Claas DISCO, CORTO, VOLTO, LINER Service Manual

DISCO 8500C (Tractor) DISCO 8500C-6, -8 (JAGUAR)

(until serial no.: 652 01278)

DISCO, CORTO, VOLTO, LINER

Technical Systems

Hydraulic / Electric System	JAGUAR 8550C	TIC

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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

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Hydraulic / Electric System	JAGUAR 8550C	TIC

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TIC	JAGUAR 8550C	Hydraulic / Electric System
1.0	Hydraulic System...................................................................................................................................	2
1.1	JAGUAR 8500C-6, C-8 hydraulic circuit diagram................................................................................	2
1.2	Function ...............................................................................................................................................	8
2.0	Electric system JAGUAR 8500C, CISCO 8500C-6, -8.......................................................................	14
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.

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1.0Hydraulic System

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

2Lift hydraulics pump, 12 cm³/rev.

5Oil 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

504/3 way solenoid valve, double-acting, for front attachments (series equ.)

513/3 way solenoid valve, lift front attachment

702/2 way solenoid valve, fold out right and left mower unit

712/2 way solenoid valve, fold in right and left Disco

722/2 way solenoid valve, raise/lower centre mower unit

732/2 way solenoid valve, raise/lower left mower unit

742/2 way solenoid valve, raise/lower right mower unit

75Reed switch (mounted on 3/3 way solenoid valve item 51 = only on Jaguar 800 series)

81Non-return valve, left mower unit

82Hydraulic cylinder, left mower unit, starting protection

83Pressure relief valve 180 bar

84Non-return valve, right mower unit

85Hydraulic cylinder, right mower unit, starting protection

86Pressure relief valve 180 bar, right mower unit

87Pressure gauge, right mower unit ground pressure

88Right mower unit accumulator, charge pressure 35 bar, 0.75 litres

89Right mower unit lock-up valve unit

(2/2 way solenoid valve, closed when deenergized)

90Right mower unit raise/lower hydraulic cylinder

91Left mower unit fold in/out hydraulic cylinder

92Right mower unit fold in/out hydraulic cylinder

93Oil pressure switch 150 bar (normally open contact)

94Oil pressure switch 85 bar (normally open contact)

95Oil pressure switch 150 bar (normally open contact)

962 oil pressure switches 140 bar (normally closed contact)

97Pressure gauge, left mower unit ground pressure

98Left mower unit accumulator, charge pressure 35 bar, 0.75 litres

99Left mower unit lock-up valve unit

(2/2 way solenoid valve, closed when deenergized)

100Hydraulic cylinder, left mower unit

101Pressure gauge, centre mower unit ground pressure

102Centre mower unit accumulator, charge pressure 35 bar, 0.75 litres

103Centre mower unit raise/lower hydraulic cylinder

104Pressure 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)

106Line to the front attachment cylinders

107Non-return valve

108Orifice plate Ø 1.2 mm

109Centre (front) mower unit lock-up valve unit

(2/2 way solenoid valve, closed when deenergized)

110Double acting front attachment cylinder, for 8500C, 8500C-6, -8

111Shut-off tap

112Screwed coupling

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JAGUAR 8500 C-6 / C-8 hydraulic circuit diagram

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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)

742/2 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

99Left mower unit lock-up valve unit

(2/2 way solenoid valve, closed when deenergized)

109Front mower unit lock-up valve unit

(2/2 way solenoid valve, closed when deenergized)

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Pressure gauge for ground pressure

87 Pressure gauge, right mower unit ground pressure

97 Pressure gauge, left mower unit ground pressure

101Pressure gauge, centre mower unit ground pressure

All pressure gauges show a ground pressure of 50 bar with the mower units lowered (working position).

Bucher 2/2 way valves

(under the cover)

702/2 way solenoid valve, fold out right and left mower unit

712/2 way solenoid valve, fold in right and left mower unit

722/2 way solenoid valve, raise/lower centre mower unit

732/2 way solenoid valve, Disco left load relief

742/2 way solenoid valve, Disco right load relief

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Jaguar front attachment cylinder pressure relief valve

104Pressure 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

Accumulator

behind the right-hand cover

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

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1.2 Function

1.2.1Actuate 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		Solenoid valve 50 goes to position B.
	the right		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
			150 bar.
3	Solenoid valves 70 and 71 are		Volume flow goes to the rod spaces of cylinder 91 and 92
	triggered.		via the solenoid valve 71.
4	The displaced volume flow from the		The side-mounted mower unit are folded in.
	ram top space flows to the tank via		The lock can be released.
	the energized solenoid valve 70.
5	Switch 2 on the CCT is actuated to		Solenoid valve 50 goes to position A.
	the left		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
			activated.
6	Cylinders travel against their end		Pressure switch 95 switches at a pressure of 150 bar.
	stop
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
			mower unit is lowered.
8	The lower command for the left		Solenoid valve 50 goes to position A.
	mower unit is issued on the control		Solenoid valve 73 is energized.
	terminal (switch 3).
9	Volume flow from cylinder 100		The left mower unit is lowered.
	flows into the tank.
10	The lower command for the right		Solenoid valve 50 goes to position A.
	mower unit is issued on the control		Solenoid valve 74 is energized.
	terminal (switch 4).
11	Volume flow from cylinder 90 flows		The right mower unit is lowered.
	into the tank.

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.

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JAGUAR 8500 C-6 / C8 hydraulic circuit diagram

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1.2.2Raising the entire mower unit

Step	Action	Reaction
1	The “Raise front attachment”	Via the 3/3 way solenoid valve of the jaguar (line 106),
	button on the forage harvester is	volume flow goes to the ram rod end of lifting cylinders
	pressed.	(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	The lock-up valve units are closed. This is required to keep
	power supply to the lock-up valve	all mower units raised while raising the overall mower unit.
	units 89, 99 and 109.	(The oil does not flow into the accumulators 88, 98 and
		102.)
4	The volume flow displaced from the	The cylinders 90 and 100 retract and thus raise the left and
	rod spaces of the cylinders (on the	right mower units.
	forage harvester) is fed to the
	cylinders 90 and 100.
5	When the volume capacity of the	the pressure rises and the pressure switches 96 switch the
	rod spaces of cylinders 90 and 100	lock-up valve units 89 and 99 so that the excess volume
	is exhausted,	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	The pressure in rod space of cylinder 85 rises.
	obstacle.
2	When the pressure reaches	the pressure relief valve 86 opens.
	180 bar,
3	Volume flow is displaced from the	This volume flow goes to the rod space of cylinder 90. The
	rod space of cylinder 85.	right mower unit is raised and folds in.

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JAGUAR 8500 C-6 / C8 hydraulic circuit diagram

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1.2.4Actuating 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	The volume flow displaced from the ram top spaces flows
	energized solenoid valve 71 into	into the tank through the energized solenoid valve 70 and
	the rod spaces of cylinders 91 and	on via the 4/3 way solenoid valve 50B.
	92.	The side-mounted mower units are folded in.

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JAGUAR 8500 C-6 / C8 hydraulic circuit diagram

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

2.1Electric circuit diagram

S1 Stop switch

S2 Disco fold in/out switch

S3 Left Disco raise/lower switch

S4 Right Disco raise/lower switch

5Indicator light, power supply

6 Control box with switches S1, S2, S3 and S4

7Socket 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

12Lock-up valve unit 89 and 99 relay

13Relay for 4/3 way solenoid valve (item 50A)

14Relay for 4/3 way solenoid valve (item 50B)

15Relay for lock-up valve unit 109

504/3 way solenoid valve for front attachment (series equipment) 50A Solenoid coil (fold out mower units)

50B Solenoid coil (fold in mower unit, raise/lower)

51Front attachment raise/lower 3/3 way solenoid valve

70Solenoid coil, fold out right and left Disco

71Solenoid coil, fold in right and left Disco

72Solenoid coil, raise/lower centre Disco

73Left Disco raise/lower solenoid coil

74Right Disco raise/lower solenoid coil

75Reed switch (only Jaguar 800 series) Mounted to solenoid valve 51 (raise).

Caution: Observe installation position = lettering must face the magnet

76Switches and 3/3 way raise solenoid valve (only on Jaguar 600 series)

89 Solenoid coil, right lock-up valve unit (closed when deenergized)

93Oil pressure switch 150 bar (normally open contact), energizes solenoid valve 70

94Oil pressure switch 85 bar (normally open contact), energizes relay 12

95Oil pressure switch 150 bar (normally open contact), energizes solenoid valve 72

962x 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

F10 A fuse

ZCentral terminal compartment (the lines in the areas with a grey background are actually conducting paths on the board).

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Electric system Jaguar 8500C, Disco 8500C-6, C-8

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2.2 Function

2.2.1Putting into operation

2.2.2Raise left Disco

2.2.3Lower left Disco

2.2.4Raise right Disco

2.2.5Lower right Disco

2.2.6Moving the Disco to working position

2.2.7Moving the Disco to transport position

Switch on stop switch 1.

Current is applied to all relays, terminal 86 and the solenoid valves.

Actuate rocker switch 3. Earth is connected to pin 7 in connector 7. 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.

Actuate rocker switch 3. Earth is connected to pin 7 in connector 8. 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.

Actuate rocker switch 4.

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.

Actuate rocker switch 4.

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.

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Electric system Jaguar 8500C, Disco 8500C-6, C-8

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2.2.8 Blocking the	When the 3/3 way raise front attachment solenoid valve is actuated on
accumulator while	the forage harvester, the Reed switch*75 connects earth to relay 15,
raising the entire	terminal 85 and relay 12, terminal 85.
mower unit.	Relay 15 cuts the current to the lock-up valve unit 109.
(quick lift)	Relay also cuts the current to the lock-up valve units 89 and 99 (the lock-
	up 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.

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Electric system Jaguar 8500C, Disco 8500C-6, C-8

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2.3Central terminal compartment

7 Central terminal compartment connector

12Lock-up valve unit 89 and 99 relay

13Relay for 4/3 way solenoid valve (item 50A)

14Relay for 4/3 way solenoid valve (item 50B)

15Relay for lock-up valve unit 109

17Terminal 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

DDiodes

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Central terminal compartment, from 2000

7 Central terminal compartment connector

12Lock-up valve unit 89 and 99 relay

13Relay for 4/3 way solenoid valve (item 50A)

14Relay for 4/3 way solenoid valve (item 50B)

15Relay 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

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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

12Lock-up valve unit 89 and 99 relay

13Relay for 4/3 way solenoid valve (item 50A)

14Relay for 4/3 way solenoid valve (item 50B)

15Relay 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

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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

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3.0Installation information

3.1Timing of drives

Arrangement of pinion units A and B and of drive input module E

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.

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

Centre mower unit

A Pinion unit A

B Pinion unit B

E Drive input module

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3.2Installation of pinion units

7Flange

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.

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3.3Safety module

SBreaking 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).

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