CLAAS Mowers COUGAR 1400 Hydraulic Technical Systems Manual - PDF DOWNLOAD

COUGAR 1400

Technical Systems Hydraulic System

2732

2

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

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Table of Content 1 Overall hydraulic system Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Overall circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 PFC pump - compensation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Graphic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 PFC pump - initial position (Engine OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Graphic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Description of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 PFC pump - low-pressure standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Graphic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Description of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 PFC pump - pump changes to delivery mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Graphic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Description of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 PFC pump - constant volume flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Graphic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Description of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 PFC pump - downstroking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Graphic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Description of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 PFC pump - maximum pressure limitation (pressure relief valve function) . . . . . . . . . . . . . . . 32 Graphic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Description of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2 Steering hydraulics System concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Emergency steering mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 The motor axle steered by the Orbitrol steering unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Fully electronic steering mode (steer-by-wire) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

3

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Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Steering hydraulics valve block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3 Working hydraulics Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Working hydraulics circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Working hydraulics valve block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Side arm solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Discription of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Front power lift solenoid valve, front mower unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Discription of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Constant-pressure system valve block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Upper link, safety frame solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Discription of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Cab rotation solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Discription of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Constant-pressure system solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Testing and measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Graphic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

4 Low-pressure hydraulic system Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Low-pressure hydraulic system circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Low-pressure hydraulic system valve block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Discription of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 4-Trac solenoid valve, differential lock, gearbox shifting, drive clutch . . . . . . . . . . . . . . . . . . 99 Graphic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

4

2732

Discription of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Testing and measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Graphic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

5 Ground drive hydraulics Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Ground drive hydraulics circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Ground drive control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Ground drive variable-displacement pump (211) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Additional feed and ground drive cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Ground drive forward/reverse solenoid coil, shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Ground drive variable-displacement motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Testing and measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Pressure testing using the signals from the high-pressure sensors B97, B98 . . . . . . . . . . . 117 Measured value table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

6 Location of components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Main sub-assemblies (I to XI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Component grid (DIN A3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

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1 Overall hydraulic system Hydraulic circuit diagram 2733

1 Overall hydraulic system Hydraulic circuit diagram

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

7

1 Overall hydraulic system Hydraulic circuit diagram 2733

Overall circuit diagram

B123

109-1 110 Z19

112

II

716-2

112

20

Z102

710

732

2bar

A3

102 B97

E

Z46

XSP

719-1

E L

Y144-2

10

U(L)

1L

Xb

210-2 355-2

210-1

3026-2

B

XB

Xa

B

B99

VIII

B98

S(P)

B

713

3016

A2

Y206-2 M12.2

M12.1

Z40

B2

759-1

218

716-1

3015

780

758

A1

3011

T

B1

Y194-2

Y194-1

M23

M24

772 Y

759-2

IX

738

Z

X

109-2 323-1

3016

209-2

773

442

734

Y206-1

211

209-1 714

377

3016 734

718

S

205

313 355-1

M20.2

3026-1

Z60

Ms Mp

719-2 U(L)

10

Y201

M20.1

B3

B10

A

721-2

Y144-1

Y200

U(L)

L(U)

L(U)

721-1

L(U)

A

XA

734

734

LS

323-2 3003 Y142

B16

Y191

p=55bar

519 Y106

Y143 BR1

BR3

644

BR2

Z80-2

VA

HA

30bar

p=2bar

642

240

732 Br1

3032

734

DS1

BR3 S3

102

V

245

516 30bar

M22

Y141

Z79-1

780

S1

725-3

BR2

784

S2

B2-1

516 516 30bar 40bar

516

40bar

DS2

732

IV

609

Z104 P=115bar

VII

763 LS

P

P

175

T

70bar

515-1

3024

726 T

P

Y205-1 S2

S1

725-1

240

P

725-2

240

362-1 909-4

901

3017-2

3017-1

VI

102 770

515

515

Y209-2

S1 S2

M5.3

909-5 909-6 909-7

Y188-2

Y189-7

Y189-5

1.2

1.7

1.5

Y209-1 M5.2

Y210-2

Y210-1

M6.3

M6.2

772

363

704 Y214 772

1.8

1.3

772

Z102-1

I

Y216

M3.2

772

I

Y218

M1.2

772

M2.2

515-2

372

Y189-8

Y188-3

772

734

362-2

734

734

734

Y212 1.1

1.4

3.2A

3.2B

3.1A

A B

Y190-2a

641 BL/L

Y188-1

Y188-4

3.1B A B

Y190-2b Y190-1a

Y189-10

Y189-6

Y189-9

1.10

1.6

1.9

Y190-1b

732-2 772

641

Y199-1

Y1

Y199-2

Y107

Y108

AR/R

729

909-1

24+1 bar

A

910

B

Y207

A

B

M5.1

Y208

A

B

M6.1

732-1

414

XP BR

909-3

M3.3

B

A

Y215

B

A

759-4

M2.3

515-6

XI

3025

515-4

B2-4

515-4

411

Z103

B

A

M1.3

Y217

80bar

3027-1

763 XP ZLP

Y213

M11.1

80bar

180

763

Y211

XP Orb

732-3

768

759-5

759-3

M11.2

Y105

706 768

M1.1

B2-2

302

P2

P1

B2-5

Y205-2

B2-6

B2-3

M3.1

B139

XP NLP

909-2

3013-1

B140-1 3028-1

515-3 3027-2

IIIa A3

Y202-2b 3016

3018-2 B162-1

A1

706 250bar

B3

Y203-1b

3022 Y204-1b

B1

A2

3018-1 B162-2

734

A1

706 250bar

B2

3016 Y203-1a

732

3019-1 732

734 B1

3022 Y204-2a

8

734

Y202-1a

3019-2

734

3022

401324

Y202-1b 3016

B2

Y203-2a Y204-2b

A2

734

A3

3013-2

B3

3016 3022

3028-2

734

Y202-2a Y203-2b

IIIb

B140-2

Y204-1a 3020-2

3021-2

3020-1

3021-1

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

1 Overall hydraulic system Hydraulic circuit diagram 2734 1 Overall hydraulic Hydraulic circuit diagram system

Designations Item

Designation

Remark

I

Working hydraulics valve block

-

II

Constant-pressure system valve block

-

IIIa

Left side arm valve block

-

IIIb

Right side arm valve block

-

IV

Orbitrol steering unit valve block

-

V

Steering sense valve block

-

VI

Steering hydraulics valve block

-

VII

Brake valve block

-

VIII

Working hydraulics pump unit

-

IX

Ground drive pump unit

-

Xa

Ground drive motor unit

-

Xb

Ground drive motor unit

-

XI

Low-pressure hydraulic system valve block

-

-

-

-

102

Pressure filter

10 µm

109-1

Hydraulic system oil cooler

-

109-2

Hydraulic system oil cooler

-

110

Oil tank

-

112

Return filter

125 µm

-

-

-

205

Working hydraulics pump

55 cm3/rev.

209-1

Ground drive feed pump

22.5 cm3/rev.

209-2

Ground drive feed pump

11 cm3/rev.

211

Ground drive variabledisplacement pump

-

210-1

Ground drive variabledisplacement motor

-

210-2

Ground drive variabledisplacement motor

-

218

Steering hydraulics pump

11 cm3/rev.

245

Emergency steering pump

16 cm3/rev. (max. 12 l/min.)

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

9

1 Overall hydraulic system Hydraulic circuit diagram 2734

Item

Designation

Remark

-

-

-

302

Four-wheel clutch hydraulic cylinder

-

313

Ground drive pump servo adjustment hydraulic cylinder

-

323-1

Rigid axle steering hydraulic cylinder

-

323-2

Floating axle steering hydraulic cylinder

-

355-1

Ground drive motor servo adjustment hydraulic cylinder

-

355-2

Ground drive motor servo adjustment hydraulic cylinder

-

362-1

Differential lock hydraulic cylinder

-

362-2

Differential lock hydraulic cylinder

-

363

Gearbox shifting hydraulic cylinder

-

377

Variable-displacement pump hydraulic cylinder

-

3003

Service brake / Parking brake hydraulic cylinder

-

3011

Unlock cab hydraulic cylinder

-

3013-1

Front power lift hydraulic cylinder

-

3013-2

Front power lift hydraulic cylinder

-

3015

Upper link hydraulic cylinder

-

3016

Safety frame hydraulic cylinder

-

3017-1

Drive clutch hydraulic cylinder

-

3017-2

Drive clutch hydraulic cylinder

-

3018-1

Side arm internal tube telescoping hydraulic cylinder

-

3018-2

Side arm internal tube telescoping hydraulic cylinder

-

3019-1

Side arm external tube telescoping hydraulic cylinder

-

3019-2

Side arm external tube telescoping hydraulic cylinder

-

10

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

1 Overall hydraulic system Hydraulic circuit diagram 2734

Item

Designation

Remark

3020-1

Side arm external tube telescoping hydraulic cylinder (swivelling)

-

3020-2

Side arm external tube telescoping hydraulic cylinder (swivelling)

-

3021-1

Collision protection hydraulic cylinder (starting protection)

-

3021-2

Collision protection hydraulic cylinder (starting protection)

-

3022

Transport lock hydraulic cylinder

-

3023

Centre front mower unit raise/lower hydraulic cylinder

-

3024

Left front mower unit raise/ lower hydraulic cylinder

-

3025

Right front mower unit raise/ lower hydraulic cylinder

-

3026-1

Cab rotation hydraulic cylinder

-

3026-2

Cab rotation hydraulic cylinder

-

3027-1

Left side arm raise/lower hydraulic cylinder

-

3027-2

Left side arm raise/lower hydraulic cylinder

-

3028-1

Right side arm raise/lower hydraulic cylinder

-

3028-2

Right side arm raise/lower hydraulic cylinder

-

3032

Left mower unit raise/lower hydraulic cylinder

-

-

-

-

411

Orifice plate

Ø 1.8 mm

414

Orifice plate

Ø 3.5 mm

442

Venturi tube

-

-

-

-

515

Pressure accumulator

6 bar, 0.16 l

515-1

Pressure accumulator

2 x 70 bar, 0.75 l

515-2

Pressure accumulator

3 x 70 bar, 0.75 l

515-3

Pressure accumulator

3 x 70 bar, 0.75 l

515-4

Pressure accumulator

3 x 80 bar, 0.75 l

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

11

1 Overall hydraulic system Hydraulic circuit diagram 2734

Item

Designation

Remark

515-5

Pressure accumulator

3 x 80 bar, 0.75 l

515-6

Pressure accumulator

0.75 l

516

Service brake pressure accumulator

-

519

Parking brake pressure accumulator

-

-

-

-

609

Orbitrol steering system rotary valve

-

641

Shut-off valve

-

642

Service brake valve

-

644

Steering sense valve

-

-

-

-

704

Bypass valve (non-return valve)

-

706

Pressure relief valve

-

710

Ground drive filter bypass valve

∆p = 3 bar

713

Ground drive multifunction valve, reverse

-

714

Ground drive multifunction valve, forward

-

716-1

Ground drive feed pressure relief valve

p = 22.5 bar

716-2

Ground drive feed pressure relief valve

p = 20 bar

718

Ground drive feed circuit cold start injector

p = 30 bar

719-1

Ground drive flush pressure control valve

p = 10 bar

719-2

Ground drive flush pressure control valve

p = 10 bar

721-1

Ground drive flush-out shuttle valve

-

721-2

Ground drive flush-out shuttle valve

-

725-1

Floating axle steering double shock valve

240 bar

725-2

Fixed axle steering double shock valve

240 bar

725-3

Orbitrol steering double shock valve

240 bar

12

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

1 Overall hydraulic system Hydraulic circuit diagram 2734

Item

Designation

Remark

726

Steering pressure relief valve

175 bar

729

Low-pressure hydraulic system pressure relief valve

24+1 bar

732

Non-return valve

-

734

Lock-up valve unit (nonreturn valve)

-

738

Ground drive servo control pilot valve

-

758

Ground drive servo control restrictor valve

-

759-1

One-way restrictor, two-sided

-

759-2

One-way restrictor, two-sided

-

759-3

One-way restrictor, two-sided

15 l/min.

759-4

One-way restrictor, two-sided

15 l/min.

759-5

One-way restrictor, two-sided

15 l/min.

763

Input pressure balance

-

768

LS signal shuttle valve

-

770

Priority valve

-

772

Volume flow controller

-

773

Pressure controller

max. 200 bar

780

Shuttle valve

-

784

Accumulator charge valve

-

-

-

-

901

Working hydraulics measuring point

-

909-1

Steering hydraulics Orbitrol measuring point

-

909-2

Steering hydraulics emergency steering pump measuring point

-

909-3

Steering hydraulics system pressure (steering/brake) measuring point

-

909-4

Steering hydraulics steering cylinder XP1 measuring point

-

909-5

Steering hydraulics steering cylinder XP2 measuring point

-

909-6

Steering hydraulics steering cylinder XS1 measuring point

-

909-7

Steering hydraulics steering cylinder XS2 measuring point

-

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

13

1 Overall hydraulic system Hydraulic circuit diagram 2734

Item

Designation

Remark

910

Low-pressure hydraulic system measuring point

-

-

-

-

B2-1

Ground pressure sensor oil pressure (front centre)

-

B2-2

Ground pressure sensor oil pressure (front left)

-

B2-3

Ground pressure sensor oil pressure (front right)

-

B2-4

Ground pressure sensor oil pressure (left side arm)

-

B2-5

Ground pressure sensor oil pressure (right side arm)

-

B2-6

Ground pressure sensor oil pressure (front power lift)

-

B10

Diesel engine speed sensor

-

B16

Transmission speed sensor (ground speed)

-

B97

Ground drive hydraulics forward high-pressure sensor

-

B98

Ground drive hydraulics reverse high-pressure sensor

-

B99

Hydraulic motor speed sensor

-

B123

Hydraulic oil temperature sensor

-

B139

Power lift sensor

-

B140-1

Left side arm position sensor

-

B140-2

Right side arm position sensor

-

B162-1

Mower unit swivel angle sensor

-

B162-2

Mower unit swivel angle sensor

-

-

-

-

Y1

4-Trac (all-wheel drive) solenoid valve

3/2-way solenoid valve

Y105

Differential lock solenoid valve

3/2-way solenoid valve

Y106

Parking brake solenoid valve

3/2-way solenoid valve

Y107

Gearbox shift 1st gear solenoid valve

3/2-way solenoid valve

14

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

1 Overall hydraulic system Hydraulic circuit diagram 2734

Item

Designation

Remark

Y108

Gearbox shift 2nd gear solenoid valve

3/2-way solenoid valve

Y141

Ground drive forward solenoid valve

4/2-way solenoid valve

Y142

Ground drive reverse solenoid valve

4/2-way solenoid valve

Y143

Ground drive/shut-off valve solenoid valve

-

Y144-1

Ground drive variabledisplacement motor solenoid valve

4/2-way solenoid valve

Y144-2

Ground drive variabledisplacement motor solenoid valve

4/2-way solenoid valve

Y188-1

Steering shut-off valve solenoid valve (1.1)

2/2-way solenoid valve

Y188-2

Steering shut-off valve solenoid valve (1.2)

2/2-way solenoid valve

Y188-3

Steering shut-off valve solenoid valve (1.3)

2/2-way solenoid valve

Y188-4

Steering shut-off valve solenoid valve (1.4)

2/2-way solenoid valve

Y189-5

Steering logics definition valve solenoid valve (1.5)

2/2-way solenoid valve

Y189-6

Steering logics definition valve solenoid valve (1.6)

2/2-way solenoid valve

Y189-7

Steering logics definition valve solenoid valve (1.7)

2/2-way solenoid valve

Y189-8

Steering logics definition valve solenoid valve (1.8)

2/2-way solenoid valve

Y189-9

Steering logics definition valve solenoid valve (1.9)

2/2-way solenoid valve

Y189-10

Steering logics definition valve solenoid valve (1.10)

2/2-way solenoid valve

Y190-1a

Automatic steering solenoid valve

5/3-way solenoid valve

Y190-1b

Automatic steering solenoid valve

5/3-way solenoid valve

Y190-2a

Automatic steering solenoid valve

5/3-way solenoid valve

Y190-2b

Automatic steering solenoid valve

5/3-way solenoid valve

Y191

Constant-pressure system solenoid valve (M22)

3/2-way solenoid valve

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15

1 Overall hydraulic system Hydraulic circuit diagram 2734

Item

Designation

Remark

Y194-1

Cab rotation solenoid valve (M24)

3/2-way solenoid valve

Y194-2

Cab rotation solenoid valve (M23)

3/2-way solenoid valve

Y199-1

Right mower unit drive clutch solenoid valve

3/2-way solenoid valve

Y199-2

Left mower unit drive clutch solenoid valve

3/2-way solenoid valve

Y200

Fold safety frame to working position solenoid valve (M20.1)

3/2-way solenoid valve

Y201

Fold safety frame to transport position (M20.2)

3/2-way solenoid valve

Y202-1a

Side arm internal tube telescoping solenoid valve (M8.3)

4/2-way solenoid valve

Y202-1b

Side arm internal tube telescoping solenoid valve (M8.4)

4/2-way solenoid valve

Y202-2a

Side arm internal tube telescoping solenoid valve (M8.3)

4/2-way solenoid valve

Y202-2b

Side arm internal tube telescoping solenoid valve (M8.4)

4/2-way solenoid valve

Y203-1a

Side arm external tube telescoping solenoid valve (M8.1)

4/2-way solenoid valve

Y203-1b

Side arm external tube telescoping solenoid valve (M8.2)

4/2-way solenoid valve

Y203-2a

Side arm external tube telescoping solenoid valve (M8.1)

4/2-way solenoid valve

Y203-2b

Side arm external tube telescoping solenoid valve (M8.2)

4/2-way solenoid valve

Y204-1a

Swivel side arm solenoid valve (M10.1)

4/2-way solenoid valve

Y204-1b

Swivel side arm solenoid valve (M10.2)

4/2-way solenoid valve

Y204-2a

Swivel side arm solenoid valve (M10.1)

4/2-way solenoid valve

Y204-2b

Swivel side arm solenoid valve (M10.2)

4/2-way solenoid valve

16

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

1 Overall hydraulic system Hydraulic circuit diagram 2734

Item

Designation

Remark

Y205-1

Transport position lock solenoid valve (M1.1)

2/2-way solenoid valve

Y205-2

Transport position lock solenoid valve (M3.1)

2/2-way solenoid valve

Y206-1

Retract upper link solenoid valve (M12.1)

3/2-way solenoid valve

Y206.2

Extend upper link solenoid valve (M12.2)

3/2-way solenoid valve

Y207

Raise left side arm solenoid valve (M5.1)

-

Y208

Raise right side arm solenoid valve

-

Y209-1

Lower left side arm solenoid valve (M5.2)

-

Y209-2

Lower left side arm solenoid valve (M5.3)

-

Y210-1

Lower right side arm solenoid valve (M6.2)

-

Y210-2

Lower right side arm solenoid valve (M6.3)

-

Y211

Raise front power lift solenoid valve (M11.1)

-

Y212

Lower front power lift solenoid valve (M11.2)

-

Y213

Raise right front mower unit solenoid valve (M3.3)

-

Y214

Lower right front mower unit solenoid valve (M3.2)

-

Y215

Raise left front mower unit solenoid valve (M1.3)

-

Y216

Lower left front mower unit solenoid valve (M1.2)

-

Y217

Raise centre front mower unit solenoid valve (M2.3)

-

Y218

Lower centre front mower unit solenoid valve (M2.2)

-

-

-

-

Z19

Hydraulic oil level (min.) actual value switch

-

Z46

Low-pressure hydraulic system / Ground drive oil pressure actual value switch

p = 12 bar

Z78

Ground drive filter actual value switch

∆p = 2 bar

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

17

1 Overall hydraulic system Hydraulic circuit diagram 2734

Item

Designation

Remark

Z79-1

Left brake circuit pressure actual value switch (emergency brake)

p = 55 bar

Z80-2

Right brake circuit pressure actual value switch (service brake)

p = 2 bar

Z102-1

Filter bypass actual value switch (bypass open)

∆p = 7 bar

Z103

Pump function actual value switch

∆p = 2 bar

Z104

Brake accumulator pressure actual value switch

p = 115 bar

18

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

1 Overall hydraulic system 2735 1 Overall hydraulic system

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

19

1 Overall hydraulic system PFC pump - compensation valve 2735

PFC pump - compensation valve Graphic

772

7

6

773

10 AA DD BB LL

13 12 11

401482

Designations Item

Component

6

Compensating valve

7

Input (load pressure from signal network)

10

Working hydraulics pump port

11

Port of control piston of working hydraulics pump

12

Tank port

13

Restrictor

772

Volume flow controller

773

Pressure controller

-

-

AA

Oil supply

BB

Pressure-reduced oil

DD

Control oil

LL

Tank (pressureless)

20

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

1 Overall hydraulic system PFC pump - compensation valve 2735

Description of function The PFC pump is an axial piston pump.

PFC means: – P (Pressure) – F (Flow) – C (Controlled) PFC pump

The compression spring of the volume flow controller (772) is designed so that the pump pressure acting on the face end is always 20 bar above the load pressure at port (7). This pressure of 20 bar is referred to as the "Margin pressure". The pressure controller (773) limits the pressure in the working hydraulics circuit to 200±5 bar (pressure relief valve).

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

21

1 Overall hydraulic system PFC pump - initial position (Engine OFF) 2735

PFC pump - initial position (Engine OFF) Graphic

7

6

772

21

377 15

2

20 16

19 LL

18

17

401483

Designations Item

Component

2

(PFC) Pump

6

Compensating valve

7

Input (load pressure from signal network)

14

Control piston

15

Control spring

16

Pump drive

17

Swash plate

18

Ram

19

Pump inlet

20

Pump outlet

21

Compression spring (margin pressure)

377

Variable-displacement pump hydraulic cylinder

772

Volume flow controller

22

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

1 Overall hydraulic system PFC pump - initial position (Engine OFF) 2735

Description of Initial position

Since the engine has been shut down, there is no pressure in the hydraulic system. The compression spring (21) has pushed the volume flow controller (772) to the right. In this position, the top side of the variable-displacement pump hydraulic cylinder (377) is connected with the tank via the volume flow controller (772). The control spring (15) has swivelled the swash plate (17) to its maximum position.

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

23

1 Overall hydraulic system PFC pump - low-pressure standby 2735

PFC pump - low-pressure standby Graphic

7

772

25

21

377 15

2

20

AA DD BB LL

401484

17

Designations Item

Component

2

(PFC) Pump

6

Compensating valve

7

Input (load pressure from signal network)

14

Control piston

15

Control spring

17

Swash plate

20

Pump outlet

21

Compression spring (margin pressure)

25

Control edge

377

Variable-displacement pump hydraulic cylinder

772

Volume flow controller

-

-

AA

Oil supply

24

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

1 Overall hydraulic system PFC pump - low-pressure standby 2735

Item

Component

BB

Pressure-reduced oil

DD

Control oil

LL

Tank (pressureless)

Description of All control units are in their neutral position. At the beginning of this example, the swash plate (17) is in its maximum end position (see also Engine OFF).

When the engine is started, the pump feeds the maximum volume flow via the pump output (20) up to the spools of all control units.

Since the spools block the flow completely, the pressure rises and is applied to the right face end of the volume flow controller (772) which is moved to the left against the compression spring (margin pressure) (21). In this process, the control edge (25) is opened so that the pressure gains access to the top side of the variable-displacement pump hydraulic cylinder (377). Now the swash plate (17) is moved to the "Minimum delivery" position against the control spring (15).

This process takes only 10 milliseconds.

In this pump position, the following happens: Volume flow is generated only to such an extent that leakage losses are compensated. The pressure required for initial actuation of a consumer is maintained.

When all control units are set to their neutral positions, the load pressure input (7) is pressureless. To move the volume flow controller (772), the pump pressure must overcome the compression spring (margin pressure) (21) and the LS residual pressure. The pressure required for this is 20 + X bar and is referred to as "Low-pressure standby". The "Low-pressure standby" is slightly higher than the "Margin pressure" of 20 bar. As a function of the setting of the volume flow controller (772) and of the pump leakage, "Low-pressure standby" and "Margin pressure" may be almost identical. However, the "Margin pressure" can never be higher. The low-pressure standby cannot be adjusted and may therefore vary from machine to machine. It changes as the leakage rate in the pump or in the system rises. The pump remains in the "Low-pressure standby" position until a control unit is actuated. In this operating position, the pump only requires little drive energy.

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

25

1 Overall hydraulic system PFC pump - pump changes to delivery mode 2735

PFC pump - pump changes to delivery mode Graphic

7

6

772

21

377 15

2

20

AA DD BB LL

401485

17

Designations Item

Component

2

(PFC) Pump

6

Compensating valve

7

Input (load pressure from signal network)

14

Control piston

15

Control spring

17

Swash plate

20

Pump outlet

21

Compression spring (margin pressure)

25

Control edge

377

Variable-displacement pump hydraulic cylinder

772

Volume flow controller

-

-

AA

Oil supply

26

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

1 Overall hydraulic system PFC pump - pump changes to delivery mode 2735

Item

Component

BB

Pressure-reduced oil

DD

Control oil

LL

Tank (pressureless)

Description of When a control unit is actuated, a load pressure builds up in the LS line. In this process, the following conditions result at the volume flow controller (772): – the pump pressure acts on the right face end – the load pressure and the spring force of the compression spring (margin pressure) (21) act in the spring space.

– Since the load pressure + the spring force of the compression spring (margin pressure) (21) is higher than the pump pressure on the right face end, the volume flow controller is moved to the right.

This: – blocks the connection of the pump pressure to the variable-displacement pump hydraulic cylinder (377).

– connects the variable-displacement pump hydraulic cylinder (377) with the tank (no pressure on the piston top).

– makes the control spring (15) swing out the swash plate (17).

The pump now delivers a higher volume flow. This process is referred to as "Upstroking". The volume flow of the pump is determined by the restrictor effect of the open spool cross-section or by the setting of a control unit.

Lower volume flow requirement When the spool cross-section is reduced (the volume flow is to be reduced), the load pressure at the input (7) drops. This changes the force ratio at the volume flow controller (772), actuating the volume flow controller to the left according to the pressure drop, against the compression spring. The variable-displacement pump hydraulic cylinder (377) is subject to pressure and the swash plate (17) is set to a flatter position, and the pump performs a downstroke until the volume flow requirement is met.

Increased volume flow requirement

Example: A control unit has been actuated. The load pressure is 140 bar, the pump pressure now goes to (160 bar). (Load pressure 140 bar + 20 bar margin pressure). When another control unit with a load pressure of 100 bar is actuated now, the pump pressure drops slightly.

This also decreases the pressure on the top face of the variable-displacement pump hydraulic cylinder (377) accordingly, the swash plate (17) is moved to a steeper position, increasing the volume flow until the additional volume flow requirement of the second circuit has been met and the pump pressure of 160 bar has been re-established. The load pressure on the controller remains stable at 140 bar.

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

27

1 Overall hydraulic system PFC pump - constant volume flow 2735

PFC pump - constant volume flow Graphic

22

7

6

772

21

377 15

2

20

AA DD BB LL

401486

17

Designations Item

Component

2

(PFC) Pump

6

Compensating valve

7

Input (load pressure from signal network)

14

Control piston

15

Control spring

17

Swash plate

20

Pump outlet

21

Compression spring (margin pressure)

22

Setscrew

25

Control edge

377

Variable-displacement pump hydraulic cylinder

772

Volume flow controller

-

-

AA

Oil supply

28

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

1 Overall hydraulic system PFC pump - constant volume flow 2735

Item

Component

BB

Pressure-reduced oil

DD

Control oil

LL

Tank (pressureless)

Description of When operating a consumer with a constant load (e.g. a hydraulic motor), the volume flow controller (772) is actuated to a stable position. This keeps both the pressure on the top face of the variable-displacement pump hydraulic cylinder (377) and the position of the swash plate (17) constant. As long as the position of the swash plate (17) remains unchanged, the pump pumps a constant volume flow.

The following pressures now result on the volume flow controller (772): – load pressure (signal) + spring force of the compression spring (margin pressure) (21) on the left side; – pump pressure on the right side.

The differential pressure is the margin pressure corresponding to the spring force of the compression spring (21). The margin pressure is to be 20 bar and may be adjusted using set screw (22).

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

29

1 Overall hydraulic system PFC pump - downstroking 2735

PFC pump - downstroking Graphic

7

6

21

772

377 15

2

20

AA DD BB LL

401487

17

Designations Item

Component

2

(PFC) Pump

6

Compensating valve

7

Input (load pressure from signal network)

14

Control piston

15

Control spring

17

Swash plate

20

Pump outlet

21

Compression spring (margin pressure)

22

Setscrew

25

Control edge

377

Variable-displacement pump hydraulic cylinder

772

Volume flow controller

-

-

AA

Oil supply

30

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

1 Overall hydraulic system PFC pump - downstroking 2735

Item

Component

BB

Pressure-reduced oil

DD

Control oil

LL

Tank (pressureless)

Description of Downstroking of the PFC pump is performed under the following conditions: – when a control unit is actuated to the neutral position and no volume flow is needed; – when an additional control unit is actuated to the fine control range and a very small volume flow is needed; – when a control unit is actuated to the neutral position or the fine control range while in parallel operation. A smaller volume flow is required.

The pump must perform a downstroke whenever a smaller volume flow is needed. The downstroking process is started when the pressure on the right face end of the volume flow controller (772) is higher than on the left face (in the spring space). In this case, the volume flow controller (772) is moved to the left against the compression spring (21), in this process opening the control edge (25). This results in a rising pressure on the top face of the variable-displacement pump hydraulic cylinder (377) that sets the swash plate (17) to a flatter position against the control spring (15) – the volume flow is reduced.When a control unit is actuated in the fine control range (a very small volume flow is to flow to the consumer), the load pressure at input (7) drops. This changes the force ratio at the volume flow controller (772) so that it is actuated to the left according to the pressure drop, against the compression spring. The control edge (25) is opened, thus subjecting the variable-displacement pump hydraulic cylinder (377) to pressure. The swash plate (17) is set to a flatter position and the pump performs a downstroke until the volume flow requirement is met.

Parallel operation of two control When operating two control units in parallel, the load pressure values are 140 units bar and 100 bar. In this process, the pump pressure adjusts to 170 bar. (Load pressure 140 bar + 20 bar margin pressure). Both the volume flow controller (772) and the swash plate (17) are in a constant position. The pump provides the volume flow required for both consumers.When the second control unit (load pressure 100 bar) is now actuated in the neutral position, the volume flow must decrease since only the first hydraulic circuit remains to be supplied. This is achieved by increasing the pump pressure for a short time following the shutdown of a hydraulic circuit, since the high volume flow flows to the first control unit only. The volume flow controller (772) is now actuated to the left, the control edge (25) opens and the pressure on the top face of the control ram rises. The swash plate (17) is set to a flatter position, thus reducing the volume flow.

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31

1 Overall hydraulic system PFC pump - maximum pressure limitation (pressure relief valve function) 2735

PFC pump - maximum pressure limitation (pressure relief valve function) Graphic

7

6

21

772

773

23 24

337 15

2

20

AA DD BB LL

401488

17

Designations Item

Component

2

(PFC) Pump

6

Compensating valve

7

Input (load pressure from signal network)

15

Control spring

17

Swash plate

20

Pump outlet

21

Compression spring (margin pressure)

22

Setscrew

26

Control edge

377

Variable-displacement pump hydraulic cylinder

772

Volume flow controller

773

Pressure controller

-

-

AA

Oil supply

32

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1 Overall hydraulic system PFC pump - maximum pressure limitation (pressure relief valve function) 2735

Item

Component

BB

Pressure-reduced oil

DD

Control oil

LL

Tank (pressureless)

Description of The pressure in the hydraulic system is limited to 200 ± 5 bar in order to prevent component damage. This function is ensured by pressure controller (773).During normal operation (working pressure < max. pressure), the pressure controller (773) is pushed to the right by compression spring (24). Under such pressure conditions: – the volume flow controller (772) is pushed to the right by compression spring (21); – the volume pressure controller (773) is pushed to the left against compression spring (24); This movement occurs at a pressure of 200 ± 5 bar. The control edge (26) is now opened, enabling the pump pressure to act upon the top face of the variabledisplacement pump hydraulic cylinder (377). The swash plate (17) is now actuated towards "Min. delivery" against the control spring (15). This takes 8 – 10 milliseconds. The PFC pump now pumps the smallest volume flow against the maximum pressure of 200 ± 5 bar. The max. pressure can be set using the set screw (23). The hydraulic system remains at the max. pressure level until the control unit is actuated in neutral position or until the load on the LS line is relieved at input (7).

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1 Overall hydraulic system PFC pump - maximum pressure limitation (pressure relief valve function) 2735

34

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2 Steering hydraulics System concept 2736

2 Steering hydraulics System concept Description The vehicle is equipped with an EHL steering system. EHL is the German abbreviation of "Electro-hydraulic steering".To improve vehicle manoeuvrability, both axles may be steered. The cab position determines the function of an axle as the front or rear axle.

Working position (mowing)

401818

A = Motor axle (rear axle) B = Mower unit axle (front axle) Transport position (road travel)

401821

A = Motor axle (front axle) B = Mower unit axle (rear axle) Operating modes

The following operating modes are distinguished: – Emergency steering mode – Motor axle steering by Orbitrol unit – Fully electronic steering mode (steer-by-wire) The operating modes are shown in the hydraulic circuit diagrams below.

Emergency steering: – The motor axle (A) is steered by an Orbitrol steering unit (steering wheel) – The mower unit axle (B) is steered by an Orbitrol steering unit (steering wheel) Motor axle steering by Orbitrol unit: – The motor axle (A) is steered by an Orbitrol steering unit (steering wheel) – Mower unit axle (B): Electro-hydraulic steering (tracking) according to steering angle of motor axle (A) and steering program.

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2 Steering hydraulics System concept 2736

Fully electronic steering mode (steer-by-wire): – The motor axle (A) is steered electro-hydraulically.

– The mower unit axle (B) is steered electro-hydraulically.

36

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2 Steering hydraulics Emergency steering mode 2737

2 Steering hydraulics

Emergency steering mode

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37

2 Steering hydraulics Emergency steering mode 2737

Hydraulic circuit diagram

110 Z19

112

112 Z102

710

2bar

102 B10 Z46

Z60

L

1L

S

L(U)

Ms Mp

U(L)

XSP

718 211

209-1 714

205

209-2 313

377

S(P)

B

VIII

713

Z40

218

716-1 758

773 T

772 Y

442 X

IX

738

Z

109-2 323-1

323-2 3003 Y142

B16

Y141

Z79-1 p=55bar

519 Y106

Y143 BR1

BR3

644

BR2

Z80-2

VA

HA

30bar

p=2bar

642

V

245

516 30bar

240

732 Br1

L

734

DS1

BR3 S3

102

780

S1

725-3

BR2

784

S2

516 516 30bar 40bar

516

40bar

DS2

732

609

Z104 P=115bar

VII

763 LS

P

IV

175

T

726 T

S2

S1

725-1

P2

P1

240

II

P

725-2

240

901

VI

102 770 704

909-4 S1 S2

909-5 909-6 909-7

Y188-2

Y189-7

Y189-5

1.2

1.7

1.5

I

1.8

1.3

641 BL/L

Y188-1 1.1

1.4

3.2A

3.2B

3.1A

A B

Y190-2a

I Z102-1

Y189-8

Y188-3

Y188-4

772

3.1B A B

Y190-2b Y190-1a

Y189-10

Y189-6

Y189-9

1.10

1.6

1.9

Y190-1b

732-2 772

641

AR/R

909-1 XP Orb

732-3

706 180

768

768 732-1

763

414

Z103

763 XP ZLP XP BR

909-3

XP NLP

909-2

401822

38

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2 Steering hydraulics Emergency steering mode 2738 2 Steering hydraulics Emergency steering mode

Designations Item

Designation

Remark

I

Working hydraulics valve block

-

II

Constant-pressure system valve block

-

IV

Orbitrol steering unit valve block

-

V

Steering sense valve block

-

VI

Steering hydraulics valve block

-

VII

Brake valve block

-

VIII

Working hydraulics pump unit

-

IX

Ground drive pump unit

-

-

-

-

102

Pressure filter

10 µm

109-1

Hydraulic system oil cooler

-

109-2

Hydraulic system oil cooler

-

110

Oil tank

-

112

Return filter

125 µm

-

-

-

205

Working hydraulics pump

55 cm3/rev.

209-1

Ground drive feed pump

22.5 cm3/rev.

209-2

Ground drive feed pump

11 cm3/rev.

211

Ground drive variabledisplacement pump

-

218

Steering hydraulics pump

11 cm3/rev.

245

Emergency steering pump

16 cm3/rev. (max. 12 l/min.)

-

-

-

313

Ground drive pump servo adjustment hydraulic cylinder

-

323-1

Rigid axle steering hydraulic cylinder

-

323-2

Floating axle steering hydraulic cylinder

-

377

Variable-displacement pump hydraulic cylinder

-

3003

Service brake / Parking brake hydraulic cylinder

-

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39

2 Steering hydraulics Emergency steering mode 2738

Item

Designation

Remark

-

-

-

442

Venturi tube

-

-

-

-

516

Service brake pressure accumulator

-

519

Parking brake pressure accumulator

-

-

-

-

609

Orbitrol steering system rotary valve

-

641

Shut-off valve

-

642

Service brake valve

-

644

Steering sense valve

-

-

-

-

704

Bypass valve (non-return valve)

-

706

Pressure relief valve

-

713

Ground drive multifunction valve, reverse

-

714

Ground drive multifunction valve, forward

-

716-1

Ground drive feed pressure relief valve

p = 22.5 bar

718

Ground drive feed circuit cold start injector

p = 30 bar

725-1

Floating axle steering double shock valve

240 bar

725-2

Fixed axle steering double shock valve

240 bar

725-3

Orbitrol steering double shock valve

240 bar

726

Steering pressure relief valve

175 bar

732

Non-return valve

-

734

Lock-up valve unit (nonreturn valve)

-

738

Ground drive servo control pilot valve

-

758

Ground drive servo control restrictor valve

-

-

-

-

763

Input pressure balance

-

40

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2 Steering hydraulics Emergency steering mode 2738

Item

Designation

Remark

770

Priority valve

-

772

Volume flow controller

-

773

Pressure controller

max. 200 bar

780

Shuttle valve

-

784

Accumulator charge valve

-

-

-

-

901

Working hydraulics measuring point

-

909-1

Steering hydraulics Orbitrol measuring point

-

909-2

Steering hydraulics emergency steering pump measuring point

-

909-3

Steering hydraulics system pressure (steering/brake) measuring point

-

909-4

Steering hydraulics steering cylinder XP1 measuring point

-

909-5

Steering hydraulics steering cylinder XP2 measuring point

-

909-6

Steering hydraulics steering cylinder XS1 measuring point

-

909-7

Steering hydraulics steering cylinder XS2 measuring point

-

-

-

-

B10

Diesel engine speed sensor

-

B16

Transmission speed sensor (ground speed)

-

-

-

-

Y106

Parking brake solenoid valve

3/2-way solenoid valve

Y141

Ground drive forward solenoid valve

4/2-way solenoid valve

Y142

Ground drive reverse solenoid valve

4/2-way solenoid valve

Y143

Ground drive/shut-off valve solenoid valve

-

Y188-1

Steering shut-off valve solenoid valve (1.1)

2/2-way solenoid valve

Y188-2

Steering shut-off valve solenoid valve (1.2)

2/2-way solenoid valve

Y188-3

Steering shut-off valve solenoid valve (1.3)

2/2-way solenoid valve

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2 Steering hydraulics Emergency steering mode 2738

Item

Designation

Remark

Y188-4

Steering shut-off valve solenoid valve (1.4)

2/2-way solenoid valve

Y189-5

Steering logics definition valve solenoid valve (1.5)

2/2-way solenoid valve

Y189-6

Steering logics definition valve solenoid valve (1.6)

2/2-way solenoid valve

Y189-7

Steering logics definition valve solenoid valve (1.7)

2/2-way solenoid valve

Y189-8

Steering logics definition valve solenoid valve (1.8)

2/2-way solenoid valve

Y189-9

Steering logics definition valve solenoid valve (1.9)

2/2-way solenoid valve

-

-

-

Y189-10

Steering logics definition valve solenoid valve (1.10)

2/2-way solenoid valve

Y190-1a

Automatic steering solenoid valve

5/3-way solenoid valve

Y190-1b

Automatic steering solenoid valve

5/3-way solenoid valve

Y190-2a

Automatic steering solenoid valve

5/3-way solenoid valve

Y190-2b

Automatic steering solenoid valve

5/3-way solenoid valve

-

-

-

Z19

Hydraulic oil level (min.) actual value switch

-

Z46

Low-pressure hydraulic system / Ground drive oil pressure actual value switch

p = 12 bar

Z79-1

Left brake circuit pressure actual value switch (emergency brake)

p = 55 bar

Z80-2

Right brake circuit pressure actual value switch (service brake)

p = 2 bar

Z102

Filter bypass actual value switch (bypass open)

∆p = 2 bar

Z102-1

Filter bypass actual value switch (bypass open)

∆p = 7 bar

Z103

Pump function actual value switch

∆p = 2 bar

Z104

Brake accumulator pressure actual value switch

p = 115 bar

42

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2 Steering hydraulics Emergency steering mode 2738

Function Emergency steering mode

In case of malfunctions (i.e. in case of trouble in the steering modes „Motor axle steering by Orbitrol unit“ or „Fully electronic steering mode“), the steered axles are brought to a "safe condition". A "safe condition" is defined as both axles being steered simultaneously and by purely hydraulic means, using the Orbitrol (steering wheel). To achieve this, the mower unit axle steering cylinder (323-1) is connected in series with the motor axle steering cylinder (323-2) via the definition valves (Y189-5, Y189-9).

Example (see circuit diagram): All definition valves (Y189) are de-energised.

When turning the steering wheel, volume flow from port L of the Orbitrol steering valve (IV) flows through the definition valve (Y189-5) into the mower unit axle steering cylinder (323-1). During this process, volume flow is displaced from the other cylinder side. This volume flow flows through the definition valve (Y189-9) into the motor axle steering cylinder (323-2).Since the cylinder spaces are identical, the steering angles of the mower unit and the motor axle are also the same, but in opposite directions.

With the diesel engine standing still and as long as the vehicle is rolling, the oil supply for the Orbitrol steering valve (IV) is ensured by the wheel-driven emergency steering pump (245).

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2 Steering hydraulics Emergency steering mode 2738

Adjusting the straight-line stability of the rigid axle (2).

When starting emergency steering mode, the current wheel position of the motor axle relative to the mower unit axle is adopted. Straight-line stability may not be provided and must be established.

In this case: – Open the shut-off valve (641); – Set the motor axle to a synchronous position with the mower unit axle, using the steering wheel.

– Close the shut-off valve (641) again.

641 401820

44

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2 Steering hydraulics The motor axle steered by the Orbitrol steering unit 2739

2 Steering hydraulics

The motor axle steered by the Orbitrol steering unit

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

45

2 Steering hydraulics The motor axle steered by the Orbitrol steering unit 2739

Hydraulic circuit diagram

110 Z19

112

112 Z102

710

2bar

102 B10 Z46

Z60

L

1L

S

L(U)

Ms Mp

U(L)

XSP

718 211

209-1 714

205

209-2 313

377

S(P)

B

VIII

713

Z40

218

716-1 758

773 T

772 Y

442 X

IX

738

Z

109-2 323-1

323-2 3003 Y142

B16

Y141

Z79-1 p=55bar

519 Y106

Y143 BR1

BR3

644

BR2

Z80-2

VA

HA

30bar

p=2bar

642

V

245

516 30bar

240

732 Br1

L

734

DS1

BR3 S3

102

780

S1

725-3

BR2

784

S2

516 516 30bar 40bar

516

40bar

DS2

732

609

Z104 P=115bar

VII

763 LS

P

IV

175

T

726 T

S2

S1

725-1

P2

P1

240

II

P

725-2

240

901

VI

102 770 704

909-4 S1 S2

909-5 909-6 909-7

Y188-2

Y189-7

Y189-5

1.2

1.7

1.5

772

I

I

Z102-1

Y189-8

Y188-3

1.8

1.3

Y188-4

641 BL/L

Y188-1

1.4

1.1

3.2A

3.2B

3.1A

A B

Y190-2a

3.1B A B

Y190-2b Y190-1a

Y189-10

Y189-6

Y189-9

1.10

1.6

1.9

Y190-1b

732-2 772

641

AR/R

909-1 XP Orb

732-3

706 180

768

768 732-1

763

414

Z103

763 XP ZLP XP BR

909-3

XP NLP

909-2

401825

46

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

2 Steering hydraulics The motor axle steered by the Orbitrol steering unit 2740 2 Steering The motor hydraulics axle steered by the Orbitrol steering unit

Designations Item

Designation

Remark

I

Working hydraulics valve block

-

II

Constant-pressure system valve block

-

IV

Orbitrol steering unit valve block

-

V

Steering sense valve block

-

VI

Steering hydraulics valve block

-

VII

Brake valve block

-

VIII

Working hydraulics pump unit

-

IX

Ground drive pump unit

-

-

-

-

102

Pressure filter

10 µm

109-1

Hydraulic system oil cooler

-

109-2

Hydraulic system oil cooler

-

110

Oil tank

-

112

Return filter

125 µm

-

-

-

205

Working hydraulics pump

55 cm3/rev.

209-1

Ground drive feed pump

22.5 cm3/rev.

209-2

Ground drive feed pump

11 cm3/rev.

211

Ground drive variabledisplacement pump

-

218

Steering hydraulics pump

11 cm3/rev.

245

Emergency steering pump

16 cm3/rev. (max. 12 l/min.)

-

-

-

313

Ground drive pump servo adjustment hydraulic cylinder

-

323-1

Rigid axle steering hydraulic cylinder

-

323-2

Floating axle steering hydraulic cylinder

-

377

Variable-displacement pump hydraulic cylinder

-

3003

Service brake / Parking brake hydraulic cylinder

-

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47

2 Steering hydraulics The motor axle steered by the Orbitrol steering unit 2740

Item

Designation

Remark

-

-

-

442

Venturi tube

-

-

-

-

516

Service brake pressure accumulator

-

519

Parking brake pressure accumulator

-

-

-

-

609

Orbitrol steering system rotary valve

-

641

Shut-off valve

-

642

Service brake valve

-

644

Steering sense valve

-

-

-

-

704

Bypass valve (non-return valve)

-

706

Pressure relief valve

-

713

Ground drive multifunction valve, reverse

-

714

Ground drive multifunction valve, forward

-

716-1

Ground drive feed pressure relief valve

p = 22.5 bar

718

Ground drive feed circuit cold start injector

p = 30 bar

725-1

Floating axle steering double shock valve

240 bar

725-2

Fixed axle steering double shock valve

240 bar

725-3

Orbitrol steering double shock valve

240 bar

726

Steering pressure relief valve

175 bar

732

Non-return valve

-

734

Lock-up valve unit (nonreturn valve)

-

738

Ground drive servo control pilot valve

-

758

Ground drive servo control restrictor valve

-

-

-

-

763

Input pressure balance

-

48

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

2 Steering hydraulics The motor axle steered by the Orbitrol steering unit 2740

Item

Designation

Remark

770

Priority valve

-

772

Volume flow controller

-

773

Pressure controller

max. 200 bar

780

Shuttle valve

-

784

Accumulator charge valve

-

-

-

-

901

Working hydraulics measuring point

-

909-1

Steering hydraulics Orbitrol measuring point

-

909-2

Steering hydraulics emergency steering pump measuring point

-

909-3

Steering hydraulics system pressure (steering/brake) measuring point

-

909-4

Steering hydraulics steering cylinder XP1 measuring point

-

909-5

Steering hydraulics steering cylinder XP2 measuring point

-

909-6

Steering hydraulics steering cylinder XS1 measuring point

-

909-7

Steering hydraulics steering cylinder XS2 measuring point

-

-

-

-

B10

Diesel engine speed sensor

-

B16

Transmission speed sensor (ground speed)

-

-

-

-

Y106

Parking brake solenoid valve

3/2-way solenoid valve

Y141

Ground drive forward solenoid valve

4/2-way solenoid valve

Y142

Ground drive reverse solenoid valve

4/2-way solenoid valve

Y143

Ground drive/shut-off valve solenoid valve

-

Y188-1

Steering shut-off valve solenoid valve (1.1)

2/2-way solenoid valve

Y188-2

Steering shut-off valve solenoid valve (1.2)

2/2-way solenoid valve

Y188-3

Steering shut-off valve solenoid valve (1.3)

2/2-way solenoid valve

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49

2 Steering hydraulics The motor axle steered by the Orbitrol steering unit 2740

Item

Designation

Remark

Y188-4

Steering shut-off valve solenoid valve (1.4)

2/2-way solenoid valve

Y189-5

Steering logics definition valve solenoid valve (1.5)

2/2-way solenoid valve

Y189-6

Steering logics definition valve solenoid valve (1.6)

2/2-way solenoid valve

Y189-7

Steering logics definition valve solenoid valve (1.7)

2/2-way solenoid valve

Y189-8

Steering logics definition valve solenoid valve (1.8)

2/2-way solenoid valve

Y189-9

Steering logics definition valve solenoid valve (1.9)

2/2-way solenoid valve

-

-

-

Y189-10

Steering logics definition valve solenoid valve (1.10)

2/2-way solenoid valve

Y190-1a

Automatic steering solenoid valve

5/3-way solenoid valve

Y190-1b

Automatic steering solenoid valve

5/3-way solenoid valve

Y190-2a

Automatic steering solenoid valve

5/3-way solenoid valve

Y190-2b

Automatic steering solenoid valve

5/3-way solenoid valve

-

-

-

Z19

Hydraulic oil level (min.) actual value switch

-

Z46

Low-pressure hydraulic system / Ground drive oil pressure actual value switch

p = 12 bar

Z79-1

Left brake circuit pressure actual value switch (emergency brake)

p = 55 bar

Z80-2

Right brake circuit pressure actual value switch (service brake)

p = 2 bar

Z102

Filter bypass actual value switch (bypass open)

∆p = 2 bar

Z102-1

Filter bypass actual value switch (bypass open)

∆p = 7 bar

Z103

Pump function actual value switch

∆p = 2 bar

Z104

Brake accumulator pressure actual value switch

p = 115 bar

50

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2 Steering hydraulics The motor axle steered by the Orbitrol steering unit 2740

Function In this system, the steering hydraulics pump (218) supplies the Orbitrol unit whereas the electro-hydraulic section is connected with the working hydraulics pump (205). When the priority valve (770) identifies a load pressure signal, the working hydraulics (205) is available for steering purposes with priority. In this steering program, the steering angle is always specified by the motor axle (323-1), regardless of the cab position. The oil flow through the Orbitrol steering unit (609) consequently acts only on the steering cylinder of that axle. The set steering angle is now measured electronically and the mower unit axle is tracked automatically.To keep the vehicle stable especially when making minor steering corrections, the mower unit axle is triggered only for steering angles >4° of the motor axle. The vehicle speed is also considered in the steering behaviour of the tracked axle.The steering sense valve (644) adapts the steering direction to the cab position.

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

51

2 Steering hydraulics The motor axle steered by the Orbitrol steering unit 2740

52

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

2 Steering hydraulics Fully electronic steering mode (steer-by-wire) 2741

2 Steering hydraulics

Fully electronic steering mode (steer-by-wire)

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

53

2 Steering hydraulics Fully electronic steering mode (steer-by-wire) 2741

Hydraulic circuit diagram

110 Z19

112

112 Z102

710

2bar

102 B10 Z46

Z60

L

1L

S

L(U)

Ms Mp

U(L)

XSP

718 211

209-1 714

205

209-2 313

377

S(P)

B

VIII

713

Z40

218

716-1 758

773 T

772 Y

442 X

IX

738

Z

109-2 323-1

323-2 3003 Y142

B16

Y141

Z79-1 p=55bar

519 Y106

Y143 BR1

BR3

644

BR2

Z80-2

VA

HA

30bar

p=2bar

642

V

245

516 30bar

240

732 Br1

L

734

DS1

BR3 S3

102

780

S1

725-3

BR2

784

S2

516 516 30bar 40bar

516

40bar

DS2

732

609

Z104 P=115bar

VII

763 LS

P

IV

175

T

726 T

S2

S1

725-1

P2

P1

240

II

P

725-2

240

901

VI

102 770 704

909-4 S1 S2

909-5 909-6

Y188-2

Y189-8 Y189-7

1.2

909-7

1.8

772

Y189-5

1.7

I

I

Z102-1

1.5

Y188-3 1.3

Y188-4

641 BL/L

Y188-1

1.4

1.1

3.2A

3.2B

3.1A

A B

Y190-2a

3.1B A B

Y190-2b Y190-1a

Y189-10

Y189-6

Y189-9

1.10

1.6

1.9

Y190-1b

732-2 772

641

AR/R

909-1 XP Orb

732-3

706 180

768

768 732-1

763

414

Z103

763 XP ZLP XP BR

909-3

XP NLP

909-2

401826

54

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2 Steering hydraulics Fully electronic steering mode (steer-by-wire) 2742 2 Steering Fully electronic hydraulics steering mode (steer-by-wire)

Designations Item

Designation

Remark

I

Working hydraulics valve block

-

II

Constant-pressure system valve block

-

IV

Orbitrol steering unit valve block

-

V

Steering sense valve block

-

VI

Steering hydraulics valve block

-

VII

Brake valve block

-

VIII

Working hydraulics pump unit

-

IX

Ground drive pump unit

-

-

-

-

102

Pressure filter

10 µm

109-1

Hydraulic system oil cooler

-

109-2

Hydraulic system oil cooler

-

110

Oil tank

-

112

Return filter

125 µm

-

-

-

205

Working hydraulics pump

55 cm3/rev.

209-1

Ground drive feed pump

22.5 cm3/rev.

209-2

Ground drive feed pump

11 cm3/rev.

211

Ground drive variabledisplacement pump

-

218

Steering hydraulics pump

11 cm3/rev.

245

Emergency steering pump

16 cm3/rev. (max. 12 l/min.)

-

-

-

313

Ground drive pump servo adjustment hydraulic cylinder

-

323-1

Rigid axle steering hydraulic cylinder

-

323-2

Floating axle steering hydraulic cylinder

-

377

Variable-displacement pump hydraulic cylinder

-

3003

Service brake / Parking brake hydraulic cylinder

-

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55

2 Steering hydraulics Fully electronic steering mode (steer-by-wire) 2742

Item

Designation

Remark

-

-

-

442

Venturi tube

-

-

-

-

516

Service brake pressure accumulator

-

519

Parking brake pressure accumulator

-

-

-

-

609

Orbitrol steering system rotary valve

-

641

Shut-off valve

-

642

Service brake valve

-

644

Steering sense valve

-

-

-

-

704

Bypass valve (non-return valve)

-

706

Pressure relief valve

-

713

Ground drive multifunction valve, reverse

-

714

Ground drive multifunction valve, forward

-

716-1

Ground drive feed pressure relief valve

p = 22.5 bar

718

Ground drive feed circuit cold start injector

p = 30 bar

725-1

Floating axle steering double shock valve

240 bar

725-2

Fixed axle steering double shock valve

240 bar

725-3

Orbitrol steering double shock valve

240 bar

726

Steering pressure relief valve

175 bar

732

Non-return valve

-

734

Lock-up valve unit (nonreturn valve)

-

738

Ground drive servo control pilot valve

-

758

Ground drive servo control restrictor valve

-

-

-

-

763

Input pressure balance

-

56

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2 Steering hydraulics Fully electronic steering mode (steer-by-wire) 2742

Item

Designation

Remark

770

Priority valve

-

772

Volume flow controller

-

773

Pressure controller

max. 200 bar

780

Shuttle valve

-

784

Accumulator charge valve

-

-

-

-

901

Working hydraulics measuring point

-

909-1

Steering hydraulics Orbitrol measuring point

-

909-2

Steering hydraulics emergency steering pump measuring point

-

909-3

Steering hydraulics system pressure (steering/brake) measuring point

-

909-4

Steering hydraulics steering cylinder XP1 measuring point

-

909-5

Steering hydraulics steering cylinder XP2 measuring point

-

909-6

Steering hydraulics steering cylinder XS1 measuring point

-

909-7

Steering hydraulics steering cylinder XS2 measuring point

-

-

-

-

B10

Diesel engine speed sensor

-

B16

Transmission speed sensor (ground speed)

-

-

-

-

Y106

Parking brake solenoid valve

3/2-way solenoid valve

Y141

Ground drive forward solenoid valve

4/2-way solenoid valve

Y142

Ground drive reverse solenoid valve

4/2-way solenoid valve

Y143

Ground drive/shut-off valve solenoid valve

-

Y188-1

Steering shut-off valve solenoid valve (1.1)

2/2-way solenoid valve

Y188-2

Steering shut-off valve solenoid valve (1.2)

2/2-way solenoid valve

Y188-3

Steering shut-off valve solenoid valve (1.3)

2/2-way solenoid valve

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2 Steering hydraulics Fully electronic steering mode (steer-by-wire) 2742

Item

Designation

Remark

Y188-4

Steering shut-off valve solenoid valve (1.4)

2/2-way solenoid valve

Y189-5

Steering logics definition valve solenoid valve (1.5)

2/2-way solenoid valve

Y189-6

Steering logics definition valve solenoid valve (1.6)

2/2-way solenoid valve

Y189-7

Steering logics definition valve solenoid valve (1.7)

2/2-way solenoid valve

Y189-8

Steering logics definition valve solenoid valve (1.8)

2/2-way solenoid valve

Y189-9

Steering logics definition valve solenoid valve (1.9)

2/2-way solenoid valve

-

-

-

Y189-10

Steering logics definition valve solenoid valve (1.10)

2/2-way solenoid valve

Y190-1a

Automatic steering solenoid valve

5/3-way solenoid valve

Y190-1b

Automatic steering solenoid valve

5/3-way solenoid valve

Y190-2a

Automatic steering solenoid valve

5/3-way solenoid valve

Y190-2b

Automatic steering solenoid valve

5/3-way solenoid valve

-

-

-

Z19

Hydraulic oil level (min.) actual value switch

-

Z46

Low-pressure hydraulic system / Ground drive oil pressure actual value switch

p = 12 bar

Z79-1

Left brake circuit pressure actual value switch (emergency brake)

p = 55 bar

Z80-2

Right brake circuit pressure actual value switch (service brake)

p = 2 bar

Z102

Filter bypass actual value switch (bypass open)

∆p = 2 bar

Z102-1

Filter bypass actual value switch (bypass open)

∆p = 7 bar

Z103

Pump function actual value switch

∆p = 2 bar

Z104

Brake accumulator pressure actual value switch

p = 115 bar

58

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2 Steering hydraulics Fully electronic steering mode (steer-by-wire) 2742

Function Fully electronic steering mode in working position (steer-bywire)

In this mode, both axles are steered electro-hydraulically. The steering behaviour of the mower unit axle can be influenced, e.g. with the footswitch activating the crab steer mode in order to counteract a slope.

When using the parallel steer mode (crab steer mode), the Orbitrol steering unit (609) has no function. Consequently this mode is not authorised for road travel and thus electrically blocked.Both the motor axle (323-1) and the mower unit axle (323-2) are triggered only by electro-hydraulic means. The electronic control unit (EHL) transmits this steering angle to both axles as the steering angle.This is achieved by the signals from the steering wheel sensors (B150-1, B150-2) on the steering column. With this all-wheel steering as well, tracking of the mower unit axle is only at a steering angle of >4° of the motor axle. The two footswitches in the cab enable steering corrections in crab steer mode in order to be able to counteract a slope if necessary.

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59

2 Steering hydraulics Fully electronic steering mode (steer-by-wire) 2742

60

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

2 Steering hydraulics Steering hydraulics valve block 2743

2 Steering hydraulics

Steering hydraulics valve block

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61

2 Steering hydraulics Steering hydraulics valve block 2743

Graphics

3.1

VI

3.1B

Y190-1b

Y190-2a Y190-1a 3.1A 3.2A

3.2B LS

909-1(XP-Orb) 909-2(XP-NLP) 772 P-Orb

Y190-2b

AR/R

S2

S1

725-1

240

706

P2

P1

725-2

240

VI

BL/L Y189-8(1.8) 3.2A

Y189-10(1.10)

909-4 S1 S2

Y189-9(1.9)

909-5 909-6

Y188-3(1.3)

Y188-2

Y189-7

Y189-5

1.2

1.7

1.5

3.1A

909-7 3.1A

NLP

1.8

1.3

3.2A Y188-2(1.2)

Y189-8

Y188-3

3.1B

3.2B

641(1.11)

VP

1.1

1.4

909-3(XBR)

3.2A

3.2B

3.1A

A B

XP-ZLP

Y190-2a

641 BL/L

Y188-1

Y188-4

3.1B A B

Y190-2b Y190-1a

Y189-10

Y189-6

Y189-9

1.10

1.6

1.9

Y190-1b

732-2 772

641

ZLP

BR

768 P1 725-2

XP Orb

732-3

180

768

P2 Y189-6(1.6)

909-1

706

T

Y189-7(1.7)

AR/R

732-1

763

414

Z103

763 XP ZLP XP BR

909-3

XP NLP

909-2

19.0 725-1 S2

Y189-5(1.5) Y188-1(1.1) Y188-4(1.4)

S1 909-7(P1)

909-6(P2)

909-4(S1)

909-5(S2)

401827

62

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

2 Steering hydraulics Steering hydraulics valve block 2744 2 Steering Steering hydraulics hydraulics valve block

Designations Item

Designation

Remark

VI

Steering hydraulics valve block

-

-

-

-

414

Orifice plate

Ø 3.5 mm

-

-

-

641

Shut-off valve

-

-

-

-

706

Pressure relief valve

-

725-1

Floating axle steering double shock valve

240 bar

725-2

Fixed axle steering double shock valve

240 bar

732

Non-return valve

-

763

Input pressure balance

-

768

LS signal shuttle valve

-

772

Volume flow controller

-

773

Pressure controller

max. 200 bar

-

-

-

909-1

Steering hydraulics Orbitrol measuring point

-

909-2

Steering hydraulics emergency steering pump measuring point

-

909-3

Steering hydraulics system pressure (steering/brake) measuring point

-

909-4

Steering hydraulics steering cylinder XP1 measuring point

-

909-5

Steering hydraulics steering cylinder XP2 measuring point

-

909-6

Steering hydraulics steering cylinder XS1 measuring point

-

909-7

Steering hydraulics steering cylinder XS2 measuring point

-

-

-

-

Y188-1

Steering shut-off valve solenoid valve (1.1)

2/2-way solenoid valve

Y188-2

Steering shut-off valve solenoid valve (1.2)

2/2-way solenoid valve

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63

2 Steering hydraulics Steering hydraulics valve block 2744

Item

Designation

Remark

Y188-3

Steering shut-off valve solenoid valve (1.3)

2/2-way solenoid valve

Y188-4

Steering shut-off valve solenoid valve (1.4)

2/2-way solenoid valve

Y189-5

Steering logics definition valve solenoid valve (1.5)

2/2-way solenoid valve

Y189-6

Steering logics definition valve solenoid valve (1.6)

2/2-way solenoid valve

Y189-7

Steering logics definition valve solenoid valve (1.7)

2/2-way solenoid valve

Y189-8

Steering logics definition valve solenoid valve (1.8)

2/2-way solenoid valve

Y189-9

Steering logics definition valve solenoid valve (1.9)

2/2-way solenoid valve

-

-

-

Y189-10

Steering logics definition valve solenoid valve (1.10)

2/2-way solenoid valve

Y190-1a

Automatic steering solenoid valve

5/3-way solenoid valve

Y190-1b

Automatic steering solenoid valve

5/3-way solenoid valve

Y190-2a

Automatic steering solenoid valve

5/3-way solenoid valve

Y190-2b

Automatic steering solenoid valve

5/3-way solenoid valve

-

-

-

Z19

Hydraulic oil level (min.) actual value switch

-

Z103

Pump function actual value switch

∆p = 2 bar

64

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

3 Working hydraulics Hydraulic circuit diagram 2745

3 Working hydraulics Hydraulic circuit diagram

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

65

3 Working hydraulics Hydraulic circuit diagram 2745

Working hydraulics circuit diagram

II

A3

734

734

Y200

Y201

M20.1

M20.2

B3

3016

3026-1 734 3026-2

Y206-1 M12.1

734

3016

A2

Y206-2 M12.2

B2

759-1 780

3016

3015 A1

3011

B1

Y194-1 M24

Y194-2 M23

759-2

LS

3032

110 B2-1

Y191 M22

112 P

70bar

515-1

3024

Y205-1 M1.1

B2-2 P

901 L

1L

S

718

T

102 770

205 Y209-2 M5.3

Y209-1 M5.2

Y210-2

Y210-1

M6.3

M6.2

772

377

704 Y214 772

772

Z102-1

I

Y216

M3.2

772

I

Y218

M1.2

772

M2.2

515-2

B

VIII

773 772

734 772

734

734

734

Y212

759-5

759-3

M11.2 X A

B

Y207

A

B

M5.1

Y208

A

B

M6.1

Y211

Y213

M11.1

M3.3

B

A

Y215

B

B

A

A

M1.3

Y217

759-4

M2.3 80bar

515-6 515-4

B2-4

515-4

3025

80bar

3027-1

B2-5

Y205-2

B2-6

B2-3

M3.1

B139 3013-1

B140-1 3028-1

515-3 3027-2

IIIa A3

Y202-2b 3016

Y202-1b 3016

3018-2 B162-1

A1

706 250bar

B2

Y203-2a Y204-2b

A2

734

A3

3013-2

B3

3016 3022

3028-2

734

Y202-2a Y203-2b

IIIb

B140-2

734 B3

Y202-1a Y203-1b

Y203-1a 732

3022 Y204-1b

B1

3022

3018-1 B162-2

A1

706 250bar

B2

3016

3019-2

734

A2

734

3019-1 732

734 B1

3022 Y204-2a

Y204-1a 3020-2

3021-2

3020-1

3021-1

401828

66

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3 Working hydraulics Designations 2746 3 Working hydraulics Designations

Designations Item

Designation

Remark

I

Working hydraulics valve block

-

II

Constant-pressure system valve block

-

IIIa

Left side arm valve block

-

IIIb

Right side arm valve block

-

VIII

Working hydraulics pump unit

-

-

-

-

102

Pressure filter

10 µm

110

Oil tank

-

112

Return filter

125 µm

-

-

-

205

Working hydraulics pump

55 cm3/rev.

-

-

-

377

Variable-displacement pump hydraulic cylinder

-

3011

Unlock cab hydraulic cylinder

-

3013-1

Front power lift hydraulic cylinder

-

3013-2

Front power lift hydraulic cylinder

-

3015

Upper link hydraulic cylinder

-

3016

Safety frame hydraulic cylinder

-

3018-1

Side arm internal tube telescoping hydraulic cylinder

-

3018-2

Side arm internal tube telescoping hydraulic cylinder

-

3019-1

Side arm external tube telescoping hydraulic cylinder

-

3019-2

Side arm external tube telescoping hydraulic cylinder

-

3020-1

Side arm external tube telescoping hydraulic cylinder (swivelling)

-

3020-2

Side arm external tube telescoping hydraulic cylinder (swivelling)

-

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67

3 Working hydraulics Designations 2746

Item

Designation

Remark

3021-1

Collision protection hydraulic cylinder (starting protection)

-

3021-2

Collision protection hydraulic cylinder (starting protection)

-

3022

Transport lock hydraulic cylinder

-

3023

Centre front mower unit raise/lower hydraulic cylinder

-

3024

Left front mower unit raise/ lower hydraulic cylinder

-

3025

Right front mower unit raise/ lower hydraulic cylinder

-

3026-1

Cab rotation hydraulic cylinder

-

3026-2

Cab rotation hydraulic cylinder

-

3027-1

Left side arm raise/lower hydraulic cylinder

-

3027-2

Left side arm raise/lower hydraulic cylinder

-

3028-1

Right side arm raise/lower hydraulic cylinder

-

3028-2

Right side arm raise/lower hydraulic cylinder

-

3032

Left mower unit raise/lower hydraulic cylinder

-

-

-

-

515-1

Pressure accumulator

2 x 70 bar, 0.75 l

515-2

Pressure accumulator

3 x 70 bar, 0.75 l

515-3

Pressure accumulator

3 x 70 bar, 0.75 l

515-4

Pressure accumulator

3 x 80 bar, 0.75 l

515-6

Pressure accumulator

0.75 l

-

-

-

706

Pressure relief valve

-

718

Ground drive feed circuit cold start injector

p = 30 bar

732

Non-return valve

-

734

Lock-up valve unit (nonreturn valve)

-

759-1

One-way restrictor, two-sided

-

759-2

One-way restrictor, two-sided

-

68

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3 Working hydraulics Designations 2746

Item

Designation

Remark

759-3

One-way restrictor, two-sided

15 l/min.

759-4

One-way restrictor, two-sided

15 l/min.

759-5

One-way restrictor, two-sided

15 l/min.

770

Priority valve

-

772

Volume flow controller

-

773

Pressure controller

max. 200 bar

780

Shuttle valve

-

-

-

-

901

Working hydraulics measuring point

-

-

-

-

B2-1

Ground pressure sensor oil pressure (front centre)

-

B2-2

Ground pressure sensor oil pressure (front left)

-

B2-3

Ground pressure sensor oil pressure (front right)

-

B2-4

Ground pressure sensor oil pressure (left side arm)

-

B2-5

Ground pressure sensor oil pressure (right side arm)

-

B2-6

Ground pressure sensor oil pressure (front power lift)

-

B139

Power lift sensor

-

B140-1

Left side arm position sensor

-

B140-2

Right side arm position sensor

-

B162-1

Mower unit swivel angle sensor

-

B162-2

Mower unit swivel angle sensor

-

-

-

-

Y191

Constant-pressure system solenoid valve (M22)

3/2-way solenoid valve

Y194-1

Cab rotation solenoid valve (M24)

3/2-way solenoid valve

Y194-2

Cab rotation solenoid valve (M23)

3/2-way solenoid valve

Y200

Fold safety frame to working position solenoid valve (M20.1)

3/2-way solenoid valve

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69

3 Working hydraulics Designations 2746

Item

Designation

Remark

Y201

Fold safety frame to transport position solenoid valve (M20.2)

3/2-way solenoid valve

Y202-1a

Side arm internal tube telescoping solenoid valve (M8.3)

4/2-way solenoid valve

Y202-1b

Side arm internal tube telescoping solenoid valve (M8.4)

4/2-way solenoid valve

Y202-2a

Side arm internal tube telescoping solenoid valve (M8.3)

4/2-way solenoid valve

Y202-2b

Side arm internal tube telescoping solenoid valve (M8.4)

4/2-way solenoid valve

Y203-1a

Side arm external tube telescoping solenoid valve (M8.1)

4/2-way solenoid valve

Y203-1b

Side arm external tube telescoping solenoid valve (M8.2)

4/2-way solenoid valve

Y203-2a

Side arm external tube telescoping solenoid valve (M8.1)

4/2-way solenoid valve

Y203-2b

Side arm external tube telescoping solenoid valve (M8.2)

4/2-way solenoid valve

Y204-1a

Swivel side arm solenoid valve (M10.1)

4/2-way solenoid valve

Y204-1b

Swivel side arm solenoid valve (M10.2)

4/2-way solenoid valve

Y204-2a

Swivel side arm solenoid valve (M10.1)

4/2-way solenoid valve

Y204-2b

Swivel side arm solenoid valve (M10.2)

4/2-way solenoid valve

Y205-1

Transport position lock solenoid valve (M1.1)

2/2-way solenoid valve

Y205-2

Transport position lock solenoid valve (M3.1)

2/2-way solenoid valve

Y206-1

Retract upper link solenoid valve (M12.1)

3/2-way solenoid valve

Y206.2

Extend upper link solenoid valve (M12.2)

3/2-way solenoid valve

Y207

Raise left side arm solenoid valve (M5.1)

-

70

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

3 Working hydraulics Designations 2746

Item

Designation

Remark

Y208

Raise right side arm solenoid valve

-

Y209-1

Lower left side arm solenoid valve (M5.2)

-

Y209-2

Lower left side arm solenoid valve (M5.3)

-

Y210-1

Lower right side arm solenoid valve (M6.2)

-

Y210-2

Lower right side arm solenoid valve (M6.3)

-

Y211

Raise front power lift solenoid valve (M11.1)

-

Y212

Lower front power lift solenoid valve (M11.2)

-

Y213

Raise right front mower unit solenoid valve (M3.3)

-

Y214

Lower right front mower unit solenoid valve (M3.2)

-

Y215

Raise left front mower unit solenoid valve (M1.3)

-

Y216

Lower left front mower unit solenoid valve (M1.2)

-

Y217

Raise centre front mower unit solenoid valve (M2.3)

-

Y218

Lower centre front mower unit solenoid valve (M2.2)

-

-

-

-

Z102-1

Filter bypass actual value switch (bypass open)

∆p = 7 bar

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

71

3 Working hydraulics Designations 2746

72

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

3 Working hydraulics Working hydraulics valve block 2747 3 Working hydraulics

Working hydraulics valve block

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

73

3 Working hydraulics Working hydraulics valve block 2747

Graphics

Z102-1 Y207

Y208

Y211

M5.1

M6.1

M11.1

102 901

Y214

Y216

Y218

M3.2

M1.2

M2.2

772

Y209-2 M5.3

Y210-2 M6.3

Y209-1 Y210-1

Y212

M5.2

M11.2

M6.2

770

Y213

Y215

Y217

M3.3

M1.3

M2.3

II 102

901 770

Y209-2 M5.3

Y209-1 M5.2

Y210-2

Y210-1

M6.3

M6.2

772

704 Y214 772

Z102-1

772

772

734

I

Y216

M3.2

772

772

M2.2

734

734

I

Y218

M1.2

734

Y212 M11.2

A

B

Y207 M5.1

A

B

Y208 M6.1

A

B

Y211

Y213

M11.1

M3.3

B

A

Y215

B

B

A

A

M1.3

Y217 M2.3

401829

74

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3 Working hydraulics Working hydraulics valve block 2747

Designations Item

Designation

Remark

A

Consumer port

-

B

Consumer port

-

LS

LS port (Load Sensing)

-

P

Pump port

-

T

Tank port

-

-

-

-

I

Working hydraulics valve block

-

II

Constant-pressure system valve block

-

-

-

-

102

Pressure filter

10 µm

770

Priority valve

-

772

Volume flow controller

-

-

-

-

901

Working hydraulics measuring point

-

-

-

-

Y207

Raise left side arm solenoid valve (M5.1)

-

Y208

Raise right side arm solenoid valve

-

Y209-1

Lower left side arm solenoid valve (M5.2)

-

Y209-2

Lower left side arm solenoid valve (M5.3)

-

Y210-1

Lower right side arm solenoid valve (M6.2)

-

Y210-2

Lower right side arm solenoid valve (M6.3)

-

Y211

Raise front power lift solenoid valve (M11.1)

-

Y212

Lower front power lift solenoid valve (M11.2)

-

Y213

Raise right front mower unit solenoid valve (M3.3)

-

Y214

Lower right front mower unit solenoid valve (M3.2)

-

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

75

3 Working hydraulics Side arm solenoid valve 2747

Item

Designation

Remark

Y215

Raise left front mower unit solenoid valve (M1.3)

-

Y216

Lower left front mower unit solenoid valve (M1.2)

-

Y217

Raise centre front mower unit solenoid valve (M2.3)

-

Y218

Lower centre front mower unit solenoid valve (M2.2)

-

-

-

-

Z102-1

Filter bypass actual value switch (bypass open)

∆p = 7 bar

Side arm solenoid valve

76

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3 Working hydraulics Side arm solenoid valve 2747

Graphics

A

B

Y209-2 Y210-2 T

T

Y209-1 Y210-1

Y207 Y208

P

772

Z102-1

Y207

Y208

M5.1

M6.1

Y211

102 901

M11.1

Y214

Y216

Y218

M3.2

M1.2

M2.2

772

Y209-2 M5.3

Y210-2 M6.3

Y209-1

Y210-1

M5.2

M6.2

Y212

770

M11.2

Y213

Y215

Y217

M3.3

M1.3

M2.3

II 102

901 770

Y209-2 M5.3

Y209-1 M5.2

Y210-2

Y210-1

M6.3

M6.2

772

704 Y214 772

Z102-1

772

772

734

I

Y216

M3.2

772

772

M2.2

734

734

I

Y218

M1.2

734

Y212 M11.2

A

B

Y207 M5.1

A

B

Y208

A

B

M6.1

401830

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

Y211

Y213

M11.1

M3.3

B

A

Y215

B

B

A

A

M1.3

Y217 M2.3

77

3 Working hydraulics Side arm solenoid valve 2747

Designations Item

Designation

Remark

A

Consumer port

-

B

Consumer port

-

LS

LS port (Load Sensing)

-

P

Pump port

-

T

Tank port

-

-

-

-

I

Working hydraulics valve block

-

II

Constant-pressure system valve block

-

-

-

-

102

Pressure filter

10 µm

770

Priority valve

-

772

Volume flow controller

-

-

-

-

901

Working hydraulics measuring point

-

-

-

-

Y207

Raise left side arm solenoid valve (M5.1)

-

Y208

Raise right side arm solenoid valve

-

Y209-1

Lower left side arm solenoid valve (M5.2)

-

Y209-2

Lower left side arm solenoid valve (M5.3)

-

Y210-1

Lower right side arm solenoid valve (M6.2)

-

Y210-2

Lower right side arm solenoid valve (M6.3)

-

Y211

Raise front power lift solenoid valve (M11.1)

-

Y212

Lower front power lift solenoid valve (M11.2)

-

Y213

Raise right front mower unit solenoid valve (M3.3)

-

Y214

Lower right front mower unit solenoid valve (M3.2)

-

78

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3 Working hydraulics Front power lift solenoid valve, front mower unit 2747

Item

Designation

Remark

Y215

Raise left front mower unit solenoid valve (M1.3)

-

Y216

Lower left front mower unit solenoid valve (M1.2)

-

Y217

Raise centre front mower unit solenoid valve (M2.3)

-

Y218

Lower centre front mower unit solenoid valve (M2.2)

-

-

-

-

Z102-1

Filter bypass actual value switch (bypass open)

∆p = 7 bar

Discription of function Neutral position (no solenoid valve is energised).

The two face-end compression springs have positioned the spool (see figure) so that port P is blocked.Port A is blocked by the non-return valves in the solenoid valves (Y209-2, Y210-2). Port B is connected with the tank T.

Solenoid valve (Y207, Y208) is energised.

When solenoid valve (Y207) is energised, the left side arm is raised. When solenoid valve (Y208) is energised, the right side arm is raised.When the solenoid valves are energised, the spool is moved to the left against the faceend compression spring.Volume flow flows from port P through the volume flow controller (772), opens the non-return valve in solenoid valve (Y209-2) and reaches the consumer via port A. Regardless of the load applied to the consumer, the volume flow controller controls the volume flow so that a constant value is maintained. Consequently the speed of the consumer is constant.Port B is connected with the tank T via the spool.

Solenoid valve (Y209-1, Y2101) is energised.

When solenoid valve (Y209-1) is energised, the left side arm is lowered.

When solenoid valve (Y210-1) is energised, the right side arm is lowered.When one of the solenoid valves is energised, the spool is moved to the right against the face-end compression spring.Volume flow flows from port P via the volume flow controller (772) to port B. Regardless of the load applied to the consumer, the volume flow controller maintains the volume flow at a constant value. Consequently the speed of the consumer is constant.The solenoid valve (Y209-2, Y210-2) is also energised and it switches so that port A is connected with the tank T.

Note:

The control valves for the two side arms have a special spool. When lowering, they are pushed beyond their point of gravity under flow control.

After this, the are lowered due to their dead weight.

Front power lift solenoid valve, front mower unit

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79

3 Working hydraulics Front power lift solenoid valve, front mower unit 2747

Graphics

A

734

B

T

T

P Y212 Y214 Y216 Y218 Y207 M5.1

Y208

772

Y211 M11.1

M6.1

102 901

Y214

Y216 Y218

M3.2

M1.2

Y211 Y213 Y215 Y217

Ø4,0

M2.2

772

Y209-2 M5.3

Y210-2 M6.3

Y209-1

Y210-1 M6.2

M5.2

Y212

770

M11.2

Y213

Y215 Y217

M3.3

M1.3

102

M2.3

II

901 770

Y209-2 M5.3

Y209-1 M5.2

Y210-2

Y210-1

M6.3

M6.2

772

704 Y214 772

Z102-1

772

772

734

I

772

M1.2

772

734

I

Y218

Y216

M3.2

M2.2

734

734

Y212 M11.2

A

B

Y207 M5.1

401831

80

A

B

Y208 M6.1

A

B

Y211

Y213

M11.1

M3.3

B

A

Y215

B

B

A

A

M1.3

Y217 M2.3

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

3 Working hydraulics Front power lift solenoid valve, front mower unit 2747

Designations Item

Designation

Remark

A

Consumer port

-

B

Consumer port

-

LS

LS port (Load Sensing)

-

P

Pump port

-

T

Tank port

-

-

-

-

I

Working hydraulics valve block

-

II

Constant-pressure system valve block

-

-

-

-

102

Pressure filter

10 µm

770

Priority valve

-

772

Volume flow controller

-

-

-

-

901

Working hydraulics measuring point

-

-

-

-

Y207

Raise left side arm solenoid valve (M5.1)

-

Y208

Raise right side arm solenoid valve

-

Y209-1

Lower left side arm solenoid valve (M5.2)

-

Y209-2

Lower left side arm solenoid valve (M5.3)

-

Y210-1

Lower right side arm solenoid valve (M6.2)

-

Y210-2

Lower right side arm solenoid valve (M6.3)

-

Y211

Raise front power lift solenoid valve (M11.1)

-

Y212

Lower front power lift solenoid valve (M11.2)

-

Y213

Raise right front mower unit solenoid valve (M3.3)

-

Y214

Lower right front mower unit solenoid valve (M3.2)

-

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81

3 Working hydraulics Constant-pressure system valve block 2747

Item

Designation

Remark

Y215

Raise left front mower unit solenoid valve (M1.3)

-

Y216

Lower left front mower unit solenoid valve (M1.2)

-

Y217

Raise centre front mower unit solenoid valve (M2.3)

-

Y218

Lower centre front mower unit solenoid valve (M2.2)

-

-

-

-

Z102-1

Filter bypass actual value switch (bypass open)

∆p = 7 bar

Discription of function Neutral position (no solenoid valve is energised).

The two face-end compression springs have positioned the spool (see figure) so that port P is blocked.Port A is shut off by the non-return valve in the solenoid valve (Y209-2, Y210-2). Port B is connected with the tank T.

Solenoid valve (Y212, Y214, Y216, Y218) is energised.

When solenoid valve (Y212) is energised, the front power lift is lowered.

When solenoid valve (Y214) is energised, the right front mower unit is lowered. When solenoid valve (Y216) is energised, the left front mower unit is lowered. When solenoid valve (Y218) is energised, the centre front mower unit is lowered. When one of the solenoid valves is energised, the spool is moved to the right against the face-end compression spring.Volume flow flows from port P via the volume flow controller (772) to the shut-off port B. Pressure is built up here that the ram uses for opening the non-return valve (734). Port A is now connected with tank T via the spool.The volume flow controller has no control function here.

The solenoid valve Y211, Y213, Y215, Y217 is energised..

When solenoid valve (Y211) is energised, the front power lift is raised. When solenoid valve (Y213) is energised, the right front mower unit is raised. When solenoid valve (Y215) is energised, the left front mower unit is raised. When solenoid valve (Y217) is energised, the centre front mower unit is raised.

When one of the solenoid valves is energised, the spool is moved to the left against the face-end compression spring.Volume flow flows from port P through the volume flow controller (772) to the non-return valve (734), opens it and flows to the consumer via port A.Regardless of the load applied to the consumer, the volume flow controller controls the volume flow so that a constant value is maintained. Consequently the speed of the consumer is constant.

Constant-pressure system valve block

82

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3 Working hydraulics Constant-pressure system valve block 2747

Graphics

Y200

Y201

Y206-1 Y206-2

Y194-1

Y194-2

Y191

P

T

401286

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83

3 Working hydraulics Upper link, safety frame solenoid valve 2747

Designations Item

Designation

Remark

Y191

Constant-pressure system solenoid valve (M22)

-

Y194-1

Cab rotation solenoid valve (M24)

-

Y194-2

Cab rotation solenoid valve (M23)

-

Y200

Fold safety frame to working position solenoid valve

-

Y201

Fold safety frame to transport position solenoid valve (M20.2)

-

Y206-1

Retract upper link solenoid valve (M12.1)

-

Y206.2

Extend upper link solenoid valve (M12.2)

-

-

-

-

A1

Cab rotation port (hydraulic cylinder, 3026-2, ON)

-

A2

Retract upper link port

-

A3

Fold safety frame to working position port

-

B1

Cab rotation port

(Hydraulic cylinder, 3026-1, ON)

B2

Extend upper link port

-

B3

Fold safety frame to transport position port

-

-

-

-

LS

LS port (Load Sensing)

-

P

Pump port

-

T

Tank port

-

Upper link, safety frame solenoid valve

84

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3 Working hydraulics Upper link, safety frame solenoid valve 2747

Graphics

A2, A3

B2, B3

734

734

T

Y200 Y206-1

Y201 Y206-2

P

II A3

734

Y200

734

Y200

Y201

M20.1

M20.2

B3

Y201

M20.1

M20.2

734 Y206-1 M12.1

Y206-1

734

A2

Y206-2 M12.2

B2

M12.1

Y206-2 M12.2

A1

Y194-1 M24

Y194-2 M23

B1

Y194-1 M24

Y194-2 M23

Y191 M22

LS

P

Y191 M22

T T

P

401832

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85

3 Working hydraulics Cab rotation solenoid valve 2747

Designations Item

Designation

Remark

A

Consumer port

-

B

Consumer port

-

LS

LS port (Load Sensing)

-

P

Pump port

-

T

Tank port

-

-

-

-

II

Constant-pressure system valve block

-

-

-

-

734

Lock-up valve unit (nonreturn valve)

-

-

-

-

Y191

Constant-pressure system solenoid valve (M22)

-

Y194-1

Cab rotation solenoid valve (M24)

-

Y194-2

Cab rotation solenoid valve (M23)

-

Y200

Fold safety frame to working position solenoid valve (M20.1)

-

Y206-1

Retract upper link solenoid valve (M12.1)

-

Y206-2

Extend upper link solenoid valve (M12.2)

-

Discription of function Each consumer port (A2, A3 and A3, B3) is shut off by non-return valves (734).According to the necessary direction of movement, one of the solenoid valves (Y200, Y201, Y206-1 and Y206-2) is energised. The pilot spool in question opens the ball in the valve insert and closes the return line to the tank. The pressure consequently rises and now opens the non-return valve (734) on port A or B. At the same time, pressure is applied to the ram which opens the opposite non-return valve. The return line of the consumer is connected with the tank via the valve insert of the non-energised solenoid valve.

Cab rotation solenoid valve

86

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3 Working hydraulics Cab rotation solenoid valve 2747

Graphics

A1

B1

T

Y194-2

Y194-1 P1

II A3

734

Y200

Y201

M20.1

Y200

Y201

M20.1

M20.2

734 3026-2

Y206-1

Y206-2

M12.1

B3

3026-1

M20.2

Y206-1

734

M12.1

734

A2

Y206-2 M12.2

B2

M12.2

759-1 Y194-1

Y194-2

M24

M23

A1 B1

Y194-1

780 Y191

3011

M22

M24

Y194-2 M23

759-2

LS

P

T

Y191 M22

T

P

401833

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

87

3 Working hydraulics Cab rotation solenoid valve 2747

Designations Item

Designation

Remark

A

Consumer port

-

B

Consumer port

-

LS

LS port (Load Sensing)

-

P

Pump port

-

T

Tank port

-

-

-

-

II

Constant-pressure system valve block

-

-

-

-

3011

Unlock cab hydraulic cylinder

-

3026-1

Cab rotation hydraulic cylinder

-

3026-2

Cab rotation hydraulic cylinder

-

-

-

-

734

Lock-up valve unit (nonreturn valve)

-

759-1

Throttle non-return valve (two-sided)

-

759-2

Throttle non-return valve (two-sided)

-

780

Shuttle valve

-

-

-

-

Y191

Constant-pressure system solenoid valve (M22)

-

Y194-1

Cab rotation solenoid valve (M24)

-

Y194-2

Cab rotation solenoid valve (M23)

-

Y200

Fold safety frame to working position solenoid valve (M20.1)

-

Y206-1

Retract upper link solenoid valve (M12.1)

-

Y206-2

Extend upper link solenoid valve (M12.2)

-

88

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3 Working hydraulics Constant-pressure system solenoid valve 2747

Discription of function The cab rotation solenoid valves (Y194-1, Y194-2) have no LS capability. For this reason, the constant-pressure solenoid valve (Y191) is energised in parallel with the cab rotation solenoid valves (Y194-1, Y194-2). The one-way restrictors (759) generate a ram pressure in the input section so that the cab unlock hydraulic cylinder (3011) is actuated first. Only after that, the cab is rotated using the cab rotation hydraulic cylinders (3026-1, 3026-2).

Constant-pressure system solenoid valve

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89

3 Working hydraulics Constant-pressure system solenoid valve 2747

Graphics

T

LS

Y191 P

II A3

734

Y200

734

Y200

Y201

M20.1

M20.2

B3

Y201

M20.1

M20.2

734 Y206-1 M12.1

Y206-1

734

A2

Y206-2 M12.2

B2

M12.1

Y206-2 M12.2

A1

Y194-1 M24

Y194-2 M23

B1

Y194-1 M24

Y194-2 M23

Y191 M22

LS

P

Y191 M22

T T

P

401834

90

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

3 Working hydraulics Constant-pressure system solenoid valve 2747

Designations Item

Designation

Remark

A

Consumer port

-

B

Consumer port

-

LS

LS port (Load Sensing)

-

P

Pump port

-

T

Tank port

-

-

-

-

II

Constant-pressure system valve block

-

-

-

-

734

Lock-up valve unit (nonreturn valve)

-

-

-

-

Y191

Constant-pressure system solenoid valve (M22)

-

Y194-1

Cab rotation solenoid valve (M24)

-

Y194-2

Cab rotation solenoid valve (M23)

-

Y200

Fold safety frame to working position solenoid valve (M20.1)

-

Y206-1

Retract upper link solenoid valve (M12.1)

-

Y206-2

Extend upper link solenoid valve (M12.2)

-

Description of function Constant pressure circuit

The load-sensing hydraulic system contains circuits which are controlled by not-load-sensing control valves. These include the functions of valve blocks II, IIIa and IIIb: – – – – – –

Cab rotation Fold safety frame to working position Extend/retract upper link Telescope side arms internal tubes Telescope side arms external tubes Swivel side arms

To build up the system pressure necessary for these functions in the working hydraulics, the load-sensing hydraulic system is set to the constant-pressure mode via the constant-pressure system solenoid coil (Y191).

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91

3 Working hydraulics Testing and measuring 2747

Testing and measuring Graphic

901

401835

901 Working hydraulics measuring point Precondition for measurement:

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

Set values:

92

– Circulation pressure 2.5 +6 bar.

– Maximum pressure 185 +15 bar.

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

4 Low-pressure hydraulic system Hydraulic circuit diagram 2748

4 Low-pressure hydraulic system Hydraulic circuit diagram

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

93

4 Low-pressure hydraulic system Hydraulic circuit diagram 2748

Low-pressure hydraulic system circuit diagram

XI

362

Y105

515 Y199-1 3017-1

732 Y1 302 Y199-2

515 732 3017-2

Y107

Y108

729 411 910 716-2

732

109

209-2

102

710

210

Z78 Z46

210

716 718 209-1

211

IX

401309

442 609 109 401836

94

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

4 Low-pressure hydraulic system Hydraulic circuit diagram 2748

Designations Item

Designation

Remark

IX

Ground drive pump unit

-

XI

Low-pressure hydraulic system valve block

-

-

-

-

102

Pressure filter

10 µm

109

Hydraulic system oil cooler

-

-

-

-

209-1

Ground drive feed pump

22.5 cm3/rev.

209-2

Ground drive feed pump

11 cm3/rev.

210-1

Ground drive variabledisplacement motor

-

210-2

Ground drive variabledisplacement motor

-

211

Ground drive variabledisplacement pump

-

-

-

-

302

Four-wheel clutch hydraulic cylinder

-

362-1

Differential lock hydraulic cylinder

-

363

Gearbox shifting hydraulic cylinder

-

3017-1

Drive clutch hydraulic cylinder

-

3017-2

Drive clutch hydraulic cylinder

-

-

-

-

411

Orifice plate

Ø 1.8 mm

442

Venturi tube

-

-

-

-

515

Pressure accumulator

6 bar, 0.16 l

-

-

-

609

Orbitrol steering system rotary valve

-

-

-

-

710

Ground drive filter bypass valve

∆p = 3 bar

716-2

Ground drive feed pressure relief valve

p = 20 bar

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

95

4 Low-pressure hydraulic system Low-pressure hydraulic system valve block 2748

Item

Designation

Remark

718

Ground drive feed circuit cold start injector

p = 30 bar

729

Low-pressure hydraulic system pressure relief valve

24+1 bar

732

Non-return valve

-

-

-

-

910

Low-pressure hydraulic system measuring point

-

-

-

-

Y1

4-Trac (all-wheel drive) solenoid valve

3/2-way solenoid valve

Y105

Differential lock solenoid valve

3/2-way solenoid valve

Y107

Gearbox shift 1st gear solenoid valve

3/2-way solenoid valve

Y108

Gearbox shift 2nd gear solenoid valve

3/2-way solenoid valve

Y199-1

Right mower unit drive clutch solenoid valve

3/2-way solenoid valve

Y199-2

Left mower unit drive clutch solenoid valve

3/2-way solenoid valve

-

-

-

Z46

Low-pressure hydraulic system / Ground drive oil pressure actual value switch

p = 12 bar

Z78

Ground drive filter actual value switch

∆p = 2 bar

Low-pressure hydraulic system valve block

96

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4 Low-pressure hydraulic system Low-pressure hydraulic system valve block 2748

Graphics

Y105

Y199-1

Y1

Y199-2

Y107

Y108

729

T P

910 401321 109

XI

210

362

Y105

716-2 732

515 Y199-1

210

Z78

3017-1

732

209-2

102

710

Y1 302

Z46

Y199-2

515 732

716

Y107

718 209-1

211

3017-2

IX

401309

Y108 442 609

729

109

411 910 401837

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4 Low-pressure hydraulic system Low-pressure hydraulic system valve block 2748

Designations Item

Designation

Remark

IX

Ground drive pump unit

-

XI

Low-pressure hydraulic system valve block

-

-

-

-

102

Pressure filter

10 µm

109

Hydraulic system oil cooler

-

-

-

-

209-1

Ground drive feed pump

22.5 cm3/rev.

209-2

Ground drive feed pump

11 cm3/rev.

210-1

Ground drive variabledisplacement motor

-

210-2

Ground drive variabledisplacement motor

-

211

Ground drive variabledisplacement pump

-

-

-

-

302

Four-wheel clutch hydraulic cylinder

-

362-1

Differential lock hydraulic cylinder

-

363

Gearbox shifting hydraulic cylinder

-

3017-1

Drive clutch hydraulic cylinder

-

3017-2

Drive clutch hydraulic cylinder

-

-

-

-

411

Orifice plate

Ø 1.8 mm

442

Venturi tube

-

-

-

-

515

Pressure accumulator

6 bar, 0.16 l

-

-

-

609

Orbitrol steering system rotary valve

-

-

-

-

710

Ground drive filter bypass valve

∆p = 3 bar

716-2

Ground drive feed pressure relief valve

p = 20 bar

98

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4 Low-pressure hydraulic system 4-Trac solenoid valve, differential lock, gearbox shifting, drive clutch 2748

Item

Designation

Remark

718

Ground drive feed circuit cold start injector

p = 30 bar

729

Low-pressure hydraulic system pressure relief valve

24+1 bar

732

Non-return valve

-

-

-

-

910

Low-pressure hydraulic system measuring point

-

-

-

-

Y1

4-Trac (all-wheel drive) solenoid valve

3/2-way solenoid valve

Y105

Differential lock solenoid valve

3/2-way solenoid valve

Y107

Gearbox shift 1st gear solenoid valve

3/2-way solenoid valve

Y108

Gearbox shift 2nd gear solenoid valve

3/2-way solenoid valve

Y199-1

Right mower unit drive clutch solenoid valve

3/2-way solenoid valve

Y199-2

Left mower unit drive clutch solenoid valve

3/2-way solenoid valve

-

-

-

Z46

Low-pressure hydraulic system / Ground drive oil pressure actual value switch

p = 12 bar

Z78

Ground drive filter actual value switch

∆p = 2 bar

Discription of function The low-pressure hydraulic system is supplied by the ground drive feed pump (209).An orifice plate (411) Ø1.8 mm limits the oil flow to the low-pressure hydraulic system valve block. This ensures that the feed pressure for the hydrostatic ground drive will not collapse even when major leaks occur in the low-pressure hydraulic system. The hydraulic functions of the low-pressure hydraulic system are located in a flange-type valve block.These functions are: – – – – –

Activation of all-wheel drive (Y1) Activation of differential lock (Y105) Shifting of 1st gear (Y107) Shifting of 2nd gear (Y108) Engaging of drive clutch (Y199)

The maximum system pressure is limited to 24+1 bar by means of a pressure relief valve (729).

4-Trac solenoid valve, differential lock, gearbox shifting, drive clutch

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4 Low-pressure hydraulic system 4-Trac solenoid valve, differential lock, gearbox shifting, drive clutch 2748

Graphic

s

Y1 Y105 Y107 Y108 Y199-1 Y199-2

T t

A P

401838

100

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4 Low-pressure hydraulic system 4-Trac solenoid valve, differential lock, gearbox shifting, drive clutch 2748

Designations Item

Designation

Remark

Y1

4-Trac (all-wheel drive) solenoid valve

3/2-way solenoid valve

Y105

Differential lock solenoid valve

3/2-way solenoid valve

Y107

Gearbox shift 1st gear solenoid valve

3/2-way solenoid valve

Y108

Gearbox shift 2nd gear solenoid valve

3/2-way solenoid valve

Y199-1

Right mower unit drive clutch solenoid valve

3/2-way solenoid valve

Y199-2

Left mower unit drive clutch solenoid valve

3/2-way solenoid valve

-

-

-

A

Consumer port

-

P

Pump port

-

S

Emergency operation screw

-

T

Tank port

-

-

-

-

t

Ram

-

Discription of function When the solenoid valve is de-energised, a connection is provided from the hydraulic cylinder port to the tank (T) return line via the conical seat of the ram (t).The applied low pressure (P) here is blocked by the ball. When the solenoid valve of a given function is energised, ram (t) opens the ball and closes connection to the return line (T) with the conical seat. The low pressure (P) is thus applied to the hydraulic cylinder via the consumer port whereas the return line to the tank (T) is blocked.

Note

For emergency operation, the screw (s) must be screwed in up to the stop so that the conical seat in the valve insert reliably seals the return line to the tank (T).

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4 Low-pressure hydraulic system Testing and measuring 2748

Testing and measuring Graphic

Y105

Y199-1

Y1

Y199-2

Y107

Y108

729

T P

910

401840

910 Low-pressure hydraulic system measuring point 24+1 bar

Designations Item

Designation

Remark

729

Pressure relief valve

-

-

-

-

910

Low-pressure hydraulic system measuring point

24+1 bar

-

-

-

Y1

4-Trac (all-wheel drive) solenoid valve

3/2-way solenoid valve

Y105

Differential lock solenoid valve

3/2-way solenoid valve

Y107

Gearbox shift 1st gear solenoid valve

3/2-way solenoid valve

Y108

Gearbox shift 2nd gear solenoid valve

3/2-way solenoid valve

Y199-1

Right mower unit drive clutch solenoid valve

3/2-way solenoid valve

Y199-2

Left mower unit drive clutch solenoid valve

3/2-way solenoid valve

-

-

-

P

Pump port

-

T

Tank port

-

102

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4 Low-pressure hydraulic system Testing and measuring 2748

Precondition for measuring

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

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4 Low-pressure hydraulic system Testing and measuring 2748

104

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5 Ground drive hydraulics Hydraulic circuit diagram 2749

5 Ground drive hydraulics Hydraulic circuit diagram

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105

5 Ground drive hydraulics Hydraulic circuit diagram 2749

Ground drive hydraulics circuit diagram

B123

109-1 110 Z19

716-2 20

Z102

710

732

2bar

102 B97 L(U)

L(U)

U(L)

U(L)

Z60

Ms Mp E

719-2

719-1 Y144-1 10

Z46

XSP

721-2

721-1

E

B10

A

718

Y144-2

10

U(L)

A

L(U)

XA

211

209-1 714

209-2 313

355-1

Xb

210-2 355-2

210-1 XB

B

B

B99

Xa

S(P)

713

Z40

218

716-1 758

B98

T

Y

442

IX

738

Z

109-2

Y142 Y141 Y143

401841

106

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5 Ground drive hydraulics Hydraulic circuit diagram 2750 5 Ground drive Hydraulic circuithydraulics diagram

Designations Item

Designation

Remark

IX

Ground drive pump unit

-

Xa

Ground drive motor unit

-

Xb

Ground drive motor unit

-

Ground drive motor unit -

-

-

102

Pressure filter

10 µm

109-1

Hydraulic system oil cooler

-

109-2

Hydraulic system oil cooler

-

110

Oil tank

-

-

-

-

209-1

Ground drive feed pump

22.5 cm3/rev.

209-2

Ground drive feed pump

11 cm3/rev.

210-1

Ground drive variabledisplacement motor

-

210-2

Ground drive variabledisplacement motor

-

211

Ground drive variabledisplacement pump

-

218

Steering hydraulics pump

11 cm3/rev.

-

-

-

313

Ground drive pump servo adjustment hydraulic cylinder

-

355-1

Ground drive motor servo adjustment hydraulic cylinder

-

355-2

Ground drive motor servo adjustment hydraulic cylinder

-

-

-

-

442

Venturi tube

-

-

-

-

710

Ground drive filter bypass valve

∆p = 3 bar

713

Ground drive multifunction valve, reverse

-

714

Ground drive multifunction valve, forward

-

716-1

Ground drive feed pressure relief valve

p = 22.5 bar

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5 Ground drive hydraulics Hydraulic circuit diagram 2750

Item

Designation

Remark

716-2

Ground drive feed pressure relief valve

p = 20 bar

718

Ground drive feed circuit cold start injector

p = 30 bar

719-1

Ground drive flush pressure control valve

p = 10 bar

719-2

Ground drive flush pressure control valve

p = 10 bar

721-1

Ground drive flush-out shuttle valve

-

721-2

Ground drive flush-out shuttle valve

-

732

Non-return valve

-

738

Ground drive servo control pilot valve

-

758

Ground drive servo control restrictor valve

-

-

-

-

B10

Diesel engine speed sensor

-

B97

Ground drive hydraulics forward high-pressure sensor

-

B98

Ground drive hydraulics reverse high-pressure sensor

-

B99

Hydraulic motor speed sensor

-

B123

Hydraulic oil temperature sensor

-

-

-

-

Y141

Ground drive forward solenoid valve

4/2-way solenoid valve

Y142

Ground drive reverse solenoid valve

4/2-way solenoid valve

Y143

Ground drive/shut-off valve solenoid valve

-

Y144-1

Ground drive variabledisplacement motor solenoid valve

4/2-way solenoid valve

Y144-2

Ground drive variabledisplacement motor solenoid valve

4/2-way solenoid valve

-

-

-

108

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5 Ground drive hydraulics Hydraulic circuit diagram 2750

Item

Designation

Remark

Z19

Hydraulic oil level (min.) actual value switch

-

Z46

Low-pressure hydraulic system / Ground drive oil pressure actual value switch

p = 12 bar

Z102-1

Filter bypass actual value switch (bypass open)

∆p = 7 bar

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109

5 Ground drive hydraulics Hydraulic circuit diagram 2750

110

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5 Ground drive hydraulics Ground drive control 2751 5 Ground drive hydraulics

Ground drive control Ground drive variable-displacement pump (211) Mechanical zero position

As soon as the ground drive variable-displacement pump (211) is not driven, it is in neutral position due to the mechanical zero position. The ground drive pump servo control hydraulic cylinder (313) is mechanically positioned in its zero position by two pre-loaded compression springs so that the ground drive variable-displacement pump (211) has zero delivery during the starting process. Precondition: the ground drive forward (Y141) and reverse (Y142) solenoid coils are not energised. The mechanical zero position is adjusted during installation of the ground drive variable-displacement pump (211) and cannot be modified externally.

Hydraulic zero position

When the ground drive variable-displacement pump (211) is driven, it is maintained in neutral position by the hydraulic zero position.Precondition: the ground drive forward (Y141) and reverse (Y142) solenoid coils are not energised.Through the centre position of the ground drive servo control forward/ reverse valve (738) and the ground drive restrictor valve (758), the feed pressure acts on both sides in the ground drive pump servo control hydraulic cylinder (313) and centres it in its neutral position. At the same time, the ground drive restrictor valve (758) is switched over from the restricted to the unrestricted position.The hydraulic zero position is adjusted on the Linde test bench.

Adjustment

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

Solenoid coil (Y 143) is energised. Upstream of the restrictor, the feed pressure is directed to the 2/2-way valves. The feed pressure servo control downstream of the restrictor actuates the 2/2-way valves to their passage position. Consequently feed pressure is applied to the non-energised 4/2-way valves.At the same time, the ground drive restrictor valve (758) is switched over from the restricted to the unrestricted position by the feed pressure servo control. The ground drive variable displacement pump (211) is now in a hydraulic zero position.

Example

When e.g. a current set by the electronic unit flows at the ground drive forward solenoid coil (Y141), a corresponding magnetic force is generated which adjusts the 4/2-way solenoid valve proportionally. According to this adjustment, a pressure is directed to the ground drive servo control forward/ reverse valve (738). The valve moves by a certain corresponding amount.

The volume displaced from the opposite side flows into the tank via the 4/2way solenoid valve (Y142). The adjustment of the ground drive servo control forward/reverse valve (738) produces a corresponding adjustment of the 4/3way valve since there is a mechanical link.This actuates the ground drive pump servo control hydraulic cylinder (313) which swivels the ground drive variable-displacement pump (211) to the corresponding position. When the electronic signal at the ground drive forward solenoid coil (Y141) becomes smaller, the proportional 4/2-way valve reduces the pressure to the ground drive servo control forward/reverse valve (738) and the swivel angle of the ground drive variable-displacement pump (211) becomes smaller.

Ground drive/shut-off valve solenoid coil (Y143)

The ground drive/shut-off valve solenoid coil (Y143) is de-energised during a "panic braking" (pedal force > 600 N).(please refer also to the "Electric System" documentation).When the ground/drive shut-off valve solenoid coil (Y143) is de-energised, the magnetic tappet is in the retracted position. The ball is lifted off its seat and relieves the servo control supply pressure to the tank.This switches the 2/2-way valves of solenoid coils (Y141 and 142) back to their closed position, thus taking away the supply pressure to the proportional 4/2-way valves. This makes them return to their initial position. As the servo control supply pressure applied to the ground drive servo control

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5 Ground drive hydraulics Ground drive control 2751

forward/reverse valve (738) collapses, the compression springs position the valve in its neutral position. Using the mechanical link, the 4/3-way valve is actuated to the centre position.The pressure drop caused by de-energising the ground drive/shut-off valve solenoid coil (Y143) switches the ground drive servo control restrictor valve (758) from the unrestricted to the restricted position. This provides a smooth start because the resetting time of the ground drive pump servo adjustment hydraulic cylinder (313) is longer.

112

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5 Ground drive hydraulics Ground drive control 2751

Additional feed and ground drive cooling Additional feed (external feed pump 209-2)

The external feed pump (209-2) supports the feed circuit with a constant 20 bar flow rate through the non-return valve (732).

Ground drive cooling

The external feed pump (209-2) additionally cools the ground drive.Oil that is not required for supporting the feed circuit flows through the ground drive feed pressure relief valve (716-2) (external). The oil cooled by the oil cooler (109-2) additionally flushes the bodies of the ground drive variable-displacement motors (210-1) and (210-2).

Oil cooling

Hot oil from the steering return line and from the oil tank flows through the Venturi tube (442) to the oil cooler (109-2). This cooled oil is sucked in by the feed pump (209-1).

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5 Ground drive hydraulics Ground drive controlComponents 2751 Components

Ground drive forward/reverse solenoid coil, shut-off valve

Y141

Y143

Y142

211

401842

P

S

Ground drive forward solenoid coil (Y141)

Solenoid coil (Y141) is energised in a modulated way by the ground drive module (A49).Solenoid coil energised = modulated control pressure = forward. The magnetic force acts against the control pressure.

Ground drive reverse solenoid coil (Y142 )

Solenoid coil (Y143) is energised in a modulated way by the ground drive module (A49).Solenoid coil energised = Pressure at port (S) = reverse

Ground drive/shut-off valve (Y143)

The solenoid coil is energised by the ground drive module (A49). It is permanently energised if the ignition (+15) is ON = the non-return valve is closed. In case of a panic braking (brake force > 55 kg), solenoid coil (Y143) is not energised (see also Electric System documentation). The open non-return valve connects the control pressure for servo-control with the tank and the ground drive variable-displacement pump (211) goes to zero delivery.

Ground drive variable-displacement pump (211) Ports (P, S)

114

Outputs to the ground drive variable displacement motors (210)

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5 Ground drive hydraulics Ground drive controlComponents 2751

Ground drive variable-displacement motor

210

A B Y144

Ground drive variable-displacement motor (210) Ground drive variable-displacement motor solenoid coil (Y144)

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

Port (A)

The entering volume flow results in ccw rotation.

Port (B)

The entering volume flow results in cw rotation.

L

B E Y144

719 355

721 max

min

210 A 401843

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5 Ground drive hydraulics Ground drive controlComponents 2751

In its initial position, the ground drive variable-displacement motor (210) is always at maximum input volume. Adjustment is infinitely variable towards minimum input volume. This adjustment is realised electro-hydraulically proportionally with the control current by the ground drive variable-displacement motor solenoid coil (Y144). When the ground drive variable displacement motor solenoid coil (Y144) is not energised, the control pressure acts via port (E) in the rod space of hydraulic cylinder (355) which positions the ground drive variable-displacement motor (210) to maximum input volume.When energising the ground drive variable displacement motor solenoid coil (Y144), the current generates a proportional magnetic force that moves the spool and acts against the spool spring. Accordingly, a control pressure is directed into the piston top space of hydraulic cylinder (355) which adjusts the swivel angle of the ground drive variable-displacement motor (210) towards minimum input volume.

116

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5 Ground drive hydraulics Testing and measuringComponents 2751

Testing and measuring Pressure testing using the signals from the high-pressure sensors B97, B98

B97

B98

401844 B97 Ground drive hydraulics forward high-pressure sensor B98 Ground drive hydraulics reverse high-pressure sensor

Measured value table Pressure

Volt

0 bar

0.2 – 0.3 Volt

20 bar

0.4 Volt

30 bar

0.4 – 0.5 Volt

40 bar

0.5 – 0.6 Volt

100 bar

1.0 Volt

200 bar

1.7 – 1.8 Volt

300 bar

2.5 Volt

400 bar

3.2 – 3.3 Volt

420 bar

3.4 Volt

440 bar

3.5 Volt

450 bar

3.6 Volt

460 bar

3.7 Volt

Precondition for pressure tests

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

Functional check of sensors

Switch on the ignition with the engine stopped and the vehicle braked.

Measured values: 0.2 - 0.3 Volt = 0 bar.

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5 Ground drive hydraulics Testing and measuringComponents 2751

Pressure fed into the highpressure circuit High-pressure measurement

Ground speed control lever in zero position.Set value: 20 +4 bar at sensors B97 and B98 (see table).

– Engage 2nd gear – Apply parking brake – Slowly move the ground speed control lever halfway to forward or reverse for 5 seconds max.

During this high-pressure measurement, the pump is in a downstroking process (maximum pressure control). The Volt display of the sensors varies, but the highest value is decisive for the measurement.Set value: 420 ... 460 bar max. at the measured value displays B97 and B98 (see table).During the measurement, the value on the corresponding low-pressure side (measured value displays B97 or B98) must not fall below 20 bar (see table).

118

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Location of components Overview 2752

6 Location of components Overview Main sub-assemblies (I to XI) 5n15

5o16

II

I

22j

23k

IIIa

IIIb

6g15

6g16

IV V

401325

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

400883

119

Location of components Overview 2752

5o14

5g15

VI

VI 400885

7h14

7h14

VIII IX

8o15

7p14

X

XI 400886

120

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Location of components Overview 2752

5n14

6b15

102

109-1 109-2

401379

401392

7h16

5n14

110

112

401390 7h14

7h14

205 400887

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

209-1 401391

121

Location of components Overview 2752

7h14

7n15

210-1

209-2 400888

400892

7k15

7h14

210-2

211 400828

400891

7f14

7k15

245

218 401388

122

400889

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Location of components Overview 2752

8n16

8p15

245

323-1

401424

400895

7i15

7q14

362-1

323-2 401393

400896

7q14

8l14

362-1

363

401405

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

401418

123

Location of components Overview 2752

8k15

6j14

3011

3003 400890

8s15

7s15

3013 3015

23e, 27k

8l16

3016

3017-1 401435

124

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Location of components Overview 2752

3018

3019

3021

3020

3023

3022

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125

Location of components Overview 2752

3025

3024

6j15

6j15

3026-1

3027

126

3026-2

3028

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

Location of components Overview 2752

6h15

515-1

442

401406

515-3

515-2

5m14

6m16

515-5

515-4

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127

Location of components Overview 2752

6p16

5h16

515-6

516 401857

5g14

5g15

519

609

401407

400897

5o14

5h14

642

641 401335

128

401858

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

Location of components Overview 2752

5h16

644

706

400882

8i14

7h14

714

713

710

401399

401408 7h14

7f14

716-1

716-2 401410

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401409

129

Location of components Overview 2752

7h14

5o14

718 725-1

401411

401352

5o14

6g15

726 725-2

401412

401351

7p14

6l15

729

759-1 T P

401333

130

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Location of components Overview 2752

6l15

5n14

759-3

759-2

401374

5n14

5n14

759-4

401375

759-5

401376

5n14

5o14

772

770 401377

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401350

131

Location of components Overview 2752

6l15

5h14

780 401413 5n14

784

5o14

901

909-1 (XP-Orb)

401380

401358

5o14

5o14

909-3 (XBR)

909-2 (XP-NLP)

401359

132

401357

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Location of components Overview 2752

5o14

401353

5o14

909-4 (S1)

401354

5o14

401355

909-5 (S2)

5o14

909-6 (P2)

401356

7p14

909-7 (P1)

7p16

T P

B2-1

910 401334

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

401429

133

Location of components Overview 2752

5n16

5n14

B2-2

B2-3

401431

401430

B2-4 B2-5

6p16

5g14

B10 B2-6

401417

134

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Location of components Overview 2752

7m16

7k15

B97

B16 401423

401427

7k15

7m16

B99 B98

401422

401428 7m16

8r16

B123 B139

401421

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135

Location of components Overview 2752

B140-2

B140-1

7p14

7p14

Y1

401326

5h14

Y105

T

T

P

P

401327

7p14

Y106

Y107

T P

401402

136

401328

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Location of components Overview 2752

7p14

7h14

Y108

T P

Y141

401414

401329

7h14

7h14

Y142

401415

Y143

401416

7k15

7k15

Y144-1 Y144-2

401426

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401425

137

Location of components Overview 2752

5o14

5o14

Y188-1 (1.1)

401348

5o14

401342

Y188-2 (1.2)

5o14

Y188-4 (1.4) Y188-3 (1.3) 401341

5o14

401349

5o14

Y189-6 (1.6)

Y189-5 (1.5)

401347

138

401346

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Location of components Overview 2752

5o14

5o14

Y189-7 (1.7) Y189-8 (1.8)

401345

401338

5o14

5o14

Y189-9 (1.9)

Y189-10 (1.10)

401340

401339

5o14

5o14

Y190-1a Y190-1b

401344

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

401337

139

Location of components Overview 2752

5o14

5o14

Y190-2a Y190-2b

401336

401343

5o16

5o16

Y194-1 Y191

401384

401383

5o16

7p14

Y199-1

T P

Y194-2

401387

140

401859

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

Location of components Overview 2752

7p14

5o16

Y199-2 Y200 T P

401381

401332

5o16

22j, 23k

Y202-1a Y202-2a

Y201

401437

401385

22j, 23k

22j, 23k

Y203-1a Y203-2a

Y202-1b Y202-2b 401438

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

401439

141

Location of components Overview 2752

22j, 23k

22j, 23k

Y204-1a Y204-2a

Y203-1b Y203-2b 401440

401441

22j, 23k

Y204-1b Y204-2b

Y205-1

401442 5o16

Y206-1

Y205-2 401382

142

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

Location of components Overview 2752

5o16

5n14

Y207

Y206-2

401386

5n14

401360

5n14

Y208

Y209-1 401361

5n14

401362

5n14

Y209-2 Y210-1 401363

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

401364

143

Location of components Overview 2752

5n14

5n14

Y211

Y210-2 401365

401366

5n14

5n14

Y212

Y213

401367

401368

5n14

5n14

Y214

Y215 401371

144

401369

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

Location of components Overview 2752

5n14

5n14

Y216

Y217 401372

401370

5n14

6h16

Y218

Z19

401373

7h14

401432 8i14

Z78

Z46

401433

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

401436

145

Location of components Overview 2752

5h14

8i14

Z79-1

Z80-2

401403

401401

8i14

5n14

Z82

Z83

401419

401420

5n14

Z102-1

Z103

401378

146

401434

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

Location of components Overview 2752

8i14

Z104

401404

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

147

Location of components Overview 2752

148

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

6 Location of components Component grid (DIN A3) 2753 6 Location of components

Component grid (DIN A3)

Figures

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

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

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

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

11 12 13 14 15 16 17 18 19

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

20 21 22 23 24 25 26 27

401331

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

149

6 Location of components Component grid (DIN A3) 2753

150

000 293 650 0 - SYS-H COUGAR 1400 - 01/06

2732

Index C Circuit diagram Ground drive hydraulics 106 Low-pressure hydraulic system 94 Overall hydraulic system 8 Working hydraulics 66 Component grid 149 Constant pressure circuit 91

E Emergency steering mode 37

G Ground drive Additional feed 113 Adjustment 111 Control 111 Cooling 113 High-pressure sensors 117 Hydraulic zero position 111 Mechanical zero position 111 Oil cooling 113 Shut-off valve 111 Variable-displacement motor 115 Variable-displacement pump 111 Ground drive hydraulics Functional check of sensors 117 High-pressure measurement 118 Precondition for measuring 117

L Location of components 119, 149

M Measuring point Ground drive hydraulics forward high-pressure sensor 117 Ground drive hydraulics reverse high-pressure sensor 117 Low-pressure hydraulic system 102 Measuring port Working hydraulics 92

O Overall circuit diagram 8

P PFC pump Compensation valve 20 Constant volume flow 28 Downstroking 30 Initial position (Engine OFF) 22 Low-pressure standby 24 Maximum pressure limitation (pressure relief valve function) 32 Pump changes to delivery mode 26 Precondition for measurement Working hydraulics 92 Precondition for measuring Low-pressure hydraulic system 103

151

2732

S Solenoid coil Ground drive forward 114 Ground drive reverse 114 Ground drive shut-off valve 114 Ground drive variable-displacement pump 114 Solenoid valve 4-Trac 99 Cab rotation 86 Constant-pressure system 89 Differential lock 99 Drive clutch 99 Front mower unit 79 Front power lift 79 Gearbox shifting 99 Safety frame 84 Side arm 76 Upper link 84 Steering Fully electronic steering mode (steer-by-wire) 53 Motor axle steered by Orbitrol steering unit 45 Operating modes 35 System concept 35 Steering hydraulics Valve block 61

T Testing and measuring 102 Transport position (road travel) 35

V Valve block Constant-pressure system 82 Low-pressure hydraulic system 96 Working hydraulics 73

W Working hydraulics 66 Working position (mowing) 35

152

2754

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

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

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

CLAAS KGaA mbH 33426 HARSEWINKEL Germany

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

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

000 293 650 0 SYS-H COUGAR 1400 EN - 01/06 Printed in Germany