0299 504 1 Sys Hy en 144

MEGA 360 - 350
Technical Systems
Hydraulic System
Hydraulic system MEGA TIC
Meg-h 12/04
TIC MEGA Hydraulic system
Table of Contents
Chapter 1 Overall hydraulic system ................................................. 1-1
Chapter 2 Steering hydraulics .......................................................... 2-1
Chapter 3 Working hydraulics .......................................................... 3-1
Chapter 4 Low-pressure hydraulic circuit ....................................... 4-1
Chapter 5 Front attachments ............................................................ 5-1
Chapter 6 Ground drive hydraulics .................................................. 6-1
Chapter 7 Rotary chaff screen cleaning .......................................... 7-1
Position of components ......................................................................R-1
Component grid..................................................................................R-14
Index ..............................................................................................index-1
12/04 Meg-h
Hydraulic system MEGA TIC
Meg-h 12/04
TIC MEGA Overall hydraulic system
Chapter 1
Overall hydraulic
system
1.1 Overall hydraulic system circuit diagram

up to serial no. 835 00146, 845 00123 ....................................... 1-4
from serial no. 835 00147, 845 00124........................................ 1-8
1.2 Oil tank, oil specification, filling quantities, oil change,

oil filter, oil pressure.................................................................. 1-12
1.3 Hydraulic pumps

up to serial no. 835 00146, 845 00123 .................................... 1-14
from serial no. 835 00147, 845 00124..................................... 1-16
12/04 Meg-h-Kap1 1-1

Overall hydraulic system MEGA TIC
1-2 Meg-h-Kap1 12/04

1.1
Overall hydraulic system circuit diagram

- up to serial no. 835 00146
845 00123
1.1 Overall hydraulic system circuit diagram

up to serial no. 835 00146, 845 00123
1-4 Meg-h-Kap1 12/04

Key to diagram: I Working hydraulics valve block

II Working hydraulics front attachment valve block
III Low-pressure hydraulics valve block
IV Steering (Orbitrol) valve block
V Ground drive hydraulics (hydrostatic motor)
102 Pressure filter .......................................................10 µm

108 Emergency steering oil tank ...............................appr. 250 cm3
109 Oil cooler
110 Oil tank
112 Return flow filter
116 Resonance tube
205 Working hydraulics pump ....................................12 cm3/rev.

209 Ground drive feed pump ......................................22 cm3/rev.
210 Ground drive fixed
displacement motor HMF 75................................75 cm3/rev.
211 Ground drive variable displacement pump
HPV 105 (MEGA 360)..........................................105 cm3/rev.
HPV 75 (MEGA 350)............................................75 cm3/rev.
218 Steering hydraulics pump ....................................6 cm3/rev.
226 Front attachment reverser drive motor
301 3-D sieve pan hydraulic cylinder

305 AUTOCONTOUR right-hand lateral control hydraulic cylinder
306 AUTOCONTOUR left-hand lateral control hydraulic cylinder
308 Diesel engine speed hydraulic cylinder
311 Threshing drum variable-speed drive hydraulic cylinder
312 Threshing mechanism clutch hydraulic cylinder
313 Ground drive pump servo control hydraulic cylinder
314 Reel raise/lower follow-up cylinder
315 Reel raise/lower main cylinder
316 Hydraulic fore and aft reel adjustment hydraulic cylinder
320 Swing grain tank unloading tube hydraulic cylinder
321 Grain tank unloading clutch hydraulic cylinder
323 Steering hydraulic cylinder
351 Front attachment raise/lower hydraulic cylinder
352 Front attachment clutch hydraulic cylinder
353 Front attachment reverse hydraulic cylinder
406 Orifice plate ..........................................................Ø 0.8 mm

410 Orifice plate .........................................................Ø 1.5 mm
441 Rotary coupling
503 AUTOPILOT accumulator

508 Front attachment dampening accumulator
601 3D sieve pan pendulum control 4/3 way valve

602 AUTOCONTOUR / lateral control shut-off valve
604 AUTOPILOT balance screw
605 Threshing drum variable-speed drive 3/3 way valve
606 Ground drive servo control 4/3 way valve
609 Orbitrol steering unit rotary disc valve
12/04 Meg-h-Kap1 1-5

Key to diagram: 703 Working hydraulics pressure relief valve ............. 180+10
710 Ground drive filter bypass valve .......................... 2 bar
713 Ground drive multi-function valve backward
714 Ground drive multi-function valve forward
716 Ground drive feed pressure relief valve............... 23-2,5 bar
718 Ground drive feed circuit cold weather starting valve
719 Ground drive tap pressure control valve.............. 10 bar
721 Ground drive oil tapping shuttle valve
725 Steering double shock valve................................ 200+20 bar
726 Steering pressure relief valve .............................. 125+5 bar
728 Anti-cavitation valve (non-return valve)
729 Low-pressure hydraulics pressure relief valve .... 19 bar
732 Non-return valve
734 Lock-up valve unit (non-return valve)
740 AUTOCONTOUR lateral control flow control valve
742 Steering safety valve
759 One-way restrictor valve, two-sided
760 One-way restrictor valve, one-sided
774 Pre-loading valve
801 Quick release coupling
901 Working hydraulics measuring point

902 Ground drive hydraulics high pressure backward measuring
point
903 Ground drive hydraulics high pressure forward measuring
point
904 Ground drive hydraulics feed pressure measuring point
909 Steering hydraulics measuring point
910 Low-pressure hydraulics measuring point
Y9/Y10 AUTOPILOT left/right solenoid valve

Y13 Diesel engine 1st step solenoid valve
Y14 Diesel engine 2nd step solenoid valve
Y21 Threshing mechanism clutch solenoid valve
Y22/Y23 Reel raise/lower solenoid valve
Y24/Y25 Reel forward/backward solenoid valve
Y33/Y34 Swing grain tank unloading tube in/out solenoid valve
Y35 Grain tank unloading solenoid valve
Y67/Y68 AUTOPILOT left/right transverse control solenoid valve
Y77 Working hydraulics circulation shut-off valve solenoid valve
Y85/Y87 Front attachment raise/lower solenoid valve
Y86 Front attachment reverse solenoid valve
Y88 Front attachment clutch solenoid valve
Z4 AUTOPILOT oil pressure actual value switch
1-6 Meg-h-Kap1 12/04

- from serial no. 835 00147
845 00124

from serial no. 835 00147, 845 00124
1-8 Meg-h-Kap1 12/04


III Low-pressure hydraulics valve block
IV Steering (Orbitrol) valve block
102 Pressure filter....................................................... 10 µm

108 Emergency steering oil tank ............................... approx. 250 cm3
109 Oil cooler
110 Oil tank
112 Return filter
116 Resonance tube
205 Working hydraulics pump .................................... 11 cm3/rev.

209 Ground drive feed pump ...................................... 22 cm3/rev.
210 Ground drive fixed displacement motor
HMF 75 ................................................................ 75 cm3/rev.
HPV 105 (MEGA 360) ......................................... 105 cm3/rev.
HPV 75 (MEGA 350) ......................................... 75 cm3/rev.
216 Rotary chaff screen motor ................................... 8.0 cm3/rev.
217 Rotary chaff screen pump.................................... 5.5 cm3/rev.
218 Steering hydraulics pump .................................... 5.5 cm3/rev.

305 AUTOCONTOUR cross levelling right hydraulic cylinder
306 AUTOCONTOUR cross levelling left hydraulic cylinder
313 Ground drive servo control pump hydraulic cylinder
314 Reel raise/lower slave cylinder
315 Reel raise/lower master cylinder
316 Horizontal reel adjustment hydraulic cylinder
351 Raise/lower front attachment hydraulic cylinder
352 Front attachment coupling hydraulic cylinder
353 Reverse front attachment hydraulic cylinder
406 Orifice plate.......................................................... Ø 0.8 mm

410 Orifice plate ......................................................... Ø 1.5 mm
441 Rotary coupling
503 AUTOPILOT accumulator

508 Front attachment dampening accumulator

609 Orbitrol steering system rotary valve
12/04 Meg-h-Kap1 1-9

Key to diagram: 703 Working hydraulics pressure relief valve............. 180+10

706 Pressure relief valve ............................................ 120 bar
710 Ground drive filter bypass valve .......................... 2 bar
713 Ground drive multi-function valve, reverse
714 Ground drive multi-function valve, forward
716 Ground drive feed pressure relief valve .............. 23-2.5 bar
718 Ground drive feed circuit cold start injector
719 Ground drive flush pressure control valve........... 10 bar
721 Ground drive flush-out shuttle valve
725 Steering double shock valve................................ 200+20 bar
726 Steering pressure relief valve .............................. 125+5 bar
729 Low-pressure hydraulic system pressure relief valve ... 19 bar
740 AUTOCONTOUR cross levelling flow control valve
760 One-way restrictor, one-sided
901 Working hydraulics measuring point

902 Ground drive hydraulics high pressure backward measuring
point
903 Ground drive hydraulics high pressure forward measuring
point
Y9/Y10 AUTOPILOT left/right solenoid valve

Y13 Diesel engine 1st step solenoid valve
Y14 Diesel engine 2nd step solenoid valve
Y21 Threshing mechanism clutch engage solenoid valve
Y77 Working hydraulics master valve solenoid valve
Y86 Reverse front attachment solenoid valve
Z4 AUTOPILOT oil pressure actual value switch
1-10 Meg-h-Kap1 12/04

12/04 Meg-h-Kap1 1-11

1.2 Oil tank, oil specification, filling quantities, oil change, oil filter, oil pressure
1-12 Meg-h-Kap1 12/04

Key to diagram: 112 Return flow filter
A Ground drive port

B Working hydraulics suction line
C Working hydraulics return line port
D Low-pressure hydraulics return line
E Steering return line
F Ground drive port
G Steering suction line
H Oil level dipstick
Z19 Hydraulic oil level (min.) actual value switch
Oil specification Multigrade hydraulic oil HV (ISO VG 46), DIN 51524 part 3
Filling quantities Total hydraulic system = 25 litres, depending on equipment fitted

Oil change = 20 litres
Oil change Once a year or after 500 operating hours

Check oil only with cutterbar cylinders retracted.
Oil filter Working hydraulics = Filtering screen inside tank (60 µm)
Hydrostatic ground drive = Filter cartridge (10 µm)
Filter change once a year or after 500 operating hours.
Oil pressure Working hydraulics = 180+10 bar

Steering = 125+15 bar
Low-pressure hydraulics = 19+2 bar
Ground drive high pressure = 420+30 bar
Ground drive feed pressure = 18+2 bar
Working hydraulics circulation pressure = 15+12 bar
Steering hydraulics circulation pressure = 10+10 bar
Note: These values refer to measurements made at a hydraulic oil

operating temperature of 45 – 50°C.
12/04 Meg-h-Kap1 1-13

1.3 Hydraulic pumps

up to serial no. 835 00146, 845 00123
1-14 Meg-h-Kap1 12/04

Key to diagram: 205 Working hydraulics pump ...................................12 cm3/rev.

218 Steering hydraulics pump ...................................6.0 cm3/rev.
12/04 Meg-h-Kap1 1-15

Hydraulic pumps
from serial no. 835 00147, 845 00124
1-16 Meg-h-Kap1 12/04

Key to diagram: 205 Working hydraulics pump .................................... 11 cm3/rev.

217 Rotary chaff screen drive pump........................... 5.5 cm3/rev.
218 Steering hydraulics pump ................................... 5.5 cm3/rev.
706 Pressure relief valve ............................................ 120 bar
12/04 Meg-h-Kap1 1-17

1-18 Meg-h-Kap1 12/04

TIC MEGA Steering hydraulics
Chapter 2
Steering
hydraulics
2.1 Steering hydraulics circuit diagram without AUTOPILOT............ 2-4
2.2 Steering hydraulics circuit diagram with AUTOPILOT................. 2-8
2.3 Steering valve unit ..................................................................... 2-10
2.4 Function of steering – neutral .................................................... 2-12
2.5 Checking the steering ................................................................ 2-16
2.6 AUTOPILOT left/right solenoid valve......................................... 2-18
2.7 Checking the AUTOPILOT System ........................................... 2-20
12/04 Meg-h-Kap2 2-1

Steering hydraulics MEGA TIC
2-2 Meg-h-Kap2 12/04

2.1
Steering hydraulics circuit diagram
- without AUTOPILOT
2.1 Steering hydraulics circuit diagram without AUTOPILOT

Key to diagram: IV Steering (Orbitrol) valve block
108 Emergency steering oil tank ............................... approx. 250 cm3

110 Oil tank
112 Working hydraulics return flow filter
205 Working hydraulics pump .................................... 12 cm3
218 Steering hydraulics pump.................................... 6 cm3
725 Steering double shock valve ............................... 200±15 bar
726 Steering pressure relief valve.............................. 125+20 bar
909 Measuring port
Note: The machines of the MEGA series are equipped with one
steering cylinder (323) only. Therefore, these machines generally
have the emergency steering tank (108) in order to compensate
the volumetric difference between the piston surface and the
piston ring surface.
Pressure measurement Circulation pressure = 10+7 bar

System pressure = 125+15 bar
Shock valve = 200±15 bar
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.
2-4 Meg-h-Kap2 12/04

Description of function:
Steering In the neutral steering position, oil flows freely through the
steering control unit = Orbitrol (609).
Turning the steering wheel to one direction causes the discs to rotate
relative to each other. At 1.5°, opening the channels towards the
chambers starts. At 4°, the neutral position channels are fully closed. At
6°, the channels to the chambers are fully open. The rotation of the discs
relative to each other is limited to ± 8°.
A feed of pressurized oil to the rotor set has the following effects:
- Rotation of rotor
- Feed of an oil quantity which is proportional to the rotation into the
steering cylinder, the rear wheels being influenced.
- An internal mechanical return from the rotor to the outside disc so
that the channels in the valve are closed when the rotor rotates to
the same angle as the steering wheel.
12/04 Meg-h-Kap2 2-5

2-6 Meg-h-Kap2 12/04

2.2
Steering hydraulics circuit diagram
- with AUTOPILOT
2.2 Steering hydraulics circuit diagram with AUTOPILOT

Key to diagram: 108 Emergency steering oil tank ................................250 cm3
110 Oil tank
112 Working hydraulics return flow filter
116 Resonance tube
205 Working hydraulics pump ....................................12 cm3
218 Steering hydraulics pump ....................................6 cm3
503 AUTOPILOT accumulator ....................................80 bar
703 Working hydraulics pressure relief valve .............180+20 bar
725 Steering double shock valve................................200±15 bar
726 Steering pressure relief valve ..............................125+20 bar
732 Non-return valve (emergency steering)
901 Working hydraulics measuring port
909 Steering hydraulics measuring port
P1 Pump port
T Tank port
Y 9/Y10 AUTOPILOT left/right solenoid valve
Z4 AUTOPILOT oil pressure (NC contact)

pressure switch ....................................................135/160 bar
Note: The machines of the MEGA series are equipped with one
steering cylinder (323) only. Therefore, these machines
generally have the emergency steering tank (108) in order to
compensate the volumetric difference between the piston
surface and the piston ring surface.
Pressure measurement Circulation pressure = 10+7 bar

System pressure = 125+15 bar
Shock valve = 200±15 bar
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.
2-8 Meg-h-Kap2 12/04

Steering In the neutral steering position, oil flows freely through the
steering control unit = Orbitrol (609).
Turning the steering wheel to one direction causes the discs to rotate
relative to each other. At 1.5°, opening the channels towards the
chambers starts. At 4°, the neutral position channels are fully closed. At
6°, the channels to the chambers are fully open. The rotation of the discs
relative to each other is limited to ± 8°.
A feed of pressurized oil to the rotor set has the following effects:
- Rotation of rotor
- Feed of an oil quantity which is proportional to the rotation into the
steering cylinder, the rear wheels being influenced.
- An internal mechanical return from the rotor to the outside disc so
that the channels in the valve are closed when the rotor rotates to
the same angle as the steering wheel.
Autopilot When the road travel circuit is unlocked and the threshing mechanism is
(see Electric system - engaged, the AUTOPILOT module A 9 is supplied with power by the main
Diagram 28) switch S 10. Following the start signal by foot switch S 9, the solenoid coil
Y9 / Y10 is actuated according to the signals from touch sensor B7 / B8.
The steering position is being checked by rear wheel position indicator
B 6.
For safety reasons, the AUTOPILOT function is interrupted immediately
by the signal of the overrider switch Z3 when actuating the steering
manually. If the driver leaves the seat, the seat contact Z5 will interrupt
the autopilot function after approx. 5 s.
The centralizing switch R3 on the switch console enables the machine to
drive precisely straight ahead even when driving on a slope.
For quick response of the steering in autopilot mode, the hydraulic system
is equipped with a accumulator 503. If the pressure in this accumulator
falls below approx. 135 bar, the oil pressure switch Z4 actuates the
circulation shut-off valve Y77 until the pressure level reaches approx.
160 bar again.
12/04 Meg-h-Kap2 2-9

2.3 Steering valve unit
2-10 Meg-h-Kap2 12/04

Key to diagram: 112 Working hydraulics return flow filter

218 Steering hydraulics pump ....................................6 cm3
229 Steering hydraulics proportioning pump
725 Steering double shock valve ................................200±15 bar
726 Steering pressure relief valve ..............................125+20 bar
Steering system Open center: with the steering in neutral position, there is a connection
between pump and tank.
Non reaction: when the steering is in neutral position, a force acting on

the steered wheels does not cause any reaction on the
steering wheel.
Valve unit DANFOSS OSPB 125 with valve block OVP 20
O = Orbit (Orbitrol)
S = Steering
P = Pump
B = Version
250 = Oil displacement in cm3/rev
V = Valve block
20 = Pressure setting of shock valves x10
Design of valve unit The steering valve consists of a steering hydraulics proportioning pump
(229) and a rotating Orbitrol rotary disc (609).
The steering gear shaft actuates the Orbitrol rotary disc (609), the
continued rotary movement driving the steering hydraulics proportioning
pump (229) by means of a socket-type shaft.
12/04 Meg-h-Kap2 2-11

2.4 Function of steering - neutral
2-12 Meg-h-Kap2 12/04

Neutral In neutral position, the oil is directed back to the tank through the steering
safety valve (742) and the Orbitrol rotary disc (609) (open center).
The circulation pressure must not exceed 10+7 bar.
Both sides of the steering hydraulic cylinder (323) are shut off by the
Orbitrol rotary disc (609). Pressure peaks due to external forces on the
steered axle are relieved to the tank via the steering double shock valves
(725) (non reaction).
12/04 Meg-h-Kap2 2-13

Steering actuation
2-14 Meg-h-Kap2 12/04

Steering actuation When actuating the steering to one or another direction, the Orbitrol rotary
disc (609) is rotated by up to 8° relative to the outside disc. During this
process, the return line from the steering hydraulics pump (218) to the
tank is closed and the connection to the steering hydraulics proportioning
pump (229) is released.
Via the steering hydraulics proportioning pump (229) and the Orbitrol
rotary disc (609), the volume flow is released as a function of the sense of
rotation, path and speed to the piston surface or the piston ring surface of
the steering hydraulic cylinder (323). Here, the displacing surface of the
steering hydraulic cylinder (323) is connected with the return line to the
tank via the Orbitrol rotary disc (609).
As soon as there is no more steering motion, leaf springs bring the inner
and the Orbitrol rotary discs (609) back to neutral position. Now both
sides of the steering cylinder are shut off again and the connection from
the steering hydraulics pump (218) to the tank is re-established.
Emergency steering When the steering system is not supplied any more externally by steering
hydraulics pump (218), the steering safety valve (742) closes and thus
ensures that no oil will escape from the steering system.
When the steering is actuated, the inner and outer disc of the Orbitrol
rotary disc (609) are rotated relative to each other. Now the oil can be
conveyed from one side of the steering hydraulic cylinder (323) via the
anti-cavitation valve (non-return valve) (728) to the other side through
human power by the drive of the steering hydraulics proportioning
pump (229).
On machines with one steering hydraulic cylinder (323), a reservoir in the

return line to the tank compensates the volumetric difference between the
piston surface and piston ring surface.
12/04 Meg-h-Kap2 2-15

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 piston rod and if stub axles move smoothly.
A pressure test at the steering hydraulics measuring port must show the
value 125+15 bar.
Adjusting the pressure relief valve on the machine in built-in condition is
not possible.
Important! Any installation work on the steering hydraulics must be

followed by venting the system on both hydraulic lines of the
steering cylinder with the diesel engine running.
2-16 Meg-h-Kap2 12/04

12/04 Meg-h-Kap2 2-17

2.6 AUTOPILOT left/right solenoid valve
2-18 Meg-h-Kap2 12/04

Key to diagram: 410 Orifice plate ..........................................................Ø 1.5 mm

503 AUTOPILOT accumulator ....................................0.7 l/ 80 bar
Y9 AUTOPILOT left solenoid valve

Y10 AUTOPILOT right solenoid valve
Z4 Autopilot oil pressure actual value switch ............135/160±5 bar
A Steering cylinder port

B Steering cylinder port
P1 Working hydraulics pump via circulation shut-off valve port
T Working hydraulics return line port
Important! Prior to dismounting items 503, 732, Z4, Y9 or Y10, the

accumulator must be relieved at the balance screw (604).
If the accumulator pressure falls below 135±5 bar while the engine is
running, the oil pressure switch (Z4) actuates the circulation shut-off valve
(Y77).
The pressure build-up within the system caused by the circulation shut-off
valve pre-loads the accumulator (503) via the non-return valve (732).
When the system pressure and consequently the accumulator pressure

reach 160±5 bar, the oil pressure switch (Z4) opens and the circulation
shut-off valve (Y77) goes back to neutral position. The non-return valve
(732) separates the energy thus stored from the remaining working
hydraulics system.
The pressure in this closed system is applied at the balls of the valve
inserts of solenoid valves (Y9/Y10).
One of the solenoid valves (Y9/Y10) is actuated by the AUTOPILOT

module, depending on the required steering direction.
The corresponding pilot spool opens the ball in the valve insert and closes
the return line to the tank. The pressure now rising builds up against the
piston and now opens the non-return valve at port A or B.
The return line of the steering cylinder is relieved to the tank via the valve
insert of the unactuated solenoid valve (Y9/Y10).
The pressure rising further now opens the non-return valve at the
opposite port and the steering cylinder is retracted or extended.
When the corresponding steering angle has been reached, the
AUTOPILOT module deenergizes the solenoid valve (Y9/Y10).
If the oil pressure inside the accumulator (503) falls below 135±5 bar
during the steering procedure, the oil pressure switch (Z4) is closed.
The circulation shut-off valve is actuated again and the accumulator (503)
is pre-loaded again (see Electric system – diagram 28).
12/04 Meg-h-Kap2 2-19

2.7 Checking the

AUTOPILOT System
When checking the steering at standstill, relieve the load from the rear
axle by slightly raising the machine.
Fault: With the AUTOPILOT activated, the rear axle does not react. Manual
steering and working hydraulics work flawlessly.
Diagnosis: When the steering reacts when the corresponding solenoid valve is
actuated manually, troubleshooting should start in the electric system.
When the steering reacts to manual actuation only if another working
hydraulics function is also actuated, check the oil pressure switch on the
valve block.
Fault: The hydraulic system is overheated in AUTOPILOT operation.

Diagnosis: If overheating is removed by disconnecting the oil pressure switch
connector, the following causes are possible:
- Accumulator defective
- Oil pressure switch defective
- Valve insert leaky
- Inlet valve leaky
- Pressure relief screw leaky
Fault: With the AUTOPILOT shut off, manual steering is heavy on one side.
Diagnosis: Check the corresponding non-return valve in the lock-up valve unit.
Fault: The machines automatically steers to one or another direction.

Diagnosis: Check the corresponding non-return valve in the lock-up valve unit and/or
the steering cylinder seals.
2-20 Meg-h-Kap2 12/04

TIC MEGA Working hydraulics
Chapter 3
Working
hydraulics
3.1 Working hydraulics circuit diagram

up to serial no. 835 00146, 845 00123 ....................................... 3-4
from serial no. 835 00147, 845 00124........................................ 3-6
3.2 Working hydraulics pressure relief valve ..................................... 3-8
3.3 Front attachment raise/lower 3/3 way solenoid valve................ 3-10
3.4 Swing grain tank unloading tube in/out

4/3 way solenoid valve............................................................... 3-14
Hydraulic cylinder with hydraulic cushion, lock-up valve unit .... 3-16
3.5 Vertical reel adjustment 3/3 way solenoid valve........................ 3-18

Hydraulic cylinders..................................................................... 3-22
3.6 Reversing the front attachment (hydraulic)

3/2 way solenoid valve............................................................... 3-24
Pre-loading valve ....................................................................... 3-26
3.7 AUTO-CONTOUR cutterbar transverse control

4/3 way solenoid valve, lock-up valve unit................................. 3-30
Hydraulic cylinder with flow control valve
- up to serial no. 835 00146, 845 00123 .......................... 3-32
- from serial no. 835 00147, 845 00124 ........................... 3-36
3.8 Hydraulic fore and aft reel adjustment

4/3 way solenoid valve, lock-up valve unit................................. 3-40
3.9 Threshing drum speed adjustment

3/3 way valve (mechanical) ....................................................... 3-44
Hydraulic cylinder with rotary coupling ...................................... 3-46
3.10 Checking the working hydraulics ............................................... 3-48
12/04 Meg-h-Kap3 3-1

Working hydraulics MEGA TIC
3-2 Meg-h-Kap3 12/04

3.1
Working hydraulics circuit diagram

3.1 Working hydraulics circuit diagram

up to serial no. 835 00146, 845 00123
II Working hydraulics valve block
110 Oil tank

112 Return flow filter
116 Resonance tube
205 Working hydraulics pump ....................................12 cm3/rev.

218 Steering hydraulics pump,
clockwise rotation, N = 2760 rpm ........................6 cm3/rev.
305 AUTOCONTOUR right-hand lateral control hydraulic cylinder

351 Front attachment raise/lower hydraulic cylinder

441 Rotary coupling
508 Accumulator

703 Working hydraulics pressure relief valve .............175+15 bar

740 AUTOCONTOUR lateral control flow control valve

A1 – A9 Port
P1 Pump port
T Tank port

Y77 Working hydraulics circulation shut-off valve solenoid valve
(only with AUTOPILOT)
Y86 Front attachment reverse solenoid valve
3-4 Meg-h-Kap3 12/04

The working hydraulics of the MEGA series is an open hydraulic system.
The hydraulic functions of the working hydraulics are realised by two

valve blocks (I+II) which may vary, depending on the equipment fitted to
the machine.
+15
The maximum system pressure is limited to 175 bar by means of a
pressure relief valve (703).
12/04 Meg-h-Kap3 3-5

Working hydraulics circuit diagram

from serial no. 835 00147, 845 00124
II Working hydraulics valve block
110 Oil tank

112 Return filter
116 Resonance tube

217 Rotary chaff screen pump.................................... 5.5 cm3/rev.
218 Steering hydraulics pump .................................... 5.5 cm3/rev.
305 AUTOCONTOUR cross levelling right hydraulic cylinder

306 AUTOCONTOUR cross levelling left hydraulic cylinder
314 Reel raise/lower slave cylinder
315 Reel raise/lower master cylinder
316 Horizontal reel adjustment hydraulic cylinder
351 Raise/lower front attachment hydraulic cylinder
353 Reverse front attachment hydraulic cylinder

441 Rotary coupling
508 Accumulator
703 Working hydraulics pressure relief valve ............. 175+15 bar

706 Pressure relief valve (rotary chaff screen)........... 120 bar
740 AUTOCONTOUR cross levelling flow control valve

A1 – A9 Port
P1 Pump port
T Tank port

(only with autopilot)
3-6 Meg-h-Kap3 12/04

The working hydraulics of the MEGA series is an open hydraulic system.
The hydraulic functions of the working hydraulics are realised by two

valve blocks (I+II) which may vary, depending on the equipment fitted to
the machine.
The maximum system pressure is limited to 175+15 bar by means of

pressure relief valve 703.
12/04 Meg-h-Kap3 3-7

3.2 Working hydraulics pressure relief valve
3-8 Meg-h-Kap3 12/04

110 Oil tank

112 Return filter
116 Resonance tube
205 Working hydraulics pump

217 Rotary chaff screen pump
(from serial no. 835 00147, 845 00124)
218 Steering hydraulics pump
703 Working hydraulics pressure relief valve ............ 175+15 bar

706 Pressure relief valve (rotary chaff screen) .......... 120 bar
(from serial no. 835 00147, 845 00124)
A1 – A9 Port
P1 Pump port
T Tank port

Pressure relief valve The pressure relief valve protects the hydraulic system or 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 175+15 bar. The pressure setting may be modified by
removing or adding shims.
- 0.5 mm shim corresponds to approx. 10 bar

- 1.2 mm shim corresponds to approx. 23 bar
Note: 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.
12/04 Meg-h-Kap3 3-9

3.3 Front attachment raise/lower

3/3 way solenoid valve
3-10 Meg-h-Kap3 12/04

110 Oil tank

112 Return filter
116 Resonance tube

(from serial no. 835 00147, 845 00124)

(from serial no. 835 00147, 845 00124)
A1 – A9 Port
P1 Pump port
T Tank port

12/04 Meg-h-Kap3 3-11

A 3/3 way solenoid valve is used for the control of single-acting functions
(hydraulic cylinders).
Neutral position In the neutral position, both solenoid coils are not energized. The volume
flow is directed from port (P) to port (S) to the downstream solenoid
valves. The output flow from P pushes the double piston 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, the one way valve and the lower pilot
valve.
Raise front attachment The solenoid coil of the raise pilot valve is actuated. The solenoid coil
plunger presses a ball against the seat. The spring-loaded other ball 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 is pushed towards P. The bore to port (S) is
closed.
Oil flows through the centre bores of the piston from P to A, via the inlet
valve.
When the solenoid coil of the raise pilot valve is de-energized, the spring-
loaded ball is pressed into the seat and the opposite ball 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.
The neutral position is reached again.
Malfunctions When the front attachment is lowered in neutral position:

- Check inlet valve
- Check conical seat and O-ring of the one way valve
- Check ball seat in the lower pilot valve
Front attachment does not raise:

- Check if solenoid coil is actuated
- Check if the double piston 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 in the solenoid valve is plugged
3-12 Meg-h-Kap3 12/04

Lower front attachment The solenoid coil of the lower pilot valve is actuated. The solenoid coil
also pressed open by the needle.
The one way valve is now opened by the pressure from A via a piston.
The oil can be drained from A to T via the open one way valve.
When the solenoid coil is de-energized, the spring-loaded ball is pressed
into the seat and the opposite ball is opened by the needle. The pressure
ahead of the piston can be reduced. The one way valve closes.
Drop rate adjustment The front attachment drop rate is adjusted at the adjustable drop rate
restrictor (613). The drop time over the entire stroke range should be
5-6 sec. (hydraulic oil temperature 50 – 60°C).
Malfunctions Front attachment cannot be lowered using the solenoid valve:

- Check if solenoid coil actuates
- Check needle in the lower pilot valve
- Check if the drop rate restrictor is open
- Check one way valve
12/04 Meg-h-Kap3 3-13

3.4 Swing grain tank unloading tube in/out

3-14 Meg-h-Kap3 12/04

110 Oil tank

112 Return filter
116 Resonance tube

(from serial no. 835 00147, 845 00124)
703 Working hydraulics pressure relief valve............. 175+15 bar

(from serial no. 835 00147, 845 00124)
A1 – A9 Port
P1 Pump port
T Tank port

A 4/3 way solenoid valve is used for the control of double-acting functions
Neutral position In the neutral position, the volume flow from port (P1) flows via port (S) to
the downstream solenoid valves.
Swing out grain tank The swing out grain tank unloading tube solenoid coil Y33 actuates the
unloading tube spool. The connections from P1 to A5 and from A4 to T are established.
The port S to the downstream solenoid valves is blocked.
Swing in grain tank The swing in grain tank unloading tube solenoid coil Y34 actuates the
unloading tube spool. The connections from P1 to A4 and from A5 to T are established.
Malfunctions The grain tank unloading tube swing hydraulic cylinder 320 cannot be
operated:
- Electric or hydraulic problem (do the solenoid coils switch?)
- Orifice plate 408 at the lock-up valve unit plugged
The grain tank unloading tube swing hydraulic cylinder 320 misadjusts in
a self-acting way:
- Non-return valves in the lock-up valve unit are leaky
- Seal in the cylinder is leaky
12/04 Meg-h-Kap3 3-15

Swing grain tank unloading tube in/out

Hydraulic cylinder with hydraulic cushion, lock-up valve unit
3-16 Meg-h-Kap3 12/04

Key to diagram: A4 Hydraulic cylinder port

A5 Hydraulic cylinder port
Hydraulic cushion Before a piston end position is reached, the remaining oil in the cylinder
space is throttled while being displaced.
This is achieved by the peg (when retracting) or the bigger diameter of the
piston rod (when extending) which considerably reduce the cross-section
to the return line.
Lock-up valve unit Pilot controlled non-return valves (734, lock-up valve unit) 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 (A4) moves the internal piston (K). This opens
the opposite non-return valve in port A5 – the return line of the hydraulic
cylinder to the tank is released (connection A1-A).
The pressure rising further now opens the non-return valve in port A4.
The cylinder extends.
12/04 Meg-h-Kap3 3-17

3.5 Vertical reel adjustment

3-18 Meg-h-Kap3 12/04

110 Oil tank

112 Return filter
116 Resonance tube

(from serial no. 835 00147, 845 00124)

(from serial no. 835 00147, 845 00124)
A1 – A9 Port
P1 Pump port
T Tank port

12/04 Meg-h-Kap3 3-19

Neutral 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 output flow from P1 pushes the double piston in the directional
control valve back against the spring. The spring space is connected with
port (T) via the raise pilot valve.
Port (A3) is shut off by the inlet valve, the one way valve and the lower
pilot valve.
Raise reel The solenoid coil of the raise pilot valve is actuated. The solenoid coil
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 is pushed towards P1. The bore to port (S) is
closed.
Oil flows through the centre bores of the piston from P1 to A3, via the inlet
valve.
When the solenoid coil of the raise pilot valve is de-energized, the spring-
loaded ball is pressed into the seat and the opposite ball 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.
The neutral position is reached again.
Malfunctions When the reel is lowered in neutral position:

- Check inlet valve
- Check conical seat and O-ring of the one way valve
- Check ball seat in the lower pilot valve
Reel will not raise:

- Check if solenoid coil is actuated
- Check needle and ball seat in the raise pilot valve
After actuating the switch, the reel continues raising in a self-acting way or
raises up to the stop:
- Check if the Ø 0.6 mm restrictor in the solenoid valve is plugged
3-20 Meg-h-Kap3 12/04

Lower reel The solenoid coil of the lower pilot valve is actuated. The solenoid coil
also pressed open by the needle.
The one way valve is now opened by the pressure from A3 via a piston.
The oil can be drained from A3 to T via the open one way valve.
When the solenoid coil is de-energized, the spring-loaded ball is pressed
into the seat and the opposite ball is opened by the needle. The pressure
ahead of the piston can be reduced. The one way valve closes.
Malfunctions The reel cannot be lowered using the solenoid valve:

- Check if solenoid coil actuates
- Check needle in the lower pilot valve
- Check if orifice plate 408 is plugged
- Check one way valve
12/04 Meg-h-Kap3 3-21

Vertical reel adjustment

Hydraulic cylinders
3-22 Meg-h-Kap3 12/04


E Vent plug
V Bottom outlet valves

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: For repairs, it is recommended to remove the hydraulic cylinders

in the raised reel position since the slave cylinder is filled only
with the master cylinder fully extended. During this process
support and secure the reel properly.
12/04 Meg-h-Kap3 3-23

3.6 Reversing the front attachment (hydraulic)

3-24 Meg-h-Kap3 12/04

110 Oil tank

112 Return filter
116 Resonance tube

(from serial no. 835 00147, 845 00124)
703 Working hydraulics pressure relief valve............. 175+15 bar

(from serial no. 835 00147, 845 00124)
A1 – A9 Port
P1 Pump port
T Tank port

Neutral The spring force displaces the oil from the reversing cylinder (353) via the
connection A1-T in the solenoid valve (Y86) to the tank.
Reversing The solenoid valve (Y86) is actuated.

The return line to the tank is now closed by the spool in solenoid valve
(Y86) and the connection from P1 to the consumer port A1 is established.
The reversing cylinder (353) now extends and swings the hydraulic motor
(226) to the drive gearwheel. Just before reaching its end position, the oil
flow from the reversing cylinder (353) to the hydraulic motor (226) is
released, ensuring reliable gearwheel engaging.
The non-return valve (732) keeps the hydraulic motor (226) from starting
when pressure peaks occur in the return line.
12/04 Meg-h-Kap3 3-25

Reversing the front attachment (hydraulic)

Pre-loading valve
3-26 Meg-h-Kap3 12/04

Key to diagram: A Front attachment reverse solenoid valve Y 86 connection

B Hydraulic cylinder port
P Pump port
S Port for downstream control valves
T Tank port
Pre-loading valve 774 Pre-loading valve 774 blocks the reverser drive against leakage oil from
the front attachment reverse solenoid valve (Y86).
12/04 Meg-h-Kap3 3-27

Reversing the front attachment (hydraulic)

Hydraulic cylinders
3-28 Meg-h-Kap3 12/04

Key to diagram: A2 Reverser drive motor connection

Adjustment The reverser support is aligned towards the feeder housing drive shaft by
adjusting an eccentric bushing on the reverser cylinder (353).
The stroke is adjusted on the adjusting screw in the piston so that the
drive pinion of the hydraulic motor (226) has a backlash of approx.
0.2 mm with the drive gearwheel at maximum engagement. To this end,
adjust the screw to 0.5 mm from the stop, with the reverser swung in.
The total stroke of the reversing cylinder (353) is 12 mm, with the oil flow
to the hydraulic motor being released at approx. 11 mm.
12/04 Meg-h-Kap3 3-29

3.7 AUTO-CONTOUR cutterbar transverse control

4/3 way solenoid valve, lock-up valve unit
3-30 Meg-h-Kap3 12/04

Key to diagram: A Hydraulic cylinder port

K Piston
P1 Pump port
T Tank port
Y 67 Left-hand transverse control solenoid valve

Y 68 Right-hand transverse control solenoid valve
Neutral In the neutral position, the volume flow from port (P1) flows via port (S) to
Transverse control rotate to The AUTOCONTOUR left-hand transverse control solenoid coil Y67
the left actuates the spool.
The connections from P1 to A4 and from A5 to T are established.
Transverse control rotate to The AUTOCONTOUR right-hand transverse control solenoid coil Y68
the right actuates the spool.
Lock-up valve unit Pilot controlled non-return valves (lock-up valve unit) are used in order to
lock functions while pressure is relieved and thus to ensure a fixed
position of a consumer.
the opposite non-return valve in port A – the return line of the hydraulic
cylinder to the tank is released (connection A-A4).
The pressure rising further now opens the non-return valve in port B. Thus
the connection B-A5 is now released - the cylinder extends.
12/04 Meg-h-Kap3 3-31

AUTO-CONTOUR cutterbar transverse control

Hydraulic cylinder with flow control valve - up to serial no. 835 00146, 845 00123
3-32 Meg-h-Kap3 12/04

Key to diagram: 305 AUTOCONTOUR right-hand lateral control hydraulic

cylinder
Flow control valve (740) Flow control valves ensure constant volume flow to the consumers even
when the load pressure changes.
This function is achieved by the fact that the ram pressure ahead of the
restrictor inside the control spool moves the control spool against the
spring. During this process, the control edge is closed more or less,
proportional to the pressure.
Thus, at a high ram pressure ahead of the control spool, more oil does
flow through the restrictor, but correspondingly less flows past the control
edge.
At a lower pressure, this ratio is reversed.
Bleeding the hydraulic - Open shut-off tap 602.

cylinders (305/306) - Loosen the screw plugs (2) of both cylinders. Loosen screw plug (1)
of the right-hand cylinder (305).
- Actuate transverse control to the right.
- Both cylinders extend.
- Close the screw plugs (1 and 2) after the air has escaped. Loosen
the screw plug (1) of the left-hand cylinder (306) with the cylinders
fully extended.
- Actuate transverse control to the left. Close the screw plug (1) after
the air has escaped. The left-hand cylinder is retracted.
- Close shut-off tap (602). Extend and retract the cylinders mutually
several times.
Compensating the hydraulic - Unhitch front attachment.

cylinder (for cutterbar, - Open shut-off valve (602).
Conspeed) - Actuate the transverse control rocker switch to the right until both
hydraulic cylinders (305/306) are fully extended.
- Actuate the transverse control rocker switch in opposite direction until
the right-hand hydraulic cylinder (305) is fully retracted.
- Close shut-off valve (602).
- Move both hydraulic cylinders (305/306) to centre position using the
transverse control rocker switch.
12/04 Meg-h-Kap3 3-33

Lowering the hydraulic - Hitch front attachment.

cylinder (for Multimaster) - Actuate the transverse control rocker switch so that the right-hand
hydraulic cylinder (305) extends and thus turns the front attachment
to the left.
- Open shut-off valve (602).
- Actuate the transverse control rocker switch in opposite direction so
that the right-hand hydraulic cylinder (305) retracts.
3-34 Meg-h-Kap3 12/04

Notes:
12/04 Meg-h-Kap3 3-35

AUTO-CONTOUR cutterbar transverse control

Hydraulic cylinder with flow control valve - from serial no. 835 00147, 845 00124
3-36 Meg-h-Kap3 12/04

Key to diagram:: 305 AUTOCONTOUR right-hand lateral control hydraulic

cylinder
V Bottom valve
Flow control valve 740 Flow control valves ensure constant volume flow to the consumers even
when the load pressure changes.
This function is achieved by the fact that the ram pressure ahead of the
restrictor inside the control spool moves the control spool against the
spring. During this process, the control edge is closed more or less,
proportional to the pressure.
Thus, at a high ram pressure ahead of the control spool, more oil does
flow through the restrictor, but correspondingly less flows past the control
edge.
At a lower pressure, this ratio is reversed.
Bottom valves The bottom valves (V) open every time an end position is reached so that
air inclusions in the connection between the two cylinders can be flushed
out.
After a repair, the cylinders must be flushed in both end positions for
approx. 15 sec.
12/04 Meg-h-Kap3 3-37

Lowering the hydraulic - Hitch front attachment.

cylinder (for Multimaster) - Actuate the transverse control rocker switch so that the right-hand
hydraulic cylinder (305) extends and thus turns the front attachment
to the left.
- Open shut-off valve (602).
- Actuate the transverse control rocker switch in opposite direction so
that the right-hand hydraulic cylinder (305) retracts.
3-38 Meg-h-Kap3 12/04

Notes:
12/04 Meg-h-Kap3 3-39

3.8 Hydraulic fore and aft reel adjustment

4/3 way solenoid valve, lock-up valve unit
3-40 Meg-h-Kap3 12/04


K Piston
P1 Pump port
T Tank port
408 Orifice plate Ø 1.2 mm
Y24 Reel forward solenoid valve

Y25 Reel backward solenoid valve
Neutral In the neutral position, the volume flow from port (P1) flows via port (S) to
Reel forward The reel forward solenoid coil Y24 actuates the spool.
Reel backward The reel backward solenoid coil Y25 actuates the spool.
Lock-up valve unit Pilot controlled non-return valves (lock-up valve unit) are used in order to
lock functions while pressure is relieved and thus to ensure a fixed
position of a consumer.
the opposite non-return valve in port A – the return line of the hydraulic
cylinder to the tank is released (connection A-A2).
The pressure rising further now opens the non-return valve in port B. Thus
the connection B-A3 is now released - the cylinder extends.
12/04 Meg-h-Kap3 3-41

Hydraulic fore and aft reel adjustment

Hydraulic cylinders
3-42 Meg-h-Kap3 12/04


A3 Hydraulic cylinder port
V Bottom outlet valves
Bottom outlet valves The bottom outlet valves (V) open every time an end position is reached
so that air inclusions in the connection between the two cylinders can be
flushed out.
After a repair, the cylinders must be flushed in both end positions for
approx. 15 sec.
12/04 Meg-h-Kap3 3-43

3.9 Threshing drum speed adjustment

3/3 way valve (mechanical)
3-44 Meg-h-Kap3 12/04


P1 Pump port
T Tank port
1 Non-return valve
2 Non-return valve
Neutral The connection from P1 to S is opened through ring channels in the

spool. The connections to port (A1) are closed without leakage oil by non-
return valves.
Increase speed The connection from P1 to A1 is released by the spool. At the same time,
port (S) is blocked. The non-return valve (1) is opened by the rising
pressure.
Reduce speed The non-return valve (2) opens after actuating the spool via the spool
inclination and via a ball. This releases the connection from A to R. The
connection from P to S remains intact.
12/04 Meg-h-Kap3 3-45

Threshing drum speed control

Hydraulic cylinder with rotary coupling
3-46 Meg-h-Kap3 12/04

441 Rotary coupling
12/04 Meg-h-Kap3 3-47

3.10 Checking the

working hydraulics
Measuring point: 901
Measuring pre-conditions: Oil temperature 45-50°C, max. diesel engine speed
Measurement 1 All working hydraulics control valves in neutral position.

Circulation pressure 15+12 bar.
Measurement 2 Move one working hydraulics consumer to its end position.

Max. system pressure 180+20 bar.
3-48 Meg-h-Kap3 12/04

TIC MEGA Low-pressure hydraulic circuit
Chapter 4
Low-pressure
hydraulic circuit
4.1 Low-pressure hydraulic circuit diagram ....................................... 4-4
4.2 Pressure relief valve .................................................................... 4-6
4.3 Low-pressure hydraulic circuit solenoid valves

Threshing mechanism clutch, grain tank unloading,
front attachment clutch 3/2 way valves........................................ 4-8
4.4 3-D cleaning system .................................................................. 4-10
4.5 Front attachment drive

Hydraulic cylinder with rotary coupling ...................................... 4-12
12/04 Meg-h-Kap4 4-1

Low-pressure hydraulic circuit MEGA TIC
4-2 Meg-h-Kap4 12/04

4.1
Low-pressure hydraulic circuit diagram

4.1 Low-pressure hydraulic circuit diagram

Key to diagram: III Low-pressure hydraulics valve block
102 Pressure filter ...................................................... 10 µm

109 Oil cooler
110 Oil tank
209 Ground drive feed pump

HPV 105 (MEGA 360) ......................................... 105 cm3/rev.
HPV 75 (MEGA 350) ........................................... 75 cm3/rev.

352 Front attachment clutch hydraulic cylinder

441 Rotary coupling

710 Ground drive filter bypass valve.......................... 2 bar

718 Ground drive feed circuit cold weather starting valve
729 Low-pressure hydraulic circuit
pressure relief valve ............................................ 19+4 bar
902 Ground drive hydraulics high pressure backward measuring port

903 Ground drive hydraulics high pressure forward measuring port
904 Ground drive hydraulics feed pressure measuring port
910 Low-pressure hydraulic circuit measuring port
Y13 Diesel engine 1st step solenoid valve (Perkins only)

Y14 Diesel engine 2nd step solenoid valve (Perkins only)
a Only for PERKINS engines
4-4 Meg-h-Kap4 12/04

On MEGA combine-harvesters, the ground drive hydraulics feed pump

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

accommodated in a flanged-on valve block (III) which may vary,
depending on the equipment fitted to the machine.
The maximum system pressure is limited to 19+4 bar by means of a

pressure relief valve (729).
12/04 Meg-h-Kap4 4-5

4.2 Pressure relief valve
4-6 Meg-h-Kap4 12/04

Key to diagram: 729 Low-pressure hydraulic circuit pressure relief valve 19+4 bar
A8 Port, volume flow input from ground drive feed pump (209)
P4 Port, volume flow input from ground drive feed pump (209)
T Tank port
f Compressed spring
k Piston
s Setscrew
The compressed spring (f) pushes the piston (k) on the seat until the
pressure (P4) overcomes the spring force. The piston (k) now opens the
connection to the tank (T). This occurs at a pressure of 19 bar.
The setscrew (s) adjusts the spring force and consequently the opening
pressure.
12/04 Meg-h-Kap4 4-7

4.3 Low-pressure hydraulic circuit solenoid valves

Threshing mechanism clutch, grain tank unloading, front attachment clutch 3/2 way valves
4-8 Meg-h-Kap4 12/04

Key to diagram: A1 Threshing mechanism clutch hydraulic cylinder port (312)

A4 Grain tank unloading clutch hydraulic cylinder port (321)
A5 Front attachment clutch hydraulic cylinder port (352)
A6 Low-pressure port 19 bar
P4 Low-pressure port 19 bar

T Tank port
s Emergency operation
v Valve insert

With the solenoid valve de-energised, the connection from the hydraulic
cylinder (A) to the return line into the tank (T) is provided via the conical
seat in the valve insert (V). Here the low pressure (P4) applied is blocked
by the spherical seat in the valve insert (V).
When the corresponding solenoid valve for a given function is actuated,

the plunger opens the ball in the valve insert (V) and closes the conical
seat to the return line (T). The low-pressure (P4) is thus applied to the
hydraulic cylinder via the consumer port (A) whereas the return line to the
tank (T) is blocked.
Note: In case of emergency operation, screw (S) must be screwed in up

to the stop to make the conical seat in the valve insert (V) close
the return line to the tank (T) tightly.
12/04 Meg-h-Kap4 4-9

4.4 3-D cleaning system

Pendulum housing with 4/3 way valve and hydraulic cylinder
4-10 Meg-h-Kap4 12/04

Key to diagram: 301 3-D sieve pan hydraulic cylinder

601 3-D sieve pan pendulum control 4/3 way valve
T Tank port
P4 Low-pressure port 19 bar
A 3-D sieve pan hydraulic cylinder (301) port
B 3-D sieve pan hydraulic cylinder (301) port
a Lid
b Pendulum
c Housing
d Spool
e Bleeding screw (M6x16)
f Linkage
Even with a slight lateral inclination of the machine, the housing (c) will
change its position relative to the spool (d) which is constantly kept in a
horizontal position by the pendulum (b) via a mechanical link.
This releases the oil flow (P4) to one of the two sides (A/B) of the 3-D
sieve pan hydraulic cylinder (301).
The corresponding opposite side (A/B) is connected to the return line to
the tank (T) by the pendulum housing (c).
The hydraulic cylinder (301) positions the housing (c) until the parallel
vertical position relative to the pendulum (b) is reached again.
In this process, the 3-D sieve pan pendulum control 4/3 way valve (601) is
returned to neutral position.
The movement of the pendulum housing (c) changes the sieve pan
linkage (f) via a rodding. The height of the 3-D effect always depends on
the inclination of the slope in question.
Bleeding of 3-D system For filling and bleeding the housing (c), first the bleed screw (e) is
loosened so the oil can flow without restriction.
With the rodding (f) to the sieve pan unhinged and at min. no-load speed
of the diesel engine, the pendulum (c) housing is moved manually until
the oil comes out without bubbles.
Now re-install the rodding (f) to the sieve pan.
Note: Leaks near the bleed screw (e) must absolutely be avoided as
otherwise there would be constant movement of the housing (c)
against the end positions.
12/04 Meg-h-Kap4 4-11

4.5 Front attachment drive

Hydraulic cylinder with rotary coupling
4-12 Meg-h-Kap4 12/04

Key to diagram: 352 Front attachment clutch hydraulic cylinder

441 Rotary coupling
a Stop
d Pressure space
t Belleville spring pack
The front attachment clutch is disengaged when the Belleville spring pack
(t) pushes the front attachment clutch hydraulic cylinder (352) against
stop (a).
To engage the front attachment clutch, low pressure is built up in the
pressure space (d). In this process, the front attachment clutch hydraulic
cylinder (352) is actuated against the Belleville spring pack (t).
12/04 Meg-h-Kap4 4-13

Low-pressure hydraulic circuit MEGA TR
4-14 Meg-h-Kap4 03/03

TIC MEGA Front attachments
Chapter 5
Front attachments
5.1 Cutterbar fold circuit diagram....................................................... 5-4
5.2 Maize picker fold /

Snapping plate adjustment circuit diagram.................................. 5-8
5.3 Folding the cutterbar

6/2 way solenoid valve with lock-up valve unit .......................... 5-10
Folding the cutterbar Hydraulic cylinders .................................. 5-12
5.4 Folding the maize picker / Snapping plate adjustment

Valve unit ................................................................................... 5-14
12/04 Meg-h-Kap5 5-1

Front attachments MEGA TIC
5-2 Meg-h-Kap5 12/04

5.1
Cutterbar fold circuit diagram

5.1 Cutterbar fold circuit diagram

314 Reel raise/lower hydraulic cylinder - follow-up cylinder

315 Reel raise/lower hydraulic cylinder - main cylinder
343 Cutterbar fold hydraulic cylinder
372 Cutterbar lock hydraulic cylinder
406 Orifice plate 0.8

408 Orifice plate 1.2
426 Restrictor 0.8
628-1 Non-return valve
734 Lock-up valve unit
Y22 Reel raise solenoid valve

Y23 Reel lower solenoid valve
Y92 Front attachment fold reversing valve
5-4 Meg-h-Kap5 12/04

Folding the cutterbar to Oil flows from solenoid valve Y92 to the ring surface of hydraulic cylinder
working position 372-1 via ports (B) and (V2). The pilot controlled non-return valve 628-1 is
still closed. At the same time, oil flows from port (S2) to the piston surface
of hydraulic cylinder 372-2 via the non-return valve of hydraulic cylinder
343. The piston rod extends and unlocks the cutterbar. The oil displaced
on the ring surface side of hydraulic cylinder 372-2 flows back to the tank.
With the lock opened, the cutterbar folds to working position. In the end
position, the non-return valve 628-1 is opened mechanically. This
releases the return line (piston surface) of hydraulic cylinder 372-1. The
cylinder piston rod retracts and locks the cutterbar. The orifice plates 401
and 402 ensure slow extension and retracting of hydraulic cylinder 343.
Folding the cutterbar to Oil flows from solenoid valve Y92 to hydraulic cylinder 372-1 (piston
transport position surface) via ports (A) and (S1) and the open non-return valve 628-1. The
piston rod of cylinder 372-1 extends and unlocks the cutterbar. The oil
from cylinder 372-1 (ring surface) flows back into the tank.
At the same time, oil flows from port (S1) to the ring surface side of
hydraulic cylinder 343. The piston rod of cylinder 343 retracts.
With the lock opened, the cutterbar folds to transport position. In the end
position of the piston rod of cylinder 343, the non-return valve 628-2 in
hydraulic cylinder 343 is opened. This releases the return line (piston
surface) of hydraulic cylinder 343 to the tank. The cylinder piston rod
retracts and locks the cutterbar.
12/04 Meg-h-Kap5 5-5

5-6 Meg-h-Kap5 12/04

5.2
Maize picker fold / Snapping plate

adjustment circuit diagram
5.2 Maize picker fold / Snapping plate adjustment circuit diagram

VI Maize picker working hydraulics valve block
327 Snapping unit fold hydraulic cylinder

330 Snapping plate adjustment hydraulic cylinder
408 Orifice plate

S Control spool
Y22 Reel raise solenoid valve

Y23 Reel lower solenoid valve
5-8 Meg-h-Kap5 12/04

Snapping plate adjustment By actuating the solenoid valves Y24 / Y25 for the reel forward/backward
(rigid maize picker) function, hydraulic cylinder 330 opens or closes the snapping plates.
Snapping plate adjustment By actuating the solenoid valves Y24 / Y25 for the reel forward/backward
(folding maize picker) function, hydraulic cylinder 330 opens or closes the snapping plates.
Upon actuation of the snapping plate adjustment, the maize picker fold
hydraulic cylinders 327 are supplied with oil in parallel with hydraulic
cylinder 330. However, the slide integrated in valve block VI blocks the
free return to the tank and thus locks hydraulic cylinders 327 hydraulically
(see Fold maize picker function).
Folding the maize picker Folding the maize picker is possible only if the reel forward/backward
function is actuated simultaneously with the reel lower function.
By actuating the solenoid valves Y24 / Y25 for the reel forward/backward
function, hydraulic cylinder 330 opens or closes the snapping plates.
Upon actuation of the snapping plate adjustment, the maize picker fold
hydraulic cylinders 327 are supplied with oil in parallel with hydraulic
cylinder 330.
The slide integrated in valve block VI blocks the free return to the tank
and thus locks hydraulic cylinders 327 hydraulically.
By actuating the reel lower solenoid valve Y23, the pressure downstream
of slide S is reduced, slide S moves. With the return line open, the
hydraulic cylinders 330 can move – the maize picker is folded.
After each folding of the snapping units, the snapping plates must be
newly adjusted by actuating the reel adjustment.
12/04 Meg-h-Kap5 5-9

5.3 Folding the cutterbar

6/2 way solenoid valve with lock-up valve unit
5-10 Meg-h-Kap5 12/04

Key to diagram: Y92 Front attachment fold reversing valve
Reversing valve not Connection from port (II-A3) via the non-return valve to port (h1) or
actuated connection from port (II-A2) via non-return valve (see detail x) to port (h2).
The ports (s1) and (s2) have a connection to the respective return flow
side by means of the centre bores in the slide and in the non-return valve
(see detail Y).
Reversing valve actuated Connection from port (II-A3) to ports (s1) and (v1) or connection from port
(II-A2) to ports (s2) and (v2).
Leakage oil in the spring spaces of the main slide is drained to the tank
via the non-return valves (detail Y). This avoids independent opening of
the non-return valves in the lock-up valve units.
12/04 Meg-h-Kap5 5-11

Folding the cutterbar

Hydraulic cylinders
5-12 Meg-h-Kap5 12/04

Key to diagram: 343 Cutterbar fold hydraulic cylinder
406 Orifice plate

426 Restrictor
K Piston rod
R Non-return valve
With the piston rod retracted, the non-return valve (R) is mechanically
open by the piston rod (K). The flow from (s3) to (s2) is free. The orifice
plates and/or restrictors cause the piston rod to extend or retract slowly.
12/04 Meg-h-Kap5 5-13

5.4 Folding the maize picker / Snapping plate adjustment

Valve unit
5-14 Meg-h-Kap5 12/04

Key to diagram: 327 Maize picker fold hydraulic cylinder

330 Snapping plate adjustment hydraulic cylinder

S Control spool
Folding out the snapping Oil flows from the reel forward/backward solenoid valve Y24/Y25 via port
units (II-A2) to the lock-up valve units 734-2 and 734-3 (Y24 is energized). The
valves are opened by pressure build-up. The oil flows via port (A1) to the
double-acting cylinders of the snapping units. The displaced oil from the
cylinders flows to slide (S) via port (B1). The slide is opened against the
control spring. The oil in the spring space of the slide is now displaced by
the orifice plate and flows from port (B1) to port (II-A3) and from there to
the tank via reel forward/backward solenoid valve Y24/Y25. During the
fold-open process, oil flows via port (A2) to hydraulic cylinder 330 of the
snapping plate adjustment. The cylinder is retracted. The displaced oil
flows through the orifice plate of the one-way restrictor valve 760 to port
(II-A3).
Folding in the snapping Oil flows from reel forward/backward solenoid valve Y24/Y25 to the
units snapping plate adjustment hydraulic cylinder 330 (Y25 being energized)
via port (II-A3), lock-up valve unit (734-3), one-way restrictor valve 760
and port (B2).
The cylinder extends and opens the snapping plates. The slide (S) is
pressure-loaded on both sides, which keeps the slide closed by the
control spring. Actuating the reel lower solenoid valve Y23 reduces the oil
pressure downstream of the slide orifice plate to port (I-A3). Slide S
opens. The oil flows to hydraulic cylinders 327 via lock-up valve unit
734-2, port (B1). The units are folded in. The oil displaced by the hydraulic
cylinders 327 flows back to the tank via ports (A1) and (II-A2) and the reel
forward/backward solenoid valve Y24/Y25.
Adjusting the snapping The snapping plates can only be adjusted with the units folded out. By
plates actuating the solenoid valves Y24 / Y25 for the reel forward/backward
function, hydraulic cylinder 330 opens or closes the snapping plates.
After each folding of the snapping units, the snapping plates must be
newly adjusted by actuating the reel adjustment.
12/04 Meg-h-Kap5 5-15

5-16 Meg-h-Kap5 12/04

TIC MEGA Ground drive hydraulics
Chapter 6
Ground drive
hydraulics
6.1 LINDE ground drive hydraulics circuit diagram ........................... 6-4
6.2 Pump unit HPV 105 ..................................................................... 6-8
6.3 Servo adjustment valve ............................................................. 6-10
6.4 Ground drive multi-function valve .............................................. 6-12
6.5 Ground drive fixed displacement motor..................................... 6-14
6.6 4-Trac drive Valve unit............................................................... 6-16
6.7 Maintenance .............................................................................. 6-18
12/04 Meg-h-Kap6 6-1

Ground drive hydraulics MEGA TIC
6-2 Meg-h-Kap6 12/04

6.1
LINDE ground drive hydraulics

circuit diagram
6.1 LINDE ground drive hydraulics circuit diagram

Key to diagram: 4 Accumulator ........................................................ 0.5 l
5 Flow control valve................................................ 110 l/min
6 4/2-way valve (control spool)
7 Non-return valve.................................................. 0.2 bar
9 Flow divider
10 Non-return valve
11 Hydraulic motor (on the steering axle)
12 5/2-way valve (short-circuit valve)

109 Oil cooler
110 Oil tank
209 Ground drive feed pump...................................... 22 cm3

210 Ground drive fixed displacement motor .............. HMF 75
HPV 105 (MEGA 360) ......................................... 105 cm3/rev.
HPV 75 (MEGA 350) ........................................... 75 cm3/rev.
412 Orifice plate ......................................................... Ø 2 mm
606 Ground drive servo adjustment valve

718 Ground drive feed circuit cold weather
starting valve ....................................................... 28±1 bar
719 Ground drive purge pressure control valve......... 10 bar
721 Ground drive purging shuttle valve
902 Ground drive hydraulics high pressure backward measuring port

903 Ground drive hydraulics high pressure forward measuring port
904 Ground drive hydraulics feed pressure measuring port
910 Low-pressure hyraulics measuring port
P3 Pump port
T Tank port
Y1 4-Trac (all-wheel drive) solenoid valve
6-4 Meg-h-Kap6 12/04

Oil supply After starting the diesel engine, the ground drive feed pump (209) is
driven.
In this process, the oil quantity is taken from the housing. The housing is
directly connected with the oil tank (110).
Feed pressure circuit The feed pressure builds up from the oil quantity pumped through the oil
cooler (109) and the pressure filter (102) by the ground drive feed pump
(209) against the ground drive feed pressure relief valve (716).
Depending on the spring setting, the oil flow is pre-stressed and then
relieved to the tank.
The feed pressure is applied at the combined ground drive multi-function

valves (713/714) and at both servo cylinders via the ground drive servo
adjustment valve (606).
When the ground drive variable displacement pump (211) is not swung
out, the feed pressure propagates to both sides of the high-pressure
circuit via ground drive feed valve (709).
Servo adjustment The cable mounted on the ground speed control lever moves the spool in
the ground drive servo adjustment valve (606) from the neutral position to
one or the other direction.
Depending on the direction of travel, one of the ground drive pump servo
control hydraulic cylinders (313) is pressure-relieved whereas the other
hydraulic cylinder remains connected to the feed pressure circuit. The
motion at the swing disc corresponds to the pressure difference between
the hydraulic cylinders.
The ground drive pump servo control hydraulic cylinders (313) swing the
ground drive variable displacement pump (211) only by the path defined
by the ground speed control lever because there is a mechanical
feedback of the swing angle to the ground drive servo adjustment valve
(606).
This mechanical feedback balances the spool in the ground drive servo
adjustment valve (606) and therefore the pressure level between the two
hydraulic cylinders at the control edge so that the defined swing angle is
maintained.
High-pressure circuit As soon as the ground drive variable displacement pump (211) is swung
out, an axial motion is added to the radial motion of the pump unit.
This axial motion displaces the oil in the cylinder space of the rotor and
thus acts on the motor unit which converts this energy into a rotating
motion by supporting against the fixed inclined disc.
The respective suction side of the ground drive variable displacement

pump (211) is pre-stressed via the feed pressure circuit and the
corresponding ground drive multi-function valve (713/714). This ensures
that the ground drive variable displacement pump (211) is sufficiently filled
and that any occurring leaks are compensated.
Since feed pressure is always applied on the suction side of the ground
drive variable displacement pump (211) as well as on the return flow side
of the ground drive fixed displacement motor (210), this area is referred to
as low-pressure side within the high-pressure circuit.
12/04 Meg-h-Kap6 6-5

High-pressure limitation If the system pressure rises above the set maximum value, this
overpressure is relieved to the feed pressure circuit by the ground drive
multi-function valves (713/714).
The high-pressure limitation should only respond for a short time during
operation since the large oil flow which has to be displaced by the heavily
pre-stressed valves would rapidly overheat the system.
Purging device The respective high-pressure side in the high-pressure circuit actuates the
ground drive purging shuttle valve (721) in the ground drive fixed
displacement motor (210) so the corresponding low-pressure side has a
connection to the motor housing via the ground drive purge pressure
control valve (719).
Since the pressure setting of the ground drive purge pressure control
valve (719) is lower than that of the ground drive feed pressure relief
valve (716), a constant oil quantity is exchanged by the ground drive feed
pump (209) via the restrictor in the ground drive purge pressure control
valve (719).
6-6 Meg-h-Kap6 12/04

Notes:
12/04 Meg-h-Kap6 6-7

6.2 Pump unit

HPV 105
6-8 Meg-h-Kap6 12/04

Key to diagram: 209 Ground drive feed pump ......................................22 cm3

B Control bottom
D Shaft seal
G Slide
K Piston
L Bearing
R Cylinder rotor
S Swing disc
V Adjusting lever
W Drive shaft
As soon as the diesel engine is started, the cylinder rotor (R) as well as
the ground drive feed pump (209) are driven by the nine pistons (K)
arranged radially around the drive shaft (W).
In this process, the pistons (K) are pressed against the swing disc (S) by
means of the slides (G) due to the feed pressure applied on both sides of
the high-pressure circuit (H).
One of the servo cylinders is actuated by the ground drive servo

adjustment valve (606) so that this cylinder swings the swing disc (S)
according to the direction of travel and the ground speed.
During the swinging motion, the pistons (K) make an axial movement on
the inclined plane of the swing disc (S) which results in the oil in the filled
cylinder space being displaced and in a pressure building up against the
resistance at the motor.
When the entire oil quantity in the cylinder space has been displaced, the
piston (K) rotating with the rotor (R) is pushed back by the feed pressure
and against the sloping inclined plane of the swing disc (S) on the low-
pressure side.
The cylinder spaces in the rotor (R) are thus filled one after the other on
the sloping side of the swing disc (S) (low pressure) and then displace this
oil quantity on the rising side (high pressure) against the motor unit.
According to the direction of travel, the swing disc (S) is moved to one or
the other direction, making high pressure and low pressure change sides
as well. The ground speed depends on the oil flow size and consequently
on the swing angle of the swing disc (S). The swing angle pre-set on the
ground speed control lever is maintained by the mechanical feedback from
the swing disc (S) to the servo adjustment valve (606).
The low-pressure side is separated from the high-pressure side inside the
pump unit above the control bottom (B). For sealing purposes, the cylinder
rotor (R) is merely pushed against the control bottom (B) with a
compressed spring.
The exact return of the swing disc to its neutral position is achieved by
compressed springs, and this factory setting cannot be modified from the
outside.
The position of the adjusting lever (V) on the shaft gearing is marked with
a punch blow on the servo adjustment housing. This position corresponds
to the neutral position of the servo adjustment valve which is achieved
within an angle of 8° of the adjusting range.
12/04 Meg-h-Kap6 6-9

6.3 Servo adjustment valve
V “Z” “Z”
606 V
X
G P
313 P
313
M
S
M
Z1023.0
6-10 Meg-h-Kap6 12/04

Key to diagram: 313 Ground drive pump servo control hydraulic cylinder
G Threaded bushing
M Mechanical feedback
P Spool
S Swing disc
V Adjusting lever
Servo adjustment valve In the neutral position of the ground drive servo adjustment valve (606),
both ground drive pump servo control hydraulic cylinders (313) are
pressure-loaded, keeping the swing disc (S) stable in any position.
The cable mounted on the adjusting lever (V) moves the spool (P) in the
ground drive servo adjustment valve (606) from the neutral position to one
or the other direction. Depending on the direction of travel, one of the
ground drive pump servo control hydraulic cylinders (313) is thus
pressure-relieved whereas the other servo cylinder remains connected to
the feed pressure circuit.
The movement at the swing disc (S) thus corresponds to the pressure
difference between the ground drive pump servo control hydraulic cylinder
(313).
The ground drive pump servo control hydraulic cylinders (313) swing the
variable displacement pump only by the path defined by the adjusting
lever (V) because there is a mechanical feedback (M) of the swing angle
to the ground drive servo adjustment valve (606).
This mechanical feedback (M) balances the spool (P) in the ground drive
servo adjustment valve (606) at the control edge to the neutral position.
The pre-set swing angle is thus maintained by the pressure compensation
in both ground drive pump servo control hydraulic cylinders (313).
Adjusting the hydraulic To align the mechanical neutral position of the adjusting lever (V) with the
neutral position: hydraulic neutral position of the variable displacement pump, the spool (P)
in the servo adjustment valve is adjusted using the threaded bushing (G).
To do this, the bushing is first set to a clearance of X=14.75 mm (X) from
the housing of the ground drive servo adjustment valve (606). A pressure
measurement on both sides of the high-pressure circuit determines the
respective pressure rise caused by rotating the bushing (G) to one or the
other direction. The centre position of the path by which the bushing (G)
has been rotated corresponds to the average neutral position.
12/04 Meg-h-Kap6 6-11

6.4 Ground drive multi-function valve
Z1022.0
6-12 Meg-h-Kap6 12/04

Key to diagram: 1 Valve plunger

2 High-pressure spring
3 Valve insert
4 Feed spring
H High pressure
N No high pressure
S Feed pressure
High-pressure limitation High pressure (H) is applied to the valve plunger (1) via the bores in the
valve cartridge.
When the system pressure exceeds to pre-set value of the high-pressure
spring (2), the valve plunger (1) backs away to the bottom against the
spring pressure and relieves the high-pressure side towards the feed
pressure circuit (S).
Feed As soon as there is no high pressure (N) applied against the valve
cartridge, the feed pressure (S) presses the entire valve insert (3)
upwards against the feed spring (4) and thus opens the feed pressure
circuit (S) to the low-pressure side (N).
12/04 Meg-h-Kap6 6-13

6.5 Ground drive fixed displacement motor

Motor unit HMF 105
6-14 Meg-h-Kap6 12/04

Key to diagram: 210 Ground drive fixed displacement motor ...............HMF 75

721 Ground drive purging shuttle valve
719 Ground drive purge pressure control valve .........10 bar
B Control bottom
D Shaft seal
G Slide
K Piston
L Bearing
R Cylinder rotor
S Fixed inclined disc
W Drive shaft
See also ground drive As soon as the diesel engine is started, the feed pump in the pump unit is
hydraulics circuit diagram also driven. In this process, the pistons (K) in the cylinder rotor (R) of the
motor unit are pressed against the fixed inclined disc (S) by means of the
slides (G) due to the feed pressure applied on both sides of the high-
pressure circuit.
As soon as the variable displacement pump is swung out, the pressure
builds up against the nine pistons (K) in the cylinder rotor (R) which is
geared to the drive shaft (W). Here the pistons (K) support themselves
against the inclined plane of the fixed inclined disc (S) and thus convert
this energy into a rotating motion against the resistance at the drive shaft
(W).
The direction of rotation here depends on the direction of the oil flow and
thus on the swing direction of the variable displacement pump, with high
pressure and low pressure changing the sides. The motor speed results
from the oil flow quantity therefore from the swing angle of the variable
displacement pump.
The low-pressure side is separated from the high-pressure side inside the
motor unit above the control bottom (B). For sealing purposes, the
cylinder rotor (R) is merely pushed against the control bottom (B) with a
compressed spring.
The respective high-pressure side in the high-pressure circuit actuates the

ground drive purging shuttle valve (721) in the fixed displacement motor
so the corresponding low-pressure side has a connection to the motor
housing via the ground drive purge pressure control valve (719).
Since the pressure setting of the ground drive purge pressure control
valve (719) is lower than that of the feed pressure relief valve, a constant
oil quantity is exchanged by the feed pump (209) via the restrictor in the
ground drive purge pressure control valve (719).
12/04 Meg-h-Kap6 6-15

6.6 4-Trac drive

Valve unit
6-16 Meg-h-Kap6 12/04

Key to diagram: 4 Accumulator ........................................................(0.5 litres)

5 Flow control valve
6 Activation spool (4/2-way valve)
7 Non-return valve .................................................(0.2 bar)
8 (Y1) 4-Trac solenoid valve
9 Flow divider
10 Non-return valve
12 Short-circuit valve (5/2-way valve)
4-Trac shut off The 4/2-way valve (6) blocks the high-pressure lines from the variable
displacement pump (P1, P2). The short-circuit valve (12) is open. The
short-circuit valve (12) opens the circuits from the rear axle motors (11)
(connections M1, M2, M3, M4). Leakage oil from the motors flows to the
variable displacement pump (1) housing. Missing oil is fed into the circuits
by the feed pump (port F) via non-return valve (7) an the bottom flow
divider (9). The accumulator (4) is pre-stressed with feed pressure. When
the machine is towed (no feed pressure), the hydraulic motors are
protected against overspeed by the declutching device. In this process,
the mounting bolts are screwed into the threaded bores which are offset
by 90° until the shut-down bushing hits its stop. Tightening torque of bolts
= 25 Nm.
Engaging 4-Trac The solenoid valve (8) is activated by electro-magnetic means. The feed
pressure switches over the 4/2-way valve (6) and the short-circuit valve
(12). The accumulator (4) ensures reliable and rapid switching-over of
both valves. The open circuits of the rear axle motors (11) are closed by
the activated short-circuit valve (12). The connection between the high-
pressure lines and the rear axle motors are opened by the 4/2-way valve
(6). The oil pumped by the variable displacement pump (1) flows to the
fixed displacement motor (3) and to the hydraulic motors (11). The oil
quantity to the hydraulic motors (11) is limited to 110 l/min. by the
respective flow control valve (5). This ensures that the fixed displacement
motor (3) is supplied with oil in critical conditions. The respective flow
divider (9) divides and/or controls the oil flow to the hydraulic motors (11),
depending on the load on the individual motor. The oil returning from the
motors flows to the pump via the non-return valves (10) of the other flow
divider.
12/04 Meg-h-Kap6 6-17

6.7 Maintenance
Filling instructions 1. Engage 3rd gear at the gearshift lever

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

2. Apply parking brake
3. Heat up the system to an operating temperature of approx. 60°C
4. Move ground speed control lever to neutral position
5. Set diesel engine to max. no-load speed
6. Measure the feed pressure: 23-2.5 bar
7. Feed pressure difference on both sides: max. 3 bar
8. Swing out the variable displacement pump fully to one direction
9. Pressure drop on low-pressure side: max. 4 bar
10. Set diesel engine to min. no-load speed
11. Engage 3rd gear in manual transmission
12. Apply service brake
13. Slowly swing the variable displacement pump forward for 5 sec.
max.
14. High pressure measurement: 420 to 450 bar
15. Low pressure measurement: min.14 bar
16. Slowly swing the variable displacement pump backward for 5 sec.
max.
17. High pressure measurement: 420 to 450 bar
18. Low pressure measurement: min.14 bar
20. Remove pressure gauge
6-18 Meg-h-Kap6 12/04

TIC MEGA Rotary chaff screen
Chapter 7
Rotary chaff screen
cleaning
7.1 Rotary chaff screen circuit diagram ............................................. 7-4
7.2 Rotary chaff screen drive............................................................. 7-6

Pump with integrated pressure relief valve.................................. 7-6
12/04 Me-h-Kap7 7-1

Rotary chaff screen MEGA TIC
7-2 Me-h-Kap7 12/04

7.1
Rotary chaff screen circuit diagram

7.1 Rotary chaff screen circuit diagram

Key to diagram: V Ground drive hydraulics (hydrostatic motor)

109 Oil cooler
110 Oil tank

209 Ground drive feed pump...................................... 22 cm3/rev.
210 Ground drive fixed displacement motor HMF 75 75 cm3/rev.
HPV 105 (MEGA 360) ......................................... 105 cm3/rev.
HPV 75 (MEGA 350) ........................................... 75 cm3/rev.
217 Rotary chaff screen pump ................................... 5.5 cm3/rev.
218 Steering hydraulics pump.................................... 5.5 cm3/rev.
313 Ground drive servo control pump hydraulic cylinder
706 Pressure relief valve............................................ 120 bar

713 Ground drive multi-function valve, reverse
714 Ground drive multi-function valve, forward
718 Ground drive feed circuit cold start injector
902 Ground drive hydraulics high pressure backward measuring point

903 Ground drive hydraulics high pressure forward measuring point
7-4 Me-h-Kap7 12/04

Notes:
12/04 Me-h-Kap7 7-5

7.2 Rotary chaff screen drive

Pump with integrated pressure relief valve
7-6 Me-h-Kap7 12/04

Key to diagram: 205 Working hydraulics pump ....................................11 cm3/rev.

217 Rotary chaff screen pump....................................5.5 cm3/rev.
218 Steering hydraulics pump ....................................5.5 cm3/rev.
706 Pressure relief valve ............................................120 bar
Pressure relief valve The pressure relief valve (706) limits the pressure in the hydraulic system
and protects the connected mechanical components against damage due
to excessive forces.
The spring in the pressure relief valve (706) is pre-stressed for a system
pressure of 120 bar.
12/04 Me-h-Kap7 7-7

7-8 Me-h-Kap7 12/04

Position of components
Component grid MEGA TIC
a – 5 j 20 b – 5 h 17
c – 5 h 17
R-2 Meg-h 12/04

TIC MEGA Component grid
102 – 5 j 20 108 – 5 h 19
Y86 – 3f13 110 – 3 i 19
102 – 3 i 19 116 – 5 j 20
12/04 Meg-h R-3

205 – 3 j 20 209 – 5 j 20
210 – 7 j 19 211 – 5 j 20
216 – 3 j 20 217 – 2 k 16
R-4 Meg-h 12/04

218 – 3 j 20 226 – 8 e 16
301 – 7 o 16 305 – 8 e 16
306 – 8 e 19 311 – 5 j 16
12/04 Meg-h R-5

312 – 4 j 19 320 – 4 n 20
321 – 4 j 19 323 – 8 q 18
351 – 8 h 17-19 352 – 5 j 19
R-6 Meg-h 12/04

353 – 8 e 16 406 – 6 o 16
412 – 5 j 20 441 Front attachment clutch rotary coupling

– 5 j 19
441 Variator rotary coupling – 5 j 16 601 – 7 o 16
12/04 Meg-h R-7

602 – 8 e 16 605 – 5 h 17
606 – 5 j 20 609 – 5 g 18
703 – 5 i 17 706 – 3 j 20
R-8 Meg-h 12/04

710 – 5 j 20
713, 714 – 5 j 20 716 – 5 j 20
12/04 Meg-h R-9

718 – 5 j 20 719 – 7 j 19
721 – 7 j 19 729 – 5 j 20
734 CONTOUR– 7 f 17 734 Grain tank unloading tube – 4 n 20
R-10 Meg-h 12/04

740 – 8 e 16 759 – 5 h 17
774 from serial no. – 8 f 17 774 up to serial no. – 5 h 16
801 – 8 e 16 901 – 5 i 17
12/04 Meg-h R-11

902 – 5 j 20 903 – 5 j 20
904 – 5 j 20 909 – 5 g 18
910 – 5 j 20
R-12 Meg-h 12/04

11/04 Meg-h-raster R-13

Component grid
Component grid
11/04 Meg-h-raster R-15

R-16 Meg-h 03/03

Index
MEGA TIC
Index
3-D cleaning system 4-10
A AUTO-CONTOUR solenoid valve 3-30

AUTO-CONTOUR transverse control 3-30
AUTOPILOT 2-8
AUTOPILOT solenoid valve 2-18
C Checking the steering 2-16

Cutterbar raise/lower 3-10
F Filter 1-13
Filling quantities 1-13
Front attachment clutch 4-8
Front attachment drive 4-12
Front attachment raise/lower solenoid valve 3-10
Front attachment reverse hydraulic cylinder 3-28
Front attachment reverse pre-loading valve 3-26
Front attachment reverse solenoid valve 3-24
G Grain tank unloading 4-8

Grain tank unloading tube hydraulic cylinder 3-16
Ground drive multi-function valve 6-12
H Hydraulic fore and aft reel adjustment 3-40

Hydraulic fore and aft reel adjustment hydraulic cylinder 3-42
Hydraulic fore and aft reel adjustment solenoid valve 3-40
Hydraulic pumps 1-14
Hydraulic rotary chaff screen 7-1
Hydraulic rotary chaff screen circuit diagram 7-4
Hydrostatic ground drive maintenance 6-18
L LINDE ground drive hydraulics 6-4

LINDE ground drive hydraulics circuit diagram 6-4
LINDE ground drive motor unit 6-14
LINDE ground drive pump unit 6-7
LINDE hydrostatic ground drive 6-1
Low-pressure hydraulics pressure relief valve 4-6
Low-pressure hydraulic system 4-1
Low-pressure hydraulic system circuit diagram 4-4
Index-2 Meg-h-Index 12/04

TIC MEGA
O Oil change 1-13

Oil filter 1-13
Oil pressure 1-13
Oil specification 1-13
Oil tank 1-13
Overall hydraulic circuit diagram 1-4
P Pumps 1-14, 7-6
R Reel vertical adjustment solenoid valve 3-18

Rotary chaff screen 7-1
Rotary chaff screen pressure relief valve 7-7
S Servo adjustment valve 6-10

Steering 2-1
Steering hydraulics 2-2
Steering hydraulics with AUTOPILOT circuit diagram 2-8
Steering hydraulics without AUTOPILOT circuit diagram 2-4
Steering valve unit 2-10
Swing grain tank unloading tube 3-14
Swing grain tank unloading tube solenoid valve 3-14
T Threshing drum speed control 3-44

Threshing drum speed control hydraulic cylinder 3-46
Threshing mechanism clutch 4-8
Threshing mechanism clutch, grain tank unloading, Front
attachment clutch solenoid valve 4-8
V Vertical reel adjustment 3-18

Vertical reel adjustment hydraulic cylinder 3-22
W Working hydraulics 3-1

Working hydraulics circuit diagram 3-4, 3-6
Working hydraulics pressure relief valve 3-8
Working hydraulics test 3-48
12/04 Meg-h-Index Index-3

MEGA TIC
Index-4 Meg-h-Index 12/04

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

Responsibility for errors or omissions not accepted.
Reproduction or translation of this publication, in whole or part, is not

permitted without the written consent of the CLAAS KGaA mbH.
All rights under the provision of the Copyright Act reserved.
CLAAS KGaA mbH

33426 Harsewinkel
Germany
Our contribution to the environment: CLAAS

have printed this manual on 100 % chlorine
free paper.
CLAAS KGaA mbH
Postfach 1163
33426 Harsewinkel
Tel. +49 (0)5247 12-0
www.claas.com
0299 504.1
SYS-H MEGA 360 - 350
EN - 02.05 - NF
Printed in Germany

0299 504 1 Sys Hy en 144

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MEGA 360 - 350

Chapter 2 Steering hydraulics .......................................................... 2-1

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

Chapter 4 Low-pressure hydraulic circuit ....................................... 4-1

Chapter 5 Front attachments ............................................................ 5-1

Chapter 6 Ground drive hydraulics .................................................. 6-1

Chapter 7 Rotary chaff screen cleaning .......................................... 7-1

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

1.1 Overall hydraulic system circuit diagram

1.2 Oil tank, oil specification, filling quantities, oil change,

1.3 Hydraulic pumps

12/04 Meg-h-Kap1 1-1

1-2 Meg-h-Kap1 12/04

Overall hydraulic system circuit diagram

1.1 Overall hydraulic system circuit diagram

1-4 Meg-h-Kap1 12/04

Key to diagram: I Working hydraulics valve block

102 Pressure filter .......................................................10 µm

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

301 3-D sieve pan hydraulic cylinder

406 Orifice plate ..........................................................Ø 0.8 mm

503 AUTOPILOT accumulator

601 3D sieve pan pendulum control 4/3 way valve

12/04 Meg-h-Kap1 1-5

801 Quick release coupling

901 Working hydraulics measuring point

Y9/Y10 AUTOPILOT left/right solenoid valve

Z4 AUTOPILOT oil pressure actual value switch

1-6 Meg-h-Kap1 12/04

Overall hydraulic system circuit diagram

1-8 Meg-h-Kap1 12/04

Key to diagram: I Working hydraulics valve block

102 Pressure filter....................................................... 10 µm

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

301 3-D sieve pan hydraulic cylinder

406 Orifice plate.......................................................... Ø 0.8 mm

503 AUTOPILOT accumulator

601 3D sieve pan pendulum control 4/3 way valve

12/04 Meg-h-Kap1 1-9

Key to diagram: 703 Working hydraulics pressure relief valve............. 180+10

801 Quick release coupling

901 Working hydraulics measuring point

Y9/Y10 AUTOPILOT left/right solenoid valve

Z4 AUTOPILOT oil pressure actual value switch

1-10 Meg-h-Kap1 12/04

12/04 Meg-h-Kap1 1-11

1-12 Meg-h-Kap1 12/04

Key to diagram: 112 Return flow filter

A Ground drive port

Z19 Hydraulic oil level (min.) actual value switch

Filling quantities Total hydraulic system = 25 litres, depending on equipment fitted

Oil change Once a year or after 500 operating hours

Filter change once a year or after 500 operating hours.

Oil pressure Working hydraulics = 180+10 bar

Note: These values refer to measurements made at a hydraulic oil

12/04 Meg-h-Kap1 1-13

1.3 Hydraulic pumps

1-14 Meg-h-Kap1 12/04

Key to diagram: 205 Working hydraulics pump ...................................12 cm3/rev.

12/04 Meg-h-Kap1 1-15

1-16 Meg-h-Kap1 12/04

Key to diagram: 205 Working hydraulics pump .................................... 11 cm3/rev.