CLASS DOMINATOR 48 - 68 Technical Systems & Hydraulic Service Manual - PDF DOWNLOAD

DOMINATOR 48 - 68 DO 48 from Serial No. 15403117 DO 68 from Serial No. 15608462

Technical Systems Hydraulic System

TIC

DOMINATOR 48 - 68

Hydraulic System

1 Overall hydraulic system

1

Overall hydraulic system ................................................................................................................ 1-3

1.1

Hydraulic system - General ............................................................................................................ 1-7 Hydraulic pumps ................................................................................................................................ 1-8 Oil pressure........................................................................................................................................ 1-9 Oil specification.................................................................................................................................. 1-9 Oil change.......................................................................................................................................... 1-9 Filling quantity .................................................................................................................................... 1-9 Oil filter head.................................................................................................................................... 1-10 Oil filter............................................................................................................................................. 1-11

1.2 1.2.1

Overall hydraulic system circuit diagram ................................................................................... 1-13 Overall hydraulic system circuit diagram – without straw collector ................................................. 1-16 Pressure measurement ................................................................................................................... 1-17 Overall hydraulic system circuit diagram – with straw collector ...................................................... 1-20 Pressure measurement ................................................................................................................... 1-21

1.2.2 2

Steering hydraulics / 3-D sieve pan control system .................................................................... 2-1

2.1

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

2.2

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

2.3

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

2.4

Function of steering ...................................................................................................................... 2-12 Steering actuation ............................................................................................................................ 2-14

2.5

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

2.6

AUTOPILOT solenoid valve .......................................................................................................... 2-18

2.7

Checking the AUTOPILOT system ............................................................................................... 2-20

2.8

3-D sieve pan control system ....................................................................................................... 2-22

11/03

DO-h-Kap1

1-3

Hydraulic System

1-4

DOMINATOR 48 - 68

TIC

DO-h-Kap1

11/03

TIC

DOMINATOR 48 - 68

Hydraulic System

3

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

3.1

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

3.2 3.2.1 3.2.2

Pressure relief valve ........................................................................................................................ 3-7 Pressure relief valve (703) – with hydraulic-driven grain tank unloading tube swing........................ 3-8 Pressure relief valve – without hydraulic-driven grain tank unloading tube swing .......................... 3-10

3.3

Swinging the grain tank unloading tube ..................................................................................... 3-12 4/3 way valve ................................................................................................................................... 3-12 Hydraulic cylinder............................................................................................................................. 3-14

3.4

Lock-up valve unit ......................................................................................................................... 3-16

3.5

Flow divider (option) – for horizontal reel adjustment and/or straw collector........................ 3-18

3.6

Automatic cutting height control (option)................................................................................... 3-20 3/3 way solenoid valve..................................................................................................................... 3-20

3.7

Horizontal reel adjustment............................................................................................................ 3-22 4/3-way valve ................................................................................................................................... 3-24 Hydraulic rams ................................................................................................................................. 3-26

3.8

Raise / lower front attachment, variator variable-speed drive, vertical reel adjustment, threshing drum variable-speed drive........................................................................................... 3-28 6/9-way multi-function valve ............................................................................................................ 3-28 Vertical reel adjustment hydraulic cylinder ...................................................................................... 3-30 Variator variable-speed drive, threshing drum variable-speed drive hydraulic cylinder .................. 3-32 Rotary coupling and throttle non-return valve.................................................................................. 3-34

3.9

Variator foot valve.......................................................................................................................... 3-36

3.10

Straw collector ............................................................................................................................... 3-38 3/3-way valve ................................................................................................................................... 3-38

Position of components...............................................................................................................................R-1 Index

11/03

.................................................................................................................................................. Index-2

DO-h-Kap1

1-5

Hydraulic System

1-6

DOMINATOR 48 - 68

TIC

DO-h-Kap1

11/03

TIC

DOMINATOR 48 - 68

Hydraulic System

1.1 Hydraulic system General

Hydraulic pumps............................................................................................................................................. 1-8 Oil pressure .................................................................................................................................................... 1-9 Oil specification .............................................................................................................................................. 1-9 Oil change ...................................................................................................................................................... 1-9 Filling quantity................................................................................................................................................. 1-9 Oil filter head ................................................................................................................................................ 1-10 Oil filter ......................................................................................................................................................... 1-11

11/03

DO-h-Kap1

1-7

Hydraulic System

DOMINATOR 48 - 68

TIC

DO-h-Kap1

11/03

Hydraulic pumps

1-8

TIC

DOMINATOR 48 - 68

Hydraulic System

Working hydraulics

Dominator 48 – 68

Sense of rotation Drive nmax Volumetr. displacement

= Counterclockwise = 2,760 rpm = 12 cm3/rev.

Steering hydraulics

Dominator 48 – 68

Sense of rotation Drive nmax Volumetr. displacement

= Counterclockwise = 2,760 rpm = 6 cm3/rev.

Note:

Oil pressure

The exact pump output can only be determined using a flowmeter. During this measurement, the output under maximum system pressure and at operating temperature (60°C) may fall by 15% max.

If the hydraulic pump output is too low, also check the drive V-belt for correct tension.

Working hydraulics = 180+10 bar Steering = 90+5 bar Neutral circulation pressure of working hydraulics = < 20 bar Neutral circulation pressure of steering hydraulics = < 20 bar Note:

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

Oil specification

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

Oil change

1. Oil change according to Operator's Manual.

After this, once a year or after 500 operating hours

Filling quantity

The filling quantity depends on the machine equipment. (see Operator's Manual) The oil level can be checked only when all cylinders for single-acting functions are retracted.

11/03

DO-h-Kap1

1-9

Hydraulic System

DOMINATOR 48 - 68

TIC

DO-h-Kap1

11/03

Oil filter head

1-10

TIC Oil filter

DOMINATOR 48 - 68

Hydraulic System

Working hydraulics = Filtering screen inside tank (60 µm) Steering hydraulics = Filter cartridge inside tank (20 µm) Caution: Do not confuse filters!

Filter change:

With each oil change. Once a year or after 500 operating hours

Installation note

The marking bore A must point upwards.

11/03

DO-h-Kap1

1-11

Hydraulic System

1-12

DOMINATOR 48 - 68

TIC

DO-h-Kap1

11/03

TIC

DOMINATOR 48 - 68

Hydraulic System

1.2 Overall hydraulic system circuit diagram

1.2.1

Overall hydraulic system circuit diagram – without straw collector ................................................. 1-16

1.2.2

Overall hydraulic system circuit diagram – with straw collector ...................................................... 1-20

11/03

DO-h-Kap1

1-13

Hydraulic System

1-14

DOMINATOR 48 - 68

TIC

DO-h-Kap1

11/03

TIC

DOMINATOR 48 - 68

Hydraulic System

1.2.1 Overall hydraulic system circuit diagram - without straw collector

11/03

DO-h-Kap1

1-15

Hydraulic System

DOMINATOR 48 - 68

TIC

1.2.1 Overall hydraulic system circuit diagram – without straw collector Key to diagram:

1-16

DO-h-Kap1

11/03

110 112 112-1 116 117

Oil tank Return flow filter (steering hydraulics 20 µm) Return flow filter (working hydraulics 60 µm) Resonance tube (silencer) Fresh air filter element

205 218

Working hydraulics pump Steering hydraulics pump

301 311 314 315 316 320 323 351 3001

3-D sieve pan hydraulic cylinder Threshing drum variable-speed drive hydraulic cylinder Reel raise/lower follow-up cylinder Reel raise/lower main cylinder Hydraulic fore and aft reel adjustment hydraulic cylinder Swing grain tank unloading tube hydraulic cylinder Steering hydraulic cylinder Front attachment raise/lower hydraulic cylinder Variator variable-speed drive hydraulic cylinder

406 408 410 434 441 441-1

Orifice plate 0.8 mm Orifice plate 1.2mm Orifice plate 1.5mm Restrictor 3.0 mm Rotary coupling Rotary coupling

601 609 619 637 638 639

3-D sieve pan pendulum control valve Orbitrol steering unit rotary disc valve Grain tank unloading tube swing valve 6/9-way multi-function valve Variator foot valve Horizontal reel adjustment valve

703 725 726 731 732 734 734-1 760 760-1 769

Working hydraulics pressure relief valve Steering double shock valve Steering pressure relief valve Return flow valve (non-return valve) Non-return valve Lock-up valve unit Lock-up valve unit One-way restrictor valve, one-sided One-way restrictor valve, one-sided Flow divider

TIC Key to diagram:

Pressure measurement

11/03

DOMINATOR 48 - 68

Hydraulic System

801 801-1 801-2

Quick release coupling Quick release coupling Quick release coupling

901 909

Working hydraulics measuring point Steering hydraulics measuring point

Y9 Y10 Y85 Y87

AUTOPILOT left solenoid coil AUTOPILOT right solenoid coil Raise front attachment solenoid coil Lower front attachment solenoid coil

A

Horizontal reel adjustment / straw collector port

+10 Working hydraulics = 180 bar +5 Steering = 90 bar neutral circulation pressure of working hydraulics = < 20 bar neutral circulation pressure of steering hydraulics = < 20 bar

DO-h-Kap1

1-17

Hydraulic System

1-18

DOMINATOR 48 - 68

TIC

DO-h-Kap1

11/03

TIC

DOMINATOR 48 - 68

Hydraulic System

1.2.2 Overall hydraulic system circuit diagram - with straw collector

11/03

DO-h-Kap1

1-19

Hydraulic System

DOMINATOR 48 - 68

TIC

1.2.2 Overall hydraulic system circuit diagram – with straw collector Key to diagram:

1-20

DO-h-Kap1

11/03

110 112 112-1 116 117

Oil tank Return flow filter (steering hydraulics 20 µm) Return flow filter (working hydraulics 60 µm) Resonance tube (silencer) Fresh air filter element

205 218

Working hydraulics pump Steering hydraulics pump

301 311 314 315 320 323 351 3001 3002

3-D sieve pan hydraulic cylinder Threshing drum variable-speed drive hydraulic cylinder Reel raise/lower follow-up cylinder Reel raise/lower main cylinder Swing grain tank unloading tube hydraulic cylinder Steering hydraulic cylinder Front attachment raise/lower hydraulic cylinder Variator variable-speed drive hydraulic cylinder Straw collector hydraulic cylinder

406 408 434 441 441-1

Orifice plate 0.8 mm Orifice plate 1.2mm Restrictor 3.0 mm Rotary coupling Rotary coupling

TIC Key to diagram:

Pressure measurement

11/03

DOMINATOR 48 - 68

Hydraulic System

601 609 619 637 638 640

3-D sieve pan pendulum control valve Orbitrol steering unit rotary disc valve Grain tank unloading tube swing valve 6/9-way multi-function valve Variator foot valve Straw collector valve

703 725 726 731 732 734 760 760-1 769

Working hydraulics pressure relief valve Steering double shock valve Steering pressure relief valve Return flow valve (non-return valve) Non-return valve Lock-up valve unit One-way restrictor valve, one-sided One-way restrictor valve, one-sided Flow divider

801

Quick release coupling

901 909

Working hydraulics measuring point Steering hydraulics measuring point

Z17

Tailgate open switch

A

Horizontal reel adjustment / straw collector port

+10 Working hydraulics = 180 bar +5 Steering = 90 bar neutral circulation pressure of working hydraulics = < 20 bar neutral circulation pressure of steering hydraulics = < 20 bar

DO-h-Kap1

1-21

Hydraulic System

2-22

DOMINATOR 48 - 68

TIC

DO-h-Kap2

11/03

TIC

DOMINATOR 48 - 68

Hydraulic System

2 Steering hydraulics / 3-D sieve pan control system

2.1

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

2.2

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

2.3

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

2.4

Function of steering ......................................................................................................................... 2-12

2.5

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

2.6

AUTOPILOT solenoid valve............................................................................................................. 2-18

2.7

Checking the AUTOPILOT system .................................................................................................. 2-20

2.8

3-D sieve pan control system .......................................................................................................... 2-22

11/03

DO-h-Kap2

2-1

Hydraulic System

2-2

DOMINATOR 48 - 68

TIC

DO-h-Kap2

11/03

TIC

DOMINATOR 48 - 68

Hydraulic System

2.1 Steering hydraulics circuit diagram - without AUTOPILOT

11/03

DO-h-Kap2

2-3

Hydraulic System 2.1

DOMINATOR 48 - 68

TIC

Steering hydraulics circuit diagram without AUTOPILOT Key to diagram:

Pressure measurement

110 112

Oil tank Return flow filter (steering hydraulics 20 µm)

218

Steering hydraulics pump

301 323

3-D sieve pan hydraulic cylinder Steering hydraulic cylinder

434

Restrictor 3.0 mm

601 609

3-D sieve pan pendulum control valve Orbitrol steering unit rotary disc valve

725 726 731 732

Steering double shock valve Steering pressure relief valve Return flow valve (non-return valve) Non-return valve

909

Steering hydraulics measuring point

Neutral circulation pressure = < 20 bar System pressure = 90+5 bar Shock valve = 150+15 bar Note:

2-4

DO-h-Kap2

11/03

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

TIC

DOMINATOR 48 - 68

Hydraulic System

Description of function: Steering

11/03

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

Turning the steering wheel to one direction causes the spools to rotate relative to each other.

At a rotation of 1.5°, the channels to the chambers start opening.

At 4°, the neutral position channels are completely closed.

At 6°, the channels to the chambers are fully open.

The rotation of the spools relative to each other is limited to ± 8°.

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

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

DO-h-Kap2

2-5

Hydraulic System

2-6

DOMINATOR 48 - 68

TIC

DO-h-Kap2

11/03

TIC

DOMINATOR 48 - 68

Hydraulic System

2.2 Steering hydraulics circuit diagram - with AUTOPILOT

11/03

DO-h-Kap2

2-7

Hydraulic System 2.2

DOMINATOR 48 - 68

TIC

Steering hydraulics circuit diagram with AUTOPILOT Key to diagram:

Pressure measurement

110 112

Oil tank Return flow filter (steering hydraulics 20 µm)

218

Steering hydraulics pump

301 323

3-D sieve pan hydraulic cylinder Steering hydraulic cylinder

434

Restrictor 3.0 mm

601 609

3-D sieve pan pendulum control valve Orbitrol steering unit rotary disc valve

725 726 731 732

Steering double shock valve Steering pressure relief valve Return flow valve (non-return valve) Non-return valve

909

Steering hydraulics measuring point

Y9 Y10

AUTOPILOT left solenoid coil AUTOPILOT right solenoid coil

Neutral circulation pressure = < 20 bar system pressure = 90+5 bar Shock valve = 150+15 bar Note:

2-8

DO-h-Kap2

11/03

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

TIC

DOMINATOR 48 - 68

Hydraulic System

Description of function: Installation of Autopilot valve into the steering hydraulics

11/03

The solenoid valves (E9, E10) are installed between the steering unit and the valve block. The return line of the steering unit is the feed line (P) to the solenoid valves. This still ensures priority oil supply to the steering unit, allowing manual steering at any time. (The graphic representation at that point does not correspond with the machine status) The return line T from the solenoid valve is fed directly to the tank.

DO-h-Kap2

2-9

Hydraulic System 2.3

2-10

DOMINATOR 48 - 68

TIC

DO-h-Kap2

11/03

Steering valve unit

TIC Key to diagram:

Steering system

DOMINATOR 48 - 68 112 218 229 323 609 725 726 728 742 909

Hydraulic System

Return flow filter (steering hydraulics 20 µm) Steering hydraulics pump ........................................... 6 cm3 Steering hydraulics proportioning pump Steering hydraulic cylinder Orbitrol steering unit rotary disc valve Steering double shock valve ....................................... 150+15 bar Steering pressure relief valve ..................................... 90+5 bar Anti-cavitation valve (non-return valve) Steering safety valve Steering hydraulics measuring point

Open center:

with the steering in neutral position, there is a connection between pump P2 and the tank.

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

Valve unit

DANFOSS OSPB 125 with valve block OVP 15 O = Orbit (Orbitrol) S = Steering P = Pump B = Version 3 125 = Oil displacement in cm /rev V = Valve block 15 = Pressure setting of shock valves x10

Design of valve unit

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

The Orbitrol rotary valve (609) is actuated by the steering gear shaft.

Continued rotary movement of the steering gear shaft drive the steering hydraulics proportioning pump (229) by means of a socket-type shaft.

11/03

DO-h-Kap2

2-11

Hydraulic System 2.4

2-12

DOMINATOR 48 - 68

TIC

DO-h-Kap2

11/03

Function of steering Neutral

TIC

DOMINATOR 48 - 68

Hydraulic System

Description of function: Neutral

11/03

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

The circulation pressure must not exceed 20 bar.

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

DO-h-Kap2

2-13

Hydraulic System

DOMINATOR 48 - 68

TIC

DO-h-Kap2

11/03

Steering actuation

2-14

TIC

DOMINATOR 48 - 68

Hydraulic System

Description of function: Steering actuation

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

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

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

-

Emergency steering

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

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

11/03

DO-h-Kap2

2-15

Hydraulic System

DOMINATOR 48 - 68

TIC

2.5 Checking the steering Steering gear shaft

Height play = 0.1 to 0.3 mm Clearance from bottom inside rotary disc = 3 mm

Return

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

Reaction

If steering reaction is insufficient, internal leaks in the steering system must be checked. To do this, disconnect the lines from the steering cylinder and plug them tightly with plugs.

With the oil at operating temperature and at max. no-load speed of the diesel engine, the steering wheel must not allow more than 4 turns/minute in both directions when using a force of approx. 25 Nm. When the actual number of turns is more than 4/minute, check the steering valve for leaks.

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

Power

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

A pressure test at the steering hydraulics measuring port must show the +5 value 90 bar.

To this end move the steering wheel up to the stop and hold it in this position.

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

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

2-16

DO-h-Kap2

11/03

TIC

DOMINATOR 48 - 68

Hydraulic System

Notes:

11/03

DO-h-Kap2

2-17

Hydraulic System 2.6

2-18

DOMINATOR 48 - 68

TIC

DO-h-Kap2

11/03

AUTOPILOT solenoid valve

TIC Key to diagram:

DOMINATOR 48 - 68 I II M V K G E

Hydraulic System

Neutral position Working position Solenoid valve 12 V, 60% OLF, 3.5 A Pilot valve Non-return valve with piston Blocking piston Spring-loaded pin

Description of function: Installation into the steering hydraulics

The solenoid valve is installed between the steering unit and the valve block. The return line of the steering unit is the feed line P to the solenoid valve. This still ensures priority oil supply to the steering unit, allowing manual steering at any time.

The return line R from the solenoid valve is fed directly to the tank. During a normal steering procedure, the spring-loaded non-return valves (K) on both sides are closed in the solenoid valve. The pressure built up in the cylinder is applied to the non-return valves (K).

Neutral ( I )

Both solenoid coils are without voltage. The oil flows from port P via the spring-loaded pin (E) on the left- and right-hand side to the blocking piston (G). The restrictor edges divide the volume flow evenly to both sides. Both blocking pistons (G) are opened by the volume flow and the oil flows to the pilot valves (V). Both pilot valves (V) are open. The oil can flow directly to the tank after passing R.

Working position ( II )

The solenoid valve is actuated. The iron core of the solenoid coil closes the bleed bore of the pilot valve (V). Pressure is built up in the pilot valve (V).

The pilot valve piston closes bore R. The pressure feedback controls piston (K) and blocking piston (G) on the left-hand side. Piston (K) opens the non-return valve and releases the return flow from the working cylinder to the tank (B to R). The blocking piston (G) closes the connection from P to R. The non-return valve (right) is opened hydraulically. The oil flows from P to A. When the other solenoid coil is actuated, the circuit is mirror-inverted with the function described above.

11/03

DO-h-Kap2

2-19

Hydraulic System

DOMINATOR 48 - 68

TIC

2.7 Checking the AUTOPILOT system Caution!

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

Let diesel engine run at full speed.

Fault:

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

Diagnosis:

Actuate a solenoid valve manually. This serves for finding out if the fault is in the hydraulic system or in the electric system. check pilot valve (V, piston jammed, or bore plugged by dirt) check blocking piston (G) or piston (K). check the restrictor bore (D).

Fault:

The steering is heavy. (The Autopilot is deactivated)

Diagnosis:

Fault: Diagnosis:

2-20

-

check the non-return valve with piston (K) check the O-rings of valve body (K)

The machines automatically steers to one or another direction.

-

check the seal in the steering cylinder. check the spring of the corresponding non-return valve (K). check the piston in the pilot valve (V).

DO-h-Kap2

11/03

TIC

DOMINATOR 48 - 68

Hydraulic System

Notes:

11/03

DO-h-Kap2

2-21

Hydraulic System 2.8

2-22

DOMINATOR 48 - 68

TIC

DO-h-Kap2

11/03

3-D sieve pan control system

TIC Key to diagram:

DOMINATOR 48 - 68 1 2 3 4

Hydraulic System

Control head Pendulum Cup Spool

Description of function: Volume flow is applied to port (P) of the control head. When the pendulum (2) is in the centre position, P is blocked at the spool (4).

When the pendulum changes its position to the right or left, relative to the cup, the spool (4) is moved. In this process, connections are made between P and A as well as B and R or between P and B as well as A and R, depending on the direction in which the pendulum moves.

11/03

DO-h-Kap2

2-23

Hydraulic System

3-24

DOMINATOR 48 - 68

TIC

DO-h-Kap3

11/03

TIC

Dominator 48 - 68

Hydraulic System

3 Working hydraulics

3.1 3.2 3.2.1 3.2.2

Working hydraulics circuit diagram .................................................................................................... 3-4 Pressure relief valve .......................................................................................................................... 3-7 Pressure relief valve (703) – with hydraulic-driven grain tank unloading tube swing........................ 3-8 Pressure relief valve – without hydraulic-driven grain tank unloading tube swing .......................... 3-10

3.3

Swinging the grain tank unloading tube........................................................................................... 3-12 4/3 way valve ................................................................................................................................... 3-12

3.4

Lock-up valve unit ............................................................................................................................ 3-16

3.5

Flow divider (option) – for horizontal reel adjustment and/or straw collector .................................. 3-18

3.6

Automatic cutting height control (option) ......................................................................................... 3-20

3.7

Horizontal reel adjustment ............................................................................................................. 3-24 Hydraulic rams ................................................................................................................................. 3-26

3.8

Raise / lower front attachment, variator variable-speed drive, vertical reel adjustment, threshing drum variable-speed drive ............................................................................................... 3-28 6/9-way multi-function valve ............................................................................................................ 3-28 Vertical reel adjustment hydraulic ram............................................................................................. 3-30 Variator variable-speed drive, threshing drum variable-speed drive hydraulic ram ........................ 3-32 Rotary coupling and throttle non-return valve.................................................................................. 3-34

3.9

Variator foot valve ............................................................................................................................ 3-36

3.10

Straw collector ................................................................................................................................. 3-38 3/3-way valve ................................................................................................................................... 3-38

11/03

DO-h-Kap3

3-1

Hydraulic System

3-2

DOMINATOR 48 - 68

TIC

DO-h-Kap3

11/03

TIC

Dominator 48 - 68

Hydraulic System

3.1 Working hydraulics circuit diagram

11/03

DO-h-Kap3

3-3

Hydraulic System 3.1

DOMINATOR 48 - 68

TIC

Working hydraulics circuit diagram without straw collector Key to diagram:

3-4

DO-h-Kap3

11/03

110 112-1 116 117

Oil tank Return flow filter (working hydraulics 60 µm) Resonance tube (silencer) Fresh air filter element

205 218

Working hydraulics pump Steering hydraulics pump

311 314 315 316 320 351 3001

Threshing drum variable-speed drive hydraulic cylinder Reel raise/lower follow-up cylinder Reel raise/lower main cylinder Hydraulic fore and aft reel adjustment hydraulic cylinder Swing grain tank unloading tube hydraulic cylinder Front attachment raise/lower hydraulic cylinder Variator variable-speed drive hydraulic cylinder

406 408 410 441 441-1

Orifice plate 0.8 mm Orifice plate 1.2mm Orifice plate 1.5mm Rotary coupling Rotary coupling

619 637 638 639

Grain tank unloading tube swing valve 6/9-way multi-function valve Variator foot valve Horizontal reel adjustment valve

703 734 734-1 760 760-1 769

Working hydraulics pressure relief valve Lock-up valve unit Lock-up valve unit One-way restrictor valve, one-sided One-way restrictor valve, one-sided Flow divider

801 801-1 801-2

Quick release coupling Quick release coupling Quick release coupling

901

Working hydraulics measuring point

Y85 Y87

Raise front attachment solenoid coil Lower front attachment solenoid coil

A

Ports for horizontal reel adjustment and/or straw collector

TIC

Dominator 48 - 68

Hydraulic System

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

The maximum system pressure is limited to 180+10 bar by means of pressure relief valve 703.

11/03

DO-h-Kap3

3-5

Hydraulic System

3-6

DOMINATOR 48 - 68

TIC

DO-h-Kap3

11/03

TIC

Dominator 48 - 68

Hydraulic System

3.2 Pressure relief valve

3.2.1

Pressure relief valve (703) – with hydraulic-driven grain tank unloading tube swing ........................ 3-8

3.2.2

Pressure relief valve – without hydraulic-driven grain tank unloading tube swing .......................... 3-10

11/03

DO-h-Kap3

3-7

Hydraulic System 3.2.1

3-8

DOMINATOR 48 - 68

TIC

Pressure relief valve (703) – with hydraulic-driven grain tank unloading tube swing

DO-h-Kap3

11/03

TIC Key to diagram:

DOMINATOR 48 - 68

Hydraulic System

I II III

Swing grain tank unloading tube neutral Swing grain tank unloading tube to the left Swing grain tank unloading tube to the right

P S R(T)

Pump port Port for downstream hydraulic valves Return line port (tank)

A B

Consumer port Consumer port

Description of function: Pressure relief valve

The pressure relief valve protects the hydraulic system and thus the connected mechanical components from damage by excessive forces.

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

-

11/03

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

Note:

The above values refer to a rated pressure of 180 bar and may deviate, depending on the actual system. Each time the setting has been modified, the system pressure must be checked.

Note:

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

DO-h-Kap3

3-9

Hydraulic System 3.2.2

3-10

DOMINATOR 48 - 68

TIC

Pressure relief valve – without hydraulic-driven grain tank unloading tube swing

DO-h-Kap3

11/03

TIC Key to diagram:

DOMINATOR 48 - 68 P M R(T)

Hydraulic System

Pump port Measuring port Return line port (tank)

Description of function: Pressure relief valve

The pressure relief valve protects the hydraulic system and thus the connected mechanical components from damage by excessive forces.

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

-

11/03

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

Note:

The above values refer to a rated pressure of 180 bar and may deviate, depending on the actual system. Each time the setting has been modified, the system pressure must be checked.

Note:

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

DO-h-Kap3

3-11

Hydraulic System 3.3

3-12

DOMINATOR 48 - 68

TIC

Swinging the grain tank unloading tube 4/3 way valve

DO-h-Kap3

11/03

TIC Key to diagram:

DOMINATOR 48 - 68

Hydraulic System

I II III

Swing grain tank unloading tube neutral Swing grain tank unloading tube to the left Swing grain tank unloading tube to the right

P S R(T)

Pump port Port for downstream hydraulic valves Return line port (tank)

A B

Consumer port Consumer port

Description of function: Neutral

The connection from P to S is open through ring channels in the spool.

The ring channels inside the body, with ports A and B, are blocked by the spool. The leak oil bores in the spool connect port A and B with R (T=tank). Pressure is built up from S to P when a downstream unit is actuated. Leakage oil may flow off to R (T=tank) through the leakage oil bores.

Swing to the right

Connection from P to B and from A to R through the ring channels in the spool and the body. Port (S) is blocked.

Swing to the left

Connection from P to A and from B to R. Port (S) is blocked.

Note:

11/03

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

DO-h-Kap3

3-13

Hydraulic System

DOMINATOR 48 - 68

TIC

Swinging the grain tank unloading tube Hydraulic cylinder

3-14

DO-h-Kap3

11/03

TIC Key to diagram:

11/03

DOMINATOR 48 - 68

Hydraulic System

320

Swing grain tank unloading tube hydraulic cylinder

S K

Securing wire Piston thread glued with liquid locking compound

DO-h-Kap3

3-15

Hydraulic System 3.4

3-16

DOMINATOR 48 - 68

TIC

DO-h-Kap3

11/03

Lock-up valve unit

TIC Key to diagram:

DOMINATOR 48 - 68 A B A1 B1

Hydraulic System

Hydraulic valve port Hydraulic valve port Consumer port Consumer port

Description of function: Lock-up valve units (pilot controlled non-return valves) are used in order to lock functions while pressure is relieved and thus to ensure a fixed position of a consumer.

A rising pressure in port (B) moves the internal piston (K). This opens the opposite non-return valve in port A – the return line of the hydraulic cylinder to the tank is released (connection A-A1).

The continued pressure increase now opens the non-return valve in port B. The connection to consumer (B-B1) is released.

11/03

DO-h-Kap3

3-17

Hydraulic System 3.5

3-18

DOMINATOR 48 - 68

TIC

Flow divider (option) – for horizontal reel adjustment and/or straw collector

DO-h-Kap3

11/03

TIC

DOMINATOR 48 - 68

Key to diagram:

P A B

Hydraulic System

Volume flow from pump Constant volume flow Residual volume flow

Description of function: Technical data

Volume flow from pump = 40 litres max.

Constant volume flow = 15 litres max.

Operating pressure = 220 bar max.

The constant flow quantity is determined by the size of the orifice plate bore.

Function

The volume flow from the pump is divided into a constant volume flow (port A) and a variable residual volume flow (port B).

The volume flow from the pump flows against an orifice plate of 1.5 mm diameter which is installed in a movable spool.

A constant volume flow of 2 l/min. flows through the orifice plate.

When the pressure ahead of the orifice plate increases, the spool is moved against the spring.

This reduces the gap made by the control edge to the constant volume flow outlet (port A) and at the same time enlarges the opening crosssection to the residual volume flow (port B).

Malfunctions: -

no constant flow

Orifice plate plugged

-

no residual flow

Orifice plate fell out of control spool (the control units fed by the residual flow have no function).

Important! Install orifice plate with bevelled side towards the spring.

11/03

DO-h-Kap3

3-19

Hydraulic System 3.6

3-20

DOMINATOR 48 - 68

TIC

Automatic cutting height control (option) 3/3 way solenoid valve

DO-h-Kap3

11/03

TIC Key to diagram:

DOMINATOR 48 - 68 410

Orifice plate 1.5mm

Y85 Y87

Raise front attachment solenoid coil Lower front attachment solenoid coil

A P1 S T

Hydraulic cylinder port Pump port Port for downstream control valves Tank port

a b c d e f g h

Double piston Ball Restrictor bore Ball Centre bore Drop rate valve Piston Inlet valve

Hydraulic System

Description of function: A 3/3 way solenoid valve is used for the control of single-acting functions (hydraulic rams).

Neutral position

In the neutral position, both solenoid coils are not energized. The volume flow is directed from port (P1) to port (S) to the downstream solenoid valves. The volume flow from P1 pushes the double piston a in the directional control valve back against the spring. The spring space is connected with port (T) via the raise pilot valve.

Port (A) is shut off by the inlet valve h, the drop rate valve f and the lower pilot valve.

Raise front attachment

The solenoid coil of the raise pilot valve is actuated. The solenoid coil plunger presses ball b against the seat. The spring-loaded ball d is also pressed open by the needle. The volume flow from P1 is now applied to both sides of the double piston.

Due to the different surfaces of the double piston and due to the spring force, the double piston a is pushed towards P1. The bore to port (S) is closed.

Oil flows from P1 via the inlet valve h to A through the centre bores of the piston.

When solenoid coil Y85 of the raise pilot valve is deactivated, the springloaded ball d is pushed into the seat and the opposite ball b is opened by the needle.

The pressure on the spring-loaded side of the double piston can slowly be relieved to T via the 0.6 mm restrictor bore c.

The neutral position is reached again.

11/03

DO-h-Kap3

3-21

Hydraulic System

DOMINATOR 48 - 68

TIC

Description of function: Lower front attachment

The solenoid coil Y87 of the lower pilot valve is actuated. The solenoid coil plunger presses a ball b against the seat. The spring-loaded ball d is pressed open by the needle.

The drop rate valve f is now opened by the pressure from A via piston g.

The oil can be drained from A to T via the open drop rate valve f.

When the solenoid coil is de-energized, the spring-loaded ball d is pressed into the seat and the opposite ball b is opened by the needle. The pressure ahead of piston g can be reduced. The drop rate valve closes.

Malfunctions

When the front attachment is lowered in neutral position: Check inlet valve Check conical seat and O-ring of the drop rate valve f Check ball seat in the lower pilot valve Front attachment does not raise: Check if solenoid coil Y85 is actuated Check if double piston a jams Check needle and ball seat in the raise pilot valve Front attachment does not stop raising: Check if the Ø 0.6 mm restrictor c in the solenoid valve is plugged Check if double piston a jams Front attachment cannot be lowered using the solenoid valve Y87: Check if solenoid coil actuates Check needle in the lower pilot valve Check drop rate valve f

3-22

DO-h-Kap3

11/03

TIC

DOMINATOR 48 - 68

11/03

DO-h-Kap3

Hydraulic System

3-23

Hydraulic System 3.7

3-24

DOMINATOR 48 - 68

TIC

DO-h-Kap3

11/03

Horizontal reel adjustment 4/3-way valve

TIC Key to diagram:

DOMINATOR 48 - 68 I II III

Hydraulic System

Neutral position Reel forward Reel backward

Description of function: A 4/3-way valve is used for the control of double-acting functions (hydraulic rams).

Neutral

The connection from P to S is open through ring channels in the spool.

The ring channels inside the body, with ports (A) and (B), are blocked by the spool. The leak oil bores in the spool connect port (A) and (B) with R (T=tank). Leakage oil may flow off to R (T=tank) through the leakage oil bores.

Reel forward

Connection from P to A and from B to R (T=tank) through the ring channels in the spool and the body. Port S is blocked.

Reel backward

Connection from P to B and from A to R (T=tank) through the ring channels in the spool and the body. Port S is blocked.

11/03

DO-h-Kap3

3-25

Hydraulic System

DOMINATOR 48 - 68

TIC

DO-h-Kap3

11/03

Horizontal reel adjustment Hydraulic rams

3-26

TIC Key to diagram:

DOMINATOR 48 - 68

Hydraulic System

316

Horizontal reel adjustment hydraulic cylinder

A2 A3 V

Hydraulic cylinder port Hydraulic cylinder port Bottom outlet valves

Description of function: Bottom outlet valves

11/03

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

After a repair, the rams must be flushed in both end positions for approx.

15 sec.

DO-h-Kap3

3-27

Hydraulic System 3.8

3-28

DOMINATOR 48 - 68

TIC

Raise / lower front attachment, variator variable-speed drive, vertical reel adjustment, threshing drum variable-speed drive 6/9-way multi-function valve

DO-h-Kap3

11/03

TIC Key to diagram:

DOMINATOR 48 - 68 I II III

Hydraulic System

Neutral position Position Raise or Fast Position Lower or Slow

Description of function: Rotary/longitudinal disc valve for 4 single-acting working rams with seated valves in the consumer ports.

Neutral position

Free oil passage from P to R (T=tank). All inlet and outlet valves are closed.

Raise front attachment / Raise reel / Fast drum speed / Fast ground speed

Pulling out the spool provides opens the connection from P to the consumer port due to the recess in the spool. The flow rate to R can be adjusted.

Lower front attachment / Lower reel / Reduce drum speed / Reduce ground speed

Pushing in the spool to the bottom opens the outlet valve due to the lug of the spool. The connection from the consumer port to R (T=tank) is established.

11/03

DO-h-Kap3

3-29

Hydraulic System

DOMINATOR 48 - 68

TIC

Raise / lower front attachment, variator variable-speed drive, vertical reel adjustment, threshing drum variable-speed drive Vertical reel adjustment hydraulic cylinder

3-30

DO-h-Kap3

11/03

TIC Key to diagram:

DOMINATOR 48 - 68 314 315

Reel raise/lower follow-up cylinder Reel raise/lower main cylinder

A3 E V

Hydraulic cylinder port Vent plug Bottom outlet valves

Hydraulic System

Description of function: Bottom outlet valves

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

Note:

11/03

For repairs, it is recommended to remove the hydraulic rams in the raised reel position since the slave cylinder is filled only with the master cylinder fully extended. During this process support and secure the reel properly.

DO-h-Kap3

3-31

Hydraulic System

DOMINATOR 48 - 68

TIC

Raise / lower front attachment, variator variable-speed drive, vertical reel adjustment, threshing drum variable-speed drive Variator variable-speed drive, threshing drum variable-speed drive hydraulic cylinder

3-32

DO-h-Kap3

11/03

TIC Key to diagram:

DOMINATOR 48 - 68 311 441 760 3001

Hydraulic System

Threshing drum variable-speed drive hydraulic cylinder Rotary coupling One-way restrictor valve, one-sided Variator variable-speed drive hydraulic cylinder

Description of function: A hydraulic cylinder moves the variable-speed drives (variator) apart or together. The respective transmission ratio at the drive belt and consequently the speed is thus changed.

11/03

DO-h-Kap3

3-33

Hydraulic System

DOMINATOR 48 - 68

TIC

Raise / lower front attachment, variator variable-speed drive, vertical reel adjustment, threshing drum variable-speed drive Rotary coupling and throttle non-return valve

3-34

DO-h-Kap3

11/03

TIC Key to diagram:

DOMINATOR 48 - 68 I II

Rotary coupling 441 One-sided throttle non-return valve 760

1 2

Oil flow restricted position Oil flow unrestricted position

Hydraulic System

Description of function: Restricted oil flow (drawing 1)

Oil flow from P to S is restricted. The laterally flattened cone is pressed against the seat by the oil flow. The oil can only flow to the cylinder through the notches.

Unrestricted oil flow (drawing 2)

Oil flow from S to R is unrestricted. The return flow line (R) is released.

The cone is pushed back by the oil flow from S to R. The oil can flow off without restriction at the laterally flattened cone.

Important!

11/03

The different throttle non-return valves are marked from the outside. (Number of notches) 2 = two notches 3 = three notches

DO-h-Kap3

3-35

Hydraulic System 3.9

3-36

DOMINATOR 48 - 68

TIC

DO-h-Kap3

11/03

Variator foot valve

TIC

DOMINATOR 48 - 68

Hydraulic System

Description of function: This valve is used in combine-harvesters with a mechanical ground drive in order to go easy on the clutch, the variable-speed drive and the gearbox.

With the clutch pedal fully depressed, the gear lever should be pulled by at least 30°.

Play between gear lever and housing = 1 ± 0.4mm.

When the clutch pedal is depressed, the foot valve 638 is opened via a linkage. The oil from the variator variable-speed drive hydraulic cylinder 3001 can flow off to R (T=tank). The ground speed variable-speed drive sets the speed to slow.

11/03

DO-h-Kap3

3-37

Hydraulic System

DOMINATOR 48 - 68

TIC

DO-h-Kap3

11/03

3.10 Straw collector 3/3-way valve

3-38

TIC Key to diagram:

DOMINATOR 48 - 68 I II III

Neutral position Open flap switch position Close flap switch position

1 2

Inlet valve Outlet valve

A P R(T) S

Consumer port Pump port Tank port Port for downstream hydraulic valves

Hydraulic System

Description of function: Neutral (I)

The connection from P to S is open through ring channels in the body.

The connections to port (A) are closed without leakage oil by non-return valves 1 and 2. Leakage oil may flow off to R (T=tank) through the leakage oil bores in the spool.

Open flap switch position (II)

The spool is actuated to the right. This releases the connection from P to A. At the same time, port (S) is blocked (non-return valve 1 is opened due to the increased pressure).

Close flap switch position (III)

When actuating the spool to the left, the non-return valve (2) is opened via the inclined surface of the spool and the ball. This releases the connection from A to R (T=tank). The connection from P to S remains intact.

11/03

DO-h-Kap3

3-39

Hydraulik

3-40

DOMINATOR 48 - 68

TIC

DO-h-Kap3

11/03

TIC

Dominator 48 - 68

Hydraulic System

Position of components

11/03

DO-h- Raster

R-1

Hydraulic System

R-2

DOMINATOR 48 - 68

TIC

DO-h- Raster

11/03

TIC

Dominator 48 - 68

110 – 2 o 20

112 – 2 o 20

112-1 / – 2 o 20

116 – 4 k 20

117 – 2 o 20

205 – 2 o 20

11/03

DO-h- Raster

Hydraulic System

R-3

Hydraulic System

DOMINATOR 48 - 68

218 – 2 o 20

311 – 5 k 16

320 – 5 m 20

323 – 7 r 18

351 – 8 h 18

3001 – 6 l 20

R-4

DO-h- Raster

TIC

07/03

TIC

Dominator 48 - 68

406 – 5 m 20

408 – 5 i 17

441 – 6 l 20

441–1 / – 5 k 16

609 – 5 h 18

619 – 4 k 19

07/03

DO-h- Raster

Hydraulic System

R-5

Hydraulic System

DOMINATOR 48 - 68

637 – 5 i 16

638 – 4 j 19

639 – 5 i 16

703 – 4 k 19

725 – 5 h 18

726 – 5 h 18

R-6

DO-h- Raster

TIC

07/03

TIC

Dominator 48 - 68

731 – 2 o 20

732 – 2 o 20

734 – 5 m 20

760 – 6 l 20

760–1 / – 5 k 16

769 – 5 i 16

07/03

DO-h- Raster

Hydraulic System

R-7

Hydraulic System 801 – 7 g 16

DOMINATOR 48 - 68

TIC

901 – 4 k 19

909 – 5 h 18

R-8

DO-h- Raster

07/03

TIC

Dominator 48 - 68

07/03

DO-h- Raster

Hydraulic System

R-9

Hydraulic System

DOMINATOR 48 - 68

TIC

Component grid

R-10

DO-h- Raster

07/03

TIC

Dominator 48 - 68

Hydraulic System

Component grid

07/03

DO-h- Raster

R-11

Hydraulic System

R-12

DOMINATOR 48 - 68

TIC

DO-h- Raster

07/03

Index Hydraulic System

Hydraulic System

Dominator 48 - 68

TR

Index 3-D cleaning system

2-22

A

Automatic cutting height control AUTOPILOT

3-21 2-18

C

Checking the AUTOPILOT system Checking the steering Cutterbar raise/lower

2-20 2-16 3-28

F

Filling quantity Flow divider Front attachment raise/lower

1-9 3-18 3-28

G

Grain tank unloading tube swing

3-12

H

Hydraulic fore and aft reel adjustment Hydraulic pumps Hydraulics, general

3-24 1-8 1-7

L

Lock-up valve unit

3-16

M

Multi-function valve

3-28

O

Oil change Oil filter Oil filter head Oil pressure Oil specification Overall hydraulic system Overall hydraulic system circuit diagram with straw collector Overall hydraulic system circuit diagram without straw collector

1-9 1-11 1-10 1-9 1-9 1-3

Position of components Pressure relief valve - for grain tank discharge tube with hydraulic drive Pressure relief valve - for grain tank discharge tube without hydraulic drive

R-1

3-10

R

Rotary coupling and one-way restrictor

3-34

S

Steering actuation Steering function Steering hydraulics Steering hydraulics circuit diagram with AUTOPILOT Steering hydraulics circuit diagram without AUTOPILOT Steering valve unit Straw collector

2-14 2-12 2-1 2-8

V

Variator foot valve Variator variable-speed drive Vertical reel adjustment

3-36 3-28 3-28

W

Working hydraulics Working hydraulics circuit diagram

3-1 3-4

P

Index-2

DO-h-Index

1-20 1-16

3-8

2-4 2-10 3-38

03/03

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 or omissions not accepted.

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

CLAAS KGaA mbH 33426 Harsewinkel Germany

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

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

0299 856.1 SYS-H DOMINATOR 68-48 EN – 12.03 – NF Printed in Germany