring port

A B M P P1 R T

Consumer port Consumer port Reverser drive motor port Pump port Working hydraulics port Reverser drive motor port Tank port

Y19/Y20 Y22/Y23 Y24/Y25 Y33/Y34 Y67/Y68 Y77

Threshing drum variable-speed drive slow/fast Reel raise/lower solenoid valve Reel forward/backward solenoid valve Swing grain tank unloading tube in/out solenoid valve AUTOPILOT left/right transverse control solenoid valve Working hydraulics master valve solenoid valve (only with autopilot) Front attachment raise/lower solenoid valve Reverse front attachment solenoid valve

Y85/Y87 Y86

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+15

bar

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Working hydraulics

Description of function: The working hydraulics of the MEGA series is an open hydraulic system.

The hydraulic functions of the working hydraulics are realised by two valve blocks (I+II) which may vary, depending on the equipment fitted to the machine.

The maximum system pressure is limited to 175+15 bar by means of pressure relief valve 703.

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Working hydraulics 3.2

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Main Valve with master valve, pressure relief valve, raise/lower front attachment

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TIC Key to diagram:

MEGA

Working hydraulics

614 703 732 743

Flow control valve ................................................5 – 50 l/min Pressure relief valve ............................................180+15 bar Non-return valve (inlet valve) Lower front attachment pilot valve

Y77 Y85 Y87

Working hydraulics master valve solenoid coil Raise front attachment solenoid valve Lower front attachment solenoid valve

A P P1 T

Raise/lower front attachment hydraulic cylinder Working hydraulics pump port Parallel port for working hydraulics of other directional control valves Tank port

E F H K L R U V

Pilot spool Compression spring Front attachment raise spool Front attachment quick lower piston Lower front attachment spool Control spool ........................................................5 – 50 l/min Master valve control spool Pilot valve

Description of function: Pressure limitation

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

0.5 mm shim corresponds to approx. 10 bar 1.2 mm shim corresponds to approx. 23 bar Note:

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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.

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Working hydraulics

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Basic setting To ensure the position of spool (H) for the function "Raise front attachment - slow", the dimension from the top edge of the spool (H) to the body must be 4.3 mm with the coil core (Y85) removed. The position may be corrected by removing or adding shims above the compression spring.

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

In order to guarantee the "Front attachment lower" function, the clearance between the top edge of spool (L) and the housing must be 4.5 mm with the coil core (Y87) removed. The position may be corrected by removing or adding shims.

Spare part no: 0.1 mm = 218 886.0 0.2 mm = 218 887.0 The drop rate of the front attachment can be adjusted to a drop time of 5 - 6 sec. over the entire stroke range.on the flow control valve (614).

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Working hydraulics

Description of function: Function of master valve

The master valve (Y77) blocks the circulating volume flow from P to T of the open hydraulic system when a working hydraulics function has been actuated. Single-acting functions are an exception to this if the consumer is relieved to the tank.

In neutral position, the master valve (Y77) 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 is successfully built up at a consumer, the master valve (Y77) is actuated simultaneously with the directional control valve of the corresponding function. Now spool (U) closes the connection from P to T, and the top ring channel being 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.

Raise front attachment function When the "Raise – fast" function is used, the directional control valve (Y85) and the master valve (Y77) 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 (A1) via the non-return valve (732) and quickly raises the front attachment.

Lower front attachment function When the "Lower – fast" function is used, only the directional control valve (Y87) 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 top side (K) and open the pilot valve (743).

The oil is now displaced by the front attachment via the pilot 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).

04/05

Me-h-Kap3

3-9

Working hydraulics

MEGA

TIC

Description of function: Flow control valve

When the "Lower front attachment – fast" function is used, the oil displaced via port A flows to the tank (T) 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 (T) as a function of the load pressure.

When the load pressure in port A changes, both the volume 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 volume flow and therefore the front attachment drop rate constant, independent of the load pressure.

The front attachment drop rate is adjusted merely by the pre-stress of the control spring at the handwheel.

Relieve tension of control spring = lower drop rate Tensioning the control spring = increase lower speed

3-10

Me-h-Kap3

04/05

TIC

MEGA

Working hydraulics

Me-h-Kap3

3-11

Notes:

04/05

Working hydraulics

MEGA

TIC

Me-h-Kap3

04/05

Raise / Lower Front Attachment Hydraulic cylinders

3-12

TIC Key to diagram:

MEGA

Working hydraulics

351

Raise/lower front attachment hydraulic cylinder

S

Cutterbar spring

Description of function: Cutterbar cylinder setting

Flawless function of AUTO-CONTOUR and CONTOUR requires correct basic setting of the cutterbar springs (S).

Since the cutterbar cylinders and consequently the cutterbar are supported by the cutterbar springs (S), the spring force determines the respective ground pressure the cutterbar exerts on the ground.

In this setting, a force of approx. 500 Nm (approx. 50 kg) exerted by the cutterbar on the ground with the spring compressed should not be exceeded.

-

04/05

Cutterbar is installed Reel in centre position Lower cutterbar to approx. 100 mm above the ground Set pre-load of compression springs at cheese-head screws Clearance between cylinder bottom plate and washer with nut: 5 - 10 mm (Increase clearance = turn screw in Reduce clearance = turn screw out)

Me-h-Kap3

3-13

Working hydraulics 3.3

3-14

MEGA

TIC

Threshing Drum Speed Control 3/3 way solenoid valve with lock-up valve unit

Me-h-Kap3

04/05

TIC Key to diagram:

MEGA

Working hydraulics

311 441 734 759

Threshing drum variable-speed drive hydraulic cylinder Rotary coupling Non-return valve (Lock-up valve unit) One-way restrictor valve, two-sided

Y19 Y20 Y33 Y34

Threshing drum variable-speed drive slow solenoid valve Threshing drum variable-speed drive fast solenoid valve Grain tank unloading tube swing out solenoid valve Grain tank unloading tube swing in solenoid valve

A P P1 T

Consumer port Working hydraulics pump port Parallel port for working hydraulics of other directional control valves Tank port

IIb

Working hydraulics valve block

Description of function: Neutral function

The threshing drum variable-speed drive hydraulic cylinder (311) is tightly closed by the ball seat in the valve insert of the threshing drum slow solenoid valve (Y19).

Increase speed function

The threshing drum fast solenoid valve (Y20) and the master valve are actuated at the same time. The corresponding pilot spool opens the ball in the valve insert and closes the return line to the tank. The pressure thus rising opens the ball in the valve insert of the unactuated threshing drum slow solenoid valve (Y19). The oil flows to consumer port A2 via the notch (a) in the one-way restrictor valve (759).

Reduce speed function

Solenoid valve (Y19) is actuated without the master valve. The pilot spool in question opens the ball in the valve insert and thus relieves the oil pressure via notches (b) of the one-way restrictor valve (597) and the valve insert of the unactuated threshing drum fast solenoid valve (Y20) to the tank.

Note:

04/05

To ensure even control function in both directions, volume flow flows via notches (b) in the one-way restrictor valve (759) when adjusting the variator.

Me-h-Kap3

3-15

Working hydraulics

MEGA

TIC

Me-h-Kap3

04/05

Threshing Drum Speed Control Hydraulic cylinder with rotary coupling

3-16

TIC Key to diagram:

04/05

MEGA

Working hydraulics

311 441 734 759

Threshing drum variable-speed drive hydraulic cylinder Rotary coupling Non-return valve (Lock-up valve unit) One-way restrictor valve, two-sided

Y19 Y20 Y33 Y34

Threshing drum variable-speed drive slow solenoid valve Threshing drum variable-speed drive fast solenoid valve Grain tank unloading tube swing out solenoid valve Grain tank unloading tube swing in solenoid valve

A P P1 T

Consumer port Working hydraulics pump port Parallel port for working hydraulics of other directional control valves Tank port

IIb

Working hydraulics valve block

Me-h-Kap3

3-17

Working hydraulics 3.4

3-18

MEGA

TIC

Me-h-Kap3

04/05

Swing Grain Tank Unloading Tube 4/3 way solenoid valve

TIC Key to diagram:

MEGA

Working hydraulics

320 408 734 759

Swing grain tank unloading tube hydraulic cylinder Orifice plate .........................................................Ø 1.2 mm Non-return valve (Lock-up valve unit) One-way restrictor valve, two-sided

Y19 Y20 Y33 Y34

Threshing drum variable-speed drive slow solenoid valve Threshing drum variable-speed drive fast solenoid valve Grain tank unloading tube swing out solenoid valve Grain tank unloading tube swing in solenoid valve

A B P P1 T

Consumer port Consumer port Working hydraulics pump port Parallel port for working hydraulics of other directional control valves Tank port

IIb

Working hydraulics valve block

Description of function: Neutral function

Both sides of the hydraulic cylinder (320) are tightly closed by the nonreturn valves (734).

Description of function

Depending on the necessary direction of movement, one of the solenoid valves (Y33/Y34) and, at the same time, the master valve (Y77) is 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 the piston in lock-up valve unit (734) of the swing grain tank unloading tube hydraulic cylinder (320) and in this process opens port A1 and/or B2.

The non-return valve (lock-up valve unit 734) is part of hydraulic cylinder (320).

The return line of the hydraulic cylinder is released to the tank via the valve insert of the unactuated solenoid valve (Y34/Y33). The pressure rising further now opens the non-return valve (lock-up valve unit 734) at the opposite port B4 and/or A4 and the hydraulic cylinder is retracted or extended.

04/05

Me-h-Kap3

3-19

Working hydraulics

MEGA

TIC

Swing Grain Tank Unloading Tube Hydraulic cylinder with hydraulic cushion and lock-up valve unit

3-20

Me-h-Kap3

04/05

TIC Key to diagram:

MEGA

Working hydraulics

320 408 734 759

Swing grain tank unloading tube hydraulic cylinder Orifice plate .........................................................Ø 1.2 mm Non-return valve (Lock-up valve unit) One-way restrictor valve, two-sided

Y19 Y20 Y33 Y34

Threshing drum variable-speed drive slow solenoid valve Threshing drum variable-speed drive fast solenoid valve Grain tank unloading tube swing out solenoid valve Grain tank unloading tube swing in solenoid valve

A B P P1 T

Consumer port Consumer port Working hydraulics pump port Parallel port for working hydraulics of other directional control valves Tank port

IIb

Working hydraulics valve block

Description of function: Safety valve

The non-return valve (lock-up valve unit) serves as a safety valve which is to keep the grain tank unloading tube from swinging out automatically when a line breaks.

Hydraulic cushion

The cylinder movement is slowed down before an end position is reached.

This is achieved by the peg (when retracting) or the bigger diameter of the piston rod (when extending) considerably reducing the cross-section of the return line.

04/05

Me-h-Kap3

3-21

Working hydraulics 3.5

3-22

MEGA

TIC

Me-h-Kap3

04/05

Reverse Front Attachment 3/2 way solenoid valve

TIC Key to diagram:

MEGA

Working hydraulics

226 314 315 353 406 731 732 734 740 776 801

Front attachment reverser drive motor Reel raise/lower slave cylinder Reel raise/lower master cylinder Reverse front attachment Orifice plate................................................................ Ø 0.8 mm Return line valve (non-return valve) Non-return valve Lock-up valve unit (non-return valve) AUTOCONTOUR cross levelling flow control valve Reversing connecting valve Quick release coupling

Y24 Y25 Y86 Y67 Y68

Reel forward solenoid valve Reel reverse solenoid valve Reverse front attachment solenoid valve AUTOCONTOUR cross levelling left solenoid valve AUTOCONTOUR cross levelling right solenoid valve

A B P P1

Consumer port Consumer port Working hydraulics pump port Parallel port for working hydraulics of other directional control valves Tank port

T

Description of function: Neutral function

The spring force displaces the oil from the reverser cylinder (353) via the connection from M to T inside the solenoid valve (Y86) to the tank. During this process, port (P1) is closed.

Reversing function

The solenoid valve (Y86) and the master valve (Y77) are actuated at the same time. During this, the return line to the tank is closed by solenoid valve (Y86) and the restrictor bore provides the connection from (P) to the consumer port (M).

When actuating the front attachment reverse solenoid valve (Y86), the restrictor bore creates a differential pressure at the reversing connecting valve (776) which in turn opens valve (776).

A notch in the main ram of reversing connecting valve (776) ensures a smooth start of the reversing process.

The reversing cylinder (353) extends and swings the hydraulic motor (226) to the drive gearwheel. Just before reaching the end position, the volume flow to the hydraulic motor (226) is released, ensuring reliable gearwheel engaging.

The non-return valve (732) keeps the hydraulic motor (226) from starting due to pressure peaks occurring in the return line.

04/05

Me-h-Kap3

3-23

Working hydraulics

MEGA

TIC

Me-h-Kap3

04/05

Reverse front attachment Hydraulic cylinder

3-24

TIC Key to diagram:

MEGA

Working hydraulics

226 314 315 353 406 731 732 734 740 776 801

Front attachment reverser drive motor Reel raise/lower slave cylinder Reel raise/lower master cylinder Reverse front attachment Orifice plate................................................................ Ø 0.8 mm Return line valve (non-return valve) Non-return valve Lock-up valve unit (non-return valve) AUTOCONTOUR cross levelling flow control valve Reversing connecting valve Quick release coupling

Y24 Y25 Y86 Y67 Y68

Reel forward solenoid valve Reel reverse solenoid valve Reverse front attachment solenoid valve AUTOCONTOUR cross levelling left solenoid valve AUTOCONTOUR cross levelling right solenoid valve

A B P P1

Consumer port Consumer port Working hydraulics pump port Parallel port for working hydraulics of other directional control valves Tank port

T

Description of function: Reversing

When the solenoid valve (Y86) is actuated, the reversing cylinder (353) extends and swings the hydraulic motor (226) to the drive gearwheel. Just before reaching its end position, the oil flow from the reversing cylinder (353) to the hydraulic motor (226) is released, ensuring reliable gearwheel engaging.

The non-return valve (732) keeps the hydraulic motor (226) from starting when pressure peaks occur in the return line.

Adjustment

04/05

The reverser support is aligned towards the feed rake conveyor drive shaft by adjusting an eccentric bushing on the reverser cylinder (353).

The piston stroke is adjusted using the set screw (E). With the reverser swung in, the set screw (E) must have a play of 0.5 mm from the end stop, then jam the set screw (E).

Me-h-Kap3

3-25

Working hydraulics 3.6

3-26

MEGA

TIC

Me-h-Kap3

04/05

Vertical Reel Adjustment 3/2 way solenoid valve

TIC Key to diagram:

MEGA

Working hydraulics

314 315 406 731 732 734 740 776 801

Reel raise/lower slave cylinder Reel raise/lower master cylinder Orifice plate................................................................ Ø 0.8 mm Return line valve (non-return valve) Non-return valve Lock-up valve unit (non-return valve) AUTOCONTOUR cross levelling flow control valve Reversing connecting valve Quick release coupling

Y24 Y25 Y67 Y68 Y86

Reel forward solenoid valve Reel reverse solenoid valve AUTOCONTOUR cross levelling left solenoid valve AUTOCONTOUR cross levelling right solenoid valve Reverse front attachment solenoid valve

A B P P1

Consumer port Consumer port Working hydraulics pump port Parallel port for working hydraulics of other directional control valves Tank port

T

Description of function: Neutral

The hydraulic cylinders are tightly closed by the non-return valve (731) in the valve insert of solenoid valve (Y23).

Raise reel

The solenoid valve (Y22) and the master valve (Y77) are actuated at the same time. The corresponding pilot spool opens the ball in the valve insert and closes the return line to the tank.

The pressure P1 which consequently rises opens the non-return valve (731) in the valve insert of the unactuated solenoid valve (Y23) and the oil flows to the consumer port A1.

Lower reel

Solenoid valve (Y23) is actuated without the master valve (Y77). The pilot spool in question opens the ball in the valve insert and thus relieves the oil pressure to the tank via the valve insert of the unactuated solenoid valve (Y22).

04/05

Me-h-Kap3

3-27

Working hydraulics

MEGA

TIC

Me-h-Kap3

04/05

Vertical Reel Adjustment Hydraulic cylinders

3-28

TIC Key to diagram:

MEGA

Working hydraulics

314 315 406 731 732 734 740 776 801

Reel raise/lower slave cylinder Reel raise/lower master cylinder Orifice plate................................................................ Ø 0.8 mm Return line valve (non-return valve) Non-return valve Lock-up valve unit (non-return valve) AUTOCONTOUR cross levelling flow control valve Reversing connecting valve Quick release coupling

Y24 Y25 Y67 Y68 Y86

Reel forward solenoid valve Reel reverse solenoid valve AUTOCONTOUR cross levelling left solenoid valve AUTOCONTOUR cross levelling right solenoid valve Reverse front attachment solenoid valve

A B P P1

Consumer port Consumer port Working hydraulics pump port Parallel port for working hydraulics of other directional control valves Tank port

T

Description of function: Synchronism function

These hydraulic synchronism cylinders are designed so that the face end of the left cylinder (315) corresponds to the piston rod side of the right cylinder (314). The cylinders therefore are synchronous, making the connecting rods retract and extend in parallel, independent of their load.

Bottom valves

The bottom valves (V) in master cylinder (315) are opened upon reaching the upper end stop position so that the slave cylinder can be filled and vented.

Note:

04/05

For repairs, it is recommended to remove the hydraulic cylinders in the raised reel position since the slave cylinder is filled only with the master cylinder fully extended.

During this process support and secure the reel properly.

Me-h-Kap3

3-29

Working hydraulics 3.7

3-30

MEGA

TIC

Me-h-Kap3

04/05

Horizontal Reel Adjustment 4/3 way valve with lock-up valve unit

TIC Key to diagram:

MEGA

Working hydraulics

316 406 408 731 732 734 740 776 801

Horizontal reel adjustment hydraulic cylinder Orifice plate.......................................................... Ø 0.8 mm Orifice plate.......................................................... Ø 1.2 mm Return line valve (non-return valve) Non-return valve Lock-up valve unit (non-return valve) AUTOCONTOUR cross levelling flow control valve Reversing connecting valve Quick release coupling

Y24 Y25 Y67 Y68 Y86

Reel forward solenoid valve Reel reverse solenoid valve AUTOCONTOUR cross levelling left solenoid valve AUTOCONTOUR cross levelling right solenoid valve Reverse front attachment solenoid valve

A B P P1

Consumer port Consumer port Working hydraulics pump port Parallel port for working hydraulics of other directional control valves Tank port

T

Description of function: Neutral

Both sides of the hydraulic cylinder are tightly closed by the non-return valves (734) in the consumer ports A and B.

Reel forward / reverse

Depending on the necessary direction of movement, one of the solenoid valves (Y24/Y25) and, at the same time, the master valve (Y77) is 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 (734) in port A2 or B2.

The return line of the hydraulic cylinder is thus released to the tank via the valve insert of the unactuated solenoid valve (Y24/Y25). The pressure rising further now opens the non-return valve (734) at the opposite port and the hydraulic cylinders are retracted or extended.

04/05

Me-h-Kap3

3-31

Working hydraulics

MEGA

TIC

Me-h-Kap3

04/05

Horizontal Reel Adjustment Hydraulic cylinders

3-32

TIC Key to diagram:

MEGA

Working hydraulics

316 406 408 731 732 734 740 776 801

Horizontal reel adjustment hydraulic cylinder Orifice plate.......................................................... Ø 0.8 mm Orifice plate.......................................................... Ø 1.2 mm Return line valve (non-return valve) Non-return valve Lock-up valve unit (non-return valve) AUTOCONTOUR cross levelling flow control valve Reversing connecting valve Quick release coupling

Y24 Y25 Y67 Y68 Y86

Reel forward solenoid valve Reel reverse solenoid valve AUTOCONTOUR cross levelling left solenoid valve AUTOCONTOUR cross levelling right solenoid valve Reverse front attachment solenoid valve

A B P P1

Consumer port Consumer port Working hydraulics pump port Parallel port for working hydraulics of other directional control valves Tank port

T

Description of function: Synchronism function

This pair of hydraulic synchronism cylinders are designed so that the face end of the left cylinder corresponds to the piston rod side of the right cylinder. The cylinders therefore are synchronous, making the connecting rods retract and extend in parallel, independent of their load.

Bottom valves

The bottom valves (V) open every time an end position is reached so that air inclusions in the connection between the two cylinders can be flushed out.

After a repair, the cylinders must be flushed in both end positions for approx. 15 sec.

04/05

Me-h-Kap3

3-33

Working hydraulics 3.8

3-34

MEGA

TIC

AUTO-CONTOUR cutterbar transverse control 4/3 way solenoid valve, lock-up valve unit

Me-h-Kap3

04/05

TIC Key to diagram:

MEGA

Working hydraulics

305 306 406 408 731 732 734 740 776

AUTOCONTOUR cross levelling right hydraulic cylinder AUTOCONTOUR cross levelling left hydraulic cylinder Orifice plate.......................................................... Ø 0.8 mm Orifice plate.......................................................... Ø 1.2 mm Return line valve (non-return valve) Non-return valve Lock-up valve unit (non-return valve) AUTOCONTOUR cross levelling flow control valve .....1.3 l/min Reversing connecting valve

Y24 Y25 Y67 Y68 Y86

Reel forward solenoid valve Reel reverse solenoid valve AUTOCONTOUR cross levelling left solenoid valve AUTOCONTOUR cross levelling right solenoid valve Reverse front attachment solenoid valve

A B P P1

Consumer port Consumer port Working hydraulics pump port Parallel port for working hydraulics of other directional control valves Tank port

T

Description of function: Both sides of the hydraulic cylinder are tightly closed by the non-return valves (734) in the consumer ports A and B. Cross levelling

Depending on the necessary direction of movement, one of the solenoid valves (Y19/Y20) and, at the same time, the master valve (Y77) is 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 (734) in 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 (Y24/Y25). The pressure rising further now opens the non-return valve (734) at the opposite port and the respective hydraulic cylinders are retracted or extended.

Flow control valve 740

04/05

Flow control valves ensure constant volume flow to the consumers even when the load pressure changes.

This function is achieved by the fact that the ram pressure ahead of the restrictor inside the control spool moves the control spool against the spring. During this process, the control edge is closed more or less, proportional to the pressure.

Thus, at a high ram pressure ahead of the control spool, more oil does flow through the restrictor, but correspondingly less flows past the control edge.

At a lower pressure, this ratio is reversed.

Me-h-Kap3

3-35

Working hydraulics

MEGA

TIC

AUTO-CONTOUR cutterbar transverse control Hydraulic cylinder

3-36

Me-h-Kap3

04/05

TIC Key to diagram:

MEGA

Working hydraulics

305 306 406 408 731 732 734 740 776

AUTOCONTOUR cross levelling right hydraulic cylinder AUTOCONTOUR cross levelling left hydraulic cylinder Orifice plate.......................................................... Ø 0.8 mm Orifice plate.......................................................... Ø 1.2 mm Return line valve (non-return valve) Non-return valve Lock-up valve unit (non-return valve) AUTOCONTOUR cross levelling flow control valve .....1.3 l/min Reversing connecting valve

Y24 Y25 Y67 Y68 Y86

Reel forward solenoid valve Reel reverse solenoid valve AUTOCONTOUR cross levelling left solenoid valve AUTOCONTOUR cross levelling right solenoid valve Reverse front attachment solenoid valve

A B P P1

Consumer port Consumer port Working hydraulics pump port Parallel port for working hydraulics of other directional control valves Tank port

T

Description of function: Bottom valves

04/05

The bottom valves (V) in master cylinder (315) are opened upon reaching the upper end stop position so that the slave cylinder can be filled and vented.

Me-h-Kap3

3-37

Working hydraulics

MEGA

TIC

3-38

Me-h-Kap3

04/05

TIC

MEGA

Low-pressure hydraulic circuit

Chapter 4 Low-pressure hydraulic circuit

04/05

4.1

Low-pressure hydraulic circuit diagram ....................................... 4-4

4.2

Pressure relief valve .................................................................... 4-6

4.3

Low-pressure hydraulic circuit solenoid valves Threshing mechanism clutch, grain tank unloading, front attachment clutch 3/2 way valves........................................ 4-8

4.4

3-D cleaning system .................................................................. 4-10

4.5

Front attachment drive Hydraulic cylinder with rotary coupling ...................................... 4-12

Me-h-Kap4

4-1

Low-pressure hydraulic circuit

MEGA

TIC

4-2

Me-h-Kap4

04/05

4.1 Low-pressure hydraulic circuit diagram

Low-pressure hydraulic circuit 4.1

MEGA

TIC

Low-pressure hydraulic circuit diagram Key to diagram:

4-4

Me-h-Kap4

04/05

III V

Low-pressure hydraulics valve block Ground drive hydraulics (hydrostatic motor)

102 109 110

Pressure filter ...................................................... 10 µm Oil cooler Oil tank

209 211

Ground drive feed pump Ground drive variable displacement pump HPV 105 (MEGA 360) ......................................... 105 cm3/rev.

HPV 75 (MEGA 350) ........................................... 75 cm3/rev.

301 308 312 313 321 352

3-D sieve pan hydraulic cylinder Diesel engine speed hydraulic cylinder Threshing mechanism clutch hydraulic cylinder Ground drive pump servo control hydraulic cylinder Grain tank unloading clutch hydraulic cylinder Front attachment clutch hydraulic cylinder

406 412 441

Orifice plate ......................................................... Ø 0.8 mm Orifice plate ......................................................... Ø 2.0 mm Rotary coupling

601 606

3D sieve pan pendulum control 4/3 way valve Ground drive servo control 4/3 way valve

710 713 714 716 718 729 760

Ground drive filter bypass valve .......................... 2 bar Ground drive multi-function valve backward Ground drive multi-function valve forward -2.5 Ground drive feed pressure relief valve .............. 23 bar Ground drive feed circuit cold weather starting valve Low-pressure hydraulic circuit pressure relief valve ............................................ 19+4 bar One-way restrictor valve, one-sided

902 903 904 910

Ground drive hydraulics high pressure backward measuring port Ground drive hydraulics high pressure forward measuring port Ground drive hydraulics feed pressure measuring port Low-pressure hydraulic circuit measuring port

Y13 Y14 Y21 Y35 Y88

Diesel engine 1st step solenoid valve (Perkins only) Diesel engine 2nd step solenoid valve (Perkins only) Threshing mechanism clutch solenoid valve Grain tank unloading solenoid valve Front attachment clutch solenoid valve

a

Only for PERKINS engines

TIC

MEGA

Low-pressure hydraulic circuit

Description of function: On MEGA combine-harvesters, the ground drive hydraulics feed pump supplies the low-pressure hydraulic circuit.

An orifice plate (412) restricts the oil flow from the hydrostatic system to the low-pressure hydraulic circuit to 5-7 litres at rated pressure. This ensures that the feed pressure for the hydrostatic ground drive will not collapse even in case of larger leaks in the low-pressure hydraulic circuit.

The hydraulic functions of the low-pressure hydraulic circuit are accommodated in a flanged-on valve block (III) which may vary, depending on the equipment fitted to the machine.

The maximum system pressure is limited to 19 pressure relief valve (729).

04/05

Me-h-Kap4

+4

bar by means of a

4-5

Low-pressure hydraulic circuit 4.2

4-6

MEGA

TIC

Me-h-Kap4

04/05

Pressure relief valve

TIC Key to diagram:

MEGA

Low-pressure hydraulic circuit

729

Low-pressure hydraulic circuit pressure relief valve 19+4 bar

A8

Port, volume flow input from ground drive feed pump (209)

P4

Port, volume flow input from ground drive feed pump (209)

T

Tank port

f k s

Compressed spring Piston Setscrew

Description of function: The compressed spring (f) pushes the piston (k) on the seat until the pressure (P4) overcomes the spring force. The piston (k) now opens the connection to the tank (T). This occurs at a pressure of 19 bar.

The setscrew (s) adjusts the spring force and consequently the opening pressure.

04/05

Me-h-Kap4

4-7

Low-pressure hydraulic circuit 4.3

4-8

MEGA

TIC

Low-pressure hydraulic circuit solenoid valves Threshing mechanism clutch, grain tank unloading, front attachment clutch 3/2 way valves

Me-h-Kap4

04/05

TIC Key to diagram:

MEGA

Low-pressure hydraulic circuit

A1 A4 A5 A6

Threshing mechanism clutch hydraulic cylinder port (312) Grain tank unloading clutch hydraulic cylinder port (321) Front attachment clutch hydraulic cylinder port (352) Low-pressure port 19 bar

P4 T s v

Low-pressure port 19 bar Tank port Emergency operation Valve insert

Y21 Y35 Y88

Threshing mechanism clutch solenoid valve Grain tank unloading solenoid valve Front attachment clutch solenoid valve

Description of function: With the solenoid valve de-energised, the connection from the hydraulic cylinder (A) to the return line into the tank (T) is provided 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 valve 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) whereas the return line to the tank (T) is blocked.

Note: 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.

04/05

Me-h-Kap4

4-9

Low-pressure hydraulic circuit 4.4

4-10

MEGA

TIC

3-D cleaning system Pendulum housing with 4/3 way valve and hydraulic cylinder

Me-h-Kap4

04/05

TIC Key to diagram:

MEGA

Low-pressure hydraulic circuit

301 406 601

3-D sieve pan hydraulic cylinder Orifice plate ..........................................................Ø 0.8 mm 3-D sieve pan pendulum control 4/3 way valve

T P4 A B

Tank port Low-pressure port 19 bar 3-D sieve pan hydraulic cylinder (301) port 3-D sieve pan hydraulic cylinder (301) port

a b c d e f

Lid Pendulum Housing Spool Bleeding screw (M6x16) Linkage

Description of function: Even with a slight lateral inclination of the machine, the housing (c) will change its position relative to the spool (d) which is constantly kept in a horizontal position by the pendulum (b) via a mechanical link.

This releases the oil flow (P4) to one of the two sides (A/B) of the 3-D sieve pan hydraulic cylinder (301).

The corresponding opposite side (A/B) is connected to the return line to the tank (T) by the pendulum housing (c).

The hydraulic cylinder (301) positions the housing (c) until the parallel vertical position relative to the pendulum (b) is reached again.

In this process, the 3-D sieve pan pendulum control 4/3 way valve (601) is returned to neutral position.

The movement of the pendulum housing (c) changes the sieve pan linkage (f) via a rodding. The height of the 3-D effect always depends on the inclination of the slope in question.

Bleeding of 3-D system

For filling and bleeding the housing (c), first the bleed screw (e) is loosened so the oil can flow without restriction.

With the rodding (f) to the sieve pan unhinged and at min. no-load speed of the diesel engine, the pendulum (c) housing is moved manually until the oil comes out without bubbles.

Now re-install the rodding (f) to the sieve pan.

Note:

04/05

Leaks near the bleed screw (e) must absolutely be avoided as otherwise there would be constant movement of the housing (c) against the end positions.

Me-h-Kap4

4-11

Low-pressure hydraulic circuit 4.5

4-12

MEGA

TIC

Me-h-Kap4

04/05

Front attachment drive Hydraulic cylinder with rotary coupling

TIC Key to diagram:

MEGA

Low-pressure hydraulic circuit

352 441

Front attachment clutch hydraulic cylinder Rotary coupling

a d t

Stop Pressure space Belleville spring pack

Description of function: The front attachment clutch is disengaged when the Belleville spring pack (t) pushes the front attachment clutch hydraulic cylinder (352) against stop (a).

To engage the front attachment clutch, low pressure is built up in the pressure space (d). In this process, the front attachment clutch hydraulic cylinder (352) is actuated against the Belleville spring pack (t).

04/05

Me-h-Kap4

4-13

Low-pressure hydraulic circuit

MEGA

TR

4-14

Me-h-Kap4

04/05

TIC

MEGA

Front attachments

Chapter 5 Front attachments 5.1

Cutterbar fold circuit diagram....................................................... 5-4

5.2

Maize picker fold / Snapping plate adjustment circuit diagram.................................. 5-8

5.3

Folding the cutterbar 6/2 way solenoid valve with lock-up valve unit .......................... 5-10 Folding the cutterbar Hydraulic cylinders .................................. 5-12

5.4

04/05

Folding the maize picker / Snapping plate adjustment Valve unit ................................................................................... 5-14

Me-h-Kap5

5-1

Front attachments

MEGA

TIC

5-2

Me-h-Kap5

04/05

5.1 Cutterbar fold circuit diagram

Front attachments 5.1

MEGA

TIC

Cutterbar fold circuit diagram Key to diagram:

I II

Working hydraulics valve block Working hydraulics front attachment valve block

314 315 316 343 372

Reel raise/lower hydraulic cylinder - follow-up cylinder Reel raise/lower hydraulic cylinder - main cylinder Hydraulic fore and aft reel adjustment hydraulic cylinder Cutterbar fold hydraulic cylinder Cutterbar lock hydraulic cylinder

406 408 426

Orifice plate 0.8 Orifice plate 1.2 Restrictor 0.8

628-1 Non-return valve

5-4

Me-h-Kap5

04/05

734

Lock-up valve unit

801

Quick release coupling

Y22 Y23 Y24 Y25 Y92

Reel raise solenoid valve Reel lower solenoid valve Reel forward solenoid valve Reel backward solenoid valve Front attachment fold reversing valve

TIC

MEGA

Front attachments

Description of function: Folding the cutterbar to working position

Oil flows from solenoid valve Y92 to the ring surface of hydraulic cylinder 372-1 via ports (B) and (V2). The pilot controlled non-return valve 628-1 is still closed. At the same time, oil flows from port (S2) to the piston surface of hydraulic cylinder 372-2 via the non-return valve of hydraulic cylinder 343. The piston rod extends and unlocks the cutterbar. The oil displaced on the ring surface side of hydraulic cylinder 372-2 flows back to the tank.

With the lock opened, the cutterbar folds to working position. In the end position, the non-return valve 628-1 is opened mechanically. This releases the return line (piston surface) of hydraulic cylinder 372-1. The cylinder piston rod retracts and locks the cutterbar. The orifice plates 401 and 402 ensure slow extension and retracting of hydraulic cylinder 343.

Folding the cutterbar to transport position

Oil flows from solenoid valve Y92 to hydraulic cylinder 372-1 (piston surface) via ports (A) and (S1) and the open non-return valve 628-1. The piston rod of cylinder 372-1 extends and unlocks the cutterbar. The oil from cylinder 372-1 (ring surface) flows back into the tank.

At the same time, oil flows from port (S1) to the ring surface side of hydraulic cylinder 343. The piston rod of cylinder 343 retracts.

With the lock opened, the cutterbar folds to transport position. In the end position of the piston rod of cylinder 343, the non-return valve 628-2 in hydraulic cylinder 343 is opened. This releases the return line (piston surface) of hydraulic cylinder 343 to the tank. The cylinder piston rod retracts and locks the cutterbar.

04/05

Me-h-Kap5

5-5

Front attachments

MEGA

TIC

5-6

Me-h-Kap5

04/05

5.2 Maize picker fold / Snapping plate adjustment circuit diagram

Front attachments 5.2

MEGA

TIC

Maize picker fold / Snapping plate adjustment circuit diagram Key to diagram:

5-8

Me-h-Kap5

04/05

I II VI

Working hydraulics valve block Working hydraulics front attachment valve block Maize picker working hydraulics valve block

327 330

Snapping unit fold hydraulic cylinder Snapping plate adjustment hydraulic cylinder

408

Orifice plate

734 760

Lock-up valve unit One-way restrictor valve, one-sided

801

Quick release coupling

S

Control spool

Y22 Y23 Y24 Y25

Reel raise solenoid valve Reel lower solenoid valve Reel forward solenoid valve Reel backward solenoid valve

TIC

MEGA

Front attachments

Description of function: Snapping plate adjustment (rigid maize picker)

By actuating the solenoid valves Y24 / Y25 for the reel forward/backward function, hydraulic cylinder 330 opens or closes the snapping plates.

Snapping plate adjustment (folding maize picker)

By actuating the solenoid valves Y24 / Y25 for the reel forward/backward function, hydraulic cylinder 330 opens or closes the snapping plates.

Upon actuation of the snapping plate adjustment, the maize picker fold hydraulic cylinders 327 are supplied with oil in parallel with hydraulic cylinder 330. However, the slide integrated in valve block VI blocks the free return to the tank and thus locks hydraulic cylinders 327 hydraulically (see Fold maize picker function).

Folding the maize picker

Folding the maize picker is possible only if the reel forward/backward function is actuated simultaneously with the reel lower function.

By actuating the solenoid valves Y24 / Y25 for the reel forward/backward function, hydraulic cylinder 330 opens or closes the snapping plates.

Upon actuation of the snapping plate adjustment, the maize picker fold hydraulic cylinders 327 are supplied with oil in parallel with hydraulic cylinder 330.

The slide integrated in valve block VI blocks the free return to the tank and thus locks hydraulic cylinders 327 hydraulically.

By actuating the reel lower solenoid valve Y23, the pressure downstream of slide S is reduced, slide S moves. With the return line open, the hydraulic cylinders 330 can move – the maize picker is folded.

After each folding of the snapping units, the snapping plates must be newly adjusted by actuating the reel adjustment.

04/05

Me-h-Kap5

5-9

Front attachments 5.3

5-10

MEGA

TIC

Folding the cutterbar 6/2 way solenoid valve with lock-up valve unit

Me-h-Kap5

04/05

TIC Key to diagram:

MEGA Y92

Front attachments

Front attachment fold reversing valve

Description of function: Reversing valve not actuated

Connection from port (II-A3) via the non-return valve to port (h1) or connection from port (II-A2) via non-return valve (see detail x) to port (h2).

The ports (s1) and (s2) have a connection to the respective return flow side by means of the centre bores in the slide and in the non-return valve (see detail Y).

Reversing valve actuated

Connection from port (II-A3) to ports (s1) and (v1) or connection from port (II-A2) to ports (s2) and (v2).

Leakage oil in the spring spaces of the main slide is drained to the tank via the non-return valves (detail Y). This avoids independent opening of the non-return valves in the lock-up valve units.

04/05

Me-h-Kap5

5-11

Front attachments

MEGA

TIC

Me-h-Kap5

04/05

Folding the cutterbar Hydraulic cylinders

5-12

TIC Key to diagram:

MEGA 343

Cutterbar fold hydraulic cylinder

406 426

Orifice plate Restrictor

K R

Piston rod Non-return valve

Front attachments

Description of function: With the piston rod retracted, the non-return valve (R) is mechanically open by the piston rod (K). The flow from (s3) to (s2) is free. The orifice plates and/or restrictors cause the piston rod to extend or retract slowly.

04/05

Me-h-Kap5

5-13

Front attachments 5.4

5-14

MEGA

TIC

Folding the maize picker / Snapping plate adjustment Valve unit

Me-h-Kap5

04/05

TIC Key to diagram:

MEGA

Front attachments

327 330

Maize picker fold hydraulic cylinder Snapping plate adjustment hydraulic cylinder

734 760

Lock-up valve unit One-way restrictor valve, one-sided

S

Control spool

Description of function: Folding out the snapping units

Oil flows from the reel forward/backward solenoid valve Y24/Y25 via port (II-A2) to the lock-up valve units 734-2 and 734-3 (Y24 is energized). The valves are opened by pressure build-up. The oil flows via port (A1) to the double-acting cylinders of the snapping units. The displaced oil from the cylinders flows to slide (S) via port (B1). The slide is opened against the control spring. The oil in the spring space of the slide is now displaced by the orifice plate and flows from port (B1) to port (II-A3) and from there to the tank via reel forward/backward solenoid valve Y24/Y25. During the fold-open process, oil flows via port (A2) to hydraulic cylinder 330 of the snapping plate adjustment. The cylinder is retracted. The displaced oil flows through the orifice plate of the one-way restrictor valve 760 to port (II-A3).

Folding in the snapping units

Oil flows from reel forward/backward solenoid valve Y24/Y25 to the snapping plate adjustment hydraulic cylinder 330 (Y25 being energized) via port (II-A3), lock-up valve unit (734-3), one-way restrictor valve 760 and port (B2).

The cylinder extends and opens the snapping plates. The slide (S) is pressure-loaded on both sides, which keeps the slide closed by the control spring. Actuating the reel lower solenoid valve Y23 reduces the oil pressure downstream of the slide orifice plate to port (I-A3). Slide S opens. The oil flows to hydraulic cylinders 327 via lock-up valve unit 734-2, port (B1). The units are folded in. The oil displaced by the hydraulic cylinders 327 flows back to the tank via ports (A1) and (II-A2) and the reel forward/backward solenoid valve Y24/Y25.

Adjusting the snapping plates

The snapping plates can only be adjusted with the units folded out. By actuating the solenoid valves Y24 / Y25 for the reel forward/backward function, hydraulic cylinder 330 opens or closes the snapping plates.

After each folding of the snapping units, the snapping plates must be newly adjusted by actuating the reel adjustment.

04/05

Me-h-Kap5

5-15

Front attachments

MEGA

TIC

5-16

Me-h-Kap5

04/05

TIC

MEGA

Ground drive hydraulics

Chapter 6 Ground drive hydraulics

04/05

6.1

LINDE ground drive hydraulics circuit diagram ........................... 6-4

6.2

Pump unit HPV 105 ..................................................................... 6-8

6.3

Servo adjustment valve ............................................................. 6-10

6.4

Ground drive multi-function valve .............................................. 6-12

6.5

Ground drive fixed displacement motor..................................... 6-14

6.6

4-Trac drive Valve unit............................................................... 6-16

6.7

Maintenance .............................................................................. 6-18

Me-h-Kap6

6-1

Ground drive hydraulics

MEGA

TIC

6-2

Me-h-Kap6

04/05

6.1 LINDE ground drive hydraulics circuit diagram

Ground drive hydraulics 6.1

MEGA

TIC

LINDE ground drive hydraulics circuit diagram Key to diagram:

6-4

Me-h-Kap6

04/05

4 5 6 7 9 10 11 12

Accumulator......................................................... 0.5 l Flow control valve................................................ 110 l/min 4/2-way valve (control spool) Non-return valve .................................................. 0.2 bar Flow divider Non-return valve Hydraulic motor (on the steering axle) 5/2-way valve (short-circuit valve)

102 109 110

Pressure filter ...................................................... 10 μm Oil cooler Oil tank

209 210 211

Ground drive feed pump...................................... 22 cm Ground drive fixed displacement motor .............. HMF 75 Ground drive variable displacement pump HPV 105 (MEGA 360) ......................................... 105 cm3/rev.

HPV 75 (MEGA 350) ........................................... 75 cm3/rev.

313

Ground drive pump servo control hydraulic cylinder

412

Orifice plate ......................................................... Ø 2 mm

606

Ground drive servo adjustment valve

710 713 714 716 718 719 721

Ground drive filter bypass valve .......................... 2 bar Ground drive multi-function valve backward Ground drive multi-function valve forward -2.5 Ground drive feed pressure relief valve .............. 23 bar Ground drive feed circuit cold weather starting valve ....................................................... 28±1 bar Ground drive purge pressure control valve ......... 10 bar Ground drive purging shuttle valve

902 903 904 910

Ground drive hydraulics high pressure backward measuring port Ground drive hydraulics high pressure forward measuring port Ground drive hydraulics feed pressure measuring port Low-pressure hyraulics measuring port

P3 T

Pump port Tank port

Y1

4-Trac (all-wheel drive) solenoid valve

3

TIC

MEGA

Ground drive hydraulics

Description of function: Oil supply

After starting the diesel engine, the ground drive feed pump (209) is driven.

In this process, the oil quantity is taken from the housing. The housing is directly connected with the oil tank (110).

Feed pressure circuit

The feed pressure builds up from the oil quantity pumped through the oil cooler (109) and the pressure filter (102) by the ground drive feed pump (209) against the ground drive feed pressure relief valve (716).

Depending on the spring setting, the oil flow is pre-stressed and then relieved to the tank.

The feed pressure is applied at the combined ground drive multi-function valves (713/714) and at both servo cylinders via the ground drive servo adjustment valve (606).

When the ground drive variable displacement pump (211) is not swung out, the feed pressure propagates to both sides of the high-pressure circuit via ground drive feed valve (709).

Servo adjustment

The cable mounted on the ground speed control lever moves the spool in the ground drive servo adjustment valve (606) from the neutral position to one or the other direction.

Depending on the direction of travel, one of the ground drive pump servo control hydraulic cylinders (313) is pressure-relieved whereas the other hydraulic cylinder remains connected to the feed pressure circuit. The motion at the swing disc corresponds to the pressure difference between the hydraulic cylinders.

The ground drive pump servo control hydraulic cylinders (313) swing the ground drive variable displacement pump (211) only by the path defined by the ground speed control lever because there is a mechanical feedback of the swing angle to the ground drive servo adjustment valve (606).

This mechanical feedback balances the spool in the ground drive servo adjustment valve (606) and therefore the pressure level between the two hydraulic cylinders at the control edge so that the defined swing angle is maintained.

High-pressure circuit

As soon as the ground drive variable displacement pump (211) is swung out, an axial motion is added to the radial motion of the pump unit.

This axial motion displaces the oil in the cylinder space of the rotor and thus acts on the motor unit which converts this energy into a rotating motion by supporting against the fixed inclined disc.

The respective suction side of the ground drive variable displacement pump (211) is pre-stressed via the feed pressure circuit and the corresponding ground drive multi-function valve (713/714). This ensures that the ground drive variable displacement pump (211) is sufficiently filled and that any occurring leaks are compensated.

Since feed pressure is always applied on the suction side of the ground drive variable displacement pump (211) as well as on the return flow side of the ground drive fixed displacement motor (210), this area is referred to as low-pressure side within the high-pressure circuit.

04/05

Me-h-Kap6

6-5

Ground drive hydraulics

MEGA

TIC

Description of function: High-pressure limitation

If the system pressure rises above the set maximum value, this overpressure is relieved to the feed pressure circuit by the ground drive multi-function valves (713/714).

The high-pressure limitation should only respond for a short time during operation since the large oil flow which has to be displaced by the heavily pre-stressed valves would rapidly overheat the system.

Purging device

The respective high-pressure side in the high-pressure circuit actuates the ground drive purging shuttle valve (721) in the ground drive fixed displacement motor (210) so the corresponding low-pressure side has a connection to the motor housing via the ground drive purge pressure control valve (719).

Since the pressure setting of the ground drive purge pressure control valve (719) is lower than that of the ground drive feed pressure relief valve (716), a constant oil quantity is exchanged by the ground drive feed pump (209) via the restrictor in the ground drive purge pressure control valve (719).

6-6

Me-h-Kap6

04/05

TIC

MEGA

Ground drive hydraulics

Me-h-Kap6

6-7

Notes:

04/05

Ground drive hydraulics 6.2

6-8

MEGA

TIC

Me-h-Kap6

04/05

Pump unit HPV 105

TIC Key to diagram:

MEGA

Ground drive hydraulics

209 606

Ground drive feed pump ......................................22 cm3 Ground drive servo adjustment valve

B D G K L R S V W

Control bottom Shaft seal Slide Piston Bearing Cylinder rotor Swing disc Adjusting lever Drive shaft

Description of function: As soon as the diesel engine is started, the cylinder rotor (R) as well as the ground drive feed pump (209) are driven by the nine pistons (K) arranged radially around the drive shaft (W).

In this process, the pistons (K) are pressed against the swing disc (S) by means of the slides (G) due to the feed pressure applied on both sides of the high-pressure circuit (H).

One of the servo cylinders is actuated by the ground drive servo adjustment valve (606) so that this cylinder swings the swing disc (S) according to the direction of travel and the ground speed.

During the swinging motion, the pistons (K) make an axial movement on the inclined plane of the swing disc (S) which results in the oil in the filled cylinder space being displaced and in a pressure building up against the resistance at the motor.

When the entire oil quantity in the cylinder space has been displaced, the piston (K) rotating with the rotor (R) is pushed back by the feed pressure and against the sloping inclined plane of the swing disc (S) on the lowpressure side.

The cylinder spaces in the rotor (R) are thus filled one after the other on the sloping side of the swing disc (S) (low pressure) and then displace this oil quantity on the rising side (high pressure) against the motor unit.

According to the direction of travel, the swing disc (S) is moved to one or the other direction, making high pressure and low pressure change sides as well. The ground speed depends on the oil flow size and consequently on the swing angle of the swing disc (S). The swing angle pre-set on the ground speed control lever is maintained by the mechanical feedback from the swing disc (S) to the servo adjustment valve (606).

The low-pressure side is separated from the high-pressure side inside the pump unit above the control bottom (B). For sealing purposes, the cylinder rotor (R) is merely pushed against the control bottom (B) with a compressed spring.

The exact return of the swing disc to its neutral position is achieved by compressed springs, and this factory setting cannot be modified from the outside.

The position of the adjusting lever (V) on the shaft gearing is marked with a punch blow on the servo adjustment housing. This position corresponds to the neutral position of the servo adjustment valve which is achieved within an angle of 8° of the adjusting range.

04/05

Me-h-Kap6

6-9

Ground drive hydraulics 6.3

MEGA

TIC

Servo adjustment valve

V

“Z”

“Z” V

606 X

G

P

313

313

P M

S

M

Z1023.0

6-10

Me-h-Kap6

04/05

TIC Key to diagram:

MEGA

Ground drive hydraulics

313 606

Ground drive pump servo control hydraulic cylinder Ground drive servo adjustment valve

G M P S V

Threaded bushing Mechanical feedback Spool Swing disc Adjusting lever

Description of function: Servo adjustment valve

In the neutral position of the ground drive servo adjustment valve (606), both ground drive pump servo control hydraulic cylinders (313) are pressure-loaded, keeping the swing disc (S) stable in any position.

The cable mounted on the adjusting lever (V) moves the spool (P) in the ground drive servo adjustment valve (606) from the neutral position to one or the other direction. Depending on the direction of travel, one of the ground drive pump servo control hydraulic cylinders (313) is thus pressure-relieved whereas the other servo cylinder remains connected to the feed pressure circuit.

The movement at the swing disc (S) thus corresponds to the pressure difference between the ground drive pump servo control hydraulic cylinder (313).

The ground drive pump servo control hydraulic cylinders (313) swing the variable displacement pump only by the path defined by the adjusting lever (V) because there is a mechanical feedback (M) of the swing angle to the ground drive servo adjustment valve (606).

This mechanical feedback (M) balances the spool (P) in the ground drive servo adjustment valve (606) at the control edge to the neutral position.

The pre-set swing angle is thus maintained by the pressure compensation in both ground drive pump servo control hydraulic cylinders (313).

Adjusting the hydraulic neutral position:

04/05

To align the mechanical neutral position of the adjusting lever (V) with the hydraulic neutral position of the variable displacement pump, the spool (P) in the servo adjustment valve is adjusted using the threaded bushing (G).

To do this, the bushing is first set to a clearance of X = 14.75 mm (X) from the housing of the ground drive servo adjustment valve (606). A pressure measurement on both sides of the high-pressure circuit determines the respective pressure rise caused by rotating the bushing (G) to one or the other direction. The centre position of the path by which the bushing (G) has been rotated corresponds to the average neutral position.

Me-h-Kap6

6-11

Ground drive hydraulics 6.4

MEGA

TIC

Me-h-Kap6

04/05

Ground drive multi-function valve

Z1022.0

6-12

TIC Key to diagram:

MEGA 1 2 3 4

Valve plunger High-pressure spring Valve insert Feed spring

H N S

High pressure No high pressure Feed pressure

Ground drive hydraulics

Description of function: High-pressure limitation

High pressure (H) is applied to the valve plunger (1) via the bores in the valve cartridge.

When the system pressure exceeds to pre-set value of the high-pressure spring (2), the valve plunger (1) backs away to the bottom against the spring pressure and relieves the high-pressure side towards the feed pressure circuit (S).

Feed

As soon as there is no high pressure (N) applied against the valve cartridge, the feed pressure (S) presses the entire valve insert (3) upwards against the feed spring (4) and thus opens the feed pressure circuit (S) to the low-pressure side (N).

04/05

Me-h-Kap6

6-13

Ground drive hydraulics 6.5

6-14

MEGA

TIC

Me-h-Kap6

04/05

Ground drive fixed displacement motor Motor unit HMF 105

TIC Key to diagram:

MEGA

Ground drive hydraulics

210 721 719

Ground drive fixed displacement motor ...............HMF 75 Ground drive purging shuttle valve Ground drive purge pressure control valve..........10 bar

B D G K L R S W

Control bottom Shaft seal Slide Piston Bearing Cylinder rotor Fixed inclined disc Drive shaft

Description of function: See also ground drive hydraulics circuit diagram

As soon as the diesel engine is started, the feed pump in the pump unit is also driven. In this process, the pistons (K) in the cylinder rotor (R) of the motor unit are pressed against the fixed inclined disc (S) by means of the slides (G) due to the feed pressure applied on both sides of the highpressure circuit.

As soon as the variable displacement pump is swung out, the pressure builds up against the nine pistons (K) in the cylinder rotor (R) which is geared to the drive shaft (W). Here the pistons (K) support themselves against the inclined plane of the fixed inclined disc (S) and thus convert this energy into a rotating motion against the resistance at the drive shaft (W).

The direction of rotation here depends on the direction of the oil flow and thus on the swing direction of the variable displacement pump, with high pressure and low pressure changing the sides. The motor speed results from the oil flow quantity therefore from the swing angle of the variable displacement pump.

The low-pressure side is separated from the high-pressure side inside the motor unit above the control bottom (B). For sealing purposes, the cylinder rotor (R) is merely pushed against the control bottom (B) with a compressed spring.

The respective high-pressure side in the high-pressure circuit actuates the ground drive purging shuttle valve (721) in the fixed displacement motor so the corresponding low-pressure side has a connection to the motor housing via the ground drive purge pressure control valve (719).

Since the pressure setting of the ground drive purge pressure control valve (719) is lower than that of the feed pressure relief valve, a constant oil quantity is exchanged by the feed pump (209) via the restrictor in the ground drive purge pressure control valve (719).

04/05

Me-h-Kap6

6-15

Ground drive hydraulics 6.6

6-16

MEGA

TIC

Me-h-Kap6

04/05

4-Trac drive Valve unit

TIC Key to diagram:

MEGA 4 5 6 7 8 (Y1) 9 10 12

Ground drive hydraulics

Accumulator ........................................................(0.5 litres) Flow control valve Activation spool (4/2-way valve) Non-return valve ..................................................(0.2 bar) 4-Trac solenoid valve Flow divider Non-return valve Short-circuit valve (5/2-way valve)

Description of function: 4-Trac shut off

The 4/2-way valve (6) blocks the high-pressure lines from the variable displacement pump (P1, P2). The short-circuit valve (12) is open. The short-circuit valve (12) opens the circuits from the rear axle motors (11) (connections M1, M2, M3, M4). Leakage oil from the motors flows to the variable displacement pump (1) housing. Missing oil is fed into the circuits by the feed pump (port F) via non-return valve (7) an the bottom flow divider (9). The accumulator (4) is pre-stressed with feed pressure. When the machine is towed (no feed pressure), the hydraulic motors are protected against overspeed by the declutching device. In this process, the mounting bolts are screwed into the threaded bores which are offset by 90° until the shut-down bushing hits its stop. Tightening torque of bolts = 25 Nm.

Engaging 4-Trac

The solenoid valve (8) is activated by electro-magnetic means. The feed pressure switches over the 4/2-way valve (6) and the short-circuit valve (12). The accumulator (4) ensures reliable and rapid switching-over of both valves. The open circuits of the rear axle motors (11) are closed by the activated short-circuit valve (12). The connection between the highpressure lines and the rear axle motors are opened by the 4/2-way valve (6). The oil pumped by the variable displacement pump (1) flows to the fixed displacement motor (3) and to the hydraulic motors (11). The oil quantity to the hydraulic motors (11) is limited to 110 l/min. by the respective flow control valve (5). This ensures that the fixed displacement motor (3) is supplied with oil in critical conditions. The respective flow divider (9) divides and/or controls the oil flow to the hydraulic motors (11), depending on the load on the individual motor. The oil returning from the motors flows to the pump via the non-return valves (10) of the other flow divider.

04/05

Me-h-Kap6

6-17

Ground drive hydraulics 6.7

MEGA

Maintenance

Filling instructions

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

Inspection regulations

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

6-18

TIC

Engage 3rd gear at the gearshift lever Disengage all-wheel drive Apply parking brake Connect pressure gauges on both high-pressure sides (M1+M2) Fill tank with hydraulic oil Pull out engine cut-off system relay and/or cable jumper Crank the diesel engine for a short period using the electric starting motor Check and correct the oil level Repeat procedure until the pressure has risen by approx. 10 bar Re-install engine cut-off system relay and/or cable jumper Start diesel engine at min. no-load speed Load the system with 50-150 bar forward for approx. 1 minute Load the system with 50-150 bar backward for approx. 1 minute Shut off diesel engine Check and correct the oil level if necessary Set gearshift lever to neutral position Start diesel engine at min. no-load speed Swing variable displacement pump forward for approx. 2 minutes Swing variable displacement pump backward for approx.

2 minutes Shut off diesel engine Check and correct the oil level if necessary Connect pressure gauges on both high-pressure sides Apply parking brake Heat up the system to an operating temperature of approx. 60 °C Move ground speed control lever to neutral position Set diesel engine to max. no-load speed Measure the feed pressure: 23-2.5 bar Feed pressure difference on both sides: max. 3 bar Swing out the variable displacement pump fully to one direction Pressure drop on low-pressure side: max. 4 bar Set diesel engine to min. no-load speed rd Engage 3 gear in manual transmission Apply service brake Slowly swing the variable displacement pump forward for 5 sec. max.

High pressure measurement: 420 to 450 bar Low pressure measurement: min. 14 bar Slowly swing the variable displacement pump backward for 5 sec. max.

High pressure measurement: 420 to 450 bar Low pressure measurement: min. 14 bar Shut off diesel engine Remove pressure gauge

Me-h-Kap6

04/05

TIC

MEGA

Rotary chaff screen

Chapter 7 Rotary chaff screen cleaning

04/05

7.1

Rotary chaff screen circuit diagram ............................................. 7-4

7.2

Rotary chaff screen drive............................................................. 7-6 Pump / motor with integrated pressure relief valve ..................... 7-6

Me-h-Kap7

7-1

Rotary chaff screen

MEGA

TIC

7-2

Me-h-Kap7

04/05

7.1 Rotary chaff screen circuit diagram

Rotary chaff screen 7.1

MEGA

TIC

Rotary chaff screen circuit diagram Key to diagram:

V

Ground drive hydraulics (hydrostatic motor)

102 109 110

Pressure filter ...................................................... 10 µm Oil cooler Oil tank

205 209 210

216 217 218 226

Working hydraulics pump .................................... 11 cm3/rev.

Ground drive feed pump...................................... 22 cm3/rev.

Ground drive fixed displacement motor HMF 75................................................................ 75 cm3/rev.

Ground drive variable displacement pump HPV 105 (MEGA 360) ......................................... 105 cm3/rev.

HPV 75 (MEGA 350) ........................................... 75 cm3/rev.

Rotary chaff screen motor ................................... 8.0 cm3/rev.

Rotary chaff screen pump ................................... 5.5 cm3/rev.

Steering hydraulics pump.................................... 5.5 cm3/rev.

Front attachment reverser drive motor

313

Ground drive servo control pump hydraulic cylinder

412

Orifice plate ......................................................... Ø 2.0 mm

706-1 706-2 710 713 714 716 718

Pressure relief valve (on pump side)................... 120 bar Pressure relief valve (on motor side) ................. 100 bar Ground drive filter bypass valve .......................... 2 bar Ground drive multi-function valve, reverse Ground drive multi-function valve, forward -2.5 Ground drive feed pressure relief valve .............. 23 bar Ground drive feed circuit cold start injector

902 903 904 910

Ground drive hydraulics high pressure backward measuring point Ground drive hydraulics high pressure forward measuring point Ground drive hydraulics feed pressure measuring point Low-pressure hydraulics measuring point

211

A - Depending on the equipment fitted to the machine, the pressure relief valves (706-1, 706-2) are integrated either in the hydraulic pump (217) or in hydraulic motor (216).

7-4

Me-h-Kap7

04/05

TIC

MEGA

Rotary chaff screen

Me-h-Kap7

7-5

Notes:

04/05

Rotary chaff screen 7.2

7-6

MEGA

TIC

Rotary chaff screen drive Pump / motor with integrated pressure relief valve

Me-h-Kap7

04/05

TIC Key to diagram:

MEGA 205 217 218

Rotary chaff screen

Working hydraulics pump.....................................11 cm3/rev.

Rotary chaff screen pump....................................5.5 cm3/rev.

Steering hydraulics pump ....................................5.5 cm3/rev.

706-1 Pressure relief valve (on pump side) ...................120 bar 706-2 Pressure relief valve (on motor side) ...................100 bar A - Depending on the equipment fitted to the machine, the pressure relief valves (706-1, 706-2) are integrated either in the hydraulic pump (217) or in hydraulic motor (216).

Description of function: Pressure relief valve

04/05

The pressure relief valve (706) limits the pressure in the hydraulic system and protects the connected mechanical components against damage due to excessive forces.

The spring in the pressure relief valve (706) is pre-stressed for a system pressure of 120 bar.

Me-h-Kap7

7-7

Rotary chaff screen

MEGA

7-8

Me-h-Kap7

TIC

04/05

Index

MEGA Chapter

Index

Index-2

TIC

3-D cleaning system

4.4

A

AUTO-CONTOUR solenoid valve AUTO-CONTOUR transverse control AUTOPILOT AUTOPILOT solenoid valve

3.8 3.8 2.6 2.6

C

Checking the steering Cutterbar raise/lower

2.5 3.2

F

Filter Filling quantities Front attachment clutch Front attachment drive Front attachment raise/lower solenoid valve Front attachment reverse hydraulic cylinder Front attachment reverse pre-loading valve Front attachment reverse solenoid valve

1.2 1.2 4.5 45 3.2 3.5 3.5 3.5

G

Grain tank unloading Grain tank unloading tube hydraulic cylinder Ground drive multi-function valve

4.3 3.4 6.4

H

Hydraulic fore and aft reel adjustment Hydraulic fore and aft reel adjustment hydraulic cylinder Hydraulic fore and aft reel adjustment solenoid valve Hydraulic pumps Hydraulic rotary chaff screen Hydraulic rotary chaff screen circuit diagram Hydrostatic ground drive maintenance

3.7 3.7 3.7 1.3, 6.2, 7.2 7 7.1 6.7

L

LINDE ground drive hydraulics LINDE ground drive hydraulics circuit diagram LINDE ground drive motor unit LINDE hydrostatic ground drive Low-pressure hydraulics pressure relief valve Low-pressure hydraulic system Low-pressure hydraulic system circuit diagram

6 6.1 6.5 6 4.2 4 4.1

Me-h-Index

04/05

TIC

04/05

MEGA O

Oil change Oil filter Oil pressure Oil specification Oil tank Overall hydraulic circuit diagram

1.2 1.2 1.2 1.2 1.2 1.1

P

Pumps

1.3, 6.2, 7.2

R

Reel vertical adjustment solenoid valve Rotary chaff screen Rotary chaff screen pressure relief valve

3.6 7 7.2

S

Servo adjustment valve Steering Steering hydraulics Steering hydraulics with AUTOPILOT circuit diagram Steering hydraulics without AUTOPILOT circuit diagram Steering valve unit Swing grain tank unloading tube Swing grain tank unloading tube solenoid valve

6.3 2.4 2 2.2 2.1 2.3 3.4 3.4

T

Threshing drum speed control Threshing drum speed control hydraulic cylinder Threshing mechanism clutch Threshing mechanism clutch, grain tank unloading, Front attachment clutch solenoid valve

3.3 3.3 4.3

V

Vertical reel adjustment hydraulic cylinder

W

Working hydraulics Working hydraulics circuit diagram Working hydraulics pressure relief valve

Me-h-Index

4.3

3 3.1 3.2

Index-3

Index-4

MEGA

TIC

Me-h-Index

04/05

At CLAAS KGaA mbH we are constantly improving our products to reflect the latest technological developments. For this reason, we may from time to time need to make changes to diagrams and descriptions in this documentation which do not reflect products which have already been delivered and which will not be implemented on these machines.

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 are reserved.

CLAAS KGaA mbH 33426 Harsewinkel Germany

Our contribution to the environment: CLAAS have printed this manual on 100 % chlorine free paper.

CLAAS KGaA mbH Postfach 1163 33426 Harsewinkel Tel. +49 (0)5247 12-0 www.claas.com

0293 811.0 SYS-H MEGA 370 - 350 from serial number: 845 00387 835 00361 EN - 12.05 - NF Printed in Germany