Hydraulics Electrics CLAAS JAGUAR 880 CLAAS JAGUAR 860 CLAAS JAGUAR 840 CLAAS JAGUAR 820Content aiphabetica order 1. Oil types, oil pressure, oil change, filters, pumps Checking pressures Complete hydraulic system at fault Filters Hydraulic pumps. ll change Oil pressures Oil reservoir... Oil types BRBBBBB8 1 1 1 1 1 1 1 1 2. Hydraulic steering system Checking the pressure of the hyrauis steering system ...... Checking the steering system Circuit diagram, from Machine No. Circuit diagram, up to Machine No. Double shock valve Function -neutral .. Function ~ right hand and feft hand turn Repairs on the steering system Return valve (circulation control valve) Solenoid valve Autopilot, from Machine No. Solenoid valve Autopft, up 0 Machine No. Valve block . - 3. Working hydraulic system Circuit diagram from Machine No. 3.02 Circuit diagram up to Machine No. 3.06 DANFOSS OMP 200 hydraulic motor. 3.10 Grindstone movement 3.20 Hydraulic ram grindstone movement 3.22 Lock-up vaive 3.23 Pressure accumulator 3.16 Pressure relief valve with 4/8 directional control valve 3.08 Pressure relief valve 100/180 bar... fh 3.24 Solencid-operated 3/3 directional control vaive . 3.12 Solenoid-operated 4/8 directional control valve | 3.18 Valve block working hydraulic system . 3.04 4. Low pressure hydraulic system Circuit diagram 4.02 Fitter 4.07 Hydraulic cylinder diesel engine rpm... 4.08 Low pressure valve block on diesel engine 4.04 Low pressure valve block under operator's platform 4.05 One-way restrictor valve, feed drive reverser ang Reversing mechanism . Seen 4.10 Rotary connector, main drive 415 Solenoid-operated 3/2 directional control valve .. 4.06 5. Front attachments. Circuit diagram for folding cutterbar Circuit diagram for GPS cutterbar from Machine No... Circuit diagram for GPS cutterbar up to Machine No. ..... Circuit diagram for maize picker head, snapping plate adjustment Circuit diagram for pick-up crop press lft Circuit diagram for 8-row maize header Cylinders - fore and aft reel adjustment Hydraulic cylinder, folding cutterbar Lock-up valve... Pilot operated one-way valve Reel lift cylinders : Solenoid-operated 2/2 directional control vaive, 8-row maize header Solenoid-operated 6/2 directional control valve, folding cutterbar 6. Ground drive hydraulics, LINDE Girl lagram for ground crive ycrauics First oil filing after a repair Fixed displacement motor : High prssure root valve and charge ‘valve unit How the system works ..... Hydraulic servo control, setting LINDE BPV pump schematic) - Pressure valves Safety feature . : Testing charge pressure . . ‘Testing high pressure Variable displacement pump. 7. LINCOLN central lubricating system Lubrication points, machine Lubrication points, 6-row maize header Lubrication points, 8-row maize header Lubricating pump, 2 litres, up to Machine No. Lubricating pump, 8 litres, from Machine No. Lubricating pump, 8 lites, from/up to Machine No. Progressive metering devices. Pump element . Reservoir empty warning. Technical data Troubleshooting 5.20 5.10 B12 5.08 5.08 5.02 5.18 5.26 B14 515 5.16 5.04 5.24 6.02 ett 6.09 6.06 6.07 6.09 6.04 6.08 6.10 6.12 6.12 6.08 7.10 TA3 712 7.03 7.04 7.03 7.08 7.05 7.04 7.02 7148. Electrics Air cleaner warning contact .....++22s400000+ 8.14 ‘Automatic engine cut-off function 8.08 ‘Automatic sharpening SII 926 ‘Automatic sharpening function 2.222.2221112 926 ‘Automatic sharpening operation 9 22211..1.... 9.29 ‘Automatic shearbar adjustment... 9.29 ‘Autopilot from Serial Number 10.16 ‘Autopilot up to Serial Number 10.18 ‘Autopilot ~ troubleshooting fan 210.14 Cab interior ight... PIII 8.26 Gab windscreen washer system 20.00.0002. 826 Carrying out tests 8.02 Cental electrics (connectors), from Serial No... 10.30 Central electrics (connectors), up to Serial No... 10.31 Gentral electrics (sticker)... . 10.28 Gentral lubricating system, LINCOLN, 2 i reservoir 10.20 Central lubricating system, LINCOLN, 8 | reservoir 10.22 Compressor-type air conditioning system circuit diagram 826 Compressor-type air conditioning system function 8.27 Compressor-type air conditioning system fault... 8.36 Connections for accessories (radio and CB radio) 8.26 Contour system cetttetrseeetesees 914 Com cracker adjusiment 9.42 Cutting height preselection. 222... 2.cs.... 944 Deflector flap position ....0.0 22.0 cccciie, O12 Diese! engine oil pressure DI ata Diesel engine speed adjustment ............. 912 Dise brake wear warning B14 Discharge chute raise/lower TULL) 10.02 Feeder ON 9.02 Feeder STOR USA : EI oto Fieldwork computer from Serial No. 221.122. 9.38 Fieldwork computer up to Serial No. 9.40 Fieldwork computer, function test : 9.38 Fieldwork computer, troubleshooting 9.39 Folding cutterbar fold in/fold out . TIT 10.04 Front attachment epeed reduction «.......... 902 Fuel gauge ........ DI ata FUSS eee socceeeecceseseesssreeeeeess 10:29 Handbrake B14 Headlamps 0.02... eo TLL) 8.20 Hitch raise/lower + 10.02 Horn . 8.16 Hourmeter ...: teers 8.04 Hyd. ground drive charge pressure B14 Key for electrical circuit diagrams TLL) 10.52 : 10.22 LINCOLN central ubicting system Main drive 9.02 Main drive SII 912 Main rolay 00202002002 aoa Master witing diagram peeeeeeereeen 10153) Metal detector circuit diagram 9.02 Metal detector troubleshooting 2 221.22.221.2) 9.06 Operations display screen... esc sseseces B14 Operations display screen 1) 10.26 Operator's seat compressor (with pneumatic, suspension) 9.42 Parking brake warning device .1.2.22221.2) 14 Programming the Contour-Plus system 1.11... 9.18 Programming the Contour system TI 916 Raise/lower front attachment 914 Reel fore/aft 10.02 Reel raise/lower .. 2 10.02 Reel speed adjustment + 10.02 Reverse feed ........ ceteeesseeees 9,02 Reversing ....0eeeeeeeeeeeeeesseeeeeees 9:03 Reversinghorn 1. ..ss.csccsssssvveeeeses 8.20 Reversing lamp Seeeeeeeeeeeeat 5.20) Road gear 9.12 Shaft speed monitor, from Serial No. ...--2.2.. 9.36 Shaft speed monitor, up to Serial No. ...--.... 9.40 Sharpening (without automatic sharpening)... 924 ‘Shearbar adjustment function niu. 929 Shearbar adjustment test 931 Starting the diesel engine (12V) .2.....ce.2. B12 Starting the diesel engine (24 V) with engine cut-off system ceeees 8.08 Starting the diesel engine 24 V) without engine cut-off system 8.10 ‘Switch console . ct £10.26 Temperature switch and sender 814 Temperature switch and sender cesol engine .. 8.14 Vehicle information unit ..... - 10.24 Vehicle lighting (headlamps) 8.20 Warning beacon from Serial NO... ...ee225 8.22 Warning beacon up to Serial No. 8.24 Warning flashers EUROPE .. Q 8.16 Warning flashers USA... 02 eee eceeeeees B18 Windscreen wiper .....0..ossssssvoeesss 8.26 Wiring from page... poeeeeneeenni0.52 Work lamps (from Serial number)” 822 Werk lamps (up to Serial Number) 824 4-Trac system... perenne 12) S-row maize header, folding... 01.22.1222) 9.281 Hydraulics Oil types Oil pressure Oil change Filters Hydraulic pumpil reservoir with filter H 2504.0Key Oil types. Oil change Oil filter Oil pressure COMPLETE HYDRAULIC SYSTEM AT FAULT Hydraulic oil overheats Hydraulic pump Specifications Connector oll drain hose Oil level dipstick and reservoir breather ‘Suction pump working hydraulic system ‘Suction pump ground drive hydraulics ‘Suction pump radiator screen drive ‘Suction pump hydraulic steering system PHY~ Connector pump housing ground drive hydraulics RH — Return flow working hydraulic system RL — Return flow hydraulic steering system RN. ~ Return flow low pressure hydraulic system 2 ut rrrra> 1 Multi-grade hydraulic oil HV (ISO VG 46), DIN 51524 part 3. Biodegradable oils: See Operator's Manual Initially after 40 working hours, thereafter once a year = 500 working hours. Only check oil level with rams retracted. Working hydraulic system Size of mesh Steering hydraulic system Size of mesh Low pressure hydraulic system Size of mesh Clean or change the filters each time the oil is changed. screen filter '75""5 bar 100" bar 175" bar 19% bar 115" bar Working hydraulic system Grindstone movement, Radiator rotary screen Low pressure hydraulic system Steering Cause: excessive circulating flow pressure in the circuits (maximum circulation oll pressure < 20 bar). = Check spools of directional control valves for correct neutral positioning (centering) = Check lines and hoses for kinks. = Check return flow filter for cleanliness. Triple gear pump ‘Speed 1 = 2690 min (rated speed) Direction of rotation = anti-clockwise rotation Capacity Pump 1 = 12cm? Pump2- 6 cm* Pump 3- 9cm? Q = 32 Vin. working hydraulic system Q = 16 Vin. hydraulic steering system Q = 23 min. radiator rotary system 13Checking pressures Low pressure hydraulics Hydraulic steering system PROBLEM Pump fails to deliver full output 14 NOTE: Check hydraulic oll pressures only when ol is at ‘operating temperature approx. 50°C in the reservoir and with the diesel engine at full throttle. = Connect the pressure measuring device to the test point. = Start Diesel engine. Fully extend one hydraulic cylinder and hold the switch (or the pedal) of the appropriate hydraulic directional control valve in that position, — The measuring device will show the hydraulic pressure reading. ~ Connect the pressure measuring device to the test point. ~ Start Diesel engine. = Pressure gauge shows pressure reading. = Please refer to chapter “Hydraulic steering system”. = Pressure compensating plates or back-up plate correded/pitted. Seal leaking. Pump output can only be accurately measured when a flow meter is used.2 Hydraulic steering system DANFOSSCircuit diagram for steering system, from Machine No....Key 1- 2- 3 140 - 441 = 142 — 143 - 144 — 145 — 146 - 447 - 148 ~ Oil reservoir (approx. 20 litres) Screen fiter working hydraulic system Gil fiter - steering, disposable filter, mesh size 25 um Gil drain Hydraulic pump 12 em, working hydraulic system Hydraulic pump 6 cm®, lift radiator screen Hydraulic pump 9 em, steering To solenoid vaive block working hydraulic system Test point working hydraulic systom Measuring device connector, steering Valve block, steering OVP 20 One way restrictor Pressure relief valve, 115+'8 bar Double shock valve, 200 bar Hydraulic cylinder, steering (diameter 63 mm) Stoering valve, DANFOSS OSPB 160 Ball check valve (emergency steering) Oil reservoir emergency steering (approx. 250 cm:) Solenoid valve, Autopilot One-way valve Pressure relief bolt Pressure accumulator, 0.7 1/ 80 bar Oil pressure switch, normally closed (N.C.) 160 bar Solenoid valve, Autopilot Llock-up vaive unit 4.5 mm diameter restrictor Master valve, Autopilot Master valve = see circuit diagram for working hydraulic system 23Circuit diagram for steering system, up to Machine No. ... 6L oe0s H 24Keys 74 76 7 78 79 80 81 82 Oil reservoir (approx. 20 litres) Oil fiter - steering, disposable fiter, mesh size 25 im Gil drain Hydraulic pump 12 em. working hydraulic system Hydraulic pump 6 cme, it radiator screen Hydraulic pump 9 on, steering Measuring device connector, steering Valve block, steering OVP 20 One way restrictor Pressure relief valve, 11548 bar Double shock valve, 200 bar Hydraulic cylinder, steering (diameter 63 mm) Solenoid valve, Autopilot Steering valve, DANFOSS OSPB 160 Ball check valve (emergency steering) Oil reservoir emergency steering (approx. 250 em) 25Right hand and left hand tum - V = valve opens only when emergency steering is used ORONeutral position sesso]Description of system Major components of steering system Steering cylinder, double-acting ‘Steering valve and valve block Pressure setting OVP 20 Checking the pressure 28 ‘The steering system is fully hydrostatic. This means that the steering motion is transmitted hydraulically with no mechanical linkage between the steering wheel and the rear wheels. Diameter = 63mm Piston rod 25 mm Stroke 145 mm Steering valve OSPB 160 Valve OvP 20 Designations: © = Orbitrol S - Steering P - Pump B ~ Version with mutti-splined shaft 160 ~ Oil displacement in cm? per revolution V ~ Valve block 20 ~ Double shock valve = 200 bar ON ~ Open centre ~ non reaction Open centre = With steering controls in neutral, the oi from the pump circulates through the steering unit back to the tank. Non reaction = With steering controls in neutral, shock loads acting on the rear wheels will cause ro reaction on the steering wheel. Pressure relief valve 115+! bar Double shock valve 200 bar, Note: The steering units are approved by the German TUV authorities. Connect pressure measuring device to test point (pressure line in front of steering valve). ~ Start Diesel engine. = Tur steering whee! to full lock and hold it there, The ‘gauge will be shown on the measuring device. IMPORTANT: With all hydraulic control valves in neutral position, hydraulic cil at operating temperature and engine ‘at maximum speed, flow pressure of circulating oil must not ‘exceed 20 bar. Flow pressure of circulating oll has to be taken into account ‘when carrying out initial pressure settings. Example: vp 20 Setting of pressure reliefe valve 15+ bar Measured flow pressure of circulating oil = 11 bar Required setting 120 bar + 11 bar 31 bar NOTE: If flow pressure of circulating oil is excessive, the system will overheat.How steering unit works Oil displacement FUNCTION Manual steering (emergency steering) The Orbitrol-unit consists of a rotor assembly (metering unit) with rotating steering valve (inner and outer spo). The roter assembly consists of rotor ring and rotor. The rotor ring is stationary and has 7 cavities. The rotor (6 lobes) revolves around the centreline of the housing as its lobes engage the cavities of the ring. The steering spindle drives the rotor by way of the cardan shaft and also actuates the steering valve, By rotating the roter inside the ring, cavities are being opened and closed. Oil flow from the pump is directed by the steering valve into the open cavities. Oil forced out of the rotor unit as cavities are being closed, is directed by the steering valve to one side of the steering cylinder. Oil forced from the opposite end of the steering cylinder flows back to the reservoir. 1/7 of a tum of the steering wheel corresponds to 1/7 of a turn of the rotor hub. This displaces oil from 6 cavities. ‘One full turn of the steering wheel equals one complete revolution of the rotor hub which causes the oil to be displaced 6 x 7 = 42 cavities. In the neutral position oll is allowed to flow freely through the valve (P to T). Turning the steering wheel in one direc- tion, causes rotation of the spools against one another. At 1.5° the oll passages begin to allow oil flow to the cavities. ‘At 4° the neutral position passages will be fully opened. Rotation of spools against one another are limited to + 8°. Feeding oll under pressure to the rotor unit results it ~ Rotation of rotor. ~ Metered oll flow to steering cylinder. Oil ow is proportional to movement of steering wheel. The cylinder moves to steer the rear wheels. = Closing of rotor access passages in valve as steering ‘wheel motion is stopped. Neutral positioning of outer spool and rotor is mechanically assisted by built-in leaf springs. By turning the steering wheel, the inner spool drives the Cuter spool by way of the cross pin, whereby the rotor within the rotor ring is turned by the cardan shaft, The rotor assembly will then act as a hand pump and pumps oil to the steering cylinder. Ollis sucked from the rotor return line through the open non-return valve (ball valve), located between T and P (reservoir and pump). In this case steering will be harder, but full control of steering is maintained 29Valve block (One way valve Repairs Practical service hints. Steering valve Valve block Relief valve Double shock valve ‘One way valve ‘Screwing valve block to steering unit 2.10 Connection (P) in valve block. This valve prevents fluid from ‘escaping if the pressure hose ruptures. reservoir is installed into the return line, connection (1), 80 that oil supply will be always sufficient for use in emergency ‘steering (different ram faces). ‘A major overhaul of the unit should only be carried out by authorized DANFOSS workshops. Service work should be limited fitting new seals and cleaning the steering valve. ~ Hold the unit upright when removing the spools, otherwise the pin might slide into an annular groove. ~ Renew all seals. = Install O-ring and Kin-ring by use of assembly tool. ~ Place the ball of the one way valve into the correct hole (screw with long pin). = Fit new washers to sorews of end cover. Cross-tighten the screws, working from the frst screw to the one ‘opposite. Tighten screws to 30° Nm (22° ft Ib). ‘Assembly tool for O-ring and Kin-ring: CLAAS part no. 178897.0 ~ Valve seating is fitted with Loctite. = One drop of Loctite is applied to the thread of the adjusting screw. = Before removing the adjusting screw, measure the depth the screw is screwed in so that the same valve rating is ‘obtained when the valve is re-assembled. ~ Check valve-rating after installation, using pressure ‘gauge, = Torque on screwed end cap 50" Nm (37°74 ft Ib). ~ Before removing the adjusting screw measure the depth the screw is turned in so that the same valve setting is obtained when the valve is re-assembled. The pressure cannot be checked on the machine. ~ The valve seating is fitted with Loctite. = Torque on threaded end cap is 401° Nm (29.5*"* ft Ib). ~ Valve seating is fitted with Loctite. = Torque socket head cap screws to 65*° Nm (48%9" ft Ib).Checking the steering system (cil at operating temperature, Diesel engine running at maximum speed, no load) ~ Check steering cylinder NOTE: The grooved seal may seal off completely in the end position, but may allow leakage in mi position. Disconnect both hydraulic hoses from the steering cylinder and securely plug them with screw plugs. ‘Turn the steering wheel until the steering contacts make contact. With a force of 25 Nm (18.4 ft Ib) the steering ‘wheel may be turned 4 revolutions per minute further on (check in both directions). Ifthe value obtained is under 4 revolutions, the steering valve is 0.k., check the cylinder. If the steering whee! can be turned more than 4 revolutions/minute, the steering valve is at faut. In that case check: a) the shock valve for leakage, »b) the rotor or spool for wear. — Ensure that the piston rod of the cylinder is straight. ~ Check king pin for smooth movement. ~ Check steering column. There must be a clearance of ‘approx. 1 mm between the splined end of the steering spindle and the mating end of the inner spool of the DANFOSS steering unit. (Adjust by positioning shims between the circlip and the steering column) Height clearance of steering spindle = 0.1 to 0.3 mm. ~ The steering wheel must automatically return to the neutral position ater it has been turned (check with Diesel engine stopped.) ~ Connect pressure gauge to test connection and check the pressure. Ifthe pressure is too low: 2) adjust the pressure setting, b) check the pressure relief valve (probably leaking). = Check pump with a flow meter NOTE: Whenever the steering system and/or its lines have been serviced, the hydraulic ines must be bled with the engine running. attSolenoid Valve CLAAS Autopilot, from Machine No.... T IeKey to diagram FUNCTION Steering with Autopilot (also cf. circuit diagram) PROBLEM With the Autopilot set to ON, there is no steering motion of the wheels. Both the manual steering system and the working hydraulic system are OK. 141 — one-way valve 142 = pressure relief bolt 143 — pressure accumulator, 0.7 1/80 bar 144 — oil pressure switch, opening 160 bar 145 ~ solenoid valve Autopilot 146 — lock-up valve unit 147 ~ restrictor 0 1.5 mm = pump working hydraulics = return flow working hydraulics connector steering cylinder = connector steering cylinder = piston WARNING: Before items 143, 144, 145 or 141 can be removed, the accumulator pressure has to be released by means of the pressure relief bolt 142. Whenever the valve cartridges (145) are removed or replaced, the copper ring 8 x 14 x 1 has to be replaced. ‘Spare part No. 094 001.0 Ra>av 1 = When the Diesel engine is running, the master return valve (circulation control valve) is actuated by the oil pressure switch 144; see working hydraulics circuit diagram, Oil flows from P through the one-way valve 141, to the pressure accumulator 143, ‘Ata pressure of 160:* bar, the oil pressure switch opens Up and the master return valve (circulation control valve) switches back to its neutral position. ‘The pre-charged pressure thus applies to the oil pressure switch 144 and to the closed balls of the solenoids 145. = The module actuates the solenoid valve 145. The corresponding pilot control spool unseats the ball, and oil flows to the lock-up valve unit 148. Due to the pressure build-up, the piston K opens up the one-way valves A or B to enable oil to flow back from the hydraulic cylinder of the steering system. The one-way valve opposite is opened hydraulically, and the oil flows. to the hydraulic cylinder. The wheels are steered until the steering angle determined by the module is attained and the solenoid therefore switches off ~~ When the oil pressure within the pressure accumulator, drops below 135: bar, the oll pressure control switch closes, and the master return valve is again actuated. ‘The pressure accumulator 143 is then hydraulically pre- charged again. NOTE: Raise the steering axle until the wheels are only just touching the ground. Run the Diesel engine at full throttle. Engage the magnet in question manually I this causes the rear wheels to move, the problem is likely to be found in the electric circuit. If there is no movement of the steering wheels, then try to engage a second function, e.g. move upper discharge ‘chute. If this causes the steering wheels to move, the oil pressure switch has to be checked. (Switch does not shut when pressure drops.) 213Hydraulic oll overheats. Steering resistance is abnormally high on ‘one side only (Autopilot is switched off Machine turns right or left on its own, 214 oll pressure switch switches on and off in short intervals. Disconnect the electrical connection of the oil pressure switch 144, and then check the oil overheating problem Possible causes for this problem are: pressure accumulator is defective. ball valves allow leakage. inlet valve allows leakage. pressure relief bolt allows leakage. oil pressure switch is defective. check one-way valves and the piston K in the lock-up valve unit 146, check grooved seals in the steering cylinders. check one-way valves and the piston K in the lock-up valve unit 146,218Return Valve (Circulation Control Valve), from Machine No.... H 2511.0 = HH Key 148 a0 The solenoid core is pressed down by the spring and closes the bore of P. Oils allowed to flow from the cylinder (A) to the return line (. ‘The solenoid core is pulled up against the spring and closes the bore to R. Oil is allowed to flow from the pressure line (P) to the hydraulic cylinder A. The solenoid core can be operated by hand by turning the ‘eccentric (H). In this way it can be determined whether the faults in the electrics or hydraulics. 20001 47Hydraulic cylinder diesel engine rom H 2525.0 48Key FUNCTION Diesel engine idling speed Diesel engine at full throttle Diesel engine rpm reduced (8% speed engaged) (Order in which to perform cylinder adjustments ‘A ~ Connector working cylinder B - Connector working cylinder E ~ Breather H ~- Threaded sleeve S ~ Mounting boit M — Setting dimension Both solenoids are de-energized. The connectors A and B are depressurized. Both pistons are retracted. Both solenoids are energized. The connectors A and B are pressurized. Both pistons are extended. Note: After performing installation work on these hydraulic circuits, ensure that the hydraulic cylinder is bled at bleed screws E. ‘One solenoid is de-energized. The L/H piston is retracted, = Preset sleeve to dimension M 20 krnv/h — approx. 208 mm 25 km/h —" approx. 220 mm Fit cylinder. Run the diesel engine at full throttle, both cylinders are extended, Set dimension 5° mm (on the threaded rod), ~ Set speed for road travel. Run the diesel engine at full throttle, engage 3° speed, the LH cylinder is retracted. Set the rpm on the sleeve: 20 km/h road travel = 1490 rpm 25 km/h road travel = 1860 rpm 49Key FUNCTION Neutral Feed Reversing Reverse Feed Solenoid valve, feed Solenoid valve, reversing Engagement cylinder Reversing cylinder Oil pressure switch Delivery Reservoir 4vonmar 3 1" When the solenoid is de-energized, the connection from P to Ais blocked. When the solenoid is energized, the seated valve is opened against the spring action. Oil can flow from A to R or from PtoA. Aliso s0¢ circuit diagram. 55Circuit diagram for maize picker head, snapping plate adjustment Lali] 2 7 a Hoh H_2519.0 56Key ar 28 29 n 73 w>za0 Solenoid-operated 4/8 directional control valve, (folding 8-row maize header) Coupling, machine side Coupling, front end attachment side Hydraulic cylinder, snapping plate adjustment (One-way restrictor valve, snapping plate adjustment Lock-up valve unit, snapping plate adjustment Connector pump Connector reservoir ‘Supply to downstream directional control valve Connector hydraulic cylinder Connector hydraulic cylinder 87Circuit diagram for pick-up crop press lift o°oesz H 58Key 21 27 - 28 - 130 — 192 - Solenoid-operated 4/8 directional control valve, sharpening Solenoid-operated 4/3 directional control valve, pick-up crop press lift Coupling Lock-up valve unit Hydraulic cylinder, pick-up crop press lift Restrictor Connector pump. Connector reservoir Connector dump/return flow 59Circuit diagram for GPS (whole crop harvesting) cutterbar Reel operation and hitch with solenoid-operated 4/3 directional control valve, from Machine No. ... z 3 104 26 ja] = aE B re H 2531.0 5.10Key 25 - 26 - 27 - 28 - 29 - 32 - 101 - 402 ~ 103 - 104 ~ 405 — 108 ~ 108 ~ 109 - m1 = 112 - Coupling, machine side Coupling, front end attachment side Solenoid-operated 4/3 directional control valve, fore and aft reel adjustment Coupling, machine side Coupling, front end attachment side Valve block port plate Solenoid-operated 4/3 directional control valve, reel raise / lower 4.2 mm diameter restrictor Lock-up valve Hydraulic cylinder, fore and aft reel adjustment Hydraulic cylinder, reel raise / lower Hydraulic cylinder, reel raise / lower Pilot operated one-way valve 1.2 mm diameter restrictor Solenoid-operated 4/8 directional control valve, bitch Lock-up valve BtKey 106 = 107 - Solenoid-operated 9/8 directional control valve, reel raise / lower Coupling, machine side Coupling, front end attachment side Solenoid-operated 4/8 directional control valve, fore and aft reel adjustment Coupling, machine side Coupling, front end attachment side ‘Solenoid-operated 3/8 directional control valve, hitch Connector, hitch Valve block port plate 4.2 mm diameter restrictor Lock-up valve Hydraulic cylinder, fore and aft reel adjust ment Hydraulic oylinder, reel raise / lower Hydraulic cylinder, reel raise / lower 1.2 mm diameter restrictor 5.13Lock-up valve, fore and aft reel adjustment [a [a = S&S id Fi ‘ (HTN 1 EN f 5 i a ee ei _ iL} @] q la H 2520.0 FUNCTION When closed, the one way valves hold the cylinder steady in one position. ‘When cil enters connection B (pressure build-up), the oil will irst act on the large surface area of the piston which ‘opens the one way valve at the opposite end. This ‘connects A with A (return fiow). The bottom valve opens by oll pressure, allowing oil to flow from B to B1. When cil enters connection A first connection is made between B, land B and then between A and A, PROBLEMS Cylinder cannot be extended or retracted Cylinder extends or retracts on its own B14 Restrictors in the connections are blocked. ll leaking past the grooved seals of the cylinder. Plunger jammed in lock-up valve. (One-way valves in lock-up valve leaking. ll leaking past the grooved seals of cylinder. il leaking past the seal carrier (piston) of the cylinder (Gealed with self-locking fluid).Pilot operated one-way valve, reel raise /lower [a 8! AY a. LS M 2521.0 FUNCTION When closed, the one-way valve holds the cylinder steady in one position. Connection B1 is closed. When oll enters connection 8 (Pressure build-up), the piston opens the one-way valve. This connects At with A (return flow). The reel lowers. When oil enters connection A, the one-way valve opens due to the pressure build-up, making the connection to AT. PROBLEMS: Restrictor in the connection is blocked. Plunger jammed in lock-up valve. Cylinder cannot be extended or retracted Cylinder retracts on its own ~ One-way valves in lock-up valve leaking. Oil leaking past the grooved seals of cylinder. 5.15Reel lift cylinders BRST Of CLL, SSR Viren ee 0 Sitti CLLLPPLIIPLEDIL ILI OH Qe 12176 5.16FUNCTION FAULTS Uneven lift, ree! lower on the right-hand side Uneven lit, ree! lower on the left-hand side Reel cannot be lifted (pressure relief valve opens) ‘Synchronized cylinders lift and lower the reel. Left = Master cylinder Right = Slave cylinder In the position “ft reel” oil is fed into the bottom chamber Of the left hand cylinder raising the piston. The piston is sealed at both ends (seals, vaives). During the upward stroke of the piston oil is pushed out of the top chamber and into othe right hand cylinder (displacement). In this manner a uniform lift and lowering of both ends is achieved despite the differing loads on the cylinders. The top valve in the left hand cylinder permits oil to transfer to the right cylinder only when the left cylinder is fully extended (top valve opens mechanically). Bleeding is necessary following assembly. For this purpose the reel must be in the fully raised position. = Unithas not been bled. ~ External leakage NOTE: Check the screw connections in the hydraulic lines. ~ Left hand cylinder seals or valves leaking, = Quick-release coupling valve not opened. 8.17Cylinders - fore and aft reel adjustment E TERS 12173 5.18FUNCTION FAULTS Reel does not move in parallel Reel cannot be moved forward or backwards. Reel creeps forward or backward by itself The two double-acting cylinders on the reel move in ‘opposite directions. The piston accomodated in the cylinders are sealed at both ends (seals and valves). Ione cylinder takes oil fed from a 4/8 directional valve, the piston rod extends. The oil displaced in this manner in the Upper chamber is forced into the second cylinder which retracts. The oil displaced from this cylinder flows back to the tank through the 4/3 directional valve. = Airin the system ~ to bleed the reel, move into the fore and aft end positions for about 1 to 20 sec. in each case; the piston-mounted valves open. = Seals or piston-mounted valves leaking. = Restrictors in lock-up valve blocked. = Quick-release couplings not connected or do not open. = See fault 4/3 directional valve. = Lock-up valves leaking 5.199 13 10 14 15 15 16 16 { L — { 17 1 “ee [lak ® il _ Po f 109 _ a _ Pe 101 + 26 25 AZT Yt oo oO 1, <0 _ 26 25 aa r i 27 Af \ 108 | MEAT ABS 2820 Door Po en ae 28 29 H 2522.0 5.20Key 6- 6- 7- a. o- 40 - 1 12 - 14 - 15- 16 - 17- 18 - 25 - 26 - 27 - 28 - 20- 101 - 108 ~ 109 - HY = He - vg ve - st - Solenoid-operated 6/2 directional control valve with lock-up valves: Solenoid-operated 6/2 directional control valve Lock-up valve, fore and aft reel adjustment Lock-up valve, folding cutterbar Hydraulic cylinder, locking cutterbar in working position Hydraulic cylinder, folding cutterbar 0.8 mm diameter restrictor 0.8 mm diameter restrictor Pilot operated one-way valve Hydraulic cylinder, locking cutterbar in drive position Hydraulic cylinder, L/H fore and aft reel adjustment Hydraulic cylinder, RVH fore and aft reel adjustment Hydraulic cylinder, ree! raise / lower, double-acting Hydraulic cylinder, reel raise / lower, single-acting Couplings, machine side Couplings, front end attachment side Solenoid-operated 4/3 directional control valve, fore and aft reel adjustment and folding cutterbar Couplings, machine side Couplings, front end attachment side Solenoid-operated 4/8 directional control valve, reel raise / lower Pilot operated one-way valve 1.2 mm diameter restrictor Connector pump Connector reservoir Connector hydraulic cylinder, R/H fore and aft reel adjustment Connector hydraulic cylinder, LTH fore and aft reel adjustment Connector hydraulic cylinder, locking cutterbar in drive position (connecting rod end) Connector hydraulic cylinder, locking cutterbar in working position (connecting rod end) Connector hydraulic cylinder, folding cutterbar and pilot operated one-way valve Connector hydraulic cylinder, folding cutterbar 521FUNCTION Reel raise / lower Fore and aft reel adjustment Fold cutterbar into working position 5.22 ‘The reel is lowered and raised by the solenoid-operated 4/3 directional control valve 101 and the hydraulic cylinders 17 and 18. ‘The fore and aft reel adjustment is performed by the solenoid-operated 4/8 directional control valve 27, the de- ‘energized solenoid-operated 6/2 directional control valve 6, the lock-up valve 7 and the hydraulic cylinders 15 and 16, As the reel is divided in the middle, the adjustment is Performed by 4 double-acting hydraulic cylinders ‘connected in series. — Ensure that the cutterbar does not touch the ground during folding. Observe sensing bands! = Lower reel completely. = Manually unlock the cutterbar and vertically engage the lever. ~ Fold out the crop divider on the L/H side. = Remove the light bar and grain litter safety bar and/or knife safety bar, ~ Fold out the crop divider on the R/H side. ~ Bring the reel to its end position. = Energize the solenoid-operated 4/3 directional control valve 27 and the solenoid-operated 6/2 directional control valve 6. il flows from the solenoid-operated 4/3 directional control valve 27 via the connection V2 to the rod end of hydraulic cylinder 9. The pilot operated one-way valve 13 is still closed. At the same time, oil lows from connection $2 via the ‘one-way vaive of hydraulic cylinder 10 to the face end of hydraulic cylinder 14. The piston rod extends, unlocking the cutterbar. ‘The oil displaced at the rod end flows back from hydraulic, cylinder 14 to the reservoir. ‘When unlocked, the cutterbar folds into working position. ‘When the cutterbar isin its end position, one-way valve 13 is mechanically opened, allowing oil to return (face end) ‘from hydraulic cylinder 9. The piston rod of the cylinder retracts, locking the cutterbar. Restrictors 11 and 12 cause the hydraulic cylinder 10 to retract or extend slowly. Move the reel fully forwards. Fit the universal drive shaft on the R/H side. Fold in the safety bar of the fore and aft reel adjustment. Mechanically lock the cutterbar (safety bar down). Fit the universal drive shaft on the L/H side.Fold cutterbar into transport position. — Ensure that the cutterbar does not touch the ground during folding. Observe sensing bands! = Lower reel completely. = Manually unlock the cutterbar. ~ Fold out the safety bar of the fore and aft reel adjustment. = Pull off the universal drive shaft on the LH side. = Pull off the universal drive shaft on the F/H side. = Return the reel to its end position ~ Energize the solenoid-operated 4/3 directional control valve 2 and the solenoid-operated 6/2 directional control valve 6. Oil flows from the solenoid-operated 4/3 directional control valve 2 via connection S1 and the opened one-way valve 18 to hydraulic cylinder 9, (face end). The piston rod of cylinder 9 extends and unlocks the cutterbar. The oil from the eylinder (rod end) flows back to the reservoir. ‘At the same time, oil lows from connection S1 to the rod fend of hydraulic cylinder 10. The piston rod of cylinder 10 retracts. When the cutterbar is unlocked, the cutterbar folds into transport position, When the piston rod of cylinder 10 reaches its end position, ‘one-way valve in hydraulic cylinder 10 opens, allowing oll to flow back (face end) from hydraulic cylinder 14 to the reservoir. The piston rod of the cylinder retracts, locking the cutterbar. Fold in the crop divider on the R/H side. Hook in the light bar and connect. Fit the grain lifter safety bar and/or the knife safety bar. Fold in the crop divider on the LIH side. 5.23Solenoid-operated 6/2 directional control valve with lock-up valves a “Ce (fee ; } CW: H 2529.0 5.24Key FUNCTION Valve" not energized Valve" energized Ht Connector hydraulic eylinder, R/H fore and aft reel adjustment H2_ — Connector hydraulic cylinder, LH fore and aft reel adjustment V1_~ Connector hydraulic cylinder, locking cutterbar in drive position (connecting rod end) V2. - Connector hydraulic cylinder, locking cutterbar in working position (connecting rod end) 1 = Connector hydraulic cylinder, folding cutterbar and pilot operated one-way valve 82 - Connector hydraulic cylinder, folding cutterbar ‘A = Connector from solenoid-operated 4/3 directional Control valve B _ ~ Connector from solenoid-operated 4/8 directional control valve Connection from connector A via the one-way valve to connector H1 or connection from connector B via the non-return valve (see detail x) to connector H2. Also see function of lock-up valve. The connectors S1 and/or S2 are connected to the respective return flow side via the centre bore of the spool and the one-way valve (see detail y) Connection from connector A to the connectors $1 and V1 or connection from connector B to the connectors S2 and V2. ‘One-way valves (detail Y) ‘Any oil leaking into the spring cavities of the main spool is rained back via the one-way valves (detall ¥) to the reservoir. This prevents the one-way valves in the lock-up valves from opening by themselves. * Solenoid-operated 6/2 directional control valve with lock-up valves. 5.25Mi aanKey $1. — Connector hydraulic cylinder, folding cutterbar and pilot operated one-way valve $2. — Connector hydraulic cylinder, folding cutterbar 83. - Connector hydraulic cylinder, locking cutterbar (face end) K = Piston ram R ~ One-way valve 14 — 0.8 mm diameter restrictor 12. = 0.8 mm diameter restrictor FUNCTION When the piston rod is retracted, the one-way valve R is mechanically opened by piston ram K, allowing oil to flow from $3 to $2. Restrictors 11 and 12 cause piston rod 10 to retract or extend slowly. 8.27Ground drive hydraulicsCircuit diagram for LINDE ground drive hydraulics O°00S% Z 62Keys 93 95 96 7 Oil reservoir (approx. 20 litres) Hydraulic pump, 12 om®, working hydraulic system Hydraulic pump, 6 cm, rotary radiator screen Hydraulic pump, 9 om, steering Gauge connector Restrictor, 2 mm-dia. Pump connection, low pressure hydraulics Gauge connector Variable cisplacment pump BPV 100 LKS Charge pump (18 cm?) Gold start vaive (ol cooler protection 25°25 bar) Gil cooler Filter with by-pass valve ‘Switch, 12 bar, normally closed (N.C.) charge pressure Charge pressure valve (18% bar) Charge and high pressure valve (high pressure = 420 bar One way valve = 0.7 bar) Servo control Gauge connector and bleed screw ‘Temperature switch (104°C) Fixed displacement motor BMF 76 TFC ‘Scavenger (purge) valve, consisting of shuttle valve and relief vaive) 63LINDE Pump BPV (schematic) waco meqoz? 109 £0 309 027 zeo0r0 a4Key Nxar = to cooler from cooler ‘scavenge (purge) oil port to servo control 65LINDE BPV pressure valves mu SN High pressure relief valve and charge valve unit Function as charge valve (0.7 bar) Function as high pressure relief valve (420 bar) Charge pressure and cold start valve (18 and 25° bar, respectively) 66 Flow from B to A: ‘The large spring-loaded check cone lifts together with its integral components and allows oll to pass through. Flow from A to B: High pressure acts on the differential area D-d and lifts the valve body, which has a sliding seal on its top end, off its seat (diameter d) and allows flows from A to B. Flow from P to R,Contents 1. How the system works 2. Lines — How the system works ~ Lines = Variable displacement pump = Fixed displacement motor = Operating the system Safety device ~ Service and maintenance = Adjustment of servo control mechanism = First oil filing following a repair ~~ Testing high pressure and charge pressure ‘The hydrostatic system transfers the power required for propelling the machine from the Diesel engine via main ‘transmission to the change-speed transmission. ‘The hydrostatic variable displacement pump is driven by a ‘spur gearbox from the engine. Pump speed is constant uring operation. The hydraulic fixed displacement motor is mounted on the cchange-speed transmission, driving the traction wheels via 3 transmission speeds. When the 3rd speed range is being engaged, the speed of the Diesel engine is reduced at the same time. ‘The ground speed lever operates the pump’s servo control device by Bowden cable. The servo control device tits the swash plate and the nine pistons. With the swash plate in neutral position no axial movement of pistons takes place and thus no oll in displaces. By operating the tilt mechanism, direction of oil flow and thus direction of travel of the machine is controlled. The ‘swash plate can be tilted from 0 to a maximum of 18 degrees. The volume of oil displaced depends on the angle the swash plate is tilted. The oil flow from the pump is delvered to the hydrostatic fixed motor which converts the fluid force into rotational motion. This closed high pressure circuit is monitored on both sides by high pressure valves which are set at 420 bar. High pressure hydraulic lines connect the variable displace- ‘ment pump with the fixed displacement motor (closed high pressure circuit). These lines are high pressure hoses to prevent damage to pump and motor flanges from twisting forces or knocks. ‘The pump housing is connected to a reservoir by two transparent hoses (the reservoir provides an oll supply in, case of leakage, and allows fluid expansion with rising temperatures) ll delivered by the charge pump flows from pump port H through the oil cooler and returns to pump port F (cooler circuit. The scavenging portion of oil and the leakage oil from the motor (connection L) flows back to the pump and enters the pump housing at connection 0 (scavenging circuit). e73. Variable placement pump ‘Specifications BPV 100 LKS Description ‘Combined charge and high pressure relief valve Charge pressure valve and cold start valve Charge pump Disposable filter 68 n= Rated speed = 2690 min (rpm) B series Pv = pump with variable displacement 100 = rated displacement in cm*/rev. L = anti-clockwise rotation ks. = servo control with cam track ‘Axial piston pump, swash plate design for application to closed circuits. = pistons, one-piece drive shatt. Force of pistons transmitted to swash plate by slippers. Retainer plate prevents slippers moving away from swash plate. Tilting swash plate supported by rigid needle roller bearings attached directly to the casing Preload of cylinder block against port plate by spring pressure. Besides driving the hydrostatic transmission, the pump rive shaft also rotates the charge pump (internal gear pump). The charge pump sucks oil from the reservoir and transfers it through the cooler to the disposable fier on the pump housing, The suction port of the charge pump is protected by a screen filter. ‘The pressure relief valve connected downstream of the charge pump acts as a cold start valve to protect the cooler against high flow resistances (e.g. when starting at low outside temperatures) ‘The entire flow of oil delivered by the charge pump and ‘coming from the cooler passes through a 10 micron disposable filter. ‘After entering the pump again, the oil flows to the charge valves and to the servo mechanism. ‘The excess oll, not required to make up for leakage, is discharged through the charge pressure valve into the return side. This way correct charge pressure and full return flow on the return side of the high pressure system is maintained. Depending on the direction of tit of the swash plate, high pressure oil fows to the corresponding port (becoming the high pressure port), which at the same time closes the integral charge valve. Replenishing oi will then only be introduced through the charge valve on the low pressure. side of the system. It high pressure exceeds the rated maximum value of the ‘combined charge and high pressure relief valve, oil flows through the connecting passage, passes through the ‘opposite charge valve and enters the low pressure side of the system. — Functions — see drawing — Factory-set, spring-loaded poppet-valves = Internal gear pump (18.3 cm*/per revolution) — 10.um (micron), WD 950Hydraulic servo control 4, Fixed displacement motor 75 TFC Description: Drive components, ‘Scavenger (purge) valve The hydraulic servo control mechanism is built into the pump cover. The swash plate is moved by 2 x 2 servo pistons which prevents misalignment of the swash plate. ‘The movernent of the adjusting lever is limited by an adjustable stop bolt which thus controls maximum speed, ‘The stop bolt is factory-set and lead sealed. max. speed = approx. 3600 min-* (tp) B = series MF ‘motor with fixed displacement 75 rated displacement in cm®/rev. TF motor with SAE-standard attachment flange c with integrated LINDE valve for circuit and pump housing scavenging Motor speeds with Diesel engine at different speeds: 1 3600 mirr* with rated engine speed = 1880 mir’ with slow idling engine speed n= 1920 mirr* with medium engine speed (domestic German market) 112550 min with medium engine speed (export) Inclined axial piston pump, swash plate fixed at a 28° angle. Oil flow from the pump enters the motor and turns the drive shaft in a rotary motion. = Tpistons = Oylinder block is forced by spring pressure against a port plate. ‘The scavenger (purge) valve is built into the motor’s valve plate and consists of: Shuttle vaive and relief valve, Exchange portion of oll: maximum 17 litres per minute. ‘These valves purge oil out of the closed circuit when the system is operated in FORWARD or RESERVE. The charge pump delivers oll to the charge pressure control valve which introduce replenishing oil into the closed circuit and lowers the temperature of the operating oil flow. ‘The scavenger valve (purge valve) is out of function: a) when no pressure difference exists within the high pressure circuit (e.g. when the machine is stationary with Diesel engine running). b) when the charge pressure drops below 10 bars (e.g. because of lack of charge oil 695. Operating the system 6. Safety feature 7. Service and maintenance Flushing the system 8. Adjustment of servo control mechanism. 6.10 Operate ground speed control lever only with engine running. ~ When starting the machine at low temperatures (thick oil, run the system a few minutes at siow idle until oil has warmed up. Only then should full load be applied to the drive. = When operating under normal driving conditions, select speed range 2. In severe conditions select speed range 1. = If the machine slows down on hillside return the ground speed lever in the direction of the neutral position. Charge pressure switch (12 bar N/C contact) In case of low charge pressure or insufficient oil supply, the safety switch activates an indicator light in the vehicle information unit and a warning device. ‘Temperature switch (104°C) ‘The temperature switch activates the indicator light in the vehicle information unit. Refer to operator's manual for oil change and fitter change frequencies. ‘The pipelines (high pressure circuit) must be flushed when. foreign objects have entered the main circuit. When replacing one component and another is left on the machine, the remaining component must be flushed too. Note: When the pistons inside the motor are broken it is ‘essential to also inspect the gears of the change-speed, ‘transmission With pump in neutral position, detach Bowden cable at servo control. = Jack up and securely support the front, LH side of the machine, engage low gear and start Diesel engine, Run engine at max. no-load speed. Ifa fll stop of the LH traction wheal is not obtained, fist carry out the tests described in the following two steps. ~ Checking mechanical neutral: 2) Remove the cover which has the adjusting mechanism builtin, ») use depth gauge and check thatthe top edge of the swash plate is parallel with the edge of the housing. ‘Adjust the eccentric bolts on the lower cover as, necessary. After adjustment has been carried out, the mark on the outside end of the eccentric bolts must ‘always point tothe centre of the pump, Le. towards the Linde logo. ~ Checking the hydraulic neutral: Jack up and securely ‘support the machine so that the drive wheels clear the ‘ground. Fun the machine and move the adjusting lever in both directions to find the neutral dwell position. ‘Adjust the lage eccentric in the centre of the upper ‘cover as necessary. ~ Attach the Bowden cable and then adjust the cable so that the hand lever neutral coincides with the servo neutral.filling after a repai — Shift transmission gear shift lever to neutral and run Diesel engine at max. no-load speed. Set hydrostatic rive to full FORWARD speed. ‘The transmission tachometer must read approx. 3600 mir (rpm). If necessary, reposition and readjust the Bowden cable or readjust the lead sealed stop bolt for the adjusting lever. ~ Position cil cooler in a horizontal position ~ Engage 3 speed, = Apply the handbrake. = Connect the pressure measuring device (0-600 bar) to connector M1 and M2. = Fill reservoir with oil = Start diesel engine (siow idling speed) and turn off again immediately. = Check the oil level and top up with oll, if necessary. = Repeat this procedure until the pressure measuring device indicates an increase of pressure of at least 15 bar and the oil level in the reservoir is constant. = Run the diesel engine at slow idling speed. = If there is a recognizable increase of pressure, load the hydrostatic system in both directions as follows: @) Move the ground speed control lever to FORWARD nti a high pressure of 50-150 bar is reached. Maintain this specified pressure for approx. 1 minute, b) Move the ground speed control lever to REVERSE until a high pressure of 50-150 bar is reached. Maintain this specified pressure for approx. 1 minute. = Check the oil level and top up with oil if necessary. ~ Put the gear in neutral = Run the diesel engine at slow idling speed, = Set the hydrostatics for approx. 2 minutes to FORWARD and subsequently for approx. 2 minutes to REVERSE, = Check the oil level again. Note: If the hydrostatic motor or the hydrostatic pump have been replaced, check the scavenging pressure and correct, if necessary. Refer to Testing high pressure and, charge pressure. ett10. Testing high pressure and charge pressure ~ Connect the low pressure gauge 0-60 bar to port (X2) or to the existing T-union (connection 84 on the circuit diagram), Thread of port on pump: M14x1.8 ~ Install the high pressure gauge 0-600 bar to one of the ports (Xt, forward or reverse operation). Thread of port on pump: M 14.x1.8 Part number of adapter: 238 712.0 ~ Start Diesel engine, if necessary apply a lite load to ‘system until the operating temperature (60°C) has been reached. = With transmission in high gear, Diesel engine at max. no- load speed and foot brakes hard on, operate the systom to the desired direction of travel. Note readings on both pressure gauges. = When the high pressure is reached, read the charge pressure (ow pressure) gauge. Set value = 18°" bar. Note: Fluid must only momentary be allowed to pass over the high pressure relief valves (otherwise system will overheat) x4 xt 020036 6127 Centralised Lubrication System LINCOLNContents 4) Technical Data Pump Quicklub Operating temperature range Number of pump elements Reservoir capacity Refilling Lubricant Motor Pump element Metering device Lubrication time Pause time ‘Switching on the lubricating pump 72 1 —Technical Data 2— Pump Quicklub 203 CS 3 ~ Progressive Metering Devices, Type SSV 4 Troubleshooting from Serial No. ... Type 203 CS. (identifiable = timer is located at bottom of housing) Up to Serial No. ... Type 103 CS (identifiable = timer is located at top in reservoir unit) 25°C 10 70°C 2 2or 8 litres via hydraulic lubrication fitting, cartridge or return flow quick release connection. ‘greases up to NLGI grade 2 DC gear motor (interference-suppressed), 12 V, power consumption max. 6.5. pump element 1 = machine ump element 2 = front attachment plunger diameter 6 mm, lubricant output approx. 2.8 cm*/min. admissible operating pressure max. 350 bar (safety vaive on pump) LINCOLN, type SSV lubricant output per outlet and stroke = 0.2 cms 8 minutes. Indicated by a green indicator light on the panel 15 minutes The lubricating pump can be manually activated when the ignition and the main drive are switched on.2. Pump Quicklub 203 CS ‘A- Lubricating pump 203 CS, 2 litres, 2500.0 B- Lubricating pump 203 CS, 8 litres, from/up to Machine No. ... Bac. ee 2501.0 Bh — Reservoir with stirring paddle = Pump elements Pressure relief valve with grease overflow Filling nipple Printed circuit board = Electrical connector ‘A ~ to the main metering device B — Return flow Lubrication cycles time. Each pump element is protected by a $50 bar pressure relief valve. If the pressure in the system exceeds 350 bar, grease ‘escapes from pressure relief valve 3. No warning is given when the reservoir is empty. min. operating time, 15 min. pause Reservoir with stiring paddle Pump element Pressure relief valve with grease return Control pin, fault indicator Grease return Filling nipple Printed circuit board Electrical connector to the main metering device Return flow Lubrication cycles = time. Each pump element is protected by a 950 bar pressure relief valve. If the pressure in the system exceeds 350 bar, the grease pushes out the red pin 4 on prossure relief valve 3 of the blocked lubricating circuit, indicating the fault. ‘The grease is returned to the reservoir via the external line 5. o> fa min, operating time, 15 min. pause 73C - Lubricating pump 203 CS, with pressure switch, B litres, from Machine No. ... D- Reservoir empty warning 2503.0 1 ~ Reservoir with stirring paddle — Pump element ~ Grease return Filling nipple Printed circuit board = Electrical connector ~~ Pressure switch 360 bar ‘A ~ to the main metering device B - Return flow Lubrication cycles = 8 min. operating time, 15 min. pause time. Each pump element is protected by a $50 bar pressure ‘switch. Ifthe pressure in the system exceeds 350 bar, pressure switch 9 switches off the electric motor of the lubricating pump. ‘The red indicator light in the function information system lights up, indicating the fault. An LED on pressure switch 9 indicates which pump element and/or which lubricating circuit has been switched off. 1 ~ Guide blade with magnet (stiring paddle) 2 ~ Solenoid switch 3 - Control cam ‘When the reservoir is full, the stirring paddle rotates clockwise during the operating time. Lubricant pushes the pivoted guide blade to the rear. Magnet 1 moves towards. the centre of rotation of the stirring paddle. With every rotation control cam 3 positively pushes the guide blade outwards. Ifthe reservoir is empty, the guide blade can no longer be returned. The magnet moves over solenoid switch 2, triggering the reservoir empty warning. ‘The red indicator light in the function information system, flashes once magnet 1 has energized switch 2 six times. ‘The indicator light extinguishes when the operating time has elapsed.Function of the pump efement 020038 — Suction phase, pump element draws in lubricant Delivery phase, pump element delivers lubricant Eccentric Plunger Spring Non-return valve Key The electric motor drives the eccentric (1). During the operating time: — Plunger () draws lubricant from the reservoir, — Plunger (2) delivers the lubricant via metering devices to the connected lubrication points. Non-return valve — Ensures the function of the pump element, — Prevents lubricant running back to the housing or reservoir. 75Setting pause time and operating time 920047 3. Progressive Metering Devices, Type SSV Function of the metering flow in the metering devices Phase 1 (Fig. 020041) o2zoo4s Phase 2 (Fig. 020042) 020042 76 ‘The lubricant volume delivered is determined by the ‘operating time of the pump and the pause time. ‘Switch on the ignition and main drive. = Remove cap 7 (see lubricating pump 208 CS), = The pause time is set with rotary switch (3) ‘Switch position 4 = 15 minutes. The operating time is set with rotary switch (4). ‘Switch position 4 = 8 minutes. Manual triggering of additional lubrication cycles ~ An additional lubrication cycle can be triggered at any time with push-button (6). A complete lubrication cycle is performed. The pause time then starts again, LED (1) lights up when the ignition and main drive are ‘switched on. LED @) lights up when the electric motor is running. ‘The figures show how the individual outlets receive and oliver their lubricant volume. Note: For the sake of simplicity, the delivery cycles for ‘outlet 2, 7, 5, 3 and 1 are shown. The remaining cycles follow from the logical sequence of delivery ‘The lubricant enters from above (upper arrow) into the metering device and flows to the right-hand end of plunger A. ‘The lubricant pressure pushes plunger A to the left and livers the lubricant trapped ahead of the left-hand end of plunger A to outlet 2. ‘When plunger A reaches its left-hand end position, it opens the connecting channel to the right-hand end of plunger B. ‘The lubricant flowing in from above (upper arrow) pushes. plunger B (side arrow) to the left also and delivers the lubricant trapped ahead of the left-hand end of plunger B. to outlet 7.joz0043 Phase 4 (Fig. 020044) nou Phase 5 (Fig. 020045) 020045 When plunger B reaches its left-hand end position, it opens the connecting channel to the right-hand end of plunger C. The lubricant flowing in from above (upper arrow) pushes plunger C (side arrow) to the left and delivers the lubricant trapped ahead of the left-hand end of plunger C to outlet 5. The connecting channel to the right-hand end of plunger D is now open (arrow at bottom right) The lubricant flowing in from above (upper arrow) pushes plunger D (side arrow) to the left, whereby the lubricant trapped ahead of the left-hand end of plunger D leaves the metering device via outlet 3. In phase 4, plunger D opens the connecting channel to the left-hand end of plunger A. The incoming lubricant (upper arrow) pushes plunger A to the right (side arrow) and delivers the trapped lubricant to outlet 1. In the further sequence of operation, plungers B - D move in turn from left to right. Acomplete delivery cycle is thus completed and a new cycle can start. In the event of an interruption in the lubricant supply = The plungers stop. — No lubricant is delivered to the lubrication point. When the metering device receives lubricant again, the cycle starts exactly at the point at which it was interrupted. 1Progressive Metering Devices, Type SSV Progressive Metering Device, Type SSV — Are plunger-type metering devices. ~ Deliver the supplied lubricant positively (progressively) to the connected lubrication points. = Deliver 0.2 cms of lubricant per outlet and plunger stroke. = Can deliver twice or more times the lubricant volume by closing individual outlets. ~The plungers move in a preset sequence and in continuously repeated cycles. — Each plunger must have completed its stroke before the next can move, irrespective of whether the lubricant supply is continuous or intermittent. ~ The plungers operate in relation to one another. 020048 1 = Inlet screw fitting 2- Delivery bore of plunger 3 Sealing plug, inserted 4~ Sealing plug, plunger 5 - Non-return valve assembly 6 ~ Clamping ring (orass) 78 7 Valve body 8- Pipe olive 9 Union nut 10 Connecting channel 11 - Copper seal ring 12 Sealing plugDetermining the delivery volume by linking outlets Single delivery rate Double or multiple de — Delivery volumes can be increased by sealing outlet bores. = Install a complete outlet port plug (see figure) in each required outlet bore. = Never remove outiet port plug 4 (with chamfer) on the plunger side. ~ Never use plug 12 as plug 4 of the plunger. Important! Always install valve body 7 in conjunction with clamping ring 6. = Clamping ring 6 blocks off the connecting channels 10, to the other outlet bores. Important! On progressive metering devices SSV 6 to ‘SSV 12, never close outlet bores 1 and/or 2. Due to their design, this would result in blocking of the metering device. — The single delivery rate is the volume of lubricant which one plunger delivers to a lubrication point per stroke and outlet bore. The volume is 0.2 em”. (Figure 020048 shows single, double and triple delivery rates) ~ If one or more lubrication points require twice or more times the single delivery rate, this is possible by sealing one or more outlets. As shown in Figure (020048), outlet bore 10 is sealed, ‘The lubricant volume delivered to this bore leaves the metering device at outlet bore 8. = The total delivery volume at outlet 8 is the volume of outlet 8 plus the volume of outlet 10. ~ If three times the single delivery rate is required, seal the outlet bores above the connected outlet bore, see outlets 1, 3 and 5. 79LINCOLN Centralised Lubrication System Jaguar 880-820, 26 Lubrication Points Hon at O= Om ovmoe bso0z0 7.10Key Lubrication points A Pump B ~ Main metering device C ~ Front attachment D - Secondary metering device - discharge blower E ~ Secondary metering device - corn cracker F — Secondary metering device — drum housing G ~ Secondary metering device - feed-in housing H ~ Secondary metering device - tower K ~ Clutch, reverse D- Secondary metering device - discharge accelerator 4 = Discharge accelerator right .............1.40.6m# 2 Discharge accelerator left... 1.40 om? 3 = Guide roller up to Machine No. 0.70 om 4— Jockey pulley up to Machine No... °..0.70.em® 5 ~ Jockey pulley arm up to Machine No. 0:70 em? 6 — Rear axle trunnion up to Machine No, 0.70 om? 6 = Rear axle trunnion from Machine No. ..... 2.10.6m? G- Secondary metering device - feeder housing 7 = Pressure roller left 0.23 om? 8 — Steering lever right «222022200 200102211 10.28 em? 9 = Plain roller right... ceecteeses 0.23 om? 10 - Compression roller fight 0.23 om? 41.= Compression roller left... ..020200022..550.23 om? 42 — Plain rolier left 0.23 om? 48 — Steering lever left ==> o 0.23 om? 14 = Steering lever right <0 22202220226. 2 20.23 om? H_~ Secondary metering device - tower 1 ~ Flange joint, upper discharge chute 0.47 om? 46 — Flange joint, upper discharge chute . . 0.47 om? 19 - Worm gear bearings 0.23 em? 20 - Pivot bearings 0.23 om? 21 = Worm eesseeccereeeeee 0.47 em? G ~ Secondary metering device - drum housing 22 - Swivel bearing 0.31 om? 23 — Cutting cylinder bearing |<... .22..22.0.62.em? 24 - Swivel bearing .... cieceeeeees 031 om? 25 ~ Cutting cylinder bearing - 0.62 om? @, ~ Secondary metering device ~ com cracker, 26 — Corn cracker bearing : 2.80 om? 27 ~ Com cracker bearing... ...2.211+ 2.80 6m? 28 Cor cracker bearing 122.22.2211211211 2180 em? 29 Gor cracker bearing <2... ...2.21++2.80 6m? aLINCOLN Lubrication Chart 8-Row Maize Header (72 Lubrication Points) gery rye £50020 712LINCOLN Lubrication Chart 6-Row Maize Header (52 Lubrication Points) 280020 7.134 Troubleshooting Electric motor of pump does not run Pump does not deliver Indicator light on the function information system and the LED on the pressure relief valve light up (from Machine No. ..). Pin on pressure relief valve is extended (from ~ up to Machine No...) Grease escapes from pressure relief valve (up to Machine No. ..). Blockage in downstream progressive system. 714 ~ Check voltage supply (fuse a13, 218) ~ Check device plugs and connector to printed circuit board, LED with battery symbol must light up. = Replace timer. = Check voltage supply to motor; if necessary, replace electric motor. ~ Check whether reservoirs filled with grease; if necessary, top up with clean grease. Trigger additional lubrication cycles until lubricant emerges from all lubrication points. Note: Depending on the ambient temperature and/or lubricant, it may take the pump elements up to 10 minutes to reach their full delivery volume. = Check the lubricant for air bubbles. ‘Trigger additional lubrication cycles. Loosen the outlet fitting on the safety valve. The lubricant must emerge bubble-free. Use lubricant specified in the lubricant chart. = Check the intake bores of the pump element. Remove the pump element, inspect the intake bores for any foreign matter and clean, if necessary. = Check pump plunger for wear. = Check non-return valve in pump element. = Check the disconnect couplings of the individual units. Bearing, lines or metering device clogged. A fault is indicated by the following symptom: — Grease leaking from the safety valve Determine cause of the blockage and remedy as described in the following example. — Allow the pump to run (see “Triggering of additional lubrication cycles") = Loosen all main line connections (G) one after the other from main metering device (B) leading to the secondary metering devices. If grease emerges under pressure eg. from outlet 1 of main metering device (B), the blockage will be found in the circuit of secondary metering device (0), ~ Allow the pump to continue to run. Loosen all lubrication point lines (E) from secondary metering device (0) one after the other. If grease ‘emerges under pressure e.g, from outlet 3 of metering device (D), the blockage will be found in the line of outlet 8 or connected bearing. = Replace safety vaive (A). Note: When checking the individual outlets, keep each ‘outlet loosened for quite some time as the plunger makes ‘only one stroke at each revolution of the pump. A complete cycle of all metering devices requires several plunger strokes.--------1 020054 Different lubricant volumes at the lubrication points A ~ Safety valve E — Lubricant line B ~ Main metering F ~ Secondary device metering device G ~ Secondary metering device G - Main line D ~ Secondary metering device In the event of a blocked metering device no lubricant ‘emerges at any of the outlets. = Pump clogged line or bearing free with a hand pump. = Replace the metering device or clean as described below. = Disconnect al pipe fittings. = Remove the plunger sealing plugs. = If possible, drive out the plunger with a soft drift (iameter < 6 mm). IMPORTANT: The plungers are precision fitted into the metering device bores. Mark the plungers with their installation location and direction after removal. ‘They must not be exchanged during reassembiy! = Thoroughly clean the metering device body in a grease- dissolving cleanser and blow out with compressed air ~ Press free the slant ducts (dia. 1.5 mm) at the thread ‘ends of the plunger holes using a pin. = Clean the metering device again and blow out. — Reassemble the metering device. ~ Replace the copper washers. ~ Before connecting the pipe fittings again, pump the metering device through with oil several times, if possible, using a hand pump. Check that the pressure ‘does not exceed 25 bar in the metering device. If the pressure is higher than this, replace the metering device. = The corresponding valve body has been installed without clamping ring. = Remove valve body and check whether a clamping ring is fitted. If not, install a clamping ring. 7188 ElectricsNOTE: The on-board voltage to operate the electrical and electronic systems must lie between 12 and 14.8 V. If the voltage on the machine is above or below these values, proper functioning of the electrical and electronic equipment is not assured, Measured value table ‘Measurement Tester Test connections | Setpoint value setting Remote switch relay R a 85-86 65-750 12V, 20/304, Coil A" version Part No. 744071.1 Starter relay R a 8586 70-750 42V, 404 “B" version. Solenoid coll R a Coil output 270 Autopilot solenoid valve 12V, 4,5A, 60% CDF Solenoid coil R a Coil output 270 4/3-way directional contro! ‘solenoid valve 12V, 4,5A, 60% CDF Solenoid coll R a Coil output 60a ‘3/2-way directional control (low-pressure hydraulics) 12V, 2A, 100% CDF Solenoid coll R a Coil output 100 Metal detector lift magnet, 12V, 11A, 16%6CDF Solenoid coil ‘Automatic engine cut-off lift magnet 12V, 44/1,1A, 1006 CDF Iron core pulled out R Iron core pushed in R Coil output ca 110, Coil output a 0.30 pp Solenoid coil R a Coil output 340 Electromagnetic clutch Compressors conditioning s} Inductive sensor (Generator) R a Coil outputg 1000-1200 2 Varistor: Cutting height indicator ‘Sender and Fuel gauge R a housing earth 10-1900 CC roll gap 82Description and data Measurement Tester Test connections | Setpoint value setting Potentiometer in control pans Contour R input - output 98k CC roll gap R input - output Number of grinding cycles 20ka ‘Adjustment motor: Connect in series Reel speed 1 A with load 2-4A 1 A without load 12-158 ‘Adjustment motor: Connect in CC roll adjustment 1 A with load 1-28 Counterblade adjustment 1 A without load 6-7A Potentiometer at 7-pin connector 47 ka Contour Plus sensor RB a Grinder resistor 17kO Pressure sensor Contour module base Contour Plus u v Ping-8 O bar = 0,25 V Pint -3 180 bar = 3,7 V R a Pint -3 7250 NOTE: Deviations in the measured values are dependent on the internal resistance and the voltage source of the ‘measuring instrument (10% is normal). infinite (very large) asMain relay circuit is 2 ue 8 aoe Gp) [>| |a@! | eB — 2552.0Ignition switch Vehicle information unit Operations display screen ‘Switch, Diese! engine speed Switch, main drive Hourmeter Buzzer Front attachment enable switch Relay, Diesel engine slow idling speed Relay, main drive Relay, main drive Relay, pulse generator Relay, engine oil pressure Relay, alternator Relay 15 Engine oil pressure switch Alternator (80 A), engine Module, engine cutoff system Diode plate FUNCTION Ignition ON — Plus from ignition switch (4), terminal 15 is supplied to relay (59), terminal 86 via fuse (a9) and diode plate (194), terminals 18 - 17 Relay (59) switches plus from terminal 30 to terminal 87. ~ From fuse (a9), plus is switched to relay (68), terminal 30 and to relay (67), terminal 86. From alternator (172), terminal 61, earth is supplied to charge indicator (6) and to relay (68), terminal 86. Relay (68) switches plus from terminals 90 - 87a to relay (67), terminal 87a. — Oil pressure switch (166) is closed and grounds automatic engine cut-out module (193) through terminal 11. This provides earth from module (193), terminal 7 to indicator light (6) and relay (57), terminal 85. The relay switches, connecting terminals 30 and 87. Diesel engine warning system Diesel engine has started =. From alternator (172), terminal 61, plus is supplied to indicator light (6) and to relay (68), terminal 86. The relay switches. Plus is switched via terminals 80 and 87 to relay (87), terminal 87. Relay (57) is not ‘switched (no ground from cil pressure switch). — Ifthe oil pressure drops, ground is switched from the closed oll pressure switch (166) to relay (67), terminal 85. The relay switches. Plus is switched from terminal 87 via terminal 30 directly to the ‘warning device. Buzzer (42) sounds continuously Until the engine is switched off, and lights (6 and 8) are continuously illuminated. ~ When the alternator belt breaks, the power supply from the alternator to relay (58), terminal 86 is inter- rupted. The relay drops out. From the ignition ‘switch plus is switched to relay (58), terminals 30 to 87a, via relay (57), terminals 87a to 30 and directly to the warning device. Buzzer (42) sounds cont: rnuously until the engine is switched off and lights {6 and 8) show continously. ~ From relay (59), plus is also switched through fuse {02) to the front attachment master switch (43). a5Diesel engine starting (24 Volt), with engine cut-off system, JAGUAR 880 - 860 50 [Pn E— 2553.0 86Key 5 15 37 39 48 50 51 582 59 166 170 1 172 173 175 183 193 - 194 - 220 Ignition switch Vehicle information unit Safety stan switch in hydrostatic drive lever Switch, Diesel engine speed Switch, main drive Rolay, safety start Relay, safety start Flay, handbrake lover Relay ~ engine siow idling speed Relay (15) Relay, engine cut-off solenoid, 12 V, 40/2.8 A, 100% CDF Engine ol pressure switch Battery, 12 Volts Batiory I, 12 Volts Lift magnet, engine cut-off system Alternator (90 A), engine Starter, Diesol engine Water ievel sender Battory sorios/paralel relay (with 2 x 80 A fuses) Module ~ engine cut-off system Diode plate Battery master switch, safety disconnect FUNCTION Start diesel engine Important: Observe the following switch positions: — Main drive must be switched off. (Switch 38). = The ground speed control lever must be in 0 position. (Switch 15). = Tum on the ignition = plus via fuse (a9), diode plate (194) terminals 18 - 17 to the relays 59, 52, 48, terminals 86. Relay (59) switches, Relay (52) switches when switch (37) is set to slow idle speed position = position shown, Relay (48) in deactivated position. — Fuse (a17) switches plus to module (19) terminals, 16-17. Module (193) switches plus via terminals 3 ~ 6 to relay (69) terminal 86 and via closed switch (16) to relay (51), terminal 86 and to relay (48), terminal 30. Relay (50) terminal 86 receives plus from relay (48) terminals 30 - 87a and thus switches over. — From starter switch (4) terminal 50a plus is switched via relay (50) to battery series/ parallel relay (189). The diesel engine starts. = If the ground speed control lever is not in neutral (with switch 18 open), then no power is supplied to relay (48) terminal 30 and thus also to relay (50) ‘terminal 86. ‘The diesel engine does not start If switch (89) is unlocked and switch (37) is set to slow idle speed position, then relay (48) switches from 30 to 87. The diesel engine does not start. If switch (89) is unlocked and switch (37) is set to the full speed position, relay (52) remains in the deactivated position. This is insignificant for the starting process of the diesel engine. Important! On machines without engine cut-off system, oil pressure switch (166) is an NC contact. Module (193) is replaced with an adaptor (module housing without LED's). ‘The cable (gn) from the oll pressure switch is inserted into the plug-in connection Y-viol terminal 7. a7AUTOMATIC ENGINE CUT-OFF FUNCTION a8 Important! On the engine cut-off system, oil pressure switch (166) is an NC contact. ‘The gn (green) wire from the oil pressure switch is connected to Y-viol terminal 2 When the ignition is switched on, plus is supplied via fuse a7 to the engine cut-off module. ‘The module activates the solenoid via relay (69) and releases the injection pump stop lever. The earth circuit from the module to the oil pressure indicator light in the vehicle information unit (5) is completed at the same moment. The light comes on. ‘The module contains a timing element which deactivates the solenoid after 7 seconds. The "Stop" light in the vehicle information unit (5) comes on. ‘When the diesel engine is to be started, the solenoid is reenergized and the timing element in the module reset 100. ‘The 7 second timing period starts after releasing the ignition key. If following the engine start the oil pressure has Not built up after 7 seconds, the solenoid is deenergized and the engine stopped. Oil pressure and “Stop” light ‘When the cooling water level is low, the engine will start briefly, but then the solenoid will stall the engine again immediately. The “Stop” light comes on. ‘When the engine has started, oil pressure switch (166) ‘closes and earths the module. This breaks the earth circuit from the module to the indicator light in the vehicle information unit. The light goes out. ‘The automatic engine cut-off system stops the engine ‘when there is not enough water in the cooling system or ‘when the oll pressure is low.Engine cut-off module Checking the water level sensor (with sensor installed) The light-emitting diodes (LED) in the engine cut-off module indicate the following conditions: yollow (water level OK) yellow (oil pressure OK) Time delay red (time running down) Operating voltage ‘green (igrition on) ‘The Diesel engine can only be stopped when the ignition has been switched off Oil pressure = Disconnect the 3-pin connector to the water level = Bridge brown (br) and purple/blue (vi/blue) wires at machine end. — Ifthe engine is no longer switched off, then: Check first the power supply to sensor (wire in connector). = If the wire is live, replace the water level sensor. a9Starting the Diesel engine, (24 Volt) without engine cut-off module, JAGUAR 840 E 2554.0 10Key 5 15 37 39 48 50 51 582 59 166 169 170 172 - 173 183 194 ~ 221 Ignition switch Vehicle information unit Safety start switch in hydrostatic drive lever ‘Switch, Diesel engine speed Switch, main drive Rolay, safety start Relay, safety start Relay, handbrake lever Relay ~ engine slow idling speed Relay (15) Engine oil pressure switch Battery |, 12 Volts, Battery I, 12 Volts Alternator (80 A), engine Starter, Diesel engine Battery series/parallel relay (with 2 x 80 A fuses) Diode plate Battery master switch, safety disconnect Module, without engine cut-off system FUNCTION Start diesel engine Important: Observe the following switch positions: = Main drive must be switched off. (Switch 39). = The ground speed control lever must be in O position. (Switch 15). = Turon the ignition = plus via fuse (a9), diode plate (194) terminals 18 ~ 17 to the relays 59, 52, 48, terminals 86. Relay (69) switches. Relay (52) switches when switch (37) is set to slow idle speed position = position shown. Relay (48) in deactivated position, = Fuse (a17) switches plus to module (221) terminals 16-17, Module (221) switches plus via terminals 3 ~ 6 to relay (69) terminal 86 and via closed switch (15) to relay (51), terminal 86 and to relay (48), terminal 30. Relay (60) terminal 86 receives plus from relay (48) terminals 30 - 87a and thus switches over. — From starter switch (4) terminal 50a plus is switched via relay (60) to battery series/ parallel relay (183). The diesel engine starts. = Ifthe ground speed control lever is not in neutral (with switch 15 open), then no power is supplied to relay (48) terminal 30 and thus also to relay (50) terminal 86. The diesel engine does not start. = If switch (89) is unlocked and switch (97) is set to slow idle speed position, then relay (48) switches from 30 to 87. The diesel engine does not start. ~ If switch (89) is unlocked and switch (37) is set to the {ull speed position, relay (62) remains in the deactivated positon. This is insignificant for the starting process of the diesel engine. Important! On machines without engine cut-off system, oil pressure switch (166) is an NC contact. Module (221) is an adaptor (module housing without LED's) ‘The cable (gn) from the oil pressure switch is inserted into the plug-in connection Y-viol terminal 7. attStarting the Diesel engine, (12 Volt), JAGUAR 820 59 52 51 48 50. E— 2555.0 at2172 190 194 220 221 Ignition switch Vehicle information unit Safety start switch in hydrostatic drive lever ‘Switch, Diese! engine speed Switch, main drive Relay, safety start Relay, safety start Relay, handbrake lever Relay - engine slow idling speed Relay (15) Engine oil pressure switch Battery, 12 Volts Alternator (20 A), engine Starter, Diesel engine Starter relay Diode plate Battery master switch, safety disconnect Module, without engine cut-off system FUNCTION Start diesel engine Important: Observe the following switch positions: ~ Main drive must be switched off. (Switch 39). ~ The ground speed control lever must be in © position. (Switch 18) ~ Turn on the ignition = plus via fuse (a9), diode plate (194) terminals 18 - 17 to the relays 59, 52, 48, terminals 86. Relay (69) switches. Relay (62) switches when switch (37) is set to slow idle speed position = position shown. Relay (48) in deactivated position. ~ Fuse (a17) switches plus to module (221) terminals 16-17. Module (221) switches plus via terminals 3 ~ 6 and via closed switch (15) to relay (51), terminal 86 and to relay (48), terminal 30. Rolay (60) terminal 86 receives plus from relay (48) terminals 30 - 87a and thus switches over. — From starter switch (4) terminal 60a plus is switched via relay (60) to starter relay (190), terminal 86. Relay (190) switches plus from 90 to 87 and to starter (173). ‘The diesel engine starts. ~ Ifthe ground speed control lever is not in neutral (with switch 1 open), then no power is supplied to relay (48) terminal 30 and thus also to relay (50) terminal 86. ‘The diesel engine does not star. ~ If switch (99) is unlocked and switch (87) is set to slow idle speed position, then relay (48) switches ‘rom 30 to 87. ‘The diesel engine does not start. ~ If switch (89) is unlocked and switch (87) is set to the {ull speed no-load position, relay (52) remains in the deactivated position. This is insignificant for the starting process of the diesel engine. Important! On machines without engine cut-off system, «il pressure switch (166) is an NC contact. Module (221) is an adaptor (module housing without LED's) 8.13Functions monitor, ar cleaner waming contact, parking brake, disc pad wear indicator, temperature switch and sender, engine oil pressure switch, oround drive overheat and charge pressure, fuel tank sender E 2556.0 fie LET |Key 4— Starter switch 5 — Vehicle information unit 8 - Operations display screen 15 — Safety start switch in hydrostatic drive lever 41 ~ Hour meter 42 — Buzzer 51 = Relay, Handbrake lever 56 - Relay, pulse generator 87 ~ Relay, engine oll pressure 58 - Relay, alternator 120 - Sender, fuel gauge 421 ~ Air cleaner warning contact 136 - Switch, parking brake 144 - Sender, disc pad wear 166 ~ Engine oil pressure switch 167 ~ Temperature switch and sender, Diesel engine 168 - Switch, ground drive overheat (104° C) 172 ~ Alternator (0 A), Diesel engine 176 - Switch, hydrostatic ground drive charge pres- sure 193 - Module - engine cut-off system 194 - Diode plate FUNCTION ~ ALTERNATOR ~ Note: The diesel engine is running, In the event of a defective alternator or torn drive belt, relay (68) cannot switch over. Plus is therefore ‘switched from terminal 87a via relay (57) terminal ‘87a 30 to buzzer (42). The buzzer (42) sounds continuously and lamps (5 and 8) stay on continuously. FUNCTION - OIL PRESSURE WITH ENGINE, CUT-OFF SYSTEM ~ Ifthe ol pressure drops, closed oll pressure switch (166) earths module (193) terminal 11 and module (193) via terminal 7 to relay (67) terminal 85. The relay ‘switches over. Plus is switched from terminal 87 via terminal 30 directly to the warning device. Buzzer (42) sounds continuously and lamps (5 and 8) stay on Continuously until the diesel engine is switched off FUNCTION - OIL PRESSURE WITHOUT ENGINE CUT-OFF SYSTEM ~ The control lamps in operations display screen (6) receive positive voltage via fuse (a12). Relay (68) terminal 30 and relay (57) terminal 86 receive positive voltage from fuse (22). When the diesel engine is running, alternator relay (68) is switched (plus from alternator (172) terminal 61 to relay (68) terminal 86). Oil pressure switch (166) (without engine cut-off system = NC) is open. Relay (67) terminal 85 is not earthed and is thus in rest position. = Ifthe oil pressure drops, switch (166) closes. Control lamp (6), relay (67) terminal 85 and, via diode plate (194) terminals 3-10, pulse generator (56) terminal 31 are earthed Relay (67) switches plus from terminal 87-30 to ‘buzzer (42), to operations display screen (8) and to control lamps (6). The buzzer sounds continuously and the lamps light up continuously. FUNCTION ~ AIR CLEANER WARNING CONTACT SWITCH = fair cleaner warning contact switch (121) closes, control lamp (5) is grounded via diode plate (194) terminals 4—10 to pulse generator (56). The pulse generator switches the warning device via terminal 49a, FUNCTION - GROUND DRIVE TEMPERATURE. SWITCH = If switch (168) is closed, control lamp (6) is grounded. FUNCTION ~ HANDBRAKE, BRAKE DISC MONITOR: ~ If switch (196) oF (144) is closed, e.g. parking brake is engaged, contro! lamp (6) and relay (51) terminal 87a are earthed. Ifthe hydrostatic drive lever is moved, switch (15) ‘opens and the positive voltage supply to relay (51) terminal 86 is interrupted Rolay (51) switches to rest position. Earth is switched from terminal 87a ~ 30 via diode plate (194) terminal 18-10 to pulse gonerator (66) terminal 31 The pulse generator switches the warning device via terminal 48a. FUNCTION ~ HYDROSTATIC GROUND DRIVE CHARGE PRESSURE ~~ If charge pressure switch (176) closes, control lamp (©) and pulse generator (66) are earthed via diode plate (194) terminals 11-10. ‘The pulse generator switches the warning device via terminal 49a, 815Turn flashers, warning flashers, reversing warning hon E 2557.0Key 5- 55 - 124 ~ 129 - 180 ~ 149 — 153 - 154 - 159 - 186 - 187 - Hazard warning flasher switch Tum flasher switch Vehicle information unit Tum flasher relay ‘Tum flasher, L/H ‘Turn flasher, F/H Connector, trailer Horn ‘Turn flasher, left front ‘Tum flasher, right front Connector, drect-cut attachment marker lights ‘Turn flasher, L/H, front attachment ‘Tum flasher, F/H, front attachment 817Turn flashers, USA onlyBaws 124 130 153 184 159 Hazard warning flasher switch Turn flasher switch Vehicle information unit Turn flasher relay, USA. Turn flasher, LH. ‘Turn flasher, F/H Connector, trailer ‘Tur flasher, left front Turn flasher, right front Connector, direct-cut attachment marker lights 8.19EE # ihoarf easy et ee 78 73 72 aa) Ba Bal Bal Bal 60. CEO ares eT ~ ae — i § q & s 3 3 s\| 4 2} g — 2558.0 8.202 — Light ewiteh 3 - Tum flasher switch 5 — Vehicle information unit 9 - Switch, headlamps cab roof 16 ~ Switch, reversing lamp 60 - Relay, dipped / main beams 72 ~ Relay, headlamp switching 78 ~ Relay, headlamp switching 74 ~ Relay, headlamp switching 75 ~ Relay, headlamp switching 88 — Marker light, upper discharge chute 116 - Headlamp, cab roof, left 117 — Headlamp, cab roof, right 123 ~ Reversing lamp 125 ~ Side light, LH 128 ~ Side light, P/H 180 ~ Connector, trator 151 — Main beam, operator's platform left 152 ~ Main beam, operator’ platform right 155 ~ Front side light, LH 158 — Front side light, P/H 157 ~ Headlamp, operator’ platform left 158 — Headlamp, operator's platform right 159 - Connector, marker lights for direct-cut attachment 184 — Marker lights, front attachment left 185 - Marker lights, front attachment right 216 ~ Reversing horn a2tWork lamps, warning beacon, from Serial No. ... ‘f| (@] [@Key 2- 4- 5 27 - 34 - 61 - 62 - 63 - 78 - 80 - 81 - 82 - 83 - 87 - 217 - 218 - 219 - Light switch Ignition switch Vehicle information unit ‘Switch, warning beacon ‘Switch, work lamps. Relay, work lamps Relay, work lamps Relay, work lamps Work lamp, cab Work lamp, cab Work lamp, cab Warning beacon, right - left Work lamp, cab Work lamp, upper discharge chute Work lamp, additional variant to cab Work lamp, additional variant to cab Work lamp, additional variant (rear) 8.23Work lamps, warning beacon, up to Serial No. ... 8.24Key 27 34 61 2 78 80 at 82 83, 87 88 Light switch Ignition switch Vehicle information unit ‘Switch, warning beacon ‘Switch, work lamps. Relay, work lamps Relay, work lamps. Work lamp, cab Work lamp, cab Work lamp, cab Warning beacon, right - left Work lamp, cab Work lamp, upper discharge chute Marker lamp, upper discharge chute 8.25Compressor-type air conditioning system, radio and CB radio connection, cab interior light, beviae 3 = ° 8.26Key FUNCTION 6 — Switch, windscreen wiper/washer 7 ~ Wiper motor 8 — Operations display screen 59 - Relay 15 (20/30 A) 64 ~ Relay (20/30), compressor-type air conditioner 77 ~ Connector radio 79 ~ Cab interior ight 84 — Thermostat, compressor-type air conditioner 85 — Motor, cab blower 86 ~ Switch, cab blower speed 103 - Safety switch, compressor-type air conditioner 150 - Pump, windscreen wiper/washer 165 — Electro-magnetic clutch (3.4 W coil) ‘compressor-type air conditioner 194 ~ Diode plate 229 - Connector CB radio 230 ~ Digital clock Positive current is supplied from the battery to relay (64) terminal 87. Earth is supplied through the closed safety ‘switches (103) to relay (64) terminal 85. When the igrition is switched on, positive current is supplied via fuse b9 to fan switch (86). When the fan switch is switched on, positive current is supplied through the switched thermostat (84) to relay (64) terminal 86 and to the fault lamp in the operations aisplay screen (8). Relay (64) switches from 87 to 90. The electro-magnetic Clutch (165) of the compressor is energised. ‘As soon as the safety switch opens, relay (64) is doenorgized. Earth is switched through the coil of electro- magnetic clutch (165), via relay (64) (from 30 to 87a) to the fault lamp in the operations display screen, which then lights up and shows a fault (plus from thermostat switch 64), The diode on the diode plate functions as an interference suppressor (induction current of the electro-magnetic clutch). 8.27Functional diagram of compressor-type air conditioning system Key 1 Compressor 8 ~ Expansion valve 2 — Electro-magnetic clutch 9 — Temperature sensor 3 - Condenser 10 - Evaporator 4 — Filter receiver-drier A. ~ High pressure liquid 5 - Filter element B — High pressure gas 6 ~ Low pressure switch CC ~ Low pressure liquid (suction pressure) 7 — High pressure switch D — Low pressure gas (suction pressure) 14005 8.28Contents 1. Fundamentals of air conditioning 2. Refrigerant — Fundamentals of air conditioning = Refrigerant Function of the air conditioning system = Compressor Electro-magnetic clutch = Condenser ~ Expansion valve Evaporator ~ Filter receiver-drier ~~ Thermostat = Lines ~ Safety switch Preventive maintenance on the air conditioning system during prolonged shut-down ~ Evacuating and charging the system (abridged) — SCHRADER charging valve = Fluids absorb heat when changing from liquid to gas. = Fluids give off heat when changing from gas to liquid. = The temperature at which a liquid will turn to gas depends on the pressure to which the fluid is subjected. = Refrigerant fluids must have a low boiling point and absorb and give off heat rapidly for optimum heat exchange. = The basic refrigeration cycle is compression, condensation, expansion and evaporation. a) Compression heats up the refrigerant gas. b) Condensation changes the gas into a liquid, releasing heat. ©) Expansion reduces the pressure, 4) Evaporation changes the liquid into a gas, absorbing heat. R 134a (quantity required = 1.8 kg) ‘CAUTION: Always observe the safety precautions when working with refrigerant (refer to installation and operating manual) 8.293. How a compressor-type air conditioning system works 4, Compressor 8.30 ‘The closed circuit of an air conditioning system contains, the refrigerant (R 134a). Its circuited through the actual ‘components of the system: compressor, condenser (which ‘changes gas to liquid), fier receiver-drier (stores liquid refrigerant, removes moisture and foreign substances), ‘expansion valve, evaporator (converts liquid to gas). After leaving the evaporator the refrigerant is returned to the ‘compressor. ‘The compressor sends gaseous, high pressure refrigerant to the condenser, where heat is dissipated to the ambient air. The refrigerant is thereby changed from gas to liquid, ‘The filter receiver-drier removes moisture and foreign ‘substances (f present) from the refrigerant. The high- pressure refrigerant is passed through the expansion valve ‘which causes the pressure and temperature of the refrigerant to drop. In the evaporator the liquid vaporizes, thereby absorbing heat and moisture from the ambient air. The resulting ‘condensate runs into the drain pan and is discharged. The ‘coo! ambient air produced in this manner is blown into the cab to effect the desired cooling. ‘After leaving the evaporator, the refrigerant vapour is, ‘sucked in by the compressor and is once again ‘compressed to a high pressure. ‘The purpose of the compressor is to circulate the refrigerant under pressure through the system and thereby to transport the heat energy absorbed in the evaporator, to the condenser. Compressor type = YORK ER 210 Rated speed 2560 pm ‘The drive power for the compressor is taken from the diesel engine via an electromagnetic clutch. Max. capacity 3.7 KW (5 DIN HP)5. Electro-magnetic clutch 6. Condenser (liquefier) 7. Expansion valve 8. Evaporator ‘The electro-magnetic clutch transmits the engine drive Power to the compressor. The clutch consists of the field Coll and a pulley with bearing and armature plate. The magnetic clutch is mounted directly on the compressor. The armature plate is mounted on the compressor ‘crankshaft and the pulley with bearing is connected to the armature plate. The belt-driven pulley always rotates. When the field coil is energized, the armature piate is pulled against the pulley and the compressor operates. When the field coil is de-energized, the armature plate and pulley separate and compressor operation is stopped. ‘The condenser changes the high pressure gas coming from the compressor into a liquid. This is accomplished by heat ‘exchange (heat fiows from the warmer substance to the ‘cooler substance). The refrigerant is forced into the condenser with a temperature of more than 60° C (140° F) ‘Tubes and fins take up the heat. Ambient air is blown through the condenser, cooling the refrigerant gas which is liquefied. ‘The process of condensing is affected by: 2) the pressure acting on the refrigerant, b) the air flow through the condenser radiator. The condenser is cooled by the fan of the diesel engine, ‘The expansion valve lowers the pressure of the liquid refrigerant. The refrigerant vaporizes and becomes a gas, The expansion valve also controls the amount of refrigerant entering the evaporator. The amount of refrigerant passing through the valve is determined by the suction pressure in the suction line to the compressor and by the temperature (on the outlet side of the evaporator. The evaporator has the reverse function of the condenser. The liquid refrigerant is injected into the evaporator. The heat required to change the liquid refrigerant to gas is absorbed by the refrigerant from the air which is blown through the evaporator fins. The air is thus cooled. ast9. Filter receiver-drier 10. Thermostat 11. Lines (hoses) 12, Safety switch 18, Maintenance operations 3.32 ‘The filter receiver-drier acts as an expansion vessel and as a supply vessel for the refrigerant. In the receiver, the refrigerant flows through a solid-state ‘drier where dirtis filtered out and moisture absorbed (6-109 depending on the temperature). The quantity Circulating can be checked at the sight glass provided on the receiver. ‘The white ball must float at the top of the sight glass when the fluid level is correct. If the floating ball is at the bottom of the sight glass, top up with refrigerant or change the fier receiver-drier, if necessary. Important: The fiter receiver-drier must be changed when the indicator bead is pink. Opening and closing of the electrical contact in the thermostat is controlled by a temperature-sensitive diaphragm. As the evaporator heats up or cools down, @ ‘gas in a capiliary tube changes its volume. This causes the diaphragm or bellows to expand or contract which, in turn, controls a spring-loaded pivoting frame. The electrical contacts are connected to the pivoting frame and to the ‘thermostat switch housing. ‘The operator can set the desired level of cooling (thereby altering the spring tension and contact gap). ‘The recommanded hose qualities must be used, e.g. hoses from the company Aeroquip, Type GH 414, 2 charging and test valves are installed in the lines. KONVEKTA combined safety switch, Type 92-077. ‘The safety switch switches the electro-magnetic clutch at the following values: Low pressure OFF = 1.5:05 bar ON = 34 bar High pressure OFF = 25.0*5 bar ON = 1805 bar CAUTION: It is of utmost importance that the protective ‘caps on the charging and test valves are securely tightened, Replace the filter receiver-drier when the indicator bead has turned pink, ‘The gas must be drawn off and fresh gas charged. ‘At the same time, check the oil level in the compressor. Use only PAG oils (see “Oil grades"),14, Evacuating the air conditioning system. (with vacuum pump) Charging the evacuated system CAUTION: If there is still any refrigerant in the system, the refrigerant has to be discharged by use of the correct recovery equipment to prevent environmental pollution. — Fit manifold gauge set hoses to the compressor service valves. igh side, hose goes to the condenser low side, hose comes from the evaporator = Connect hose from centre connection (yellow) of manifold gauge set to inlet fitting of vacuum pump. (Open vacuum pump (see decal on the pump). = Fully open both manifold gauge hand valves. = Switch on the vacuum pump. The low side pressure gauge must show a vacuum reading of up to approx. =0.9 bar within 5 minutes. Ifnot, check the connections, for leaks. = After approx. 10 minutes, close both manifold gauge hand valves and turn off the vacuum pump. Check that the vacuum is holding. — If the vacuum reading remains constant for approx. 5 minutes, turn the vacuum pump on again and open both hand vaives of the manifold gauge set. Evacuate the system for about 45 to 60 minutes. NOTE: If the vacuum does not hold, again check connections. Possibly charge system with refrigerant and check system for leaks using leak detector. ~ Close both hand valves on the manifold gauge set, shut, off and disconnect the vacuum pump. NOTE: Before charging the system, cheok the oil level in the compressor, = The system should be charged as soon as possible after evacuating the compressor-type air conditioning system. = Connect the hose from the centre connection (yellow) of the manifold gauge set to the refrigerant bottle. Keep refrigerant bottle in an upright position with the valves at the top (charge with gaseous refrigerant). — Open the dispensing valve on the refrigerant bottle. Loosen the yellow centre service hose connection to the manifold centre port in order to purge the hose of air (a hiss is heard). — Open the low side hand valve on the manifold gauge set. Allow the gas to enter the system until a pressure of approx. 3.4 bar is obtained (low pressure switch closes), ‘With the ignition on, blower on and thermostat actuated, the electormagnetic clutch must now engage. If the pressure of 3.4 bar is not obtained due to cold weather, warm up the refrigerant bottle by placing it in a receptable containing warm water (max. 50° C), WARNING: Only gaseous refrigerant must be sucked in by the compressor. No liquid refrigerant must be allowed ‘to enter the suction side, as otherwise the compressor will be damaged. 8.3315, Charging valves TL pe airy 334 — Run the diesel engine at idling speed and charge the system until the white ball floats in the sight glass of the filter receiver-drier. = Required amount of refrigerant = 1.8 kg, = Close the low side hand valve of the manifold gauge set and the refrigerant bottle vaive. Unscrew the manifold gauge set connections at the ‘compressor. = Use a leak detector and again check the system for leaks. On the 3/3-way directional control valve, the necessary valve setting is adjusted by turning the spindle. | — Valve closed Il — Valve half open (testing and charging position) ll — Valve completely open (operating position) ‘A ~ Hose connection B - Compressor — Charging and test connection = Spindle‘Troubleshooting on the system ‘SCHRADER charging valves (On compressors with SCHRADER valve, the hose must have a valve core depressor. As the hose is screwed onto the valve, the valve core is depressed and the valve ‘opened. When the hose is removed the valve closes automatically. Screw on the protective caps again. = Check the V-belt tension of the compressor drive. = Check thatthe condenser is clean. ~ Cheek the retigerant level. With the Diesel engine running and the system switched on and operating for {Sminute, the white ball must float andthe refrigerant rust flow through the sight glass bubble-free. ~ Turn the fan contro to all speed settings and check that the fan operates correctly ifitdoes not operate correctly, check fuse (b8) ‘Check live wire and earth wire on connector (x) for continuity and check connectors in cab root = Check fan switch and fan motor. = Turn temperature switch to max, cooing, With the fan switched on, the electro-magnetic clutch switches with an audible click It not: check fuse (617), relay (64), thermostat switch, safety switch, connectors (eee wiring dlagram) and ejectro-magnete elute, = Connect the manifold gauge set to the compressor valves, check condensing and suction pressure. = Open the door and the windows. Run the diesel engine at maximum revs. = Turn the fan control to position 3 and turn the A/C thermostat switch to "max: = Hold a thermometer in front ofan air louvre inthe cab roof. The pressures shown by the low side and high side gauges of the manifold gauge set should more or less correspond to the pressires specified inthe chart. “The actual pressure reagings may lifer from those shown in the chart due to varying outside temperatures, humidity or atmospheric pressures. After operating the Unit for 15 minutes, the white ballin the sight glass must float. The high pressure side ofthe system must be warm and the low pressure side must be cool. ~ Check the pressure atthe inlet and outlet ofthe fier recelver-rer If the temperatures differ, the unit is notin working order. 8.35FAULT No cooling. Air from air louvres not cooled. ‘Compressor fails shortly after the system has been charged. Loss of refrigerant in system. Air conditioner provides cool air for a time and after a short while discharges warm air again. Air conditioner system automatically shuts down. Warning and indicator lights in the operations display screen on oo! air blown through air louvres into cab, but airflow is insufficient for cooling the cab. Fan not operating at full capacity. ‘Compressor too noisy. Moisture in cab. Water dripping from air louvres. 8.36 Check fuse (b9 and b17). Compressor not pumping refrigerant. Expansion valve frozen. Replace filter receiver-drier (discharge/evacuate the system and recharge). Cable connections loose. Tighten disconnected cables. ‘Magnetic clutch on compressor not engaging. Inspect clutch and replace if necessary. Incorrectly charged system. Check charge pressure. The white ball in the filter receiver-drier must float, Discharge any excess refrigerant (f present Condenser dirty. Refrigerant line or fitings leaking. Compressor oly. Fit new seals. Ice forming in the expansion valve. Filter receiver-drier saturated. The blue bead in the sight glass has turned. pink. Repiace the filter receiver-drier. Extremely high outside temperature. Allow the system to cool down, then turn on again. Close the door and windows. Evaporator blocked. Clean evaporator. Refrigerant level too low. Check for correct refrigerant level and recharge system if necessary. Outside air gets into the cab. Completely shut windows, and door. Check cable connections. Oil level in compressor too low (indicated by external leakage). Repair compressor. Water drain hoses blocked or not property routed. Ensure that drain water can pass freely through the hoses, blow through with compressed ai, if necessary.Inspection chart (reference values) Refrigerant R 134a Machine in shade Cab door and windows closed ‘Maximum compressor speed Fan at “high” = position 3 Do not switch off the refrigerant compressor at the control switch during the measurement Outside temperature | Low side pressure | High side pressure Air discharge Temperature (intake pressure at compressor temperature at ‘at compressor ‘at compressor) rearmost louvre suction valve “c bar bar c c 20 08 9.0 = = 25 085 11,0 2.0 30,0 30 09 13,0 30 34,0 35 095 15,0 40 38,0 40 1.0 17.0 55 43,0 45 15 19,0 7.0 49,0 Fault diagnosis for pressure variations (HP = High pressure, LP = Low pressure) Suction pressure (LP) Too high Too low ~ Compressor valve plate seal or valve ~ Moisture or foreign substances in plate defective, system, thus expansion valve blocked. 8 = = Excessive clearance or piston ring = Insufcient refrigerant in system. = defective A : ~ Expansion valve defective or = Evaporator iced up or ditty, £ incorrectly set. fiter plugged ze |e 2 |2 s — Expansion valve sensor loose or z poorly insulated, 6 8 ~ Excessive amount or efigerant ~ Compressor generates too much | insystem capacity, wrong electro-magnetic 2 clutch oF bett pulley fied e& = Condenser dity or fan defective. 837Note when carrying out repairs: Checking the compressor oil level Oil types (special refrigerant oil) 8.38 Excercise care and cleanliness when breaking into refrigerant circuit, immediately seal of all openings air tight. = Exchange the filter receiver-drier whenever the refrigerant circuit is opened, e.g. for changing a part — The refrigerant cannot be used again once it has been drained. Note: Replacement compressors are supplied from the factory ready filed with oil = The oil level in the compressor can only be checked when repairs are carried out or before charging the system initially. Check the oil level with the dipstick, made from a 4 mm copper, brass or bronze rod. Top up as required = Capacity: a = 475 mi initial fill of a new system b = 370 mi-oil level check mark ESTER/RETROFIX Il oil (CLAAS Serial No. 241 706.0 in 410 ml can) ‘This oil can be mixed with the PAG oil. Fit a new seal to the oll filler plug, ‘Torque specification = 15 Nm,9 ElectricsMain drive, feeder reversing, front attachment speed reduction, metal detector Eel (es) E 2560.0Key 17 - 18 - 30 37 39 52 53 54 89 95 96 98 132 133 134 135 138 162 191 194 Operations display screen Switch, reverse feed ‘Switch, feeder ON ‘Switch, front attachment high/low speed range ‘Switch, engine speed ‘Switch, main drive Relay, diesel engine slow idling speed Relay, main drive Relay, main drive Solenoid, front attachment speed reduction Solenoid, low-pressure hydraulics - feeder ON Solenoid, low-pressure hydraulics ~ reverse feed Solenoid, low-pressure hydraulics - main drive Connector, metal detector Solenoid, metal detector quick stop Magnetic box, metal detector Magnetic pick-up, feed roller housing gearbox Pressure switch (NO), jockey pulley arm External switch, reverse feed Module, feeder control, metal detection Diode plate FUNCTION Engaging the main drive Note: The main drive can only be engaged with the engine running at idle speed (switch 37 closed), Relay (62) is switched. Turn on switch (39). Stage 1 Stage 2 = Touch lightly, the switch remains in the 1st latching position, Relays (63 and 54) switch to latching. Plus (+) is switched from relay (54) via fuse (a1) to solenoid (98). ‘The main drive is engaged. Plus (+) is switched from relay (54) via fuse (a14) to the Control lamp in operations display screen (8), solenoids. (95, feed drive) and (96, reverse feed), lit solenoid (133) and module (191), terminal 1. From module (191), terminal 16, ground is switched to lift solenoid (133), which is switched for approx. 3 seconds. Ground is also switched from terminals 14 and 15 of module (191) to the green control lamp (metal detector ready) and the red control lamp (metal detected) in the operations display screen (8). The feed drive is stopped. It must first be reversed before the stop pulse from the module is cancelled. jelease, ground to relay 63, terminal 87. Reversing Operate switch (17) and keep pressed. Module (191) is earthed via terminal 11. From idler pulley arm pressure switch (138 closed), module (191) is earthed via terminal 12. ‘The module earths solenoid (86, reverse feed) via terminals 8-9 and the control lamp in the operations display screen (8). The feed drive runs in reverse and the control lamp (reverse feed) lights up. During reversing of the feed drive, reset switch (138) ‘transmits pulses to module (191). The stop pulse is cancelled and the control lamp “metal detected" goes out. Feed drive Operate switch (18). Module (191) is earthed via terminal 4, From idler pulley arm pressure switch (138 closed = drive belt disengaged), module (181) is earthed via terminal 12. Arelay in the module is operated to latching mode, whereby solenoid (95, feed dive) and the control lamp in operations display screen (8) are permanently earthed via terminal 23. The feed drive is engaged. ‘The metal detector is now ready for operation. Note: Ifthe clutch slips due to a machine overload, solenoid (95, feed drive) is de-energised by generator (135) via module (191), 93Metal detector ‘The metal detector consists of the following ‘components. 1— Construction and function of magnetic box O48 The front feed roller incorporates a magnetic box (134) which develops a permanent (vertical) magnetic field. The front feed roller and upper compressing rollers, including shatts, are made of non-magnetisable steel. If piece of iron passes through the magnetic field, a stop signal is transmitted to module (191) via terminal 26, Module (181), terminal 16, completes the earth circuit to solenoid (193) and the contro! lamp “metal detected” in ‘operations aisplay screen (8). The control lamp lights up. ‘Solenoid (183) actuates a pawl for approx. 3 seconds which stops the drive. The cut-out clutch is disengaged. ‘At the same time, solenoid (95, feed drive) and the control lamp in operations display screen (8) are de-energised by ‘generator (196) via module (191), terminal 2~3, ‘The feed drives must then be reversed as described above. Note: If the cut-out does not engage, the reversing procedure must be repeated. Magnetic box Plug-in module Solenoid Reset switch Cut-out clutch ‘The magnetic box incorporates 8 permanent magnets. Coils are installed above the magnets. The box also includes an impulse amplifier. The box is filed with clear Araldite. A current-carrying wire runs from the module to the box and an earth wire runs from the chassis to the box. ‘The magnets create a magnetic field. The magnets are all buried in the box with the N pole upwards and due to the thick walls of the box, the lines of force are directed upwards. The magnetic force decreases with the square of the distance from the magnet. ‘The coils are situated above the magnets. The lines of the ‘magnetic field move through the coils. When ferrous material is picked up, the lines of the magnetic field are. ‘changed and a voltage is induced. The voltage is amplified in the box and directed to the module, acting as a stop impulse. ‘The sensitivity of the box is set at the factory.Formation of the magnetic field 2e ° $ 9643 2- Plug-in module CLAAS Service part O2000 H1234 3-Solenoid 4~ Reset switch 5~Cut-out clutch ‘The magnetic field is directed upwards. The magnetic force decreases with the square of the distance from the magnet, e.g. at a distance of 3 cm, the field strength will be reduced to 1/9 of its original strength. Field lines flow through the coil. As ferrous material passes through the magnetic field, its lines of force are changed and a voltage is induced. The LEDs light up: 1 - red Solenoid (133) energised 2 = yellow = No signal trom generator (135) of feed roller housing gearbox 3 — yellow = Pressure switch (138) closed = drive belt disengaged 4 — green = Operating voltage - main drive engaged Thoma solenoids, Type GBHX 6082, 11. A 1103 - 34 12V, 11 A, CDF = 16%, F = 180 N, stroke 6 mm. Consists of a generator (inductive senso. During reversing, the feed drive runs in reverse. The inductive sensor transmits pulses to the module. Walterscheid cut-out clutch type 95TROUBLESHOOTING ‘The feed drives cannot be switched to reverse 96 Caution! The main drive must be engaged. Press switch (17, reverse feed) and hold depressed. Ifthe {feed drive belt is tensioned, the electric and hydraulic, circuits are functioning correctly. Now check whether a ‘gear has been engaged and the reversing cylinder is correctiy attached, = Check fuse (a1). = Operate solenoid (reverse) by hand and check whether the drive beitis tensioned and the feed rollers rotate in reverse. If not, see “Troubleshooting, low-pressure hydraulics”. — Check switch (17, reverse feed) for continuity. For thi remove plug-in module (191). When the switch is pressed, terminal 11 of the terminal strip must be earthed, (External switch 162, reverse feed, has the same function as switch 17). If not, check the cable of terminal strip P-br (brown) according to the wiring diagram. Check switch (17) = Check pressure switch (138, idler pulley) for continuity. For this, remove plug-in module (191). Pull both cables from switch (138) and short-circuit the tends. Terminal 12 of the terminal strip must be earthed. If not, check the cable of terminal strip Q- (ed) according to the wiring diagram, Check pressure switch (138). ~ Remove plug-in module (191). Positive current must be received at the terminals 1, 2-3, 8-9, 14, 15 and 16 of the terminal strip (terminal numbers visible in the module housing) If not, check the cables of the corresponding terminal strips according to the wiring diagram. Check the 7-pin plug connector on the operator's platform. Check the cables in the plug of the solenoid. Check the iron core in the solenoid. = Remove plug-in module (191). Positive current must be received at the terminal 5~6 of the terminal strip (terminal numbers visible in the module housing). = Replace plug-in module (191).‘The feed drives cannot be engaged Caution! The main drive must be engaged. The feed drives can only be engaged when the red control lamp ~ metal detector actuated ~ has gone out, The stop pulse is then also cancelled. ~ Pross switch (18, feeder ON). The green control lamp in the operations display screen must come on. If the feed drive belt is tensioned, the electric and hydraulic circuits are functioning correctly. Now check whether a gear has bbeen engaged and the reversing cylinder is correctly attached = Check fuse (at4). ~ Operate solenoid (feed) by hand and check whether the drive bet is tensioned and the feed rollers rotate. If not, see “Troubleshooting, low-pressure hydraulics”. = Check switch (18, feed) for continuity. For this, remove plug-in module (181). When the switch is pressed, terminal 4 ofthe terminal strip must be earthed (terminal ‘numbers visible in the module housing). If not, check the cable of terminal strip P-br (brown) according to the wiring diagram. Check switch (18). ~ Check pressure switch (138, idler pulley) for continuity For this, remiove plug-in module (191) Pull both cables from switch (188) and short-circuit the ends. Terminal 12 of the terminal strip must be earthed. not, check the cable of terminal strip Q-rt (red) according to the wiring diagram. Check pressure switch (138) = Remove plug-in module (191), Positive current must be received at terminals 1, 2-3, 8-9, 14, 15 and 16 of the terminal strip (terminal numbers visible in the module housing). I not, check the cables of the corresponding terminal strips according to the wiring diagram, Check the 7-pin plug connector in the operator's platform. Check the cables in the solenoid. Check the iron core in the solenoid. = Remove plug-in module (191). Positive current must be received at terminal 5~6 of the terminal strip (terminal ‘numbers visible in the module housing). = Replace plug-in module (191). a7Solenoid is not activated when the main drive is switched on. ‘Stop pulse is not cancelled when feed drives. are reversed. Feed cannot be switched on. 98 ~ Check fuse (a14). — Check terminals 54 and L in the 7-pin plug connector for continuity. = Check the solenoid and the paw! for smooth operation, the solenoid for continuity Remove plug-in module (191). Positive current must be received at terminals 1 and 16 of the terminal strip (terminal numbers visibie in the module housing). If not, check the cable of terminal strip ZZ-ws (white) according to the wiring diagram. = Replace plug-in module (191). Caution: The stop pulse can only be cancelled when ‘a gear is engaged and the reversing cylinder is correctly attached. The feed drive can only operate in reverse when the cut-out clutch is engaged. = Check: Pull both cables from generator (135) and rub the tends together. If the stop pulse can now be cancelled, the generator (136) is defective or not correctly adjusted (observe 2 mm clearance), = Remove plug-in module (191). Terminal 12 of the terminal strip must now be grounded when pressure switch (138) is short-circuited (terminal numbers visible in the module housing). If not, check the cable of terminal strip Q-rt (red) according to the wiring diagram. Check the cable in the 7-pin connector according to the wiring diagram. = Check the diodes in the power supply plugs for solenoid (189) and solenoid valve (36) = Check the screw connections to and on the magnetic box. ~ Replace plug: module (191).Metal detector trips and stops the mechanism without ferrous material. — Check whether pre-compressing roller was welded with a normal welding rod or whether a magnetic foreign body is jammed in (check with magnet). = Check contacts in 7-pin connector; they should not be loose. — Carry out test by using a resistor (see drawing 11357). I metal detector no longer trips the stop mechanism, then check the magnetic box, its mountings (metal chips) and the cable to the box. Have CB radio checked (aerial). ~ Fit the radio with an interference suppressor. Caution: If the stop mechanism is tripped when the deflector or the front attachment is actuated, check the appropriate diode in the plug. 11357 100-120 Q} 99Operator's seat switch (feeder sT0F, USA only, see also circuit diagram page E— 2551.0Key FUNCTION ‘Switch on feed drives Feed drives stop 8 — Operations display screen 17 — Switch, reverse feed 18 ~ Switch, feeder ON 29 — Autopilot ON/OFF indicator light 54 — Relay, main drive 95 — Solenoid, low-pressure hydraulics - feeder ON 96 - Solenoid, low-pressure hydraulics - reverse feed 98 — Solenoid, low-pressure hydraulics - main drive 131 — Autopilot seat switch 182 — Connector, metal detector 185 — Magnetic pick-up, feed roller housing gearbox 138 - Pressure switch (NC), jockey pulley arm 462 — External switch, reverse feed 191 — Module, feeder control, metal detection 232 — Relay, feeder stop 233 — Timer relay, 7 seconds, feeder stop Note: If the main drive is switched on, the drives must first be switched to reverse so that the stop pulse of the metal detector is cancelled. ‘The operator is sitting on the operator's seat. Seat switch (181) is therefore closed. ‘Switch (131) is earthed via relay (282), terminal TK and indicator light (29). When the main drive is switched on, plus is switched from relay (54) via fuse (a14) to relay (232), terminal 30 and to relay (231), terminal 86. Both relays switch over and indicator light (29) comes on, Operate switch (18). Module (191) is earthed via terminal 4, From idler pulley arm pressure switch (138 closed = drive belt disengaged), module (191) is earthed via terminal 12, A relay in the module is operated to latching mode. Module (191) terminals 2-3 earths relay (231) terminals 8730 to solenoid (95, feed drive) and to the control lamp in operations display screen (8). The feed drive is engaged. ‘The metal detector is now ready for operation. If seat switch (131) is opened, relay (232) is de-energised after 7 seconds and the earth connection to terminal 85 of relay (231) is also interrupted. Relay (231) switches to rest position and de-energises solenoid valve (85). Generator (135) releases the relay latching in module (191). After briefly actuating switch (18), the feed drives can be ‘switched on again. Note: I the clutch slips due to a machine overload, the feed drives wil also be disengaged by generator (135) via module (191). ottMain drive, 4-Trac system, diesel engine speed adjustment, deflector flap position, road gear 53 6 (o> [os] | 32 a>Key 19- 20 - 85 - 37 - 39 - 40 48 52 53 54 59 - 7 - 99 - 100 101 - 102 - 194 - Switch, deflector flap narrow ‘Switch, deflector flap wide Switch, 4-Trac System ‘Switch, diesel engine speed Switch, main drive ‘Switch, road gear Relay, safety start, 20/90 A Relay, Diesel engine slow idling speed, 20/30 A Relay, main drive, 20/30 A Relay, main drive, 20/30 A Relay 15, 20/30 A Solenoid, low pressure hydraulics, min. engine speed, 12 V, 2.A, 100% CDF Solenoid, main drive low pressure hydraulics, 12 V, 2A, 100% CDF Solenoid, 4-Trac low pressure hydraulics, 12 V, 2A, 100% CDF Solenoid, low pressure hydraulics, max. engine speed, 12 V, 2.A, 100% CDF Solenoid, low pressure hydraulics, deflector flap narrow, 12 V, 2A, 100% CDF Solenoid, low pressure hydraulics, deflector flap wide, 12'V, 24, 100% CDF Diode plate 9.13Raise/lower front attachment, Contour system and cutting height preselection € 2562.0Key at 22 24 - 26 - 31- 36 - 39 - 43- 44— 45 - 46 - 47 - 53 — 110 - 11 114- 115 - 140 - 145 - 195 - 196 - 197 - 198 - ‘Switch, front attachment lower ‘Switch, front attachment raise ‘Switch, Contour ON ‘Switch, cutting height preselection ON Indicator, cutting height and Corn Cracker clearance Connector link when Corn Cracker adjustment is not installed ‘Switch, Corn Cracker clearance indicator Plug, Contour ‘Switch, main drive Master switch, front attachment enable Switch, Contour Potentiometer, Contour 22 kW Potentiometer, cutting height preselection (22 kW) ‘Switch, manual lateral levelling Relay, main drive, 20/30 A. Relay 15, 20/30 A Solenoid, front attachment raise (12, 3.5 A, 60% CDF) Solenoid, front attachment lower (12, 3.5 A, 60% CDF) ‘Switch, front attachment raise, externally Switch, front attachment raise, externally Pressure sensor, Contour Sender, cutting height Module, Contour control system LED, ground pressure LED, cutting height Plug, lateral levelling solenoid FUNCTION Cutting height preselection ~ Start Diese! engine, switch on main switch (89), Contour switch (44) and front attachment enable switch (43). ~ Plus is supplied via fuse (b16) and (a17) to module (1985) terminals 18 and 14. Earth is switched through relay (59), terminal 87 and switch (44) to module (195), terminal 13 and to switch (24) = Switched power is supplied from relay (59) via fuse (02) and switch (43) to pressure sensor (140), to solenoids (110, 111) via the colls of the solenoids to ‘module (195), terminals 14 and 12. ~ Earth is switched to module (195), terminals 8 and 17. ~ Push switch (24) once. Power is switched by switch (24) to module (195) terminal 2. This closes the Circuit to earth from module terminal 11 or 12 to solenoids (111 or 110). LED (197) lights up. The front attachment lowers or raises. ~ Select cutting height at potentiometer (46). = When the front attachment reaches the pre-set cutting height, lowering or raising is stopped (signal from sender 145). LED (197) lights up. = Repeated power pulses ensure accurate positioning Of the front attachment to the pre-set height, selected with potentiometer (46). The micro electro- nics programme activates the fine positioning controls as the front attachment approaches the pre-set cutting height. = Cutting height indicator (26) shows the current ccutting height (earth switch from sender 145 to the indicator), Contour system (automatic ground pressure contro!) = The Contour System automatically controls the {ground pressure of the front attachment on uneven, ground. If switch (23) is touched briefly, the front attachment is automatically adjusted vertically until the ground pressure preset on the Contour potentiometer (45) is reached. Fully automatic adaptation of the front attachment to the ground contours exists inthis switch position. ~ Pressure pick-up (140) is connected to the hydraulic cylinders for front attachment raise/lower. In the event of a change in pressure in the hydraulic system, pressure pick-up (140) is activated and the Contour System adjusts the front attachment vertically. ‘The ground pressure can be read off at the pressure gauge. — The ground pressure is varied at potentiometer (45) See also chapter “Programming Potentiometer position 0 = high ground pressure Potentiometer position 10 = low or no ground Pressure 9.15Programming the CONTOUR system ‘Adjustment of sensor 145 M 2500.0 Note before commissioning Programming the Contour System Learning the end stops of the sensors. 9.16 Hook in the spring as shown in the drawing. P ~ Pickup position M-~ Maize header position S - Grub screw Raise the front attachment to its highest position. Loosen the grub screw and turn the lever until the potentiometer has reached its end position. Turn the lever slightly back and tighten the grub screw. Important! The spring of the potentiometer must not be tensioned. Be sure to carry out the following adjustment and checks: = Set the rate-of-drop of the front attachment at the drop rate restrictor of the 3/3-way directional control solenoid with the hydraulic oil at operating temperature (5-6 seconds). = Check the proper function of the cutting height indicator, = Check the proper function of the ground pressure control system. = Ensure that the tyres of the diving wheels have the correct inflation pressure, Caution! Precondition forall the following programmings: ~ Switch (43) "Front attachment function enable” ON = Switch (89) "Main drive” ON = Switch (44) “Contour” ON = Switch (82) “Cracker gap” OFF ~ Pros switch (21) “Lower” and switch (22) “Raise” simultaneously until LEDs (197 and 196) flash, — Press switch (22) "Raise" until LEDs (196 and 197) come on, = Press switch (21) "Lower" until LEDs (197 and 198) come on, = The position of potentiometers (45 and 46) is of no significance for this adjustment. Caution! After replacement or repair of the microelectro- nics, of pressure pick-up (140) or sensor (145), the programming described above must be carried out again.Activating the cutting height preselection Storing a cutting height Storing a pressure for ground pressure control Pickup: 20020 197 £ g 196 OF Oo \8/ \8/ 3 7 3 7 1 ? a 941 y A 9 20021 — Press switch (24) “Cutting height preselection’, LED (197) lights up. = Set the front attachment height with setpoint potentiometer (46) "Cutting height preselection”. ~ Activate cutting height preselection with switch (24), LED (197) comes on, = Set the desired front attachment height with setpoint potentiometer (46). = Pros switch (24) "Cutting height preselection’ until LED (197) flashes. ~ This value is now stored, Example: = Tum setpoint potentiometer (46) to position "9" and activate cutting height preselection with switch (24). Store the cutting height as described above. = Now turn setpoint potentiometer (46) to position "4" and ‘wait until the front attachment reaches this position, = Pross switch (24) “Cutting height preselection” => the front attachment moves to position “9”, ~ Press switch (24) “Cutting height preselection" again => the front attachment moves to position “4” again, etc, Lower the pickup until the land wheels are just clear of the ground. ~ Hold switch (23) "Contour" depressed until LED (196) flashes. The pressure displayed on the pressure gauge is. now stored ize header: = Lower the maize header until the header tips are just clear of the ground. ~ Hold switch (23) "Contour" depressed until LED (196) flashes. The pressure displayed on the pressure gauge is, now stored Example: The land wheels of the pickup are just touching the ground. (Pressure gauge reading = 40 bar) ‘To store this pressure, hold switch (23) “Contour” depressed until LED (196) flashes. ‘The 40 bar pressure is now stored and corresponds to potentiometer position “5” on setpoint potentiometer (45). This setpoint can be freely varied by up to -15 bar downwards and by up to + 10% of the stored pressure upwards via setpoint potentiometer (45) “Ground pressure”. 9.17Programming the CONTOUR-PLUS system (maize header with sensing bands) Adjustment of sensor 145 M_2500.0 Note before commissioning Programming the Contour-Plus System Learning the end stops of the sensors. 9.18 Hook in the spring as shown in the drawing. P. = Pickup position M — Maize header position S - Grub screw Raise the front attachment to its highest position Loosen the grub screw and turn the lever until the potentiometer has reached its end position. Turn the lever slightly back and tighten the grub screw. Important! The spring of the potentiometer must not be tensioned, Be sure to carry out the following adjustment and checks: ~ Sot the rate-of-drop of the front attachment atthe drop rate restrictor of the 3/3-way directional control solenoid with the hydraulic oil at operating temperature (6-6 seconds). — Check the proper function of the cutting height indicator, = Check the proper function of the ground pressure control system. — Ensure that the tyres of the diving wheels have the correct inflation pressure. Caution! Precondition forall the following programmings: = Switch (43) “Front attachment function enable” ON — Switch (89) “Main drive” ON — Switch (44) “Contour” ON ~ Switch (82) “Cracker gap” OFF — Press switch (21) “Lower” and switch (22) “Raise simultaneously until LEDs (197 and 196) flash. = Press switch (22) “Raise” until LEDs (196 and 197) ~ Pross switch (21) "Lower" until LEDs (197 and 198) come on. — The position of potentiometers (45 and 46) is of no significance for this adjustment. Caution! After replacement or repair of the microelectro- nies, of pressure pick-up (140) or sensor (145), the programming described above must be carried out again.Activating the Contour system 20020 Storing a second cutting height 197 £ g 196 OF O \S8/ Neo (A). 1 , 8 1 >} <8 20021 — Press switch (23) “Contour”. LED (196) lights up. ~ Set the cutting height with setpoint potentiometer (48) “Contour”, = Activate Contour with switch (23). LED (196) comes on. ~ Set the desired cutting height with setpoint potentiometer (45) = Then hold switch (28) “Contour" depressed until the LED. flashes. The value is now stored. Example: ‘Tun setpoint potentiometer (4) to position “9” and activate Contour with switch (23). Store the cutting height {as described above. Now turn the setpoint potentiometer to position “3" and wait unti the cutting height is reached. Then: Press switch (28) “Contour” => The front attachment moves to cutting height Press switch (23)'Contour” again => The front attachment moves to position “ 9.19Meaning of the displays with the LEDs, Contour and Contour-Plus LED (197) “Cutting height preselection” flashes slowly: 1. Function stil possible: Upper and lower end stops of channel potentio- meter differ only slightly probably oscillation occurs 2. No function: No signal received from channel potentiometer 145 LED (197) “Cutting height preselection” flashes. slowly whilst learning the end stops: No signal received from channel potentiometer (145), the end stops cannot be learned in this case LED (196) “Contour flashes slowly: 1. Function stil possible, but strong tendency to oscillation 2. No function: = Front attachment with sensing bands — Front attachment without sensing bands LED (196) “Contour” flashes slowly whilst learning the end stops: No signal received from pressure sensor (140), he end stops cannot be learned in this case LED 196 or 197 flashes rapidly 9.20 Remedy: Check setting of channel potentiometer (145) and learn again. Remedy: - Switch 26 in panel in position “Cracker gé = Signal line to channel potentiometer (145) or the potentiometer is defective. (Display also shows an incorrect value) Remedy: ~ Switch 26 in panel in position "Cracker gap” ~ Signal line to channel potentiometer (145) or the potentiometer is defective. (Display also shows an incorrect value) = On front attachment with sensing bands, the end ‘stops are too close together. Remedy: Check sensing bands for free movement, repair any mechanical damage, learn end stops again. = One sensor supplying no signal Remedy: Check plug contacts on potentiometer, check plugs on the machine (right-hand side pale grey), check cables for damage. = No signal from pressure sensor (140) Remedy: Check plug contacts on pressure sensor (140) or pressure ‘sensor defective. Remedy: ‘Check plug contacts on pressure sensor (140) or pressure ‘sensor defective. = This occurs only when learning the end stops or ground pressure,9.21Folding 8-row maize headerKey 43 — Master switch, front attachment 59 — Relay No. 15 (20/30 A) 148 — Connection, fold-in maize header 194 ~ Diode plate 222 ~ Switch, fold-in maize header 223 — Function selector switch 224 ~ 7-pin plug connector 225 ~ Solenoid, gathering units folding 226 - Solenoid, gathering units forward / backward 227 ~ Solenoid, crop guard folding 9.23‘Sharpening (without automatic sharpening) «| fol fal sss a] [2] [=Key 8 ~ Harvest display screen 37 ~ Switch, Diesel engine speed 39 ~ Switch, main drive 52 - Relay - Diesel engine slow idling speed,20/30 A 53 - Relay ~ main drive, 20/30 A 54 — Relay - main drive, 20/30 A. 59 - Relay 15, 20/30 A 70 ~ Sharpening relay, 20/30 A 71 = Sharpening relay, 20/30. A 90 ~ Solenoid ~ sharpening forward (12V, 4.5 A, 60% CDF) 91 ~ Solenoid ~ sharpening back (12, 4.5 A, 60% CDF) 92 ~ Switch - sharpening forward (NO contact) 93 ~ Switch ~ sharpening back (NC contact) 98 - Solenoid ~ main drive low pressure hydraulics (12,2, 100% CDF) 161 ~ Sharpening switch 182 - Connection - automatic shearbar adjust men 194 ~ Diode plate ‘Operation (without auto sharpening) ~ Diesel engine at slow idle speed. = Turn on main drive switch (39). = Open sharpening cover. = Turn on switch (161), ~ If switch (161) is turned off, the grindstone wil travel to the right to its park position = Close sharpening cover. Important! Note the following when adjusting the shearbar: The clearance between the shearbar and cutting cylinder changes when lowering the front attachment to rest on the ground (bearing play of cutting cylinder) FUNCTION ‘Sharpening the knives (without auto sharpening) — Diesel engine at slow idle speed. Relay (52) is ‘energised. Touch main drive switch (39) just once. Relays (53 and 54) switch to latching. Power is supplied from relay (54) via fuse (a5) to main drive solenoid (98). — Turn on sharpening switch (161). Power is supplied via the closed pressure switch (93) to relay (70) terminal 86. Relay (70) operates, connection is made from 30 to 87 and power flows to indicator light (8) and, via relay (71), terminals 30 ~ 87a, to the solenoid (@0); Relay (70) is retained in the latching mode through diode plate (194), from terminal 6 to 7. The grindstone moves to the left. At end of travel pressure switch (92) closes at approx. 90 bar. This connects plus from fuse (a15) via closed switch (62) to relay (71), terminal 86. Relay (71) operates, terminals 30 and 87 connect and plus is supplied to solenoid (91). Through diode plate (194) from terminal numbers 7 08, relay (70) kept in latching and through the diode plate from terminals 8 to 5, relay (71) is kept in latching. The grindstone travels to the right. At the end of its travel, pressure switch (93) ‘momentarily opens at approx. 90 bar. Relay (70) is thereby de-energised for a short period of time. ‘Once the hydraulic pressure has dropped, prossure ‘switch (93) closes again and solenoid (90) is reactivated as described above. if switch (161) is turned off, the grindstone moves to the right to its park position. Momentatily opening pressure switch (83) cancels latching of relays (70 and 71). This switches off grindstone movement. 9.25‘Automatic sharpening, automatic shearbar adjustment € 2565.0161 - 200 - 201 ~ 202 - 203 - 204 - 205 - 206 ~ 207 - 208 209 - 210 - an - Harvest display screen Sharpening relay, 20/30 A ‘Sharpening relay, 20/30 A Solenoid ~ sharpening forward (12, 4.5, 60% CDF) Solenoid ~ sharpening back (12, 4.5 A, 60% CDF) ‘Switch - sharpening forward (NO contact) ‘Switch - sharpening back (NC contact) ‘Sharpening switch Diode plate ‘Sharpening master switch Potentiometer (1 kW), number of grinding cycles Solenoid - low pressure hydraulics ~ sharpening cover 12 V, 2 A, 100% CDF Socket, front attachment ‘Module - remote sharpening control / electric shearbar adjustment ‘Shearbar clearance potentiometer (1 kW) Reed switch - grindstone Knock sensor, L/H ~ shearbar Electric motor, L/H ~ shearbar Electric motor, R/H - shearbar Knock sensor, F/H - shearbar Relay ~ sharpening cover, 20/30 A FUNCTION Automatic sharpening: Operation ~ Diesel engine at slow idling speed, Relay (52) is energised. Briefly touch main drive switch (3), Relays (53 and 54) switch to latching mode. Plus flows from relay (54) va fuse (at) to main drive solenoid (98) (see wiring diagram "Main drive engaged” = Push switch (200) to the 1st step. Plus flows to potentiometer (201) and module (204), terminal 4 Select number of grinding cycles. ~ Unlock switch (200) and set tothe 2nd step. The earth cireuit to module (204), terminal 21 is completed which activates the electronics. Module (204) switches plus from its terminal 2 to relay (211), terminal 86. Relay (211) switches from 30 0 87. Solenoid (202) is de-energised and the sharpening cover opens. After approx. 8 seconds module (204) will supply plus from its terminal 1 via the closed pressure ‘switch (83) to the terminal 86 of relay (70). The relay (70) supplies plus through terminals 30 and 87 to indicator light (G), via the relay (71), terminals 30 ~ 87a, and to solenoid (90). Through diode plate (194), terminals 6 to 7, relay (70) is retained in the sel-holding mode. The giindsione ‘moves to the left. When in end position, pressure switch (92) closes at approx. 90 bar. This allows plus from fuse (15a) via the closed pressure switch (82) to relay (71), terminal 86. Relay (71) switches plus through terminals 30-87 to solenoid (91). Through diode plate (194), from 8 to 7, relay (70) is retained in latching and through the diode from 8 to 5 relay (71) is retained in latching The grindstone moves tothe right. When the grindstone isin end position, pressure switch (83) ‘momentarily opens at approx. 90 bar Relay (70) is thereby de-energised for a short period of ime. Once the hydraulic pressure has dropped, pressure switch (83) closes again and solenoid (80) is reactivated as described above. Reed switch (206) counts the grinding cycles and earth pulses are transmitted through terminal 8 into the module (204). When the predetermined number of grinding cycles, set at potentiometer (201), has been reached, ‘module (204) interrupts the circuit to earth at terminal +. The grindstone travels tothe right to its park position Briefly opening pressure switch (83) cancels the self- holding mode of relays (70 and 71). This stops grindstone movement. Module (204) interrupts in proper delayed sequence the plus supply to relay (211), terminal 86. The relay switches from 30 to 87a. The solenoid (202) is ener- gised and the sharpening cover hydraulically closes. 9.27Indicator lights in harvest display screen c 2502.0 Grinding cycles and shearbar clearance potentiometer 201 205 % Ae 0 og = “U=(@) 1 "80 MIN MAX 2501.0, Key to terminal designation of module (204) 9.28 Harvest display screen Indicator light (green) Indicator light (red) Indicator light (orange) 9000 201 ~ Potentiometer, number of grinding cycles 205 - Shearbar clearance potentiometer Set grinding cycles G — Set shearbar clearance ° 1 ~ Solenoid ~ sharpening (°) 2 ~ Solenoid - sharpening cover (P) 3~ Greenlight 4~Master switch, 12V 5-CAN-H 6 ~ Signals from R/H knock sensor 7 = Pulses to PVH shearbar motor 8 ~ Reed switch - grindstone 9 ~ Set valve ~ shearbar clearance 10 Sensor, /H 41 — Electric motor, R/H 42 Electric motor, UH 13 Electric motors (bridge) 14 Continuous power supply 15 - Continuous power supply 16 Red indicator ight 17~ Analog ground/earth 18-CAN-L 419. Signals from R/H knock sensor 20 Pulses to LH shearbar motor 21 ~ Switch ~ shearbar adjustment ON 22 Set value - number of grinding cycles 23 - Sensor, L/H 23 Ground/earth 25 - Ground/earth‘A) Sharpening knives: B) Adjusting the shearbar: {after sharpening the knives at least once) Important: Electronic module (204) has another part number ifthe machine comes without automatic shear bar adjustment. When the cutterbar is lowered to rest on the ground, the clearance between the cutting cylinder and shearbar changes (bearing play of cutting cylinder ~ Engine at stow idling speed, = Switch on main switch. = Select number of grinding cycles on potentiometer (201), eg. 10 cycles. = Push main switch (200) to the 1st step. Wait until only ‘the green indicator light B is lit or, if the previous pro- gram was interrupted, until only red indicator light C is it ~ Unlock main switch (200) and push into the 2nd step. The sharpening cover is now opened hydraulically and the grinding process is performed for the preset number of cycles. The orange indicator ight (G) is lit and green indicator light (B) flashes during the grinding process. When grinding is finished, the orange indicator light (G) goes out. The sharpening cover closes automatically and green indicator light (B) comes on continuously. The number of grinding cycies can also be altered at the potentiometer during grinding, = Continue with the shearbar adjustment or turn off main switch (200). = Lower the front attachment to the ground, ~ Preselect the distance between shearbar and cutting cylinder at potentiometer (205). = Tur switch (200) to the 2nd step again. The green indicator light (B) flashes and the shearbar is moved forward parallel to the cutting cylinder by the amount previously ground off the knives until it contacts the Cutting cylinder and then backed off again by the amount set on potentiometer (205). ‘When the adjustment has been completed, the green indicator light (B) comes on continuously. If the cutting cylinder strikes too hard against the shearbar, the shearbar can be moved back to the 2! step by pressing and holding switch (200) again. = Tum off switch (200), 9.29©) Resetting the grinding cycle counter: D) Moving back the shearbar: 9.30 Red indicator light (C) flashes briefly several times after ‘approx. 450 grinding cycles to indicate the grindstone ‘wear. If the grindstone is adjusted or replaced, the grinding ‘cycle counter must be reset. Run the engine at slow idling speed, ~ Engage main drive. Turn potentiometer (201) to position “1”, ~ Push sharpening switch (200) to the 1st step and wait, Until only red indicator light C (f the program was previously interrupted) or until only the green indicator light Bis i ~ Unlock switch (200) and hold in the 2nd step until indicator lights B and C come on. The grinding process now runs as described under A) with the reset grinding cycle counter until the green indicator light B comes on again. = Turn off switch (200) ~ Diesel engine switched off = Turn on ignition and main drive. = Tum potentiometers (201) and (208) to the middle position = Tum switch (200) to the 1 step and wait until only red indicator light C is it — Unlock the switch and hold in the 2nd step until indicator lights B and C come on. = Tap against the shearbar several times to extend it gradually to a distance of 275 mm from the cylinder shaft. = Tum off switch (200). Ifthe cutting cylinder has colided with the shearbar at least 6 times during adjustment, the electronics goes into its basic position so that after a further adjustment (after atleast two sharpening cycles) the cutterbar is moved gradually up to the cutting cylinder and positioned under control of the knock sensors (adjustment step).Error code and system test Error code signalled by red indicator light C lit ‘When the red indicator light C is lit, this indicates an interruption of the grinding process or of the shearbar adjustment or between the two processes. After at least one grinding cycle, the shearbar adjustment process can be started again and the error message is cancelled. ‘System errors are indicated by a flash code of red indicator light C: 1 flash | Number of grinding cycles set on grinding cycle counter has expired. The grindstone must be adjusted. 2 flashes *| The shearbar is up against the front stop. (Adjust knifes) S flashes | Grindstone limit switch is not tripped. (Grinding cover closed?) 4 flashes" | During forward positioning, the shearbar has not travelled the calculated distance to the cutting cylinder. 5 flashes * | Earthing cable of the knock sensors defective. Knock sensor defective. 6 flashes * | Interference signals, too many knock signals received. 7 flashes * | No frictional resistance (levers, spindles or gearbox defective). 8 flashes * | No motor impulses received. 9 flashes‘ | Supply voltage too small. Nominal value > 11 Volt 10 flashes | Controller defective. “with electrical adjustment of the shearbar gap only System test: a) Potentiometer test: b) Switch test: ~ Diesel engine switched off. = Turn on ignition and main drive. = Turn potentiometers (201) and (205) towards one another to their end positions (potentiometer (201) to position "30" and potentiometer (205) to position “MIN"). = Turn switch (200) to the tst step and wait until only the green indicator light B is lt or, ifthe previous program Was interrupted, until only red indicator light C is lt. = Unlock switch (200) and hold in the 2nd step until indicator lights B and C come on. Release switch (200) Only the green indicator light (B) should now be it. If the red indicator light C is also lit, one of the Potentiometers is not in its end position, the grinding cycle counter reed switch has been tripped or the cable to one of the knock sensors has been interrupted. When one of the potentiometers is turned slightly out of the end position, the red indicator light C must come on. If not, the potentiometer or the cable connection is defective. When a magnet is moved towards the grinding cycle counter reed switch, the red indicator light C must come, on. If not, the reed switch or the cable connestion is defective. 9.31) Sensor test: 4) Servornotor test @,) Interference signal test: 9.32 If the plug connector is now disconnected from the right- hand or left-hand knock sensor, the red indicator light C must come on. If not, the cable to the interrupted knock ‘sensor has a short-circuit to ground, ‘When the plug connector of the right-hand or left-hand knock sensor is disconnected, the green indicator light 8 must come on and go out when the shearbar is tapped lightly. If not, the connected knock sensor or its cable ‘connection is defective. ‘When the shearbar is struck hard with the knock sensors connected, the servomotors must move the shearbar back for approx. 3 seconds. If not, the cable connection to one of the servomotors is interrupted, one of the servomotors is defective or, if the motor runs in the wrong direction, the ‘cable connection has the wrong polarity. Hf the green indicator light changes its condition when the radio or CB radio is switched on, these must not be switched on during shearbar adjustment due to the interference signals.PROBLEM Grinding process No flash code, display C. ‘Sharpening device does not react. No flash code, display C. Grinding is not completed when potentiometer D is in position “1”. No flash code, display C. Grindstone wobbles. No flashing, display C. (One grinding cycle, then program stops. No flashing, display ©. The grindstone does not continue to tum in the housing 1 x periodic flashing, display C. Grindstone does not come back or stops. 1x periodic flashing, display C. (Grindstone does not start) 3.x periodic flashing, display C. Grinding interrupted after 1-3 cycles, 3x periodic flashing, display C. Grinding cover does not open. CAUSE AND REMEDY 1. Tum off the sharpening device and start again. 1, Potentiometer is incorrectly connected and gives maximum value instead of value "1 Check connections according to circuit diagram then carry out sensor test. 2. The connections of potentiometer D and potentiometer G have been reversed. Check connections according to circuit diagram then carry out sensor test. 1. Oil pressure switch defective. Check oll pressure switch and replace, if necessary. 2. Hydraulic oil temperature too low. Bring hydraulic oil up to operating temperature. 3. Obstacles in grinding area. Remove obstacles. 4, Mechanical linkage binding. Clean sharpening device. 1. No voltage at potentiometer D. Check connections and replace potentiometer, if necessary. 1. The chain of the grinding device is too slack. ‘The clamps on the cylinders have come loose. ‘Tension chain and tighten clamps. 1. Oil pressure switch does not reach switching pressure. Check oil pressure switch and replace, if necessary. 2. Latching of diode plate not OK. Check diode plate and replace, if necessary, 1. 450 grinding cycles have been performed. Adjust grindstone and reset electronic grinding cycle counter. 1. Grindstone limit ewitch is not tripped. Check adjustment. 2. Reed switch does not trip. Check limit switch and magnet on grindstone. Check cable to module. Function ‘of switch can be checked in sensor test. 1. Grinding cover valve is not driven. Check relay for grinding cover (next to module). Ignition ON => Relay pick uf Solenoid valve OFF => Cover opens. 2. Oil pressure too low. Check oil hoses according to circuit diagram (connections on cylinder reversed) 9.33Grinding with failed remote control Electronic shearbar adjustment 2x periodic flashing, display C. ‘Adjustment completed without knocking, 4x periodic flashing, display C. ‘Adjustment completed with/without knocking. 5x periodic flashing, display C. ‘Adjustment interrupted. 6 x periodic flashing, display C. Adjustment interrupted, 7 x periodic flashing, display C. Motors start briefly, adjustment interrupted. 8x periodic flashing, display C. Motors run only briefly, adjustment interrupted. 8 x periodic flashing, display C. Motors do not start, adjustment interrupted. 9.34 1. Tum off electronics at switch 200. 2, Disconnect hydraulic cylinder for opening the grinding cover. 8, Switch (161) must be in position “OFF” (see “Sharpening ‘device without remote contro”) 4. On switch (161), the non-connected cable (SW/BL/GN or BR/VIOL) must always be connected in the middle or at the bottom. 5. Carry out grinding as described in “Sharpening device without remote contro" 1 Shearbar at end of adjustment range due to worn knives. Back off shearbar, then adjust or replace knives, then sharpen and adjust shearbar again as instructed, 1. The distance between shearbar and knives is larger than calculated. Adjust shearbar parallel (see "Backing off shearbar’), possibly turn over and adjust knives. 1. Knock sensor defective. Check cable harness for continuity or loose contact. Check earth connection on feeder housing, carry out sensor test. 1. Interference or knock signals. Switch off CB radio, telephone and large electrical consumers, eliminate metallic knocking caused e.g. by loose parts. 1, Motor gearbox or angle-drive gearbox defective. Shaft pulled out of gearbox. ‘3, Thread in bronze bushing worn. Replace bronze bushing 4, Brake bearing loose or fiction force inadequate (oly, ‘greasy). Check breakaway torque of friction bearings, remove oil or grease. 1. Crop has become trapped between the feeder housing and machine. Open feeder housing and remove crop. 1. Motors are running under excessive load. Carry out sensor test. Check motor connections and leads for continuity9x periodic flashing, display C. Adjustment interrupted. 10x periodic flashing, display C. Adjustment interrupted. 10 x periodic flashing, display C. Grindstone does not start. Adjust shearbar with remote contro! failed. |. Supply voltage has dropped below 10 Volt. Check the Vehicle electrics such as battery, governor, carbon brushes on alternator, etc. Switch off large consumers (ight, fan). |. Internal error discovered in module during self-test. Replace module and adjust the grindstone. Connections on oll pressure switch of the sharpening device reversed. Correct connections on switch. . Diode plate: Diode defective Disconnect the adjustment motors. Install the hand lever, at the T-screws. Adjust the shearbar (see “Adjusting shearbar without electric drive"). 9.35Fieldwork computer, shaft speed monitor, from Serial No. ... E 2566.0Key Fieldwork Computer 13430 5 — Vehicle information unit 43 — Master switch, front attachment enable 49 — Frequency converter ~ engine speed. 94 ~ Fieldwork computer 185 - Magnetic pick-up, feed roller gearbox 187 — Magnetic pick-up, Corn Cracker 141 = Reed switch, ground speed 143 — Magnetic pick-up, ground speed 163 - Feeder housing position pull switch, fieldwork computer 164 — Pick-up, engine speed 191 ~ Module - Feeder control / metal detector 231 — Magnetic pick-up, main drive Digital display Light indicating operating position ‘Set’ keys for machine constants Key with light, indicating service interval ‘Clear’ keys Programming key Keys with light, indicating cutterbar width Rotary switch function selection ‘Total area harvested (ha) Total working hours: ~ km covered = Ground speed (krn/h) ~ Rate of work (ha/h) ~ Area harvested (ha) Working hours Engine rpm 17. = Engine load drop 18 ~ Com Cracker rpm 19 - Compression roller rpm, up to Serial No. ... Pulses from magnetic pick-up (136) Insert programming card and turn rotary switch to position “20”. Using ‘set’ keys (9), enter value 003200 and programme. ‘The precise speed of the compression rollers is now indicated on the digital display. For programming and operation please also refer to the Operator's Manual. From Serial No. ... Pulses from magnetic pick-up (231) Insert programming card and turn rotary switch to position “20”. Using ‘set’ keys (3), enter value 000000 and programme. The operating hours are now indicated on the digital display. For programming and operation please also refer to the Operator's Manual. 9.37Reed contact switch (141) (Ground travel speed) os Cee M 15151 Magnetic pick-up 164 (engine rpm) saat 9.38 Settings. Install magnets (M) and the reed contact switch (G) ‘according to drawing, Width across corners X must be 3:2 mm. ‘The magnets must be fastened with brass screws and. mounted so that their poles face opposite directions. Pull switch (163) Lower the front attachment until the distance between the centre of the coupling shaft on the front attachment and the {ground is 400 mm. Pull the actuating pin of the pull switch all the way out and attach the chain so that the pin is. maintained in this position. 1 = Pulley 2 — Magnet 3 - Magnetic pick-up Dimension ¥ = 62 mm Important! The magnet must be fastened with a brass screw. Magnetic pick-up 137 (Corn Cracker) Distance between cam and pick-up = 1:21 mm. Magnetic pick-up 135 (gearbox - feed roller housing) Distance between cams and magnetic pick-up = 2*! mm, Function test = Connect the fieldwork computer. = Switch on the ignition. The indicator lights of the fieldwork computer come on briefly and the warning buzzer of the fieldwork computer sounds briefly — Programme the fieldwork computer (see operating manual). = Lower the feeder housing: green indicator light - working Position - comes on. Start the engine and raise the feeder housing; green indicator light - working position - goes out. Run the engine up to full revs and check the engine speed display. Engine speed = see operating manual. If the displayed value differs significantly from the value in the specifications, check the distance between the motor output shaft and the magnetic pick-up. = Check the kilometre display. Move the selector lever to position “Kilometre”. Drive the machine and compare the distance travelled with the kilometre display. If the distance travelled and the kilometre display differ significantly 1a) Check magnets and reed switches ') Redefine the distance factor and programme again.