Claas XERION 3300 Service Manual
XERION 3300
Technical
Systems
Hydraulic System
410
Content
1 Overall hydraulic system
Overall circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overall circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PFC pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Compensating valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Initial position (engine OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Low-pressure standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pump starts pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Constant volume flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Downstroking the PFC pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Maximum pressure limitation (pressure relie f valve function), maximum standby pressure . 24
2 Steering hydraulics
System concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Fully hydraulic steering (Emergency steering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Orbitrol axle = Floating axle (1), the rigid axle (2) is tracked by electro-hydraulic means . . . 37
Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Orbitrol axle = Rigid axle (2), the floating axle (1) is tracked by electro-hydraulic means . . . 43
Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
The floating axle (1) and the rigid axle (2) are steered electro-hydraulically – the Orbitrol
steering circuit is closed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Steering valve VI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Content
410
3 Working hydraulics
Working hydraulics circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Main valve block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Key to diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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Content
410
4 000 293 646 0 - SYS-H XERION 3300 - 04/05
1 Overall hydraulic system
Overall circuit diagram
1 Overall hydraulic system
Overall circuit diagram
387
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1 Overall hydraulic system
Overall circuit diagram
Circuit diagram
387
323-1 323-2
408
400996
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1 Overall hydraulic system
Overall circuit dia gram
Key to diagram
Item Component
I Main valve block
II Cab valve block
III Distributor block
IV Orbitrol steering valve
V Steering sense valve
VI EHL valve block – Electro-hydraulic steering
VII Main brake valve
VIII Working hydraulics variable-displacement pump
IX Steering hydraulics variable-displacement pump
1 Overall hydraulic system
Overall circuit diagram
391
-102-1 Working hydraulics pressure filter
102-2 Steering hydraulics pressure filter
107 Oil drain
109 Hydraulic system oil cooler
110 Oil tank
112 Return filter
113-1 Working hydraulics suction filter
113-2 Steering hydraulics suction filter
113-3 Emergency steering suction filter
116 Resonance tube (Silencer)
117 Fresh air filter element
-205 Working hydraulics pump
214 Hydraulic motor
218 Steering hydraul ics pump
245 Emergency steering pump
-323-1 Floating axle steering hydraulic cylinder
323-2 Rigid axle steering hydraulic cylinder
377 Variable-displacement pump hydraulic cylinder
3007-1a Service brake hydraulic cylinder
3007-1b Service brake hydraulic cylinder
3007-2a Service brake hydraulic cylinder
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1 Overall hydraulic system
Overall circuit diagram
Item Component
3007-2b Service brake hydraulic cylinder
3008 Parking brake hydraulic cylinder
3009 Floating axle lock hy dr au lic cylind e r
3010 Cab raise/lo we r hy dr a ulic cylin de r
3011 Unlock cab hydraulic cylinder
3012 Rear power lift hydraulic cylinder
3013 Front power lift hydraul ic cylinder
3014 Swing lower link hy dr aulic cylin de r
-406 Orifice plate F (Ø 0. 8 mm)
414 Orifice plate F (Ø 3. 5 mm)
421 Restrictor
391
-515 Pressure accumula to r
516 Service brake pressur e ac cu m ulato r
519 Parking brake pr essure accumulator
-609 Orbitrol steering system rotary valve
641 Shut-off valve
642 Service brake valve
644 Steering sense valve
-704 Bypass valve (non-return valve)
706 Pressure relief valve
725-1 Floating axle steering double shock valve
725-2 Fixed axle steering double shock valve
725-3 Orbitrol steering double shock valve
726 Steering pressure relief valve
732 Non-return valve
734 Lock-up valve unit (non-return valve)
742 Steering safety valve
760 One-way restri ctor valve, one-sided
763 Input pressure balance
768 LS signal shuttle valve
772 Volume flow contr oller
772-1a Volume flow controller (red A)
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Item Component
772-1b Volume flow controller (red B)
772-2a Volume flow controller (EHR A)
772-2b Volume flow controller (EHR B)
772-3a Volume flow controller (white A)
772-3b Volume flow controller (white B)
772-4a Volume flow controller (yellow A)
772-4b Volume flow controller (yellow B)
772-5a Volume flow controller (green A)
772-5b Volume flow controller (green B)
772-6a Volume flow controller (swing lower link A)
772-6b Volume flow controller (swing lower link B)
773 Pressure controller
1 Overall hydraulic system
Overall circuit diagram
391
774 Pressurizing valve
780 Shuttle valve
783 Trailer brake valve
784 Accumulator charge valve
785 LS pressure relief valve
786 Thermostat valve
787 Pressure balance
-801-1 Quick-release coupling (P power beyond)
801-2a Quick-release coupling (T power beyond rear)
801-2b Quic k- re le as e co up lin g (T fro n t)
801-3 Quick-release coupling (LS power beyond)
801-4 Quick- rel e as e co up lin g (r ed A rea r)
801-5 Quick- rel e as e co up lin g (r ed A fro nt )
801-6 Quick- rel e as e co up lin g (r ed B rea r)
801-7 Quick- rel e as e co up lin g (r ed B fro nt )
801-8 Quick-re le as e coup lin g (white A front)
801-9 Quick-re le as e coup lin g (white A rear)
801-10 Quic k- rele ase coupling (white B rear)
801-11 Quick- re le as e co up lin g (y ello w A fro nt)
801-12 Quick- re le as e co up lin g (y ello w A rear )
801-13 Quick- re le as e co up lin g (y ello w B rear )
801-14 Quick- re le as e co up lin g (y ello w B fro nt)
801-15 Quick-release coupling (green A front)
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1 Overall hydraulic system
Overall circuit diagram
Item Component
801-16 Quick-release coupli ng (green A rear)
801-17 Quick-release coupli ng (green B rear)
801-18 Quick-release coupli ng (green B front)
-B123 Hydraulic oil temperature
-Y106 Parking brake solenoid valve
Y188-1 Steering logics shut-off valve solenoid valve
Y188-2 Steering logics shut-off valve solenoid valve
Y188-3 Steering logics shut-off valve solenoid valve
Y188-4 Steering logics shut-off valve solenoid valve
Y189-5 Steering logics definition valve solenoid v alve
391
Y189-6 Steering logics definition valve solenoid v alve
Y189-7 Steering logics definition valve solenoid v alve
Y189-8 Steering logics definition valve solenoid v alve
Y189-9 Steering logics definition valve solenoid v alve
Y189-10 Steering logics definition valve solenoid valve
Y190-1a Automatic steering solenoid valve
Y190-1b Automatic steering solenoid valve
Y190-2a Automatic steering solenoid valve
Y190-2b Automatic steering solenoid valve
Y191 Constant-pressure s ystem solenoid valve
Y192 Floating axle locking sole no id valve
Y193 Floating axle unlock ing sole n oid valv e
Y194-1 Cab rotation solenoid valve ?
Y194-2 Cab rotation solenoid valve ?
Y195-1 Unlock cab solenoid valve
Y195-2 Unlock cab solenoid valve (not used)
Y196 Cab raise solenoid valve
Y197 Cab lower solenoid valve
Y198-1a Pilot valve solenoid valve (red A)
Y198-1b Pilot valve solenoid valve (red B)
Y198-2a Pilot valve solenoid valve (EHR A)
Y198-2b Pilot valve solenoid valve (EHR B)
Y198-3a Pilot valve solenoid valve (white A)
Y198-3b Pilot valve solenoid valve (white B)
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Item Component
Y198-4a Pilot valve solenoid valve (yello w A)
Y198-4b Pilot valve solenoid valve (yello w B)
Y198-5a Pilot valve solenoid valve (g ree n A)
Y198-5b Pilot valve solenoid valve (g ree n B)
Y198-6a Pilot valve solenoid valve (swi ng low er link A)
Y198-6b Pilot valve solenoid valve (swi ng low er link B)
-Z12 Parking brake actual value switch
Z19 Hydraulic oil level (min.) actual value switch
Z81 Service brake pressure actual value switch
Z102-1 Working hydraulics filter bypass actual value switch (bypass open)
Z102-2 Steering hydraulics filter bypass actual value switch (bypass open)
1 Overall hydraulic system
Overall circuit diagram
391
Z102-3 Return line filter bypass actual value switch (bypass open)
Z103 Pump function actual value switch
Z104 Brake accumulator pressure actual value switch
Z105-1 Floating axle lock 55 bar pressure
Z105-2 Floating axle lock 115 bar pressure
Z12 Parking brake actual value switch
Z19 Hydraulic oil level (min.) actual value switch
Z81 Service brake pressure actual value switch
Z102-1 Working hydraulics filter bypass actual value switch (bypass open)
Z102-2 Steering hydraulics filter bypass actual value switch (bypass open)
Z102-3 Return line filter bypass actual value switch (bypass open)
Z103 Pump function actual value switch (emergency steering pump)
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1 Overall hydraulic system
PFC pump
PFC pump
Compensating valve
6
391
772
7
773
AA
13
DD
BB
LL
401482
Item Component
6 Compensating valve
7 Input (load pressure from signal network)
10 Working hydraulics pump port
11 Port of control piston of working hydraulics pump
12 Tank port
13 Restrictor
772 Volume flow controller
773 Pressure controller
10
12
11
-AA Oil supply
BB Pressure-reduced oil
DD Control oil
LL Tank (pressureless)
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1 Overall hydraulic system
PFC pump
Description of function The PFC pump (2) is an axial piston pump.
PFC means:
– P (Pressure)
– F (Flow)
– C (Controlled)
PFC pump The compression spring of the volume flow controller (772) is designed so that
the pump pressure acting on the face end is always 20 bar above the load
pressure acting via port (7). This pressure of 20 bar is ref erred to as "Margin
pressure". The pressure controller (773) limit s the pressure in the working
hydraulics circuit to 200±5 bar (Pressure relief valve function).
391
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1 Overall hydraulic system
PFC pump
Initial position (engine OFF)
391
401483
LL
21
20
19
18
7
6
772
377
15
2
16
17
Item Component
2(PFC) Pump
6 Compensating valve
7 Input (load pressure from signal network)
14 Control piston
15 Control spring
16 Pump drive
17 Swash plate
18 Ram
19 Pump inlet
20 Pump outlet
21 Compression spring (margin pressure)
377 Hydraulic cylinder variable-displacement pump
772 Volume flow controller
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1 Overall hydraulic system
PFC pump
Initial position Since the engine has been shut down, there is no pressure in the hydraulic
system. The compression spring (21) has pushed the vol u me flow controller
(772) to the right. In this po sition , the top side of the varia ble-di splaceme nt pump
hydraulic cylinder (37 7) i s conn ec te d wit h th e tank via the volume flow contr oll er
(772). The control spri ng (15) has swi vell ed the swash plat e (17) to its maximum
position.
391
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1 Overall hydraulic system
PFC pump
Low-pressure standby
391
401484
21
20
AA
DD
BB
LL
7
772
377
15
2
17
Item Component
2(PFC) Pump
6 Compensating valve
7 Input (load pressure from signal network)
14 Control piston
15 Control spring
17 Swash plate
20 Pump outlet
21 Compression spring (margin pressure)
25 Control edge
377 Hydraulic cylinder variable-displacement pump
772 Volume flow controller
-AA Oil supply
BB Pressure-reduced oil
DD Control oil
LL Tank (pressureless)
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1 Overall hydraulic system
PFC pump
391
Description of function All control units are i n their neutral posi tion. At t he beginnin g of this exa mple, the
swash plate (17) is in its maximum end position (see also Engine OFF).
When the engine is started, the pump feeds the maximum volume flow via the
pump output (20) up to the spools of all control units.
Since the spools block the flow completely, the pr essure rises and is applied to
the right face end of the volume flow controller (772) which is moved to the left
against the compression spring (margin pressure) (21). In this process, the
control edge (25) is opened so that the pressure gains ac cess to the top side of
the variable-displacement pump hydraulic cylinder (377). Now the swash plate
(17) is moved to the "Minimum vo lume flow" position against the control spring
(15). This process takes only 10 milliseconds.
In this pump position, the following happens: Volume flow is generated only to
such an extent that lea kage losses are compensated. The pressure required for
initial actuation of a consum er is ma in tained.
When all control units are set to their neutral positions, the load pres sure input
(7) is pressureless. To move the volume flow controller (772), the pum p pressure
must overcome the compres sion spring (margin pressu re) (21) and the LS
residual pressure. The pressure required for this is 20 + X bar and is referred to
as "Low-pressure standby". The "Low-pressure standby" is slightly higher than
the "Margin pressure" of 20 bar. As a function of the setting of the volume flow
controller (772) and of the pump leakage, "Low-pressure standby" and "Margin
pressure" may be almost i dentical. However, the "Margin pr essure" c an never be
higher. The low-pressure standby cannot be adjusted and may therefore vary
from machine to machine. It changes as the leakage rate i n the pump or in the
system rises. The pump remains in the "Low-pressure standby" position until a
control unit is actuated. In this operating position, the pump only requires little
drive energy.
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1 Overall hydraulic system
PFC pump
Pump starts pu mping
391
401485
21
20
AA
DD
BB
LL
7
6
772
377
15
2
17
Item Component
2 (PFC) pump
6 Compensating valve
7 Input (load pressure from signal network)
14 Control piston
15 Control spring
17 Swash plate
20 Pump outlet
21 Compression spring (margin pressure)
25 Control edge
377 Variable-displacement pump hydraulic cylinder
772 Volume flow controller
-AA Oil supply
BB Pressure-reduced oil
DD Control oil
LL Tank (pressureless)
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1 Overall hydraulic system
PFC pump
391
Description of function When a control unit is actuated, a load pressure builds up in the LS line. In this
process, the following conditions result at the volume flow controller (772):
– the pump pressure acts on the right face end
– the load pressure and the spring force of the compression spring (margin
pressure) (21) act in the spring space.
– Since the load pressure + the spring force of the compression spring
(margin pressure) (21) is higher than the pump pressure on the right face
end, the volume flow controller is moved to the right .
This :
– shuts off the passage of the pump pressure to the variable-displacement
pump hydraulic cylinder (377);
– connects the variable-displacement pump h ydraulic cylinder (377) wi th the
tank (no pressure on top side of ram)
– makes the control spring (15) swing out the swash plate (17).
The pump now feeds a higher volume flow. This process is referred to as
"Upstroking". The volume flow of the pump is determined by the restrictor effect
of the open spool cross-section or by the setting of a control unit.
Lower volume flow requirement: When the spool cross-section is reduced (the volume flow is to be reduced), the
load pressure at the input (7) drops. This changes the force ratio at the volume
flow controller (772), actuating the volume flow controller to the left according to
the pressure drop, against the compression spring. The variable-displ acement
pump hydraulic cylinder (377) is subject to pressure and the swash plate (17) is
set to a flatter position, and the pump performs a downstroke until the volume
flow requirement is met.
Higher volume flow requirement.
An example: A control unit h as been ac t uat ed. Th e l oa d pr essu re i s 140 ba r, the
pump pressure now goes to (160 bar).(Load pressure 140 bar + 20 bar margin
pressure). When another co nt ro l uni t wi th a l oa d pr ess ure of 100 ba r is actu at ed
now, the pump pressure drops slightly.
This also decreases the pressure on the top face of th e variable-displacement
pump hydraulic cylinder (377) accordingly, the swash plate (17) is moved to a
steeper position, increasing the volume flow until the additional volume flow
requirement of the second circuit has been met and the pump pressure of 160
bar has been re-established. The load pressure on the controller remai ns stable
at 140 bar.
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1 Overall hydraulic system
PFC pump
Constant volume flow
391
401486
21
20
AA
DD
BB
LL
22
7
6
772
377
15
2
17
Item Component
2(PFC) Pump
6 Compensating valve
7 Input (load pressure from signal network)
14 Control piston
15 Control spring
17 Swash plate
20 Pump outlet
21 Compression spring (margin pressure)
22 Setscrew
25 Control edge
377 Variable-displacement pump hydraulic cylinder
772 Volume flow controller
-AA Oil supply
BB Pressure-reduced oil
DD Control oil
LL Tank (pressureless)
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1 Overall hydraulic system
PFC pump
Description of function When operating a consumer with a constant load (e.g. a hydraulic motor), the
volume flow controller (772) is actuated to a stable position. This keeps both the
pressure on the top face of the variable-displacement pump hydraulic cylinder
(377) and the posit ion of the swash plat e (17) co nstant. As long as the positi on of
the swash plate (17) remains unchanged, the pump pumps a constant volume
flow.
The following pressure s now result on the volume flow controller (772):
– Load pressure (signal) + s pring force of the compression spring (margin
pressure) (21) on the left side.
– ·Pump pressure on the right side.
The differential pressure is the margin pressure corresponding to the spring
force of the compression sp ring (21). The margin pressur e is to be 20 bar and
may be adjusted using set screw (22).
391
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