How it Works
Claas
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CORTO
Service Manual
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Claas DISCO, CORTO, VOLTO, LINER Service Manual

DISCO 8500C (Tractor) DISCO 8500C-6, -8
(until serial no.: 652 01278)
DISCO, CORTO, VOLTO, LINER
(JAGUAR)
Technical Systems
10/04
TIC JAGUAR 8550C Hydraulic / Electric System

Chapter 1 JAGUAR 8500 C,

JAGUAR 8500 C- 6, JAGUAR 8500 C- 8
2 DISCO 8500 C
3 CORTO 8100 F/T
4 LINER 3000,
LINER 1550 TWIN, LINER 650 TWIN
5 VOLTO 1050,
VOLTO 870H
6 DISCO 3000TC, TRC, AS, FG
CORTO 3100, 300, 252, 250
10/04
10/04
TIC JAGUAR 8550C Hydraulic / Electric System
Hydraulic System...................................................................................................................................2
1.0
1.1
JAGUAR 8500C-6, C-8 hydraulic circuit diagram................................................................................2
1.2 Function ...............................................................................................................................................8
Electric system JAGUAR 8500C, CISCO 8500C-6, -8.......................................................................14
2.0
2.1
Electric circuit diagram.......................................................................................................................14
2.2 Function .............................................................................................................................................16
2.3 Central terminal compartment............................................................................................................20
3.0 Installation information.......................................................................................................................24
3.1
Timing of drives..................................................................................................................................24
3.2 Installation of pinion units...................................................................................................................25
3.3 Safety module ....................................................................................................................................26
3.4 Tightening torques .............................................................................................................................27
4.0 Drive diagram.......................................................................................................................................28
Attention The description of the Jaguar 8500C also applies to
- Disco 8500C-6
- Disco 8500C-8
The only exception is: The Reed switch (75) does not exist on the Disco 8599C-6.
10/04 1-1

1.0 Hydraulic System

1.1 JAGUAR 8500C-6, C-8 hydraulic circuit diagram

2 Lift hydraulics pump, 12 cm³/rev. 5 Oil filter, lift hydraulics, mesh size 0.06 mm 9 Pressure relief valve with 4/3 way valve, square tube adjustment 10 Pressure gauge connection, lift hydraulics 50 4/3 way solenoid valve, double-acting, for front attachments (series equ.) 51 3/3 way solenoid valve, lift front attachment 70 2/2 way solenoid valve, fold out right and left mower unit 71 2/2 way solenoid valve, fold in right and left Disco 72 2/2 way solenoid valve, raise/lower centre mower unit 73 2/2 way solenoid valve, raise/lower left mower unit 74 2/2 way solenoid valve, raise/lower right mower unit 75 Reed switch (mounted on 3/3 way solenoid valve item 51 = only on
Jaguar 800 series) 81 Non-return valve, left mower unit 82 Hydraulic cylinder, left mower unit, starting protection 83 Pressure relief valve 180 bar 84 Non-return valve, right mower unit 85 Hydraulic cylinder, right mower unit, starting protection 86 Pressure relief valve 180 bar, right mower unit 87 Pressure gauge, right mower unit ground pressure 88 Right mower unit accumulator, charge pressure 35 bar, 0.75 litres 89 Right mower unit lock-up valve unit
(2/2 way solenoid valve, closed when deenergized) 90 Right mower unit raise/lower hydraulic cylinder 91 Left mower unit fold in/out hydraulic cylinder 92 Right mower unit fold in/out hydraulic cylinder 93 Oil pressure switch 150 bar (normally open contact) 94 Oil pressure switch 85 bar (normally open contact) 95 Oil pressure switch 150 bar (normally open contact) 96 2 oil pressure switches 140 bar (normally closed contact) 97 Pressure gauge, left mower unit ground pressure 98 Left mower unit accumulator, charge pressure 35 bar, 0.75 litres 99 Left mower unit lock-up valve unit
(2/2 way solenoid valve, closed when deenergized) 100 Hydraulic cylinder, left mower unit 101 Pressure gauge, centre mower unit ground pressure 102 Centre mower unit accumulator, charge pressure 35 bar, 0.75 litres 103 Centre mower unit raise/lower hydraulic cylinder 104 Pressure relief valve 180 bar
(Jaguar 800 series on the left of the front attachments cylinder,
Jaguar 600 series on the right of the front attachments cylinder) 106 Line to the front attachment cylinders 107 Non-return valve 108 Orifice plate Ø 1.2 mm 109 Centre (front) mower unit lock-up valve unit
(2/2 way solenoid valve, closed when deenergized) 110 Double acting front attachment cylinder, for 8500C, 8500C-6, -8 111 Shut-off tap 112 Screwed coupling
1-2 10/04
TIC JAGUAR 8550C Hydraulic / Electric System
JAGUAR 8500 C-6 / C-8 hydraulic circuit diagram
10/04 1-3
Directional control valves subassembly
Jaguar 800 series, left side
75 Reed switch 94 Oil pressure switch 85 bar
Attention
The lettering on the Reed switch (75) must face the lift magnet of the 3/3
way solenoid valve = safe switching (the Reed switch in the picture is not
properly mounted).
Directional control valves, oil pressure switches and pressure relief valves
(under the cover)
74 2/2 way solenoid valve, raise/lower right mower unit
Next to this: the other Bucher directional control valves 73, 72, 71 and 70. 83 Pressure relief valve 180 bar (left mower unit) 86 Pressure relief valve 180 bar (left mower unit) 89 Right mower unit lock-up valve unit
(2/2 way solenoid valve, closed when deenergized) 93 Oil pressure switch 150 bar (normally open contact), front mower unit 96L Oil pressure switch 140 bar (normally closed contact), left mower unit 96R Oil pressure switch 140 bar (normally closed contact), right mower unit 95 Oil pressure switch 150 bar (normally open contact), fold out mower units 99 Left mower unit lock-up valve unit
(2/2 way solenoid valve, closed when deenergized) 109 Front mower unit lock-up valve unit
(2/2 way solenoid valve, closed when deenergized)
1-4 10/04
TIC JAGUAR 8550C Hydraulic / Electric System
Pressure gauge for ground pressure
Bucher 2/2 way valves
(under the cover)
87 Pressure gauge, right mower unit ground pressure 97 Pressure gauge, left mower unit ground pressure 101 Pressure gauge, centre mower unit ground pressure
All pressure gauges show a ground pressure of 50 bar with the mower
units lowered (working position).
70 2/2 way solenoid valve, fold out right and left mower unit 71 2/2 way solenoid valve, fold in right and left mower unit 72 2/2 way solenoid valve, raise/lower centre mower unit 73 2/2 way solenoid valve, Disco left load relief 74 2/2 way solenoid valve, Disco right load relief
10/04 1-5
Jaguar front attachment cylinder pressure relief valve
Accumulator
behind the right-hand cover
104 Pressure relief valve 180 bar
Jaguar 800 series on the left of the front attachments cylinder, Jaguar 600 series on the right of the front attachments cylinder
1-6 10/04
88 3 x right mower unit accumulator, charge pressure 35 bar, 0.75 litres 98 3 x left mower unit accumulator, charge pressure 35 bar, 0.75 litres 102 3 x centre mower unit accumulator, charge pressure 35 bar, 0.75 litres
TIC JAGUAR 8550C Hydraulic / Electric System
10/04 1-7

1.2 Function

1.2.1 Actuate from
transport to working position
Caution:
1 = Main switch ON-OFF. Set to OFF when parking the machine.
Step Action Reaction
1 Switch 2 on the CCT is actuated to
the right
Solenoid valve 50 goes to position B. Volume flow goes to the solenoid valves 71, 72, 73 and 74.
2 Solenoid valve 72 is triggered The applied volume flow goes to cylinder 103.
The front mower unit is raised to its end position = the pressure rises and oil pressure switch 93 switches at
3 Solenoid valves 70 and 71 are
triggered.
4 The displaced volume flow from the
ram top space flows to the tank via the energized solenoid valve 70.
5 Switch 2 on the CCT is actuated to
the left
150 bar. Volume flow goes to the rod spaces of cylinder 91 and 92 via the solenoid valve 71. The side-mounted mower unit are folded in. The lock can be released.
Solenoid valve 50 goes to position A. Solenoid valves 70 and 71 are triggered. This makes volume flow flow through solenoid valves 70: into cylinders 82 and 85 (but also the non-return valves 81 and 84). into cylinders 91 and 92. The side-mounted mower units are now folded out and the starting protections are
6 Cylinders travel against their end
stop
activated. Pressure switch 95 switches at a pressure of 150 bar.
7 Solenoid valve 72 is triggered Volume flow from cylinders 103 flows through 72 and
solenoid valve 50 (position A) into the tank. The front
8 The lower command for the left
mower unit is issued on the control terminal (switch 3).
9 Volume flow from cylinder 100
mower unit is lowered. Solenoid valve 50 goes to position A. Solenoid valve 73 is energized.
The left mower unit is lowered.
flows into the tank.
10 The lower command for the right
mower unit is issued on the control terminal (switch 4).
11 Volume flow from cylinder 90 flows
into the tank.
Solenoid valve 50 goes to position A. Solenoid valve 74 is energized.
The right mower unit is lowered.
During work, the working pressures of all cylinders are supported by the accumulators 88, 98 and 102. The lock-up valve units are opened at switch 94 below 80 bar. When the pressure rises to above 85 bar, the lock-up valve units are closed and the mower units remain in their position. The ground pressure of the mower units can be seen on pressure gauges 87, 97 and 101.
1-8 10/04
TIC JAGUAR 8550C Hydraulic / Electric System
JAGUAR 8500 C-6 / C8 hydraulic circuit diagram
10/04 1-9
1.2.2 Raising the entire
mower unit
Step Action Reaction
1 The “Raise front attachment”
button on the forage harvester is pressed.
Via the 3/3 way solenoid valve of the jaguar (line 106), volume flow goes to the ram rod end of lifting cylinders (110).
2 The mower unit is raised. When a pressure of 85 bar is reached while raising, the
pressure switch 94 (normally open contact) switches.
3 The relays 12 and 15 now cut the
power supply to the lock-up valve units 89, 99 and 109.
4 The volume flow displaced from the
rod spaces of the cylinders (on the
The lock-up valve units are closed. This is required to keep all mower units raised while raising the overall mower unit. (The oil does not flow into the accumulators 88, 98 and
102.) The cylinders 90 and 100 retract and thus raise the left and
right mower units. forage harvester) is fed to the cylinders 90 and 100.
5 When the volume capacity of the
rod spaces of cylinders 90 and 100 is exhausted,
the pressure rises and the pressure switches 96 switch the
lock-up valve units 89 and 99 so that the excess volume
flow is displaced into the accumulators 88 and 98. This
ensures that no oil will escape from this circuit.
1.2.3 Starting protection
Step Action Reaction
1 If e.g. the right mower unit hits an
obstacle.
2 When the pressure reaches
180 bar,
3 Volume flow is displaced from the
rod space of cylinder 85.
The pressure in rod space of cylinder 85 rises.
the pressure relief valve 86 opens.
This volume flow goes to the rod space of cylinder 90. The
right mower unit is raised and folds in.
1-10 10/04
TIC JAGUAR 8550C Hydraulic / Electric System
JAGUAR 8500 C-6 / C8 hydraulic circuit diagram
10/04 1-11
1.2.4 Actuating from working to transport position
Step Action Reaction
1 Shut down the mower unit. The mower discs must not rotate any more. 2 Push the “Raise” key in the ground
until the mower units have no more ground contact. speed control lever (3/3 way solenoid valve is energized)
3 Push switch 2. Solenoid valve 72 is energized.
Solenoid valve 50 goes to switch position B.
4 Volume flow goes to hydraulic
The cylinders 103 raise the centre mower unit. cylinders 103.
5 Cylinders 103 travel to their end
The pressure rises. stop.
6 When the pressure reaches
Solenoid valves 70 and 71 are energized. 150 bar, the oil pressure switch 93 switches
7 Volume flow flows through the
energized solenoid valve 71 into the rod spaces of cylinders 91 and
92.
The volume flow displaced from the ram top spaces flows
into the tank through the energized solenoid valve 70 and
on via the 4/3 way solenoid valve 50B.
The side-mounted mower units are folded in.
1-12 10/04
TIC JAGUAR 8550C Hydraulic / Electric System
JAGUAR 8500 C-6 / C8 hydraulic circuit diagram
10/04 1-13

2.0 Electric system JAGUAR 8500C, CISCO 8500C-6, -8

2.1 Electric circuit diagram

S1 Stop switch S2 Disco fold in/out switch S3 Left Disco raise/lower switch S4 Right Disco raise/lower switch
5 Indicator light, power supply 6 Control box with switches S1, S2, S3 and S4 7 Socket outlet beneath the operator's platform 17 Terminal strip, plus in central terminal compartment
(located above the relays) 19 Left terminal strip 19a Right terminal strip
12 Lock-up valve unit 89 and 99 relay 13 Relay for 4/3 way solenoid valve (item 50A) 14 Relay for 4/3 way solenoid valve (item 50B) 15 Relay for lock-up valve unit 109 50 4/3 way solenoid valve for front attachment (series equipment) 50A Solenoid coil (fold out mower units) 50B Solenoid coil (fold in mower unit, raise/lower) 51 Front attachment raise/lower 3/3 way solenoid valve
70 Solenoid coil, fold out right and left Disco 71 Solenoid coil, fold in right and left Disco 72 Solenoid coil, raise/lower centre Disco 73 Left Disco raise/lower solenoid coil 74 Right Disco raise/lower solenoid coil 75 Reed switch (only Jaguar 800 series)
Mounted to solenoid valve 51 (raise).
Caution: Observe installation position = lettering must face the magnet
76
Switches and 3/3 way raise solenoid valve
(only on Jaguar 600 series)
89 Solenoid coil, right lock-up valve unit (closed when deenergized) 93 Oil pressure switch 150 bar (normally open contact), energizes solenoid
valve 70 94 Oil pressure switch 85 bar (normally open contact), energizes relay 12 95 Oil pressure switch 150 bar (normally open contact), energizes solenoid
valve 72 96 2x oil pressure switch 140 bar (normally closed contact), see chapter
2.2.8. 99 Solenoid coil, left lock-up valve unit (closed when deenergized) 109 Solenoid coil, centre lock-up valve unit (closed when deenergized)
D Diodes F 10 A fuse Z Central terminal compartment (the lines in the areas with a grey
background are actually conducting paths on the board).
1-14 10/04
TIC JAGUAR 8550C Hydraulic / Electric System
Electric system Jaguar 8500C, Disco 8500C-6, C-8
10/04 1-15

2.2 Function

2.2.1 Putting into operation Switch on stop switch 1.
2.2.2 Raise left Disco Actuate rocker switch 3. Earth is connected to pin 7 in connector 7.
2.2.3 Lower left Disco Actuate rocker switch 3. Earth is connected to pin 7 in connector 8.
2.2.4 Raise right Disco Actuate rocker switch 4.
2.2.5 Lower right Disco Actuate rocker switch 4.
2.2.6 Moving the Disco to working position
2.2.7 Moving the Disco to transport position
Current is applied to all relays, terminal 86 and the solenoid valves.
Earth is also connected to relay 14 on terminal 85 and to solenoid valve
73. Relay 14 connects earth to the 4/3 way directional control valve 50B.
Earth is also connected to relay 13 on terminal 85 and to solenoid valve
73. Relay 13 connects earth to the 4/3 way directional control valve 50A.
Earth is connected via pin 9 of connector 7 to relay 14 on terminal 85 and to the solenoid valve 74. Relay 14 connects earth to the solenoid valve 50 which goes to switch position B.
Earth is connected via pin 10 of connector 7 to relay 13 on terminal 85 and to the solenoid valve 74. Relay 13 connects earth to the solenoid valve 50 which goes to switch position A.
Actuate rocker switch 2.
Earth is connected via pin 2 of connector 7 to relay 13 on terminal 85 and to the solenoid valves 70 and 71. Relay 13 connects earth to the solenoid valve 50 which goes to switch position A. The mower unit folds out. Upon reaching the end position and 150 bar, the oil pressure switch 95 connects earth to the solenoid valve 72. The front mower unit is lowered via the energized solenoid valve 72.
Actuate rocker switch 2.
Earth is connected via pin 1 of connector 7 to relay 14 on terminal 85 and to the solenoid valve 72. Relay 14 connects earth to the solenoid valve 50 which goes to switch position B. The centre mower unit is raised. Upon reaching the end position and 150 bar, the oil pressure switch 93 connects earth to the solenoid valves 70 and 71. The mower units are folded in.
1-16 10/04
TIC JAGUAR 8550C Hydraulic / Electric System
Electric system Jaguar 8500C, Disco 8500C-6, C-8
10/04 1-17
2.2.8 Blocking the accumulator while raising the entire mower unit. (quick lift)
When the 3/3 way raise front attachment solenoid valve is actuated on
the forage harvester, the Reed switch*75 connects earth to relay 15, terminal 85 and relay 12, terminal 85. Relay 15 cuts the current to the lock-up valve unit 109. Relay also cuts the current to the lock-up valve units 89 and 99 (the lock­up valve units are closed when deenergized).
When raising is complete, the mower units’ weight generates a pressure of > 85 bar in the cylinders of the Jaguar front attachment. The oil pressure switch 94 connects earth to relay 12, terminal 85 as long as the pressure in the lift cylinders is > 80 bar. Relay 12 switches and cuts the power supply to the lock-up valve units 89, 99 and 109. This is necessary to make the mower units remain in their position when lifting is complete on the turning area. When the pressure in cylinders 90 and 100 rises to above 140 bar, the oil pressure switches 96 open briefly. Earth connected to relay 12, terminal 85 drops out and the relay connects the current supply to the lock-up valve units 89 and 99. The lock-up valve units open and the accumulators receive oil from the ram rod end (from the front attachment cylinders on the Jaguar) so that there is no oil loss and no oil can flow from the system into the tank (pressure relief valve 104).
* On the Jaguar 800, the Reed switch connects earth.
On the Jaguar 600, earth is supplied directly from the 3/3 way „Raise“ solenoid valve.
1-18 10/04
TIC JAGUAR 8550C Hydraulic / Electric System
Electric system Jaguar 8500C, Disco 8500C-6, C-8
10/04 1-19

2.3 Central terminal compartment

7 Central terminal compartment connector 12 Lock-up valve unit 89 and 99 relay 13 Relay for 4/3 way solenoid valve (item 50A) 14 Relay for 4/3 way solenoid valve (item 50B) 15 Relay for lock-up valve unit 109 17 Terminal strip, plus in central terminal compartment
(located above the relays) 19 Left terminal strip 19a Right terminal strip
K1 Raise/lower right side-mounted mower unit, solenoid valve 74 K2 Raise/lower left side-mounted mower unit, solenoid valve 73 K3 Front mower unit, solenoid valve 72 K4 Right mower unit lock-up valve unit, solenoid valve 89 K5 Left mower unit lock-up valve unit, solenoid valve 99 K6 Front mower unit lock-up valve unit, solenoid valve 109 K7 Fold out side-mounted mower unit, solenoid valve 70 K8 Fold in side-mounted mower unit, solenoid valve 71 K9 140 bar pressure switch, item 96 K10 140 bar pressure switch, item 96 K11 150 bar pressure switch (fold in side-mounted mower units), item 93 K12 150 bar pressure switch (fold out side-mounted mower units), item 95
D Diodes
1-20 10/04
TIC JAGUAR 8550C Hydraulic / Electric System
Central terminal compartment, from 2000
7 Central terminal compartment connector 12 Lock-up valve unit 89 and 99 relay 13 Relay for 4/3 way solenoid valve (item 50A) 14 Relay for 4/3 way solenoid valve (item 50B) 15 Relay for lock-up valve unit 109 17 Terminal strip, plus in central terminal compartment
(located above the relays) 19 Left terminal strip 19a Right terminal strip
K1 Raise/lower right side-mounted mower unit, solenoid valve 74 K2 Raise/lower left side-mounted mower unit, solenoid valve 73 K3 Front mower unit, solenoid valve 72 K4 Right mower unit lock-up valve unit, solenoid valve 89 K5 Left mower unit lock-up valve unit, solenoid valve 99 K6 Front mower unit lock-up valve unit, solenoid valve 109 K7 Fold out side-mounted mower unit, solenoid valve 70 K8 Fold in side-mounted mower unit, solenoid valve 71 K9 140 bar pressure switch, item 96 K10 140 bar pressure switch, item 96 K11 150 bar pressure switch (fold in side-mounted mower units), item 93 K12 150 bar pressure switch (fold out side-mounted mower units), item 95
10/04 1-21
Central terminal compartment, up to 2000
Differences as compared with central terminal compartment “from 2000”:
The assignment of inputs 1 to K5 is different. The connecting terminals on the board have not been changed.
7 Central terminal compartment connector 12 Lock-up valve unit 89 and 99 relay 13 Relay for 4/3 way solenoid valve (item 50A) 14 Relay for 4/3 way solenoid valve (item 50B) 15 Relay for lock-up valve unit 109 17 Terminal strip, plus in central terminal compartment (located above the
relays) 19 Left terminal strip 19a Right terminal strip
K1 Raise/lower right side-mounted mower unit, solenoid valve 74 K2 Raise/lower left side-mounted mower unit, solenoid valve 73 K3 Front mower unit, solenoid valve 72 K4 Right mower unit lock-up valve unit, solenoid valve 89 K5 Left mower unit lock-up valve unit, solenoid valve 99 K6 Front mower unit lock-up valve unit, solenoid valve 109 K7 Fold out side-mounted mower unit, solenoid valve 70 K8 Fold in side-mounted mower unit, solenoid valve 71 K9 140 bar pressure switch, item 96 K10 140 bar pressure switch, item 96 K11 150 bar pressure switch (fold in side-mounted mower units), item 93 K12 150 bar pressure switch (fold out side-mounted mower units), item 95
1-22 10/04
TIC JAGUAR 8550C Hydraulic / Electric System
Pin assignment of switches in the CCT (as seen from the rear)
S1 Stop switch S2 Disco fold in/out switch S3 Left Disco raise/lower switch S4 Right Disco raise/lower switch
10/04 1-23

3.0 Installation information

3.1 Timing of drives

Arrangement of pinion units A and B and of drive input module E
Left mower unit
A Pinion unit A B Pinion unit B E Drive input module
Right mower unit
A Pinion unit A B Pinion unit B E Drive input module
In addition to the drive input module E, 6 rows of pinions are provided in
the mower head.
These are sub-divided into four 4 versions and two B versions. The B
versions are marked with red paint at the bottom.
Centre mower unit
A Pinion unit A B Pinion unit B E Drive input module
1-24 10/04
TIC JAGUAR 8550C Hydraulic / Electric System

3.2 Installation of pinion units

7 Flange 13 Pinion shaft
Pinion unit A The marking M on the pinion shaft (13), the tooth centre Z and the centre
of the flange bore must be aligned.
Pinion unit B The marking M on the shaft, the tooth centre Z and the centre between
two flange bores must be aligned.
10/04 1-25

3.3 Safety module

S Breaking point for cases of sudden load
S1 Safety screw (when sudden loads occur and the pinion has been sheared
off the shaft, this screw holds both parts together and thus avoids major
damage in the mower head).
1-26 10/04
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