TECHNICAL TRAININGTARGO TARGO K50, K60, K70 1.0 TechnicaI data 2.0 Operation 3.0 Safety / Ioad dispIay 4.0 Engine 5.0 Gearbox 6.0 Drive shaft 7.0 AxIe / steering 8.0 Brakes 9.0 Working hydrauIics 10.0 EIectrics 11.0 Diagnostics 12.0 Air conditioning / heating 13.0 Options 14.0 Frame, boom 15.0 Maintenance and care Chapter CLAAS ACADEMY TARGO Chapter 11/2001 1.0 Data tabIes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 2.0 Drive schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 2.1 K 50, K 60, K 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Contents CLAAS ACADEMY TARGO K Technical data 11/2001 1-1 1.0 Data tabIes 500 mm 500 mm 500 mm Load centre from the back of the forks 4200 mm 3400 mm 3200 mm Reach (max) 7200 mm 6200 mm 6000 mm Lifting height (max) 3500 kg 4000 kg 3000 kg Lifting capacity (max) Specification K 70 K 60 K 50 3500 mm 3500 mm 3500 mm Outer turning circle 410 mm 410 mm 410 mm Ground clearance 2800 mm 2800 mm 2800 mm Wheel spacing 2380 mm 2380 mm 2380 mm Total height 2300 mm 2300 mm 2300 mm Total width 4705 mm 4705 mm 4705 mm Total length Measurements 240 kg 240 kg 240 kg Weight, gearbox without oil 340 kg 340 kg 340 kg Weight, engine without oil 7260 kg 7260 kg 6620 kg Total weight Weight 200 litres 200 litres 200 litres Fuel tank 1.5 bar 1.5 bar 1.5 bar Oil pressure, slow idling speed 3.5 bar 3.5 bar 3.5 bar Oil pressure, maximum speed - no load 9 litres 9 litres 9 litres Engine oil capacity with filter 80°C approx/0.68 bar 80°C approx/0.68 bar 80°C approx/0.68 bar Coolant thermostat 31 litres 31 litres 31 litres Coolant capacity 850 min -1 850 min -1 850 min -1 Slow idling speed 2350-2500 min -1 2350-2500 min -1 2350-2500 min -1 Max. speed - no load 2300 min -1 2300 min -1 2300 min -1 Full load speed 78 Kw/106hp 91 Kw/120hp 78 Kw/106hp 91 Kw /120hp 78 Kw/106hp 91 Kw/120hp Power (Optional) Perkins 1004-40 Perkins 1004-40 Perkins 1004-40 Type Engine Technical data TARGO K CLAAS ACADEMY 1-2 11/2001 50 L/min 50 L/min 50 L/min Pump capacity 16.5-19.5 bar 16.5-19.5 bar 16.5-19.5 bar Gearbox oil pressure 8-10 bar 8-10 bar 8-10 bar Torque converter pressure 0.4 Litres 0.4 Litres 0.4 Litres Oil capacity transfer gearbox 16 Litres 16 Litres 16 Litres Oil capacity (inc. oil filter) 20, 25, 40 Km/h 20, 25, 40 Km/h 20, 25, 40 Km/h Speed max 6 for / 3 rev gears 6 for / 3 rev gears 6 for / 3 rev gears Standard 5 for / 3 rev gears 5 for / 3 rev gears 5 for / 3 rev gears Option 4 for/ 2 rev gears 4 for/ 2 rev gears 4 for/ 2 rev gears Option With gearbox module (APC) With gearbox module (APC) With gearbox module (APC) Type With torque converter With torque converter With torque converter Powershift gearbox K 70 K 60 K 50 50 L/min 50 L/min 50 L/min Pump capacity 16.5-19.5 bar 16.5-19.5 bar 16.5-19.5 bar Gearbox oil pressure 8-10 bar 8-10 bar 8-10 bar Torque converter pressure 0.4 Litres 0.4 Litres 0.4 Litres Oil capacity transfer gearbox 16 Litres 16 Litres 16 Litres Oil capacity (inc. oil filter) 25, 40 km/h 25, 40 km/h 25, 40 km/h Speed max 4 for / 3 rev gears 4 for / 3 rev gears 4 for / 3 rev gears Standard 4 for / 3 rev gears 4 for / 3 rev gears 4 for / 3 rev gears Option 3 for/ 3 rev gears 3 for/ 3 rev gears 3 for/ 3 rev gears Option Without gearbox module (APC) Without gearbox module (APC) Without gearbox module (APC) Type With torque converter With torque converter With torque converter Powershift gearbox 0.8 Litres 0.8 Litres 0.8 Litres Planetary gearbox capacity 10 Litres 10 Litres 10 Litres Differential gearbox capacity 2 2 2 Steering axle 1 1 1 Self lock differential 2 2 2 Drive axle AxIe See operator's manual See operator's manual See operator's manual Option 15.5/80-24 15.5/80-24 15,5/80-24 Series Tyres CLAAS ACADEMY TARGO K Technical data 11/2001 1-3 100 Litres 100 Litres 100 Litres Complete hydraulic oil 65 Litres 65 Litres 65 Litres Hydraulic tank 175 bar 175 bar 175 bar Shock valve, front attachment incline back 265 bar 265 bar 265 bar Shock valve, front attachment incline 250 bar 250 bar 250 bar Pressure relief valve 120 L/min 120 L/min 120 L/min Pump capacity Load sensing Load sensing Load sensing Pump type HydrauIics K 70 K 60 K 50 250 ml 250 ml 250 ml Oil 1.1 kg 1.1 kg 1.1 kg Gas R134A Air conditioning 65 Amps 65 Amps 65 Amps Alternator output 110 Ah 110 Ah 110 Ah Battery EIectrics Technical data TARGO K CLAAS ACADEMY 1-4 11/2001 2.0 Drive axIe 2.1 K50, K60, K70 A Front axle final drive B Gearbox DANA T12000 C Perkins engine 1004-40T D Rear axle final drive E Rear axle differential F Rear axle final drive H Drive shaft Ì Transfer gearbox J Torque converter K Drive shaft L Front axle final drive M Self locking front differential CLAAS ACADEMY TARGO K Technical data 11/2001 1-5 From operator's book 319565.3 1.0 Cap and operating components . . . . . . . . . . . . . . . . . . . . 2-2 1.1 Control instruments and warning lights . . . . . . . 2-4 1.2 Switches and instrument panel . . . . . . . . . . . . . . 2-8 1.4 Components on the side console . . . . . . . . . . . . 2-10 1.5 Kick down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 2.0 Towing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Contens CLAAS ACADEMY TARGO K Operation 11/2001 2-1 1.0 Cap and operating components 1 Steering wheel Turn the steering wheel in the direction you wish to travel in. 2 Selected gear display Only with gearbox's fitted with the APC control will display the selected gear. 3 Ìnstrument panel 4 Switches on the instrument panel 5 Load indicator 6 Forwards and reverse gear selection as well as kick down. 7 Ìgnition key 8 Multifunction switch 9 Accelerator The accelerator changes the engine speed. The further down it is pressed the higher the engine speed. Operation TARGO K CLAAS ACADEMY 2-2 09/2001 10 Brake pedal The brake pedal operates the servo braking system. Press the brake pedal down in order to slow or stop the machine. By operating the brake pedal will automatically activate the brake lights. NOTE: When the brake pedal is pressed, the brake/clutch switch is operated which switches off the drive from the gearbox. 11 Parking brake CAUTÌON! The parking brake should only be used in an emergency to slow the machine. Should the parking brake be used in an emergency for slowing the machine, then the brake linings will have to be changed. The machine is fitted with an accumulator on the front axle which is released with hydraulic pressure. The parking brake is activated by a rocker switch with integrated lock. To activate the parking brake, the machine must firstly be stationary, then unlock the lock on the rocker switch and press into the ON position. The machine should be in idle, then when activated the parking brake light should come on. Ìn the case of an engine and or electric / hydraulic failure then the parking brakes will be automatically activated. 12 Joystick 13 Standard front attachment 14 Front attachment 15 Rotary switch for joystick 16 Steering mode switch 17 Wheel position lights 18 Operating components on the side console 19 Operating components for heating and air conditioning 20 Fuses and relays can be found under the switches to the left of the instrument panel 21 Radio (fitted on option by the customer) CLAAS ACADEMY TARGO K Operation 11/2001 2-3 1.1 ControI instruments and warning Iights The instruments and warning lights can be found to the right hand side of the steering column on the instrument panel. 1 Ìnstrument: Tachometer The tachometer displays the engine speed in revs per minute. 2 Operating hours The operating hours indicator shows the number of hours that the engine has run. The hours should be used for calculating maintenance intervals. 3 Ìnstrument: Tank The tank displays the amount of fuel remaining in the fuel tank. NEVER allow the fuel gauge to drop to the zero point, otherwise it will be necessary to bleed the fuel system. Operation TARGO K CLAAS ACADEMY 2-4 09/2001 4 Ìnstrument: Engine coolant temperature The gauge displays the temperature of the engine coolant. The display will vary slightly depending on ambient temperatures. NEVER operate the machine when the temperature reading is abnormally high or when the warning light FLASHES. 5 Ìndicator This flashes when the left hand indicators are operated. 6 Engine oil pressure This illuminates when the engine oil pressure drops to below the normal operating pressure. The light may flash when the engine is being started, but must go out once it is running. The machine MUST NOT be operated when the light is illuminated. 7 Not used 8 Air filter blocked This is illuminated, when the air flow to the engine is restricted. The machine MUST NOT be operated when this light is illuminated. CLAAS ACADEMY TARGO K Operation 11/2001 2-5 9 Parking brake The light is illuminated when the parking brake has been applied. Do not attempt to move the machine when the parking brake has been applied. 10 Gearbox oil pressure This illuminates when the gearbox oil pressure drops to below the normal operating pressure. The light may flash when the engine is being started, but must go out once it is running. The machine MUST NOT be operated when the light is illuminated. 11 Gearbox temperature This is illuminated when the gearbox temperature climbs above the normal. DO NOT operate the machine when this warning is illuminated. Warning Iights (continued) Operation TARGO K CLAAS ACADEMY 2-6 09/2001 12 Battery charge indicator This may illuminate for a short period after starting the engine. Should it remain illuminated, then there is a fault. DO NOT operate the machine if the light remains illuminated. 13 Hydraulic filter blocked This is illuminated when the filter is blocked due to dirt and therefore not filtering the oil. NOTE! When the machine is started in cold conditions (below 0°C) then the light may illuminate. Operate the machine gently for a few minutes in order to allow the machine to warm up. DO NOT operate the machine, should the light remain illuminated. 14 Brake pressure system Shows the critical oil pressure in the brake system. The machine MUST NOT be operated when this is illuminated. 15 High beam The warning is illuminated when the high beam have been switched on. 16 Ìndicator This flashes when the right hand indicators are operated. 17 Trailer indicators CLAAS ACADEMY TARGO K Operation 11/2001 2-7 1.2 Switches and instrument paneI 1 Switch: high beam and head lights Rocker switch. The high beam and head lights are controlled from the multifunction switch. 2 Switch: Beacon Rocker switch. Press in order to switch on the beacons. 3 Switch: Fog lights Rocker switch. Press in order to switch on the fog lights. The side lights must be already on before. 4 Switch: Hazard lights Rocker switch. When this switch is switched ON, then the hazard lights will operate. The indicator lights on the instrument panel will also flash. Operation TARGO K CLAAS ACADEMY 2-8 09/2001 5 Switch: Front working lights Rocker switch. Press in order to switch on the front work lights. The working lights will only come on when the side lights are switched on. 6 Switch: Rear working lights (optional) Rocker switch. Press in order to switch on the rear work lights. The working lights will only come on when the side lights are switched on. 7 Switch: Side working lights (optional) Rocker switch. Press in order to switch on the side work lights. 8 Switch: Outer limit lighting (optional) Rocker switch. Press in order to switch on the outer limit work lights. 9 Warning light: Servo steering (optional) This is illuminated when the pressure in the servo steering drops too low. Stop and find fault. NOTE! This lamp illuminates each time the machine is started. 10 Warning light: Brake operation This shows when the pressure in the brake system is too low. Stop and determine the fault. 11 Parking brake Rocker switch (lockable) 12 Switch: Ìgnition CLAAS ACADEMY TARGO K Operation 11/2001 2-9 1.4 Components on the side consoIe 1 Joystick lock switch 2 Steering type switch 3 Wheel alignment lights 4 Brake / clutch switch Rocker switch. When the switch is switched on, the gearbox is disengaged when the brakes are applied. The brake / clutch switch can only be switched when the machine is out of operation and not when loading or moving. 5 Wash / wiper switch for the rear wiper 6 Switch for the rear control 7 Switch for the air control on / off 8 Heater blower switch ÷ 3 stage This switch switches the fan speed to the three speeds available. 9 Heating regulation switch Turn the switch clockwise in order to switch the heating on, and turn it anticlockwise in order to switch the heating off. NOTE! Before switching on the air conditioning, the heater must be switched off. Operation TARGO K CLAAS ACADEMY 2-10 09/2001 1.5 Kick down Using kick down: This function works in all the gear ranges, and in both direction except for first gear. When the button (E) on the end of the control lever has been pressed, then the gearbox will switch down one range. When it has not been possible for the gearbox to switch down to the lower range, for instance when the revolutions would exceed permissible limits, then within 5 seconds the kick down command will be ignored. When the gearbox has switched down into kick down, then it can be switched back up in three different ways: 1 Press the button (E) again 2 Select a new gear on the levers rotary switch. 3 Switching the lever to the neutral position or in the opposite direction. CLAAS ACADEMY TARGO K Operation 11/2001 2-11 Notes Operation TARGO K CLAAS ACADEMY 2-12 09/2001 2.0 Towing the machine The machine is fitted with an accumulator brake system of the front axle which needs to be released hydraulically. Should a problem develop with either the engine and or electrics / hydraulics then the brakes will be automatically applied. Ìn order to be able to move the machine, the brakes can be released by hand, by equally slackening off the screws (A, B and C) (6 off). CAUTION! Ensure that the machines wheels have been chocked so that they are unable to roll, otherwise a fatal or serious injury will occur due to the machine moving. CLAAS ACADEMY TARGO K Operation 11/2001 2-13 After the wheels have been chocked, then locate the bolts on the front axle. Using a 8 mm allen key turn each bolt about one turn clockwise (inwards) until all have been turned approx 5 to 5.5 turns and resistance is met. The bolts must be turned in this fashion in order to prevent internal damage to the gearbox. The same procedure must then be carried out on the next group. DANGER! When the parking brakes have been released, then the machine must not be driven. Before towing the machine, ensure that both drive shafts have been removed. Once the drive shafts have been removed, attach the towing bar to both machines, then very carefully remove the wheel chocks. The machine can now be moved. The machine must NEVER be towed faster than 8km/h as the steering and braking system will only work slowly. ALWAYS use a towing bar to tow the machine, never use a chain or a tow rope. Operation TARGO K CLAAS ACADEMY 2-14 09/2001 Towing the machine (continued) After the repair, the brakes must be reinstated as before. CAUTION! Ensure that the machines wheels have been chocked so that they are unable to roll, otherwise a fatal or serious injury will occur due to the machine moving. Using a 8 mm allen key turn each bolt about one turn anticlockwise (outwards) until all have been turned approx 5 to 5.5 turns and big resistance is met (the bolts must be undone in this fashion in order to prevent internal damage to the gearbox). Then turn each bolt a quarter of a turn clockwise (inwards) again. Carry out the procedure on the other side. The parking brakes have now been reinstated. The machine wheels should chock. Before using the machine, ensure that the brakes work correctly. CLAAS ACADEMY TARGO K Operation 11/2001 2-15 1.0 Operation, Load indicator . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 2.0 Adjusting the Ioad indicator . . . . . . . . . . . . . . . . . . . . . . . 3-3 2.1 Load diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 2.3 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.0 Load signaI test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.1 Operational test of the load indicator . . . . . . . . . 3-6 3.2 Operational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 4.0 FauIt diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 4.1 Load indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 5.0 Load sensor signaI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 5.1 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 5.2 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Contents CLAAS ACADEMY TARGO K Safety / load display 11/2001 3-1 The load indicator can be found in the cab of the machine. Using an LED display, the load on the forks can be monitored. A green LED shows that the system is switched on. The 2 nd LED (red) shows that the machine is 50% loaded. Each LED after that approx equates to 6.5% From 50% loading to 100%, there are a total of 9 LEDs (red). When 100% loading is achieved, then the LEDs flash and an additional buzzer is sounded. Should the top LED (red) illuminate, then the machine is loaded to 110%. For the indicator to work, there is a load cell that supplies the signal and is mounted on the rear axle. The resistance of the load cell changes when pressure or tension is applied to the rear axle. Using the "B" button, the Ioad indicator needs to be checked on a daiIy basis. The Ioad indicator is OK if when pressing the button, aII the LEDs fIash and the warning buzzer can be heard. 1.0 Operation, Load indicator Load indicator B This button is to test the load indicator and to mute the warning buzzer. The button ¨B¨ has two uses. Safety / load display TARGO K CLAAS ACADEMY 3-2 11/2001 2.0 Adjusting the Ioad indicator Using the standard forks (125 Kg) the load centre is 500 mm from the rear of the forks. 2.1 Load diagram Standard forks must be used when lifting a load (W), in order to calculate the load centre (F) at 500 mm from the rear of the forks (G). Should the load (W) on the forks have a load centre (F) greater than the 500 mm from the rear of the forks (G), then for every 100 mm The total weight must be reduced by 200 Kg. ExampIe: Ìf the machine is capable of lifting 3875 Kg, then if the load centre was 800 mm. The forks are 125 Kg therefore the machine is derated to 3150 Kg (3875Kg ÷ 125 Kg ÷ 600 Kg = 3150 Kg). Caution CLAAS ACADEMY TARGO K Safety / load display 11/2001 3-3 2.2 CaIibration Side view of a removed load indicator 3002 The side on the load indicator shows the calibration button. The SPAN+% button is not used. 3003 1. Drive the machine for approx. 15 min (So axle reaches operational temperature) 2. Stop the machine 2a. On straight and level ground 2b. With the wheels straight 2c. With the parking brake off 2d. With the boom in the road travel position 2e. With the boom fully retracted 2f. Without forks or front attachment 3. Remove the load indicator and start the engine. Procedure Safety / load display TARGO K CLAAS ACADEMY 3-4 11/2001 Carrying out the caIibration The SPAN+% button is not used. Now all the LEDs must flash and the buzzer sounds intermittently. Without any load on the boom, wait for approx 15 seconds. Switch the engine off, ignition on. Test the function by pressing the button "B" 10 All the LEDs flash and the buzzer sounds intermittently. Start the engine 9 Wait 10 seconds Switch the engine and the ignition off 8 The calibration mode has been left. All the LEDs flash and the buzzer tone pulses. Momentary press the CAL button. 7 The second red LED from the top illuminates for a second and the buzzer sounds twice shortly. The 100% load is now set. The lower green and the second red LED from the top flash again. After approx 15 seconds of the machine standing still press the SPAN button momentary. 5 4a. On straight and level ground 4b. With the wheels straight 4c. With the parking brake off 4d. With boom at point A and angle point B at the same height Stop the machine: 4 The calibration can be carried out with either the boom being extended or retracted. With the boom retracted: K50 = calibration weight 2875 Kg K60 = calibration weight 3875 Kg K70 = calibration weight 3375 Kg With the boom extended: K50 = calibration weight 1125 Kg K60 = calibration weight 1375 Kg K70 = calibration weight 1375 Kg Load the boom with the test weight. Using the standard forks (125 kg), position the load so that the load centre is 500 mm from the rear of the forks. Observe the Ioad diagram 3 The lower green LED is illuminated for a second constantly and the buzzer is sounded momentarily. The zero point for the unloaded condition is now set. The lower green and the second red LED from the top now flash again. Without a load on the machine, wait approx 15 seconds and then momentary press the "B" button on the front. 2 The lower green and the second red LED should now flash quickly. The flashing shows that the unit is now in calibration mode. Should they not flash, then momentarily press the CAL button again. Using a screwdriver, momentary press the CAL button 1 Reaction Procedure CLAAS ACADEMY TARGO K Safety / load display 11/2001 3-5 3.0 Load signaI test 1. - Switch on the ignition - Switch the road travel switch on, and the bottom green light should come on to show that there is power. 2. - Press button ¨B¨ - Now all the LED should flash and buzzer must be heard 3.1 OperationaI test of the Ioad indicator 1. Drive the machine for approx 15 min (So that the axle reaches the operating temperature) 2. Stop the machine: 2a On straight and level ground 2b With the wheels straight 2c With the parking brake released. 2d With the boom point A and the swivel point B at the same height 2e With the boom fully retracted 2f Without forks or front attachment fitted 2g Connector A released. 3.2 OperationaI A Connector A 11 Accumulator (braking circuit) The connector A, connects the load sensor to the load indicator. Safety / load display TARGO K CLAAS ACADEMY 3-6 11/2001 3001 A Connector A 97 Load sensor 3. The reading must be taken between pins 3 + 4 (connector A) Cable colour Green = + Signal voltage Cable colour YeIIow = - Signal voltage The reading can be obtained by using the test probes (part number 365 747.0) without having to damage the cables. 4. With the test probes connected set the multimeter to mV 5. Switch on the ignition and the main hydraulic switch 6. Carry out the tests a) Note the readings when the machine is not loaded b) With maximum permissible weight (test weight). The reading should be approx. 1.5 ... 2.0 mV less than the reading obtained in a). NOTE! The reading can indicate a negative value. CLAAS ACADEMY TARGO K Safety / load display 11/2001 3-7 4.0 FauIt diagnostics 4.1 Load indicator 1. Check the wiring connection to the load sensor 2. Replace the load sensor and recalibrate No load sensor signal LED's 2 and 11 flash permanently and LED 1 flashes quickly. 1. Refit a new load sensor and recalibrate the load indicator 2. Fit a new load sensor and recalibrate the load indicator The signal for the load indicator is well over the 100% reading LED's 4 and 5 are permanently illuminated and LED 1 flashes quickly Replace the load indicator and calibrate Ìnternal fault with the load indicator LED's 2, 3, 4, 5, 6 and 7 flash constantly 1. Check the fuses 2. Cable connection broken 3. Replace the load indicator and calibrate Power supply voltage broken Even though the ignition is switched on, no LEDs are illuminated HeIp Cause ProbIem Safety / load display TARGO K CLAAS ACADEMY 3-8 11/2001 5.0 Load sensor signaI (fitted to the rear axIe) 5 0 5.1 Position Ìn the cab Load indicator 98 The Targo series of machines have the set unit part number 318 029.0 Load sensor 97B The steering position switch is the sensor for the wheel position warning. Fitted to the steering ram. Colour code yellow = Controlled by a magnetic field in the steering ram. Steering position switch 21/22 Comment Description Pos. CLAAS ACADEMY TARGO K Safety / load display 11/2001 3-9 5.2 Fitting Goes for all types 1. Drive the machine for approx. 15 min (So axle reaches operational temperature) 2. Stop the machine: a) On straight level ground b) With the wheels straight c) With the parking brake released d) With the boom in the road travel position e) With the boom fully retracted f) Without forks or a front attachment. 3. Clean the surface to which the sensor fixes to (metal blank) 4. Fit the sensor. General tip: Apply loctite 638 to the surface to which the sensor fits too. Do not allow the loctite on the threads or enter the holes. 5. Tighten the bolts. 5.1 Use 3 off M8 x 20 bolts tightened to 25 Nm 6. Leave the machine at least 2 hrs without moving it in order to allow the glue to dry. 7. Carry out the calibration of the load indicator. CAUTION! Safety / load display TARGO K CLAAS ACADEMY 3-10 11/2001 1.0 TechnicaI data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 2.0 Gearbox overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 3.0 Gearbox type identification pIate . . . . . . . . . . . . . . . . . . . 5-5 4.0 Speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 4.1 Speed sensor assembly instructions . . . . . . . . . 5-7 4.2 Sensor test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 4.3 Connection from the speed sensor to the module . . . . . . . . . . . . . . . . . . . . . . 5-8 5.0 Layout of the soIenoid vaIves . . . . . . . . . . . . . . . . . . . . . . 5-9 5.1 Connection from the solenoid valves to the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 6.0 Gearbox moduIe APC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 6.1 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 7.0 DispIay menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 7.1 Normal display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 - Gear display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 - Failure codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 7.2 Gearbox input speed . . . . . . . . . . . . . . . . . . . . . . . 5-16 7.3 Speed display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 7.4 Ìnput display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 - Ìnput test table . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 8.0 Connection from the controI Iever to the moduIe APC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 8.1 Pin layout for the control lever (company Hobbs) . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 8.2 Pin layout APC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 9.0 APC dispIay test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 9.1 Explanation of display . . . . . . . . . . . . . . . . . . . . . . 5-24 10.0 Kick down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 11.0 Automatic switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 12.0 Gearbox Iayout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 12.1 Layout of the clutches . . . . . . . . . . . . . . . . . . . . . . 5-26 12.2 Structure of the double clutch . . . . . . . . . . . . . . . 5-27 13.0 Power shift gearbox T 12000 . . . . . . . . . . . . . . . . . . . . . . . 5-29 14.0 Switching arrangement of the soIenoids . . . . . . . . . . . . 5-30 Contents CLAAS ACADEMY TARGO K Gearbox 11/2001 5-1 15.0 Gearbox hydrauIics and power train . . . . . . . . . . . . . . . 5-31 15.1 Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 15.2 1 st gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 15.3 2 nd gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 15.4 3 rd gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38 15.5 4 th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 15.6 5 th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42 15.7 6 th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44 15.8 Reverse, 1 st gear . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46 15.9 Switching pairs for R3 and R5 . . . . . . . . . . . . . . . 5-48 15.10 Gearbox pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48 15.11 Modulation valve . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48 15.12 System pressure sensor . . . . . . . . . . . . . . . . . . . . 5-49 15.13 Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . 5-49 15.14 Test ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50 15.15 Pressure values . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51 16.0 Targo K without gearbox moduIe (APC) . . . . . . . . . . . . 5-52 16.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52 16.2 Gearbox overview . . . . . . . . . . . . . . . . . . . . . . . . . 5-52 16.3 Gearbox type identification plate . . . . . . . . . . . . . 5-52 16.4 Speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52 16.5 Layout of the solenoid valves . . . . . . . . . . . . . . . 5-52 16.6 Gearbox module . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52 16.7 Display menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52 16.8 Control lever (company Britax) . . . . . . . . . . . . . . 5-53 - Control lever pin layout . . . . . . . . . . . . . . . . . . . 5-53 16.9 Connections from the control lever to the solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54 16.10 Kick down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55 16.11 Automatic switching . . . . . . . . . . . . . . . . . . . . . . . 5-55 16.12 Gearbox assembly, layout of the clutches and assembly of the double clutch . . . . . . . . . . . . . . . 5-55 16.13 Power shift gearbox T12000 . . . . . . . . . . . . . . . . 5-55 16.14 Solenoid switching pairs . . . . . . . . . . . . . . . . . . . . 5-56 16.15 Gearbox hydraulics and power train . . . . . . . . . 5-56 Gearbox TARGO K CLAAS ACADEMY 5-2 11/2001 1.0 TechnicaI data 12V/10 Ω 12V/10 Ω 12V/10 Ω 4/2 way solenoid valve 3,0-4,0 bar 3,0-4,0 bar 3,0-4,0 bar Lubrication oil pressure 50°C/2000 min -1 16,5-19,5 bar 16,5-19,5 bar 16,5-19,5 bar System pressure 50°C/2000 min -1 8,5-10 bar 8,5-10 bar 8,5-10 bar Pressure relief valve Torque converter 6,5-8,0 bar 6,5-8,0 bar 6,5-8,0 bar Oil pressure torque Converter 50°C/2000 min -1 50-53 l/min 50-53 l/min 50-53 l/min Gearbox oil pump 50°C/2000 min -1 0,65:1 0,65:1 0,65:1 Gear ratio 6 gear 0,91:1 0,91:1 0,91:1 Gear ratio 5 gear 1,54:1 1,54:1 1,54:1 Gear ratio 4 gear 2,16:1 2,16:1 2,16:1 Gear ratio 3 gear 3,03:1 3,03:1 3,03:1 Gear ratio 2 gear 4,24:1 4,24:1 4,24:1 Gear ratio 1 gear 2,0:1 2,0:1 2,0:1 Torque converter 16 Litre 16 Litre 16 Litre Oil quantity (inc. cooler) 175 Kg 175 Kg 175 Kg Weight without oil 40 Km/h 40 Km/h 40 Km/h Speed (Standard) 20, 25 Km/h 20, 25 Km/h 20, 25 Km/h Speed (Option) 4/3 4/3 4/3 OPTION 40 Km/h No. of gears (forwards/reverse) 3/3 3/3 3/3 OPTION 25 Km/h No. of gears (forwards/reverse) Without gearbox module Without gearbox module Without gearbox module Type 6/3 6/3 6/3 STANDARD 40 Km/h No. of gears (forwards/reverse) 5/3 5/3 5/3 OPTION 25 Km/h No. of gears (forwards/reverse) 4/2 4/2 4/2 OPTION 20 Km/h No. of gears (forwards/reverse) With gearbox module (APC) With gearbox module (APC) With gearbox module (APC) Type DANA T12000 DANA T12000 DANA T12000 Gearbox type K 70 K 60 K 50 CLAAS ACADEMY TARGO K Gearbox 11/2001 5-3 2.0 Gearbox overview A Left view B Gearbox output view C Right hand view 1 From gearbox to cooler 2 Oil cooler 3 From oil cooler to gearbox Gearbox TARGO K CLAAS ACADEMY 5-4 11/2001 3.0 Gearbox type identification pIate The type identification can be found on the side of the gearbox. CLAAS ACADEMY TARGO K Gearbox 11/2001 5-5 4.0 Speed sensor D Speed sensor The speed sensor generates the signal (Ìmpulses) for the module. The signal is required for: ! The speed display ! The control of the gear change and for changing the direction of the machine. ! With 5/3 and 6/3 gearbox's, the automatic switching up or down from to 4th gear. Gearbox TARGO K CLAAS ACADEMY 5-6 11/2001 4.1 Speed sensor assembIy instructions A Rotation of gear B Marks C O ring The marks (B) can be found on the hexagonal on the sensor. This must face in the direction (A) to the gear. 4.2 Sensor test 1. Connect the multimeter in series. Setting = mA 2. Start the machine 3. The readings should be equal to between 7mA and 14mA. 4. Should the value be over 60mA, then the sensor could be incorrectly connected. 5. Should the value be over 20mA, then the sensor is drawing too much power. CLAAS ACADEMY TARGO K Gearbox 11/2001 5-7 4.3 Connection from the speed sensor to the moduIe A Module B Speed sensor PÌN 1 Plus PÌN 2 Minus Pin Iayout PÌN1 Plus PÌN2 Minus Gearbox TARGO K CLAAS ACADEMY 5-8 11/2001 5.0 Layout of the soIenoid vaIves D Breather R Reverse solenoid valve F Solenoid valve F S Solenoid valve S 1 Solenoid valve 1 2 Solenoid valve 2 The solenoid valves are mounted on the left hand side of the gearbox. ! The Reverse solenoid valve is for disengaging or engaging the reverse gear. ! The F solenoid valve sends oil either to the S solenoid or the reverse solenoid. ! The S solenoid engages or disengages either the forwards clutch or 4 th high clutch. ! The 1 solenoid engages or disengages the 1 clutch ! The 2 solenoid engages or disengages clutches 2 and 3 CLAAS ACADEMY TARGO K Gearbox 11/2001 5-9 5.1 Connection from the soIenoid vaIves to the moduIe A Gearbox module B Max of 2A allowed per output C Not in use D Earth (-31) R Solenoid valve reverse F Solenoid valve F S Solenoid valve S 1 Solenoid valve 1 2 Solenoid valve 2 4 Pin 4 of the APC module 5 Pin 5 of the APC module 6 Pin 6 of the APC module 7 Pin 7 of the APC module 13 Pin 13 of the APC module Gearbox TARGO K CLAAS ACADEMY 5-10 11/2001 6.0 Gearbox moduIe APC The APC module control the gearbox and three gearbox options 20km/h, 25km/h and 40km/h. The 20km/h has 4 forward gears and 2 reverse The 25km/h has 5 forward gears and 3 reverse The 40km/h has 6 forward gears and 3 reverse APC = Automatic Powershift Control - - 6 R6 - 5 5 R5 3 3 3 R4 3 3 3 R3 3 3 3 R2 1 1 1 R1 N 1 1 1 F1 2 2 2 F2 3 3 3 F3 4 4 4 F4 - 5 5 F5 - - 6 F6 Gear possibiIities with the 20 Km/h gearbox Gear possibiIities with the 25 Km/h gearbox Gear possibiIities with the 40 Km/h gearbox ControI Iever position CLAAS ACADEMY TARGO K Gearbox 11/2001 5-11 6.1 DispIay A Display M Touch panel button T LED ! Ìs illuminated when the Targo is stationary (no signals from the speed sensor) F LED ! Ìs illuminated permanently when there is a software problem ! Ìs also illuminated for a short time when the ignition is switched on (self test) The APC controls the gearbox. At the same time the display shows the control lever position. ! The gearbox module (APC) and the display are one of the same thing. ! The button M has 3 functions ! Ìn the normal display the gear is displayed and if present the failure codes. ! Press the button once: The gearbox input speed will be displayed. ! Press the button twice, then the speed will be displayed. Gearbox TARGO K CLAAS ACADEMY 5-12 11/2001 7.0 DispIay menu Ìn the display for the gearbox module APC, the following menus will be displayed: - Normal display - Gearbox speed display - Speed display - Ìnput display The flow chart shows the menus displayed when by pressing the M button. 1100 CLAAS ACADEMY TARGO K Gearbox 11/2001 5-13 Displayed information: - The current gear and the failure codes. 7.1 DispIay normaI Displayed information: - The current gear (with a number) - The travel direction (with a letter) F forwards R reverse N neutral Gear dispIay Forwards and 1 st gear ExampIe 11001 Neutral and 5 th gear 11001 Reverse and 3 rd gear 11001 By selecting a gear on the control lever (R1 to R6) will enable the gearbox to select a gear (R1, R3, R5). The gear the gearbox has selected will be displayed, this as the diagram shows may not always be the position of the control lever. Note Gearbox TARGO K CLAAS ACADEMY 5-14 11/2001 Ìn the gear display, a full stop (D) may flash. ! The right full stop denotes that the speed for the gear change is too high. ! The left full stop denotes that the speed is too high for a gear change whilst on the move. Note D = Full stop D The active failure codes will be displayed. When a failure code is displayed, then the T LED will flash. The following failure codes can be displayed: FaiIure codes This failure code will be displayed, when one or more of the outputs from the APC has a short circuit. The gearbox will in this situation not switch on its own to neutral. 11002A The APC has an input from both the forwards and the reverse inputs. With this failure, the gearbox will switch automatically to neutral. 11002A CLAAS ACADEMY TARGO K Gearbox 11/2001 5-15 7.2 Gearbox input speed ! Press the button M1 once: The gearbox input speed will be displayed in 1/min. ! Ìn order to obtain the speeds, the following is to be noted. - Ìf there is no decimal point displayed, then the displayed figure needs to be times by 10. - Ìf there is a decimal point displayed, then the displayed figure needs to be times by 100. ! During the ¨Display gearbox input speed¨, the T LED is illuminated. The speed is between 70 ÷ 79 1/min ExampIe 11003 The speed is between 120 ÷ 129 1/min 11003 The speed is between 1200 ÷ 1299 1/min 11003 Gearbox TARGO K CLAAS ACADEMY 5-16 11/2001 ! Press the M button twice: The speed will then be displayed ! The display is in km/h ! The point in this display is a comma. ! The T LED is switched off in the ,Speed display¨ menue. 7.3 Speed dispIay The speed is 6.7 km/h ExampIe 11004 The speed is approx 12 km/h 11004 CLAAS ACADEMY TARGO K Gearbox 11/2001 5-17 This function allows certain inputs to the gearbox module APC to be checked. 7.4 Input dispIay ! Press the M button three times: The display will then highlight a particular segment that relates to the relative input. See example. ! With the relative operation (gear change, travel direction, kick down or brake clutch switch), the relative segment will be highlighted. ! Each segment denotes that from the relative operation, there is a signal to the gearbox module APC. Ìt is therefore possible to check the relative pins from the APC and the relative wiring loom. S =Segment S ExampIe 1105 By switching into 1st gear, a signal is sent from pin 5 of the component (control lever) to the gearbox module APC on pin 14. The signal can be measured on pin 14 of the gearbox module APC, so that the component and the wiring loom can be shown to be in order. 5 14 Active pins on the controI Iever Active pins on the APC (ModuIe) Gearbox TARGO K CLAAS ACADEMY 5-18 11/2001 Ìn the following table the various segments of the display will be identified (1..8). The segment in position 7 is not available. 1 2 3 4 5 6 7 8 Input test tabIe 14 + 16 9 + 2 2 + 3 Control lever 6 th gear 16 + 15 9 + 13 3 + 6 Control lever 4 th gear 14 + 15 2 + 13 2 + 6 Control lever 2 nd gear 25 Pin in switch 8 Parking brake 25 Pin in switch 8 Brake clutch switch + Foot brake operated 19 8 5 Control lever in reverse 26 1 4 Kick down button 16 9 3 Control lever 5 th gear 15 13 6 Control lever 3 rd gear 14 2 2 Control lever 1 st gear 12 3 1 Control lever forwards Pin no of the gearbox APC (See page 8.2) Pin no of the dispIay Position of the segment Operation Should all the inputs to the APC need to be checked, then the operations as per the table need to be carried out. Ìf all the segments light up, then the APC is receiving all the signals. CLAAS ACADEMY TARGO K Gearbox 11/2001 5-19 8.0 Connection from the controI Iever to the moduIe APC -- -- --- 8 Neutral -- -- 19 8 Reverse -- -- 12 3 Forwards r 5 F 6 16, 14 9 + 2 6 r 5 F 5 16 9 5 r 3 F 4 16, 15 13 + 9 4 r 3 F 3 15 13 3 r 3 F 2 15, 14 13 + 2 2 r 1 F 1 14 2 1 DispIay by traveI direction reverse DispIay by traveI direction forwards Input pin of the controI Iever Output pin of the controI Iever Position ControI Iever (co. Hobbs) The machine is fitted with a control lever from the Hobbs company. Gearbox TARGO K CLAAS ACADEMY 5-20 11/2001 8.1 Pin Iayout for the controI Iever (company Hobbs) To pin 15 on the APC black 13 not used brown 12 not used - 11 not used - 10 To pin 16 on the APC orange 9 To pin 19 on the APC (reverse) yellow 8 Power supply blue 7 not used - 6 not used - 5 not used - 4 To pin 12 on APC (forwards) violet 3 To pin 14 on APC green 2 kick down and to pin 26 on APC red 1 Note Wiring coIour Pin on controI Iever CLAAS ACADEMY TARGO K Gearbox 11/2001 5-21 8.2 Pin Iayout APC Not used 28 Not used 27 Signal from the kick down switch 26 Signal from the brake clutch switch or the parking brake 25 Not used 24 Machine earth 23 Speed sensor earth 22 Machine earth 21 Power supply, speed sensor 20 Signal from control lever pin 8 19 Not used 18 Signal from road travel switch (hydraulic). When the road travel switch is operated, then the display switches from the gear to the travel speed = Option 17 Signal from control lever pin 9 16 Signal from control lever pin 13 15 Signal from control lever pin 2 14 Signal to solenoid valve S 13 Signal from the control lever pin 3 12 31 11 30 10 Not used 9 Not used 8 Solenoid valve reverse 7 Solenoid valve F 6 Solenoid valve 2 5 Solenoid valve 1 4 Not used 3 earth (-31) 2 Power supply (+30) 1 Operation Pin Gearbox TARGO K CLAAS ACADEMY 5-22 11/2001 9.0 APC dispIay test ! Ìn this menu, the signal from the output pins of the APC can be checked to the component. ! Ìn order to select the function ¨APC output test¨, the ignition must be switched on and the button M pressed. ! Ìn the display, the following information will be displayed: G = Good S = Short to earth O = Open circuit or short circuit Output 1 to the component is good (G) ExampIe 11006 Output 2 to the component is shorted to earth (S) 11006 Output 3 has an open circuit to the component or is shorting to the positive (O) 11006 CLAAS ACADEMY TARGO K Gearbox 11/2001 5-23 The number (1.8) in the display relates to definite output pins of the APC. Pins 3, 8 and 9 are not active, that is why the display shows a ¨O¨ for open circuit. 9.1 ExpIanation of dispIay No operation, in display shows 8 O 3 8 No operation, in display shows 7 O 8 7 Signal to solenoid valve S 13 6 No operation, in display shows 5 O 9 5 Solenoid valve 2 5 4 Solenoid valve 1 4 3 Solenoid valve reverse 7 2 Solenoid valve F 6 1 Comment APC output pins DispIay 10.0 Kick down When the kick down button is pressed, depending on the speed, the APC will switch down to the next gear. Ìf the speed is too high, then the APC will wait for 5 sec for the speed to drop. Ìf after 5 sec the speed is not low enough, then the instruction will be ignored. 11.0 Automatic switching The gearbox will switch between 5/3 and 6/3 automatically. At the desired speed, the gearbox will automatically switch up or down. The automatic only works in the 4 th , 5 th and 6 th gear. Gearbox TARGO K CLAAS ACADEMY 5-24 11/2001 12.0 Gearbox Iayout The T 12000 gearbox has 5 main elements, which have been highlighted by the different colours in the diagram. Turbine, pump drive and pressure regulation valve Ìnput shaft, travel direction clutches and 4 th high clutch Travel speed clutches 1, 2 and 3 Output shaft CLAAS ACADEMY TARGO K Gearbox 11/2001 5-25 12.1 Layout of the cIutches Reverse and forwards 1 and 2 clutches Reverse intermediate gear 4 th high and 3 clutch Output shaft The gearbox clutches are multi plate. They are for: ! Change over clutches for changing direction of travel ! To allow for the switching of individual gears. The gearbox clutches are either individual or double clutches. With the double clutches, two clutch plates are used together for one function. Gearbox TARGO K CLAAS ACADEMY 5-26 11/2001 12.2 Structure of the doubIe cIutch This supplies lubrication to the clutch pack which is required in the take up phase. Lubrication C Pressurisation of the right ram (right clutch pack) Oil supply B pressurisation of the left ram (left clutch pack) Oil supply A With slot for the pressurisation of the ram (5) as well as for lubrication (not shown) Drive shaft 7 Ìs coupled to both clutch housings. Drive gear 6 Forces the multi-plate clutch pack together when pressurised Ram 5 Splined to the clutch housing (outer) Clutch plates 4 Splined to the clutch carrier (inner) Clutch lining 3 Pushes the ram (5) onto the end stop of the drive gear (1). The multi-plate clutch pack is then open. Pressure spring 2 Splined to the drive shaft (7) Output gear 1 Comments Description Position CLAAS ACADEMY TARGO K Gearbox 11/2001 5-27 With a double clutch is in use, then only one of the clutches will be closed. The cutch housing will be driven either via the drive gear (6) or by the drive shaft (7). For example, if pressure was supplied to connector A from the relative solenoid valve, it will press against the ram (5), the clutch plate (4) presses against the lining (3) and therefore the clutch is closed. The clutch plate (4) is now tied in with the drive shaft (1) via the clutch housing and so the clutch drives. The power goes from the drive shaft (7), via the closed clutch packet onto the drive gear (1). The connection B for the non operated clutch has a connection via the relative solenoid valve back to tank, the spring (2) and the ram (5) are in the disengaged position and therefore the clutch is open. The clutch multi plates are lubricated via connection C. The lubrication oil flows through the grooves and reduces the heat during the take up phase. The lubrication oil comes from the gearbox pump, via the oil cooler to the clutch packs. Operation Gearbox TARGO K CLAAS ACADEMY 5-28 11/2001 13.0 T12000 Powershift gearbox Z1 Gear 1 bolted to reverse clutch Z2 Gear 2 bolted to the forwards clutch Z3 Gear 3 bolted to the input shaft Z4 Gear 4 bolted to the 4 th high clutch Z5 Gear 5 bolted to the clutch 3 Z6 Gear 6 bolted to the intermediate drive shaft Z7 Gear 7 bolted to the clutch 1 Z8 Bolted to the clutch 2 E Ìnput shaft V1 Ìntermediate shaft 1 V2 Ìntermediate shaft 2 CLAAS ACADEMY TARGO K Gearbox 11/2001 5-29 14.0 Switching arrangement of the soIenoids Reverse and 3 Reverse R5 Reverse and 2 Reverse and 2 R3 Reverse and 1 Reverse 1 and 2 R1 Forwards and 1 F, 1 and 2 F1 4 th high and 1 F, S, 1 and 2 F2 Forwards 2 clutch F and 2. F3 4th high and 2 F, S and 2 F4 Forwards, 3 rd clutch F F5 4 th high and 3 F und S F6 Switched cIutch Active soIenoid vaIve Gear TabIe 6/3 gearbox E-MV = Solenoid valve F = Forwards R = Reverse Reverse and 3 Reverse R5 Reverse and 2 Reverse and 2 R3 Reverse and 1 Reverse 1 and 2 R1 Forwards and 1 F, 1 and 2 F1 4 th high and 1 F, S, 1 and 2 F2 Forwards 2 clutch F and 2 F3 4 th high and 2 F, S and 2 F4 Forwards, 3 rd clutch F F5 Switched cIutch Active soIenoid vaIve Gear TabIe 5/3 gearbox E-MV = Solenoid valve F = Forwards R = Reverse Reverse and 2 Reverse and 2 R3 Reverse and 1 Reverse 1 and 2 R1 Forwards and 1 F, 1 and 2 F1 4 th high and 1 F, S, 1 and 2 F2 Forwards 2 clutch F and 2 F3 4 th high and 2 F, S and 2 F4 Switched cIutch Active soIenoid vaIve Gear TabIe 4/2 gearbox E-MV = Solenoid valve F = Forwards R = Reverse With the 5/3 gearbox, the gear F6 is closed. With the 4/2 gearbox, gears F5, F6 and R5 are closed. Gearbox TARGO K CLAAS ACADEMY 5-30 11/2001 15.0 Gearbox hydrauIics and power train The terms listed in this table apply for each circuit diagram that follows TransIation E-MV bestromt ! 1. Kupplung 1ST Clutch 2. Kupplung 2ND Clutch 3. Kupplung 3RD Clutch 4. Hoch Kupplung (4TH-High) Clutch Vorwärtskupplung Forward Clutch Rückwärtskupplung Reverse Clutch Closes the clutch 1 E-MV 1 1 st Solenoid Close the clutch 2 or 3 E-MV 2 2 nd Solenoid Controls the pressure to the E-MV S or to the E-MV reverse. E-MV F Forward Solenoid Controls the pressure to the clutch 4 th high or to the clutch forwards E-MV S Splitter Solenoid Closes the reverse clutch E-MV Rückwärts Reverse Solenoid Build the pressure up in the forwards and reverse clutch slowly Druckaufbauventil Modulation Valve Pressure in this circuit is at 2.9..4.0 bar Schmierung 4. Hoch- und Geschwindigkeits kupplungen Lubrication 4 th -High- and Range Clutch Connects the engine to the gearbox. Wandler Torque Converter Pressure in the lubrication line runs at 2.9..4.0 bar Schmierung Vor- und Rückwärts Kupplung Lubrication Forward and Reverse Clutch Ölkühler Cooler Secures the torque converter and cooling circuit to 8.27.10.2 bar Druckbegrenzungs ventil Safety Valve Regulates the system pressure to 16.5.19.3 bar Druckregelventil Pressure Regulator Valve Comments German EngIisch E-MV = Solenoid valve CLAAS ACADEMY TARGO K Gearbox 11/2001 5-31 The clutch 3 is active; no solenoid valve is yet switched. 15.1 NeutraI Gearbox TARGO K CLAAS ACADEMY 5-32 11/2001 Notes CLAAS ACADEMY TARGO K Gearbox 11/2001 5-33 Solenoids 1, 2 and F are powered. The speed clutch 1 and the forward travel direction clutch are engaged. 15.2 1 st Gear Gearbox TARGO K CLAAS ACADEMY 5-34 11/2001 Engaged are: - the speed clutch 1 (1ST) and - the forward travel clutch (FWD) CLAAS ACADEMY TARGO K Gearbox 11/2001 5-35 Solenoids 1, 2, F and S are powered. The speed clutch 1 and 4 th - High clutch are engaged. 15.3 2 nd Gear Gearbox TARGO K CLAAS ACADEMY 5-36 11/2001 Engaged are - the speed clutch 1 (1 st ) and the 4 th - High clutch CLAAS ACADEMY TARGO K Gearbox 11/2001 5-37 The solenoids 2 and F are powered. Speed clutch 2 and forwards travel direction clutch are engaged. 15.4 3 rd gear Gearbox TARGO K CLAAS ACADEMY 5-38 11/2001 Engaged are: - speed clutch 2 and - forwards travel clutch. CLAAS ACADEMY TARGO K Gearbox 11/2001 5-39 The solenoid valves 2, F and S are powered. Speed clutch 2 and clutch 4 th high are engaged. 15.5 4 th gear Gearbox TARGO K CLAAS ACADEMY 5-40 11/2001 Engaged are: - speed clutch 2 and - clutch 4 th high CLAAS ACADEMY TARGO K Gearbox 11/2001 5-41 The solenoid valve F is powered. Speed clutch 3 and forwards travel clutch are engaged. 15.6 5 th gear Gearbox TARGO K CLAAS ACADEMY 5-42 11/2001 Engaged are: - speed clutch 3 and - forwards travel clutch. CLAAS ACADEMY TARGO K Gearbox 11/2001 5-43 The solenoid valves F and S are powered. Speed clutch 3 and clutch 4 th High are engaged. 15.7 6 th gear Gearbox TARGO K CLAAS ACADEMY 5-44 11/2001 Engaged are: - speed clutch 3 and - clutch 4 th High CLAAS ACADEMY TARGO K Gearbox 11/2001 5-45 The solenoids 1, 2 and reverse are powered. Speed clutch 1 and reverse travel clutch are engaged. 15.8 Reverse 1 st gear Gearbox TARGO K CLAAS ACADEMY 5-46 11/2001 Engaged are: - speed clutch 1 and - reverse travel direction clutch CLAAS ACADEMY TARGO K Gearbox 11/2001 5-47 Reverse and 3 Reverse R5 Reverse and 2 Reverse and 2 R3 Active cIutch Active soIenoid vaIve Gear 15.9 Switching pairs for R3 and R5 15.10 Gearbox pump P Gearbox pump 15.11 ModuIation vaIve A Modulation valves Gearbox TARGO K CLAAS ACADEMY 5-48 11/2001 15.12 System pressure sensor 32 Sensor for the system pressure (16,5 - 19,5 bar) Should the system pressure become too low, then the sensor switches on the warning light in the claas display unit. 15.13 Temperature sensor 71 Sensor for the gearbox temperature Should the gearbox temperature become too high, then the sensor will switch on the warning light on the Claas display unit. CLAAS ACADEMY TARGO K Gearbox 11/2001 5-49 15.14 Test ports M12 Return line oil cooler M41 1. speed clutch M42 2. speed clutch M71 Gearbox oil temperature M43 3. speed clutch M11 Flow to oil cooler M31 System pressure M44 Speed clutch 4 high M45 forwards travel clutch M46 Reverse travel clutch Gearbox TARGO K CLAAS ACADEMY 5-50 11/2001 M31 System pressure M32 Ìnput oil cooler pressure M33 Output oil cooler pressure 70 - 120° C Gearbox temperature M71 16,5 - 19,5 bar Reverse travel clutch M46 16,5 - 19,5 bar Forwards travel clutch M45 16,5 - 19,5 bar Speed clutch 4 high M44 16,5 - 19,5 bar 3 speed clutch M43 16,5 - 19,5 bar 2. speed clutch M42 2,9 - 4,0 bar Output oil cooler pressure and Lubrication M33 2,9 - 6,4 bar Ìnput oil cooler pressure M32 16,5 - 19,5 bar System pressure M31 Pressure reading Description Test port 15.15 Pressure vaIues Required adaptor: 2 pieces, part number 217068.0 CLAAS ACADEMY TARGO K Gearbox 11/2001 5-51 16.0 Targo K without gearbox moduIe (APC) This option is easy to identify, as there is no display in the cab. 16.1 TechnicaI data See sub chapter 1.0 16.2 Gearbox overview See sub chapter 2.0 16.3 Gearbox identification pIate See sub chapter 3.0 16.4 Speed sensor Not available 16.5 Layout of the soIenoid vaIves See sub chapter 5.0 16.6 Gearbox moduIe APC Not available 16.7 DispIay menus Not available Gearbox TARGO K CLAAS ACADEMY 5-52 11/2001 16.8 ControI Iever (Company Britax) Britax controI Iever F Control lever S1 Connector from the control lever to the solenoid valves M Multifunction lever S2 Connector, multifunction lever to the functions Pin Iayout for the controI Iever Connector (S1) not available 12 Power supply (+15) blue 11 Not in use not available 10 Not in use not available 9 Reverse solenoid White/Green 8 Solenoid valve F Blue/Yellow 7 Not in use Brown 6 Travel direction switch (+15) Red 5 Solenoid valve S White 4 Not in use Green 3 Solenoid valve 2 Yellow 2 Solenoid valve 1 grey 1 Comment CabIe coIour ControI Iever pin CLAAS ACADEMY TARGO K Gearbox 11/2001 5-53 16.9 ControI Iever connection to the soIenoid vaIves not in use 12 Power supply via K4 Blue 11 ÷ Not in use 10 ÷ Not in use 9 W105 (Solenoid valve reverse) White/Green 8 W106 (Solenoid valve F) Blue/Yellow 7 not in use Brown 6 Switch (Direction travel F/N/R) power supply via K4 Red 5 W99 (Solenoid valve S) White 4 not in use Green 3 W97 (Solenoid valve 2) Yellow 2 W98 (solenoid valve 1) Grey 1 Comment CabIe coIour Pin W101+W102 (ControI Iever) Gearbox TARGO K CLAAS ACADEMY 5-54 11/2001 The solenoid valve controls The relative clutch in the gearbox Solenoid valve F W 106 Reverse solenoid valve W 105 From Britax Gear change switch (travel lever) W 102 Switch, travel direction (V, N, R lever) W 101 The solenoid valve controls The relative clutch in the gearbox Solenoid valve S W 99 The solenoid valve controls The relative clutch in the gearbox Solenoid valve 1 W 98 The solenoid valve controls The relative clutch in the gearbox Solenoid valve 2 W 97 Separate near fuse box Starting lock (travel lever in reverse position) K 11a Separate near fuse box Starting lock (travel lever in forwards position) K 11 Separate near fuse box Brake clutch relay K 4 Comment ReIay Position 16.10 Kick down Not available 16.11 Automatic switching Not available 16.12 Gearbox assembIy, Iayout of the cIutches and assembIy of the doubIe cIutch See sub chapter 12.0, 12.1 and 12.2 16.13 Power shift gearbox T12000 See sub chapter 13.0 CLAAS ACADEMY TARGO K Gearbox 11/2001 5-55 16.14 SoIenoid switching pairs Reverse and 3 Reverse R3 Reverse and 2 Reverse and 2 R2 Reverse and 1 Reverse,1 and 2 R1 Forwards and 1 F, 1 and 2 F1 4 th high and 1 F, S, 1 and 2 F2 Forwards, clutch 2 F and 2 F3 4 th high and 2 F,S and 2 F4 Switched cIutch Active soIenoid vaIve Gear TabIe 4/3 gearbox E-MV = Solenoid valve F= Forwards R = Reverse Ìn travel lever ÷ position R4 the gearbox switches into the R3 gear Reverse and 3 Reverse R3 Reverse and 2 Reverse and 2 R2 Reverse and 1 Reverse,1 and 2 R1 Forwards and 1 F, 1 and 2 F1 4 th high and 1 F, S, 1 and 2 F2 Forwards, clutch 2 F and 2 F3 Switched cIutch Active soIenoid vaIve Gear TabIe 3/3 gearbox E-MV = Solenoid valve F= Forwards R = Reverse Ìn travel lever - position F4 the gearbox switches into the F3 gear. Ìn travel lever - position R4 the gearbox switches into the R3 gear. 16.15 Gearbox hydrauIics and power train See sub chapter 15.0 Gearbox pump see sub chapter 15.10 Modulation valve see sub chapter 15.11 System pressure sensor see sub chapter 15.12 Temperature sensor see sub chapter 15.13 Measurement table see sub chapter 15.14 Pressure values see sub chapter 15.15 Gearbox TARGO K CLAAS ACADEMY 5-56 11/2001 1.0 Steering hydrauIics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 1.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 2.0 Steering operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 2.1 Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 2.2 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 3.0 Steering unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 3.1 Adaptor connection . . . . . . . . . . . . . . . . . . . . . . . . 7-9 3.2 Steering pressure monitoring . . . . . . . . . . . . . . . 7-10 3.3 Steering measurement table . . . . . . . . . . . . . . . . 7-11 4.0 AxIe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 4.1 Adjustment notes on the bevel gear shaft . . . . . 7-12 Contents CLAAS ACADEMY TARGO K Axle / steering 11/2001 7-1 1.0 Steering hydrauIics Axle / steering TARGO K CLAAS ACADEMY 7-2 11/2001 2 LS pump 3 Compensator 4 Sieve in tank 10 Brake valve kick plate 15 Front steering ram 19 Rear steering ram 21 Danfoss OSPF steering unit 21a Rotary plate valve 22 4/3 way solenoid valve for steering type 23 PRV 175 bar 24 Shock valve 225 ÷ 245 bar 25 Base plate PVSP 26-31 Working hydraulics solenoid valve 41 Working hydraulics priority valve 42 Steering priority valve 44 Accumulator charge valve 47 Trailer hydraulic braking 62 Steering pressure oil pressure switch (optional) M5 Steering test port T Tank 1.1 Components CLAAS ACADEMY TARGO K Axle / steering 11/2001 7-3 2.0 Steering operation 2.1 NeutraI 1 Axle / steering TARGO K CLAAS ACADEMY 7-4 11/2001 01 Hydraulic tank 03 LS pump 04 Pressure filter 22 Priority valve 23 Pressure relief valve 24 Shock valve 25 Rotary plate valve 26 Steering ram Key Ìn the neutral position, the pressure is dumped to tank 1 via the spring area of the priority valve 22 and the rotary valve 25 and the supply from the pump 3 is locked. The build up of back pressure builds up against the spool of the priority valve 22 against the spring which allows the oil flow for the working hydraulics 30. Operation CLAAS ACADEMY TARGO K Axle / steering 11/2001 7-5 2.2 Steering 1 Axle / steering TARGO K CLAAS ACADEMY 7-6 11/2001 01 Hydraulic tank 03 LS pump 04 Pressure filter 22 Priority valve 23 Pressure relief valve 24 Shock valve 25 Rotary valve 26 Steering ram Key By turning the wheel, back pressure on the spool in the priority valve 22 is momentarily connected together and the control line to the spring area of the priority valve 22 and the back pressure side of the rotary valve 25 are connected. The spring in the priority valve 22 and the change in pressure in the steering, moves the spool into one position which distributes the required oil to the steering. Overpressure Should the pressure exceed 175 bar, then the pressure relief valve 23 is opened which dumps oil from the spring area of the priority valve 22 back to tank 1. The higher pressure on the opposite side operates the spool against the spring, so the oil flow is redirected to the working hydraulics 30. Operation CLAAS ACADEMY TARGO K Axle / steering 11/2001 7-7 3.0 Steering unit O Steering unit OSPF250 A Adaptor E Steering mode valve The components (O, A, E) can be found on the floor area directly next to the brake valve kicker plate. The connection from steering to the wheels is done by the steering orbital. The hydraulic lines for the steering is done via the adaptor. The steering valve enables the different steering modes. Axle / steering TARGO K CLAAS ACADEMY 7-8 11/2001 3.1 Adaptor connection C2 C1 P C4 T 002 C1 Steering ram rear axle C2 Steering ram rear axle C4 Steering ram front axle P LS pump T Tank The P connection from the LS pump is via the base plate PVSP (working hydraulics) A O E C3 003 C3 Steering ram front axle O Steering orbital OSPF250 A Adaptor E Steering mode valve CLAAS ACADEMY TARGO K Axle / steering 11/2001 7-9 LS 004 LS Connection The LS connection is via the base plate PVSP (working hydraulics) to the LS pump (compensator). 3.2 Steering pressure monitoring (OptionaI) 7005 L Oil pressure steering switch (10bar) V Transfer gearbox 13 Oil pressure switch Brake coupling circuit (16bar) Should the system pressure of the steering drop below the required amount, then the steering oil pressure switch (L) sends a signal to the warning light (9) in the cab. Axle / steering TARGO K CLAAS ACADEMY 7-10 11/2001 Warning Iight 9 Warning light steering pressure 10 Warning light brake pressure Should the system pressure of the steering drop below the required amount, then the steering oil pressure switch (L) sends a signal to the warning light (9) in the cab. 3.3 Steering measurement tabIe 7005 M 5 Steering test port L Steering oil pressure switch (10bar) (optional) V Transfer gearbox 13 Brake circuit (16bar) Return = 35 +7 bar System pressure = 170 +15 bar Shock valve = 230 ±15 bar NOTE! The readings are taken with the engine at full speed and the oil at working temperature of 60°C. Pressure readings CLAAS ACADEMY TARGO K Axle / steering 11/2001 7-11 4.0 AxIe 7002 The tracking with the front axle is 0 - 2 mm The tracking with the rear axle is 0 mm 1 2 3 4.1 Adjustment notes on the beveI gear shaft This note is not available in the workshop manual. ran-038 Axle / steering TARGO K CLAAS ACADEMY 7-12 11/2001 1 Upsetting bush always renew 2 Thrust washer 3 Nut determines the pretension of the roller bearings and thus the correct rolling torque of the shaft: Rolling torque of the shaft without the crown wheel: 92 .138 N Rolling torque with the crown wheel installed and adjusted correctly: 115.7 . 173.6 N. Gear tooth play 0.18 . 0.25 mm S B Y D/2 D Determining the thrust washer (2) ran-039 1. Determine the dimension B: B=D/2-Y+S 2. Determine the thrust washer required: Remove the crown wheel and deduct from B e.g crown wheel: 107.00 = 1.07 ran-040 The max allow washer thickness must not exceed ± 0.1 mm CLAAS ACADEMY TARGO K Axle / steering 11/2001 7-13 1.0 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 1.1 kicker plate ÷ brake valve . . . . . . . . . . . . . . . . . . . 8-2 1.2 kicker plate ÷ brake valve for dual braking . . . . 8-3 1.3 Kicker plate ÷ brake valve of single braking circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 1.4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 1.5 Accumulator valve . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 1.6 Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 1.7 Oil return switch for the brake clutch switch . . . 8-13 1.8 Oil pressure switch for the brake lights . . . . . . . 8-14 2.0 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 2.1 Parking brake hydraulics . . . . . . . . . . . . . . . . . . . 8-15 2.2 Constant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 2.3 Pressure reduction valve . . . . . . . . . . . . . . . . . . . 8-16 2.4 Oil pressure switch for the parking brake . . . . . 8-17 2.5 Adjusting the parking brake . . . . . . . . . . . . . . . . . 8-18 2.6 Parking brake from machine number 51200318 8-21 2.7 Pressure reduction valve from 51200318 . . . . . 8-23 2.8 Oil pressure switch for the parking brake from machine number 51200318 . . . . . . . . . . . . . . . . . 8-24 2.9 Setting the parking brake from 51200318 . . . . . 8-25 3.0 Front axIe brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27 3.1 Brake elements . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27 3.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29 Contents CLAAS ACADEMY TARGO K Brakes 11/2001 8-1 The brakes are hydraulically operated and are either single circuit or dual circuit. The supply for the hydraulic pressurisation is from the pump. 1.0 Brakes 1.1 Kicker pIate - brake vaIve Those point marked with a point are available in the repair kit (316 893.0) Brakes TARGO K CLAAS ACADEMY 8-2 11/2001 1.2 Kicker pIate - brake vaIve for duaI braking 10 Kicker plate brake valve P Connection to pump (pressure) T Connection to tank (return) A Connection to the rear brake rams B Connection to the front brake rams The kicker plate brake valve can be found in the foot area next to the orbital. The pump connections (P) are connected via the accumulator valve (base plate PVSP) from the LS pump. CLAAS ACADEMY TARGO K Brakes 11/2001 8-3 H8106.1 8 Brakes TARGO K CLAAS ACADEMY 8-4 11/2001 Accumulator pressure Test port M4 LS pressure Test port M1 Accumulator charge Pressure Test port B3 For trailer braking Quick release coupling 48 The valve controls the pressure to the trailer brakes (Hydraulic braking) 3/3 way valve 47 During starting the P connection is connected to the tank Start valve 45 Loads between 139 ÷ 158 bar Accumulator valve 44 Filter 43 For steering Priority valve 42 For working hydraulics Priority valve 41 Change over valve 37 Additional equipment 4/3 way valve 31 Front and rear quick release couplings 4/3 way valve 30 Boom raise and lower 4/3 way valve 29 Front attachment crowd 4/3 way valve 28 Boom reach and retract 4/3 way valve 27 With PRV, pressure balance, pressure reduction valve (14 bar) End plate 26 With priority valve and accumulator valve. Base plate PVSP 25 Danfoss OSPF 250 Steering unit 21 Ìn accumulator ÷ pressure system One way valve 20 Rear axle 18 parking brake activation (NC) Oil pressure switch 17 5 bar brake lights (NO) Oil pressure switch 16 With brake rams and parking brake ram front axle 14 Brakes ÷ clutch switch (cab) is switched when the pressure is obtained then opens the clutches. NO 16 bar Oil pressure switch 13 Should the pressure drop to below 116 bar, then the switch is activated and switches on the warning in the cab. NC 116 bar Oil pressure switch 12 41 bar pre-pressurised Accumulator 11 for dual brakes Kicker plate brake valve 10 17-20 bar (parking brake) Pressure reduction valve 8 in tank Suction sieve 4 Flanged to the LS pump Compensator 3 max 120 l/min LS pump 2 80 litres Hydraulic tank 1 Comments Description Pos CLAAS ACADEMY TARGO K Brakes 11/2001 8-5 1.3 Kicker pIate - brake vaIve of singIe braking circuit 10 Kicker plate valve P Connection to pump (pressure) T Connection to tank (return) A Connection to the rear brake rams The kicker plate brake valve can be found in the foot area next to the steering orbital. The pump connection (P) is connected via the accumulator valve (base plate PVSP) from the LS pump. Brakes TARGO K CLAAS ACADEMY 8-6 11/2001 Notes CLAAS ACADEMY TARGO K Brakes 11/2001 8-7 8 Brakes TARGO K CLAAS ACADEMY 8-8 11/2001 Accumulator pressure Test port M4 LS pressure Test port M1 Accumulator charge Pressure Test port B3 For trailer braking Quick release coupling 48 The valve controls the pressure to the trailer brakes (Hydraulic braking) 3/3 way valve 47 During starting the P connection is connected to the tank Start valve 45 Loads between 139 ÷ 158 bar Accumulator valve 44 Filter 43 For steering Priority valve 42 For working hydraulics Priority valve 41 Change over valve 37 Additional equipment 4/3 way valve 31 Front and rear quick release couplings 4/3 way valve 30 Boom raise and lower 4/3 way valve 29 Front attachment crowd 4/3 way valve 28 Boom reach and retract 4/3 way valve 27 With PRV, pressure balance, pressure reduction valve (14 bar) End plate 26 With priority valve and accumulator valve. Base plate PVSP 25 Danfoss OSPF 250 Steering unit 21 Ìn accumulator ÷ pressure system One way valve 20 Rear axle 18 parking brake activation (NC) Oil pressure switch 17 5 bar brake lights (NO) Oil pressure switch 16 With brake rams and parking brake ram front axle 14 Brakes ÷ clutch switch (cab) is switched when the pressure is obtained then opens the clutches. NO 16 bar Oil pressure switch 13 Should the pressure drop to below 116 bar, then the switch is activated and switches on the warning in the cab. NC 116 bar Oil pressure switch 12 41 bar pre-pressurised Accumulator 11 for single brakes Kicker plate brake valve 10 17-20 bar (parking brake) Pressure reduction valve 8 in tank Suction sieve 4 Flanged to the LS pump Compensator 3 max 120 l/min LS pump 2 80 litres Hydraulic tank 1 Comments Description Pos CLAAS ACADEMY TARGO K Brakes 11/2001 8-9 3 2 1 10 P T A 1.4 AssembIy Working hydraulics tank Connection T Here sits the system pressure (128...159 bar) from the accumulator. Connection P To the wheel brake ram for the brakes Max brake pressure = 44 bar Connection A Operates from the brake pedal against the return spring (3) Ram 10 Pushes the ram (10) against the brake pedal. Return spring 3 Ìs held by its spring (1) in the neutraI position. Therefore: The pressure connection (P) is closed. The connection to the brakes (A) and the tank (T) are joined. When braking the control spool is operated therefore: The connection (A) is made to the connection (T). And via the control edge, the connection from (P) to (A) is opened. On this control edge the brake pressure is regulated. Less force on the pedal = less movement of the control spool = less opening of the control edge = less brake pressure. The brake pressure is via a small hole in the control spool spring (1). With the operating pressure (from top) and the brake pressure (from below), the spool is regulated. Control spool 2 Spring control spool 1 Comments Description Pos Brakes TARGO K CLAAS ACADEMY 8-10 11/2001 1.5 AccumuIator vaIve 44 Accumulator valve B1 Connection to the kicker plate valve (P) B2 Connection, trailer hydraulic braking M4 Test port for the charge pressure The accumulator valve (44) is found in the base plate PVSP (control unit). When the accumulator pressure is charged, then the actual charge pressure is found on the LS sensing line of the pump. The pump reacts. Ìf the load pressure is reached, then the load line is released to tank. The regulates to the standby condition. The max accumulator pressure can reach approx 160 bar. CLAAS ACADEMY TARGO K Brakes 11/2001 8-11 1.6 AccumuIator 8003 11 Accumulator 41 bar pre pressurised 12 Oil pressure switch 116 bar 20 One way valve On a single braking system, there is only one accumulator and one oil pressure switch. The accumulator can be found on the rear axle, left of the drive shaft. Brakes TARGO K CLAAS ACADEMY 8-12 11/2001 1.7 OiI return switch for the brake cIutch switch 13 Oil pressure switch for the brake clutch circuit (15 bar) 62 Oil pressure switch for the steering pressure (10bar) The brake clutch switch in the cab is switched. Activate the brakes using the brake pedal. The brake pressure activates the oil pressure switch for the brake clutch circuit (13) which in turn sends a signal to the APC module. This signals allows the module to control the solenoid valves for the transmission clutches and the clutches open. CLAAS ACADEMY TARGO K Brakes 11/2001 8-13 1.8 OiI pressure switch for the brake Iights 16 Oil pressure switch for the brake lights (5bar) 17 Oil pressure switch for the parking brake (16bar) S Steering adjustment switch When the brake pedal is pressed, the brake light oil pressure switch is activated (16) which then completes the circuit for the brake lights. The signal from the parking brake (17) is available when the parking brake is activated. The switch can be found on the front axle. Ìf the wheels are standing straight, then the steering adjustment switch (S) is active. This will illuminate the light in the cab. Brakes TARGO K CLAAS ACADEMY 8-14 11/2001 2.0 Parking brake The parking brake is a sprung loaded braking system, that's released hydraulically. By switching on the switch in the cab, allows the pressure reduction valve to operate supplying a limited amount of oil pressure to the wheel rams. The oil supply is from the constant pump (Parker) which also supplies the oil to the oil motor for the fan. Additionally the constant pump send oil through the filter. 2.1 HydrauIic 6 Constant pump 50 litres 7 Fan motor (16 cm 3 /rpm) 8 pressure reduction valve 9 Pressure filter with by-pass 10 Front axle with hand brake ram 16 Brake light oil pressure switch (NO) 17 parking brake oil pressure switch (NC) M2 Test port for the parking brake CLAAS ACADEMY TARGO K Brakes 11/2001 8-15 2.2 Constant pump 6 Constant pump (parker) 50 l/min 2.3 Constant pump 8 Pressure reduction valve R Position potentiometer The pressure reduction valve (8) is controlled from the position potentiometer (R). The potentiometer is adjustable for when the parking brake pressure is outside the tolerated limits. The oil should have a temperature of 60°C. Brakes TARGO K CLAAS ACADEMY 8-16 11/2001 2.4 OiI pressure switch for the parking brake 8006 17 Parking brake oil pressure switch (NC) The ¨parking brake¨ light is illuminated, when the parking brake oil pressure switch (17) sends back a signal. CLAAS ACADEMY TARGO K Brakes 11/2001 8-17 2.5 Adjusting the parking brake OperationaI M2 Parking brake test port ! Bring the oil temperature up to 60°C ! Park the machine on level ground ! Chock the front and rear wheels ! Connect a 60 bar test gauge to the test port M2 ! Start the engine and wait for the charging light to extinguish ! Release the parking brake ! Measure the pressure and note down. ! The values should be between 17-19 bar ! Should the value not lie between these values, then adjust the potentiometer (E) until the pressures end up between 17-19 bar (see next page). Brakes TARGO K CLAAS ACADEMY 8-18 11/2001 P Potentiometer S Fixing bolt X Do not slacken these bolts ! Slacken off the fixing bolts (S) and unbolt the back side of the cover (G). ! NO DOT SLACKEN OFF THE BOLTS (X) ! Should the pressure not be within tolerance, then adjust the adjusting screw (E) until the values come to between 17-19 bar. E Potentiometer adjusting screw G Housing cover The rear side of the potentiometer with housing cover is shown in the picture. CLAAS ACADEMY TARGO K Brakes 11/2001 8-19 Notes Brakes TARGO K CLAAS ACADEMY 8-20 11/2001 2.6 Parking brake from machine serial number 51200318 CLAAS ACADEMY TARGO K Brakes 11/2001 8-21 Accumulator pressure Test port M4 Parking brake Test port M2 LS pressure Test port M1 Accumulator charge Pressure Test port B3 For trailer braking Quick release coupling 48 The valve controls the pressure to the trailer brakes (hydraulic brake) 3/3 way valve 47 During starting the P connection is connected to the tank Start valve 45 Loads between 139 ÷ 158 bar Accumulator valve 44 Filter 43 For steering Priority valve 42 For working hydraulics Priority valve 41 Change over valve 37 Additional equipment 4/3 way valve 31 Front and rear quick release couplings 4/3 way valve 30 Boom raise and lower 4/3 way valve 29 Front attachment crowd 4/3 way valve 28 Boom extension/retraction 4/3 way valve 27 With PRV, pressure balance, pressure reduction valve (14 bar) End plate 26 With priority valve and accumulator valve. Base plate PVSP 25 Danfoss OSPF 250 Steering unit 21 Ìn accumulator ÷ pressure system One way valve 20 Rear axle 18 parking brake activation (NC) Oil pressure switch 17 5 bar brake lights (NO) Oil pressure switch 16 With brake rams and parking brake ram front axle 14 Brakes ÷ clutch switch (cab) is switched when the pressure is obtained then opens the clutches. (NO) 16 bar Oil pressure switch 13 Should the pressure drop to below 116 bar, then the switch is activated and switches on the warning in the cab. (NC) 116 bar Oil pressure switch 12 41 bar pre-pressurised Accumulator 11 for dual brakes Kicker plate brake valve 10 17-20 bar (parking brake) Pressure reduction valve 8 in tank Suction sieve 4 Flanged to the LS pump Compensator 3 max 120 l/min LS pump 2 80 litres Hydraulic tank 1 Comments Description Pos The modified parking brake also influences the single braking system which works by only using an accumulator (11), a one way valve and a kicker plate brake valve (10) with one 3/3 way valve. From machine serial number 51200318 the parking brake is supplied by the LS pump (2). Note: Single braking system Brakes TARGO K CLAAS ACADEMY 8-22 11/2001 2.7 Pressure reduction vaIve from machine no. 51200318 8 Pressure reduction valve Z Steering ram on the front axle P Position potentiometer The pressure reduction valve (8) is controlled from the potentiometer (P). The potentiometer is adjustable, should the pressure be outside the tolerances. The oil should be run at a temperature of 60°C. CLAAS ACADEMY TARGO K Brakes 11/2001 8-23 2.8 OiI pressure switch for the parking brake from machine number 51200318 17 Parking brake oil pressure switch (NC) Z Front axle steering ram The ¨Parking brake display¨ is active in the cab via the parking brake oil pressure switch (17) signal. Brakes TARGO K CLAAS ACADEMY 8-24 11/2001 2.9 Setting the parking brake from machine no. 51200318 OperationaI M2 Parking brake test port Z Front axle steering ram ! Bring the oil temperature up to 60°C ! Park the machine on level ground ! Chock the front and rear wheels ! Connect a 60 bar test gauge to the test port (M2) ! Start the engine and wait for the charging light to extinguish ! Release the parking brake ! Measure the pressure and note down. ! The values should be between 17-19 bar ! Should the value not lie between these values, then adjust the potentiometer (E) until the pressures end up between 17-19 bar (see next page). CLAAS ACADEMY TARGO K Brakes 11/2001 8-25 P Potentiometer S Fixing bolt X Do not slacken these bolts ! Slacken off the fixing bolts (S) and unbolt the back side of the cover (G). ! NO DOT SLACKEN OFF THE BOLTS (X) ! Should the pressure not be within tolerance, then adjust the adjusting screw (E) until the values come to between 17-19 bar. E Potentiometer adjusting screw G Housing cover The rear side of the potentiometer with housing cover is shown in the picture. Brakes TARGO K CLAAS ACADEMY 8-26 11/2001 3.0 Front axIe brake 3.1 brake eIements 1 Guide pins 2 Parking brake plunger 6 Snap ring 7 Spacer 8 Bellville washers Ìn order to activate the parking brake 9 O ring 10 Ram with pressure stop in order to release the parking brake 11 O ring 12 O ring 13 Brake ram, controlled from the kicker plate brake valve. 14 Clutch plate 15 Brake pads, splined to the shaft 16 Outer brake discs, splined to the hub. CLAAS ACADEMY TARGO K Brakes 11/2001 8-27 Notes Brakes TARGO K CLAAS ACADEMY 8-28 11/2001 3.2 AssembIy CLAAS ACADEMY TARGO K Brakes 11/2001 8-29 ! Connects the planetary drive to the differential ! This is where the brake discs of the disc packet (L) are splined to Shaft 17 When the brake pedal is applied, oil flows from the input A to the pressure chamber 13a. The ram 13 moves to the left, and the disc packet ¨L¨ is closed. = Power engaged. Pressure chamber 13a Ìs operated to the left and therefore closes the disc pack ¨L¨. The brake ram is pressed towards the left: ! When pressure builds up in pressure chamber 13a ! With the Belleville springs 8 brake ram for the working brakes 13 When the engine is running, and the parking brake switch has been released, then the oil flows via the input B to the pressure chamber 10a. The ram 10 is then pressed towards the right and the Belleville springs 8 are compressed. The disc pack ¨L¨ is then open and the parking brake is released. Pressure chamber 10a For the parking brake. ! Pressed towards the left by the Belleville springs 8 ! Ìs pressed to the right, when there is no pressure in the pressure chamber 10a ram 10 Presses the ram 10 to the left, when there is no pressure in the pressure chamber 10a Belleville springs 8 ! Fitted with a securing ring on the right hand side ! Pressed to the left hand side by the Belleville springs ! Pressed to the right hand side (via the securing ring) by the ram 10 Parking brake plunger 2 For the working and the parking brakes ! Ìs splined onto the shaft 17 ! Ìs compressed by the brake ram (13). (closed = power engaged) Disc pack L For oil pressure when releasing the parking brake. The ¨Parking brake¨ switch must be activated. Ìnput B For oil pressure when operating the brakes Ìnput A Comments Description Pos Brakes TARGO K CLAAS ACADEMY 8-30 11/2001 1.0 HydrauIic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 1.1 Hydraulic system (dual braking system) . . . . . . 9-2 1.2 Hydraulic system (single braking system) . . . . . 9-6 1.3 Hydraulic system (dual braking system) From machine serial number 51200318 . . . . . . 9-10 1.4 Hydraulic system (single braking system) From machine serial number 51200318 . . . . . . 9-14 2.0 LS pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18 2.1 Compensator valve assembly . . . . . . . . . . . . . . . 9-18 2.2 Function: initial position (engine off) . . . . . . . . . . 9-19 2.3 Low pressure standby . . . . . . . . . . . . . . . . . . . . . . 9-20 2.4 Upstroking of the pump . . . . . . . . . . . . . . . . . . . . 9-22 2.5 Constant flow control . . . . . . . . . . . . . . . . . . . . . . 9-24 2.6 Derating of the pump . . . . . . . . . . . . . . . . . . . . . . 9-26 2.7 Maximum pressure limiting (PRV operation) . . 9-28 2.8 LS pump connections . . . . . . . . . . . . . . . . . . . . . . 9-30 2.9 Test port working hydraulics . . . . . . . . . . . . . . . . 9-31 3.0 ControI unit working hydrauIics . . . . . . . . . . . . . . . . . . . . 9-32 3.1 Base plate PVSP . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33 3.2 End plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34 4.0 AccumuIator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35 5.0 Switching vaIve - front - rear quick reIease coupIings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35 6.0 Overview vaIves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36 Contents CLAAS ACADEMY TARGO K Working hydraulics 11/2001 9-1 1.0 HydrauIic system 1.1 HydrauIic system (duaI braking system) Steering Priority valve 42 For working hydraulics Priority valve 41 Not proportionally controlled Control spool 40 265 bar Shock valve 39 Proportionally controlled Control spool 38 Change over valve 37 7 bar pre pressurised (pilot oil) Accumulator 36 175 bar Shock valve 35 14 bar pilot oil supply Pressure reducing valve 34 Pressure differential 10 bar Pressure balance 33 290 bar PRV 32 Additional equipment 4/3 way valve 31 Front and rear quick release couplings or hitch 4/3 way valve 30 Boom raise and lower 4/3 way valve 29 Front attachment crowd 4/3 way valve 28 Boom reach and retract 4/3 way valve 27 With PRV, pressure balance, pressure reduction valve (14 bar) End plate 26 With priority valve and accumulator valve. Base plate PVSP 25 225-245 bar Shock valves 24 175 bar PRV steering 23 required for steering modes 4/3 way valve 22 Danfoss OSPF 250 Steering unit 21 Ìn accumulator ÷ pressure system One way valve 20 Rear axle Steering ram 19 Rear axle 18 parking brake activation (NC) Oil pressure switch 17 5 bar brake lights (NO) Oil pressure switch 16 Front axle Steering ram 15 With brake rams and parking brake ram front axle 14 Brakes ÷ clutch switch (cab) is switched when the pressure is obtained then opens the clutches. NO 16 bar Oil pressure switch 13 Should the pressure drop to below 116 bar, then the switch is activated and switches on the warning in the cab. NC 116 bar Oil pressure switch 12 41 bar pre-pressurised Accumulator 11 For dual brakes Kicker plate brake valve 10 With bypass 3,5 bar Pressure filter 9 17-20 bar Pressure reduction valve 8 16 cm 3 Oil motor fan 7 50 l/min supply: fan, filter and parking brake Constant pump 6 Tank breather 5 in tank Suction sieve 4 Flanged to the LS pump Compensator 3 max 120 l/min LS pump 2 80 litres Hydraulic tank 1 Comments Description Pos Working hydraulics TARGO K CLAAS ACADEMY 9-2 11/2001 CLAAS ACADEMY TARGO K Working hydraulics 11/2001 9-3 For the steering pressure. The warning display is illuminated when the steering pressure is not obtained. (Option) Oil pressure switch 62 Tilting the trailer Rear quick release coupling 61 Front quick release coupling 60 Front quick release coupling 59 Hitch 58 Distributes to the hitch and the rear quick release coupling Distribution block 57 Front or rear quick release coupling and hitch Switching valve 56 Boom raise and lower Ram 55 Keeps the front attachment level Compensator ram 54 Front attachment crowd Ram 53 Boom extension / retraction Ram 52 Load release valve 50 For hydraulic trailer brake Quick release coupling 48 This valve controls the pressure to the trailer brakes (hydraulic brakes) 3/3 way valve 47 Operated manually. This will release the ram side from hitch to tank. 2/2 way valve 46 During starting the P connection is released to tank Start valve 45 Charges between 139-158 bar Accumulator valve 44 Filter 43 Comments Description Pos Working hydraulics TARGO K CLAAS ACADEMY 9-4 11/2001 CLAAS ACADEMY TARGO K Working hydraulics 11/2001 9-5 1.2 HydrauIic system (singIe braking system) Steering Priority valve 42 For working hydraulics Priority valve 41 Not proportionally controlled Control spool 40 265 bar Shock valve 39 Proportionally controlled Control spool 38 Change over valve 37 7 bar pre-pressurised (pilot oil) Accumulator 36 175 bar Shock valve 35 14 bar pilot oil supply Pressure reducing valve 34 Pressure differential 10 bar Pressure balance 33 290 bar PRV 32 Additional equipment 4/3 way valve 31 Front and rear quick release couplings or hitch 4/3 way valve 30 Boom raise and lower 4/3 way valve 29 Front attachment crowd 4/3 way valve 28 Boom extension/retraction 4/3 way valve 27 With PRV, pressure balance, pressure reduction valve (14 bar) End plate 26 With priority valve and accumulator valve Base plate PVSP 25 225-245 bar Shock valve 24 175 bar PRV steering 23 required for steering modes 4/3 way valve 22 Danfoss OSPF 250 Steering unit 21 Ìn accumulator ÷ pressure system One way valve 20 Rear axle Steering ram 19 Rear axle 18 parking brake activation (NC) Oil pressure switch 17 5 bar brake lights (NO) Oil pressure switch 16 Front axle Steering ram 15 With brake rams and parking brake ram front axle 14 Brakes ÷ clutch switch (cab) is switched when the pressure is obtained then opens the clutches. (NO) 16 bar Oil pressure switch 13 Should the pressure drop to below 116 bar, then the switch is activated and switches on the warning in the cab. (NC) 116 bar Oil pressure switch 12 41 bar pre-pressurised Accumulator 11 for single brakes Kicker plate brake valve 10 With bypass 3,5 bar Pressure filter 9 17-20 bar Pressure reduction valve 8 16 cm 3 Oil motor fan 7 50 l/min supply: fan, filter and parking brake Constant pump 6 Tank breather 5 in tank Suction sieve 4 Flanged to the LS pump Compensator 3 max 120 l/min LS pump 2 80 litres Hydraulic tank 1 Comments Description Pos Working hydraulics TARGO K CLAAS ACADEMY 9-6 11/2001 CLAAS ACADEMY TARGO K Working hydraulics 11/2001 9-7 For the steering pressure. The warning display is illuminated when the steering pressure is not obtained. (Option) Oil pressure switch 62 Tilting the trailer Rear quick release coupling 61 Front quick release coupling 60 Front quick release coupling 59 Hitch 58 Distributes to the hitch and the rear quick release coupling Distribution block 57 Front or rear quick release coupling and hitch Switching valve 56 Boom raise and lower Ram 55 Keeps the front attachment level Compensator ram 54 Front attachment crowd Ram 53 Boom extension / retraction Ram 52 Load release valve 50 For hydraulic trailer brake Quick release coupling 48 This valve controls the pressure to the trailer brakes (hydraulic brakes) 3/3 way valve 47 Operated manually. This will release the ram side from hitch to tank. 2/2 way valve 46 During starting the P connection is released to tank Start valve 45 Charges between 139-158 bar Accumulator valve 44 Filter 43 Comments Description Pos Working hydraulics TARGO K CLAAS ACADEMY 9-8 09/2001 CLAAS ACADEMY TARGO K Working hydraulics 09/2001 9-9 1.3 HydrauIic system (duaI braking system) From machine serial number 51200318 Steering Priority valve 42 For working hydraulics Priority valve 41 Not proportionally controlled Control spool 40 265 bar Shock valve 39 Proportionally controlled Control spool 38 Change over valve 37 7 bar pre-pressurised (pilot oil) Accumulator 36 175 bar Shock valve 35 14 bar pilot oil supply Pressure reducing valve 34 Pressure differential 10 bar Pressure balance 33 290 bar PRV 32 Additional equipment 4/3 way valve 31 Front and rear quick release couplings or hitch 4/3 way valve 30 Boom raise and lower 4/3 way valve 29 Front attachment crowd 4/3 way valve 28 Boom extension/retraction 4/3 way valve 27 With PRV, pressure balance, pressure reduction valve (14 bar) End plate 26 With priority valve and accumulator valve Base plate PVSP 25 225-245 bar Shock valve 24 175 bar PRV steering 23 required for steering modes 4/3 way valve 22 Danfoss OSPF 250 Steering unit 21 Ìn accumulator ÷ pressure system One way valve 20 Rear axle Steering ram 19 Rear axle 18 parking brake activation (NC) Oil pressure switch 17 5 bar brake lights (NO) Oil pressure switch 16 Front axle Steering ram 15 With brake rams and parking brake ram front axle 14 Brakes ÷ clutch switch (cab) is switched when the pressure is obtained then opens the clutches. (NO) 16 bar Oil pressure switch 13 Should the pressure drop to below 116 bar, then the switch is activated and switches on the warning in the cab. (NC) 116 bar Oil pressure switch 12 41 bar pre-pressurised Accumulator 11 for dual brakes Kicker plate brake valve 10 With bypass 3.5 bar Pressure filter 9 17-20 bar Pressure reduction valve 8 16 cm 3 Oil motor fan 7 50 l/min supply: fan, filter and parking brake Constant pump 6 Tank breather 5 in tank Suction sieve 4 Flanged to the LS pump Compensator 3 max 120 l/min LS pump 2 80 litres Hydraulic tank 1 Comments Description Pos Working hydraulics TARGO K CLAAS ACADEMY 9-10 11/2001 CLAAS ACADEMY TARGO K Working hydraulics 11/2001 9-11 For the steering pressure. The warning display is illuminated when the steering pressure is not obtained. (Option) Oil pressure switch 62 Tilting the trailer Rear quick release coupling 61 Front quick release coupling 60 Front quick release coupling 59 Hitch 58 Distributes to the hitch and the rear quick release coupling Distribution block 57 Front or rear quick release coupling and hitch Switching valve 56 Boom raise and lower Ram 55 Keeps the front attachment level Compensator ram 54 Front attachment crowd Ram 53 Boom extension / retraction Ram 52 Load release valve 50 For hydraulic braking Quick release coupling 48 This valve controls the pressure to the trailer brakes (hydraulic brakes) 3/3 way valve 47 Operated manually. This will release the ram side from hitch to tank. 2/2 way valve 46 During starting the P connection is released to tank Start valve 45 Charges between 139-158 bar Accumulator valve 44 Filter 43 Comments Description Pos From machine serial number 51200318, the parking brake is supplied by the LS pump (2). Due to this the pressure reduction valve has changed (see parking brake) Caution: Working hydraulics TARGO K CLAAS ACADEMY 9-12 11/2001 CLAAS ACADEMY TARGO K Working hydraulics 11/2001 9-13 1.4 HydrauIic system (singIe braking system) From machine serial number 51200318 Steering Priority valve 42 For working hydraulics Priority valve 41 Not proportionally controlled Control spool 40 265 bar Shock valve 39 Proportionally controlled Control spool 38 Change over valve 37 7 bar pre-pressurised (pilot oil) Accumulator 36 175 bar Shock valve 35 14 bar pilot oil supply Pressure reducing valve 34 Pressure differential 10 bar Pressure balance 33 290 bar PRV 32 Additional equipment 4/3 way valve 31 Front and rear quick release couplings or hitch 4/3 way valve 30 Boom raise and lower 4/3 way valve 29 Front attachment crowd 4/3 way valve 28 Boom extension/retraction 4/3 way valve 27 With PRV, pressure balance, pressure reduction valve (14 bar) End plate 26 With priority valve and accumulator valve Base plate PVSP 25 225-245 bar Shock valve 24 175 bar PRV steering 23 required for steering modes 4/3 way valve 22 Danfoss OSPF 250 Steering unit 21 Ìn accumulator ÷ pressure system One way valve 20 Rear axle Steering ram 19 Rear axle 18 parking brake activation (NC) Oil pressure switch 17 5 bar brake lights (NO) Oil pressure switch 16 Front axle Steering ram 15 With brake rams and parking brake ram front axle 14 Brakes ÷ clutch switch (cab) is switched when the pressure is obtained then opens the clutches. (NO) 16 bar Oil pressure switch 13 Should the pressure drop to below 116 bar, then the switch is activated and switches on the warning in the cab. (NC) 116 bar Oil pressure switch 12 41 bar pre-pressurised Accumulator 11 for single brakes Kicker plate brake valve 10 With bypass 3.5 bar Pressure filter 9 17-20 bar Pressure reduction valve 8 16 cm 3 Oil motor fan 7 50 l/min supply: fan, filter and parking brake Constant pump 6 Tank breather 5 in tank Suction sieve 4 Flanged to the LS pump Compensator 3 max 120 l/min LS pump 2 80 litres Hydraulic tank 1 Comments Description Pos Working hydraulics TARGO K CLAAS ACADEMY 9-14 11/2001 CLAAS ACADEMY TARGO K Working hydraulics 11/2001 9-15 For the steering pressure. The warning display is illuminated when the steering pressure is not obtained. (Option) Oil pressure switch 62 Tilting the trailer Rear quick release coupling 61 Front quick release coupling 60 Front quick release coupling 59 Hitch 58 Distributes to the hitch and the rear quick release coupling Distribution block 57 Front or rear quick release coupling and hitch Switching valve 56 Boom raise and lower Ram 55 Keeps the front attachment level Compensator ram 54 Front attachment crowd Ram 53 Boom extension / retraction Ram 52 Load release valve 50 For hydraulic trailer brake Quick release coupling 48 This valve controls the pressure to the trailer brakes (hydraulic brakes) 3/3 way valve 47 Operated manually. This will release the ram side from hitch to tank 2/2 way valve 46 During starting the P connection is released to tank Start valve 45 Charges between 139-158 bar Accumulator valve 44 Filter 43 Comments Description Pos From machine serial number 51200318, the parking brake is supplied by the LS pump (2). Due to this the pressure reduction valve has changed (see parking brake). Caution: Working hydraulics TARGO K CLAAS ACADEMY 9-16 11/2001 CLAAS ACADEMY TARGO K Working hydraulics 11/2001 9-17 The LS pump (2) is an axle pump for working hydraulics. 2.0 LS Pump 2.1 Compensator vaIve assembIy D45814 (Folie = H 6022.0) 6 Compensator valve 7 Ìnput, load pressure 8 Flow regulator 9 Pressure regulator 10 Connection pump ÷ working hydraulics 11 Connection to rams of the pump working hydraulics 12 Connection to tank 13 Restrictor AA Oil supply BB Pressure reduced oil DD Control oil LL Tank The spring in the flow control regulator (8) is there so that the pump pressure on the end is always 20 bar greater than the load pressure that is acting on the input (7). This pressure of 20 bar is known as ¨differential pressure¨. The pressure regulator (9) limits the pressure in the working hydraulics to 250 ± 5 bar (PRV function). Working hydraulics TARGO K CLAAS ACADEMY 9-18 11/2001 2.2 Function: initiaI position (engine off) D45815 (Folie = H6023.0) 2 LS pump 6 Compensation valve 7 Ìnput, load pressure 8 Flow control regulator 14 Regulating ram 15 Regulating spring 16 Pump drive 17 Swash plate 18 Ram 19 Pump input 20 Pump output 21 Pressure spring The motor is not operated and so there is no pressure in the hydraulic system. The spring (21) has pushed the flow control regulator (8) to the right. Ìn this position the top side of the regulating ram (14) over the flow control regulator (8), is connected to the tank. The regulating spring (15) has swashed the swash plate (17) into its max position. CLAAS ACADEMY TARGO K Working hydraulics 11/2001 9-19 2.3 Low pressure standby D45816 (Folie = H 6024.0) 2 LS pump 6 Compensation valve 7 Ìnput, load pressure 8 Flow control regulator 14 Regulating ram 15 Regulating spring 17 Swash plate 18 Ram 19 Pump input 20 Pump output 21 Pressure spring (differential pressure) 25 Control edge AA Oil supply BB Pressure reduced oil EE Filling oil LL Tank Working hydraulics TARGO K CLAAS ACADEMY 9-20 11/2001 All the control units are in the neutral position. To begin with, the swash plate (17) is in the max swash position (see engine off). When the engine is started, the pump pumps max oil flow via the pump output (20) up to the control spools of all the units. Because the spool is closed, the pressure increases on the right hand side of the flow control regulator (8) and then against the pressure spring (differential pressure) (21) which moves towards the left. The control edge (25) therefore opens and the pressure flows over the top side of the regulating ram (14). The swash plate (17) now moves against the regulating spring (15) into the ¨minimal¨ position. The whole sequence is carried out within 10 milliseconds. With the pump in this position: ! Only enough oil flow is created to counteract any losses. ! The available pressure is held until required by a consumer. Ìf each control unit is in the neutral position, then the input for the load pressure (7) is depressurised. For the flow control regulator (8) to operate, the pump pressure must overcome the pressure spring (differential pressure) (21) and the LS remaining pressure. This pressure is known as low operating pressure. The ¨low operating pressure¨ is slightly higher than the differential pressure of 20 bar. Depending on the adjustment of the flow control regulator (8) and the pump leakage, the ¨low operating pressure¨ and the ¨differential pressure¨ can be almost the same. The ¨differential pressure¨ can never be higher. The low operating pressure is non-adjustable and can vary between machines. The differences are due to internal leaks within the pump or system. The pump remains in the ¨low operating pressure¨ condition until a spool is operated. This system means that the pump only uses minimal energy in which to drive it. CLAAS ACADEMY TARGO K Working hydraulics 11/2001 9-21 2.4 Upstroking of the pump D45817 (Folie = H 6025.0) 2 LS pump 6 Compensation valve 7 Ìnput, load pressure 8 Flow control regulator 14 Regulating ram 15 Regulating spring 17 Swash plate 18 Ram 19 Pump input 20 Pump output 21 Pressure spring (differential pressure) 25 Control edge AA Oil supply BB Control oil EE Filling oil LL Tank Working hydraulics TARGO K CLAAS ACADEMY 9-22 11/2001 Should a spool be operated, then the load pressure builds up in the LS line. On the fIow controI reguIator (8) the foIIowing condition is met: ! On the right hand side is standing the pump pressure ! Ìn the spring area, there is the load pressure + the spring pressure (Differential pressure) (21). The load pressure + the pressure of the spring (Differential pressure) (21) is greater than that of the pump pressure on the right hand side, so the flow regulator moves to the right. So: ! The connection for the pump pressure to the regulating ram (14) is closed ! The regulating ram (14) is connected to the tank (no pressure on the ram end) ! The swash plate (17) is swashed by the regulating spring (15). The pump now creates a larger oil flow. This is called as ¨upstroking¨. The flow is either regulated by the restrictor of the opened spool or by the control unit. SmaIIer fIow required. Should the cross section of the spool valve be restricted, (flow rate is also restricted) then the load pressure on the input (7) will drop. The power of the flow regulator (8) is therefore changed then against the spring, the pressure drop goes towards the left. The regulating ram (14) stokes and the swash plate (17) is moved straighter and so the pump is regulated back until the flow rate is met. Increasing the fIow rate e.g: A control unit is used. The load pressure is 140 bar, and the pump pressure increases (160 bar). (load pressure 140 bar + 20 bar differential pressure) Should then another service be used, that has a load pressure of 100 bar, the pressure will for a short period of time drop. This will result in the consumers requiring more flow, than the pump can deliver. This results in the pressure on the top side of the regulating ram (14) reducing so that the swash plate (17) is adjusted to a more acute angle, which increase to flow rate until the flow rate of the second service is reached and the pump pressure has returned to 160 bar. The load pressure of the regulator remains at 140 bar. CLAAS ACADEMY TARGO K Working hydraulics 11/2001 9-23 2.5 Constant fIow controI D45818 (Folie = H 6026.0) 2 LS pump 6 Compensation valve 7 Load pressure 8 Flow control regulator 14 Regulating ram 15 Regulating spring 17 Swash plate 20 Pump output 21 Pressure spring (differential pressure) 25 Control edge AA Oil supply BB Pressure reduced oil DD Control oil EE Filling oil LL Tank Working hydraulics TARGO K CLAAS ACADEMY 9-24 11/2001 When using a consumer that requires a constant load (e.g. oil motor), the flow control regulator (8) sit in a stable position. This means that the pressure on the top side of the regulating ram (14) and also the setting of the swash plate (17) are constant. As long as the swash plate (17) remains in that position, then the pump will produce a constant output. The fIow controI reguIator (8) has the foIIowing characteristics: ! Load pressure (signal) + spring pressure from the spring (differential pressure) (21) on the left hand side. ! Pump pressure on the right hand side. The pressure difference in the differential pressure, that act on the spring pressure of the pressure spring (21). The differential pressure should be 20 bar and can be adjusted by the adjusting screw (22). CLAAS ACADEMY TARGO K Working hydraulics 11/2001 9-25 2.6 Derating of the pump 9003 2 Pump ÷ working hydraulics (LS pump) 6 Compensation valve 7 Ìnput (Load pressure from the signal network) 8 Flow control regulator 14 Regulating ram 15 Regulating spring 17 Swash plate 20 Pump output (in the base plate of the control unit) 21 Spring (margin pressure) 25 Control edge AA Oil supply BB Pressure reduced oil DD Control oil EE Filling oil LL Tank (depressurised) Working hydraulics TARGO K CLAAS ACADEMY 9-26 11/2001 Under the foIIowing conditions the PFC pump wiII be derated. ! A control unit is put into the neutral position and therefore no flow rate is required. ! The additional unit is in the fine control area and therefore very little flow rate is required. ! Ìn parallel use where the control unit is either in the neutral position or in the fine control area when the flow rate is very small. The pump must always derate when very little oil is required. The pump will derate when the pressure on the right hand side of the flow control regulator (8) is greater than that on the left hand side (in spring area). Ìn this condition, the flow control regulator (8) moves towards the left against the pressure spring (21) so that the control edge (25) is opened. This will result in an increase of pressure on the top side of the regulating ram (14), the swash plate (17) moves against the control spring (15) to a more level position and the flow rate is reduced. Should the control unit operate in the fine control area (requires very little flow rate), then the load pressure on the input (7) drops. The load on the flow control regulator (8) is changed and due to the drop in pressure moves towards the left. The control edge (25) is controlled and so the regulating ram (14) is pressurised. The swash plate (17) becomes more level, the pump derates until the flow rate requirement is fulfilled. ExampIe: Ìn parallel use of two control units the load pressures are 140 bar and 100 bar. The pump pressure amounts to 160 bar (load pressure 140 bar + 20 bar differential pressure). The flow control regulator (8) as well as the swash plate (17) is in a constant position. The pump then provides for both units. Should now the second unit (100 bar load) is put into the neutral position, the flow rate needs to be reduced, and supply sufficient flow for the first service. By shutting down one service, momentarily increases the pump pressure and increase the flow to the first service. The flow control regulator (8) then is moved to the left, and the control edge (25) is opened, so the pressure on the top side of the regulating ram increases. The swash plate (17) will become more level and so the flow rate will be reduced. CLAAS ACADEMY TARGO K Working hydraulics 11/2001 9-27 2.7 Maximum pressure Iimiting (PRV operation) 9004 2 Pump ÷ working hydraulics (LS pump) 6 Compensation valve 7 Ìnput, load pressure 8 Flow control regulator 14 Regulating ram 15 Regulating spring 17 Swash plate 20 Pump output 21 Spring (margin pressure) 23 Adjusting screw 24 Pressure spring 26 Control edge AA Oil supply BB Pressure reduced oil DD Control oil EE Filling oil LL Tank Working hydraulics TARGO K CLAAS ACADEMY 9-28 11/2001 Under the foIIowing conditions the PFC pump wiII be derated ! A control unit is put into the neutral position and therefore no flow rate is required. ! The additional unit is in the fine control area and therefore very little flow rate is required. ! Ìn parallel use where the control unit is either in the neutral position or in the fine control area when the flow rate is very small. The pump must always derate when very little oil is required. The pump will derate when the pressure on the right hand side of the flow control regulator (8) is greater than that on the left hand side (in spring area). Ìn this condition, the flow control regulator (8) moves towards the left against the pressure spring (21) so that the control edge (25) is opened. This will result in an increase of pressure on the top side of the regulating ram (14), the swash plate (17) moves against the control spring (15) to a more level position and the flow rate is reduced. Should the control unit operate in the fine control area (requires very little flow rate), then the load pressure on the input (7) drops. The load on the flow control regulator (8) is changed and due to the drop in pressure moves towards the left. The control edge (25) is controlled and so the regulating ram (14) is pressurised. The swash plate (17) becomes more level, the pump derates until the flow rate requirement is fulfilled. ExampIe: Ìn parallel use of two control units the load pressures are 140 bar and 100 bar. The pump pressure amounts to 160 bar (load pressure 140 bar + 20 bar differential pressure). The flow control regulator (8) as well as the swash plate (17) is in a constant position. The pump then provides for both units. Should now the second unit (100 bar load) is put into the neutral position, the flow rate needs to be reduced, and supply sufficient flow for the first service. By shutting down one service, momentarily increases the pump pressure and increase the flow to the first service. The flow control regulator (8) then is moved to the left, and the control edge (25) is opened, so the pressure on the top side of the regulating ram increases. The swash plate (17) will become more level and so the flow rate will be reduced. CLAAS ACADEMY TARGO K Working hydraulics 11/2001 9-29 2.8 LS pump connections L Leak oil connection 2 LS pump 3 Compensator 20 High pressure connection 8 Pressure regulator, standard adjustment: 250 bar 9 Flow control regulator X Connection to the LS pressure and to additional test port S Pump suction line LS = Load sensing When changing the pump, approx 0,25 lts of oil must be put into the leak oil connection so that the new pump has some lubrication. Working hydraulics TARGO K CLAAS ACADEMY 9-30 11/2001 2.9 Test port working hydrauIics 8 Flow control regulator 9 Pressure regulator H Pump pressure measurement On the position of the bung (M8 x 1) a pressure gauge can be fitted in order to measure the high pressure. The pressure gauge must be fitted to the original position of the bung. CAUTION! CLAAS ACADEMY TARGO K Working hydraulics 11/2001 9-31 3.0 ControI unit working hydrauIics Connection to tank T 14 bar, supply to pressure reduction valve (pilot oil) Pressure reduction valve with pilot oil line 36 With PRV, pressure balance and pressure reduction valve Endplate 26 Boom extend/retract 4/3 way solenoid valve 27 Front attachment crowd 4/3 way solenoid valve 28 mast raise / lower 4/3 way solenoid valve 29 front/rear quick release couplings or hitch 4/3 way solenoid valve 30 Additional unit 4/3 way solenoid valve 31 The valve switches after the steering and the brakes are used. Working hydraulics priority valve 41 Accumulator valve for the brakes Accumulator valve 44 Steering priority valve 42 With priority valve and accumulator valve base plate (PVSP) 25 From the LS pump Pump input P Comment Description Pos Working hydraulics TARGO K CLAAS ACADEMY 9-32 11/2001 3.1 Base pIate PVSP 44 Accumulator valve for braking system LS LS connection to the steering system OSPF B1 Connection to the kicker plate brake valve B3 Accumulator pressure M4 test port CF Connection for the steering unit OSPF P Connection to the LS pump 100 Anchor bolt 25 Nm The base plate PVSP from the control units has more internal valves: 2 Priority valves 1 Accumulator valve 1 Change over valve 1 One way valve CLAAS ACADEMY TARGO K Working hydraulics 11/2001 9-33 3.2 End pIate 32 PRV min. 290 bar 33 Pressure balance 34 Pressure reduction valve for pilot oil (14 bar) A LS connection from the control units B LS connection to the compensator (LS pump) C Bung D Restrictor LS Load sensing M Test port T Tank P LS pump PP Pilot oil The closed centre option is fitted with a restrictor (D) and a bung (C). The input pressure balance (33) is open to tank when the pressure difference is approx 10 bar. Working hydraulics TARGO K CLAAS ACADEMY 9-34 11/2001 4.0 AccumuIator 36 Accumulator for the pilot oil (14) S Control unit (working hydraulics) 5.0 Switching vaIve 56 Switching valve for front and rear quick release couplings A1 From control unit 30 A2 From control unit 30 B1 Front quick release coupling B2 Front quick release coupling C Rear quick release coupling and hitch The valve switches between the front and the rear quick release couplings as well as the rear hitch by means of the rocker switch (switching valve) in the cab. CLAAS ACADEMY TARGO K Working hydraulics 11/2001 9-35 6.0 Overview vaIves Working hydraulics TARGO K CLAAS ACADEMY 9-36 11/2001 Not proportionally controlled Control spool 40 Shock valve 39 Shock valve 35 Proportionally controlled Control spool 38 Change over valve 37 Pilot oil (14 bar) Pressure reduction valve 34 Pressure balance 33 290 bar PRV 32 Additional units 4/3 way valve 31 Front / rear quick release couplings and hitch 4/3 way valve 30 Boom raise / lower 4/3 way valve 29 Front attachment crowd 4/3 way valve 28 Boom extension, retraction 4/3 way valve 27 With PRV, pressure balance and pressure reduction valve (14 bar) End plate 26 With priority valve and accumulator valve Base plate PVSP 25 Tank T With the end stop bolt S, the travel of the spool D is limited in both directions End stop bolt S Pilot oil supply Pi LS pump Connection P Test port M 3 Load signal line LS One way valve E Restrictor B1 Ram connection B Bung A1 Ìs stamped into the housing (near the spring cartridge) Ram connection A Comments Description Pos CLAAS ACADEMY TARGO K Working hydraulics 11/2001 9-37 1.0 TARGO K with gearbox moduIe (APC) . . . . . . . . . . . . . . 10-3 2.0 Legends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 2.1 Circuit legends . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 2.2 Fuse legends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 2.3 Relay legends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 3.0 TARGO without gearbox moduIe (APC) . . . . . . . . . . . 10-15 4.0 Legends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18 4.1 Circuit legends . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18 4.2 Fuse legends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24 4.3 Relay legends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26 5.0 TraveI cIutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28 - Pin layout of the control lever . . . . . . . . . . . . . . 10-29 Contents CLAAS ACADEMY TARGO K Electrics 11/2001 10-1 Notes Electrics TARGO K CLAAS ACADEMY 10-2 11/2001 1.0 TARGO K with gearbox moduIe (APC) CLAAS ACADEMY TARGO K Electrics 11/2001 10-3 1RWHV Electrics TARGO K CLAAS ACADEMY 10-4 11/2001 CLAAS ACADEMY TARGO K Electrics 11/2001 10-5 2.0 Legends 2.1 Circuit Iegends Not used W 41 Not used W 40 Switch in the left hand console Switch (work lights boom) W 39 Work lights (boom) W 38 Work lights (boom) W 37 Side work lights W 36 Switch in the left hand console switch (side work lights) W 35 Side work lights W 34 Rear work lights W 33 Rear work lights W 32 Not available W 31 Switch in the left hand console Switch (rear work lights) W 30 CLAAS display Control light (rear working lights) W 29 Front working lights W 28 Front working lights W 27 Not available W 26 Switch (working lights) W 25 CLAAS display Control light (front work lights) W 24 Fog light switch W 23 Fog light W 22 CLAAS display Control light (high beam) W 21 Left hand high beam W 20 Right hand high beam W 19 left hand head lights W 18 Right hand head lights W 17 Ìntegrated in the Multifunction lever Switch for high beam/head lights W 16 Not available W 15 Not available W 14 Not available W 13 On boom (optional) Pin 58L (7 pin connector) W 12 Trailer (optional) Pin 58L (7 pin connector) W 11 Rear left side light W 10 Front left side light W 9 Switch mounted in the left hand console Light switch W 8 On boom (optional) Pin 58R (7 pin connector) W 7 Trailer (optional) Pin 58R (7 pin connector) W 6 Ìnstrument illumination W 5 Rear right side light W 4 Front right side light W 3 Switch mounted in the left hand console Light switch W 2 Battery W 1 Comments Description Pos Electrics TARGO K CLAAS ACADEMY 10-6 11/2001 Cab, and fitted in the side console Connector (internal) W 44a Control light in switch Control light (beacons) W 44 Switch (beacons) W 43 Fitted on the rear cab wall Connector (beacons) W 42 Comments Description Pos Switch in the windscreen wiper motor Switch (end position of the front wiper motor) W64a Ìntegrated in the multifunction lever Switch for the front windscreen wiper motor W 64 front windscreen wiper motor W 63 Ìntegrated in the multifunction lever Horn switch W 62 Horn W 61 Control light in switch Control light (hazard lights) W 60 CLAAS display Control light (LHS indicators) W 59 Fitted to boom (option) Pin L (7 pin connector) W 58 Trailer (option) Pin L (7 pin connector) W 57 LHS Ìndicator (rear) W 56 LHS Ìndicator (front) W 55 RHS indicator (front) W 54 RHS indicator (rear) W 53 Trailer (optional) Pin R (7 pin connector) W 52 Fitted to the boom (optional) Pin R (7 pin connector) W 51 CLAAS display Control light (RHS indicator) W 50 Ìntegrated in the multifunction lever Switch (indicators) W 49 CLAAS display Control light (trailer indicators) W 48 Switch (hazard lights) W 47 Not used W 46 Switch on the inner lighting Switch and inner lighting W 45 CLAAS ACADEMY TARGO K Electrics 11/2001 10-7 The solenoid valve controls various clutches in the gearbox Solenoid valve S W 99 The solenoid valve controls various clutches in the gearbox Solenoid valve 1 W 98 The solenoid valve controls various clutches in the gearbox Solenoid valve 2 W 97 Power is either broken or switched Oil pressure switch (brakes) W 96 Ìn side console Switch with control light (Brake clutch) W95 Not used W84...W94 behind the cab roof Axial fan, condenser (air conditioning) W 83 behind the cab roof Axial fan, condenser (air conditioning) W 82 Not used W 81 Not used W 80 Compressor (air conditioning) W 79 Monitors pressure in the high pressure circuit Pressure safety switch W 78 Switch dependent on temperature near condenser Thermostat (air conditioning) W 77 Ìn side console Switch (air conditioning) W 76 Not used W 75 resister in cab fan motor resistance (cab fan motor) W 74 Ìn side console Switch (cab fan) W 73 3 steps Cab fan motor W 72 Not used W 71 Rear washer motor W 70 Rear windscreen wiper motor W 69 Fitted in side console Switch (rear windscreen wiper motor) W 68 Switch in wiper motor Switch (end position of the rear wiper motor) W 67a Ìntegrated in the Multifunction lever Switch (front windscreen wiper motor) W 67 Front windscreen motor W 66 Ìntegrated in the Multifunction lever Switch (windscreen wiper motor (front)) W 65 Switch in wiper motor Switch (end position of the wiper motor) W64a Ìntegrated in the Multifunction lever Switch (front windscreen wiper motor) W 64 Comments Description Pos Electrics TARGO K CLAAS ACADEMY 10-8 11/2001 Fitted near Orbitrol Solenoid valve (steering mode rear axle) W 133 Ìn side console Rotary switch (steering mode) W 132 Fitted near Orbitrol Solenoid valve (steering mode front axle) W 131 Fitted to rear axle Load sensor W 130 Load indicator W 129 Not used W 128 Switches from the front quick release couplings to the rear quick release or the hitch Change over valve (way valve) W 127 Ìn side console Switch, activating the change over valve W 126 Not used W 122....W 125 Rotary switch positioned in the side console Road travel switch W 121 Solenoid valve valve, additional hydraulicfunctions W 120 Solenoid valve Valve, front and rear couplings or hitch W 119 Solenoid valve Valve, boom raise / lower W 118 Solenoid valve Valve, boom extend / retract W 117 Solenoid valve Valve, front attachment crowd W 116 Joystick (optional) Switch, hydraulic attachments W 115 Joystick Switch for front / rear or hitch couplings W 114 Joystick Boom raise / lower control W 113 Joystick Boom extend / retract control W 112 Joystick Front attachment crowd W 111 Signal horn (reverse) W 110 reversing light W 109 Not used W 108 Speed sensor W 107 The solenoid valve controls various clutches in the gearbox Solenoid valve F W 106 Solenoid valve reverse W 105 Near the battery Ìsolator switch Potentiometer (parking brake) W 104b Near the battery isolator switch Solenoid valve (parking brake) W 104a Switch in left hand console Switch with control light (parking brake) W 104 Kickdown (control lever) W 103 From company Hobbs Gear selection switch (control lever) W 102 Switch, travel direction (F,N,R) W 101 Various options gearbox module (APC) W 100 Comments Description Pos CLAAS ACADEMY TARGO K Electrics 11/2001 10-9 Regulator (alternator) W 203 Alternator W 202 Fitted in the fuel injection pump. Active until the temp reaches 47°C Fuel adjustment W 201 positioned near the fuel injection pump solenoid (engine) W 200 Not used W 186....W 199 Terminal W (alternator) Signal from alternator (speed display, km/h) W 185 CLAAS display Display (speed, km/h) W 184 Screwed into gearbox Switch (gearbox temp) W 183 CLAAS display Control light (gearbox temp) W 182 Fitted to hydraulic filter Switch (hydraulic filter) W 181 CLAAS display Control light (hydraulic filter) W 180 Ìnstalled in the parking brake line (front axle) oil pressure switch (parking brake) W 179 CLAAS display Control light (parking brake) W 178 positioned near air filter Switch (air filter) W 177 CLAAS display Control light (air filter) W 176 Oil pressure switch (engine) W 175 CLAAS display Control light (engine oil pressure) W 174 Fitted to alternator Regulator (alternator) W 173 CLAAS display Control light (battery charging) W 172 CLAAS display Display (coolant temperature) W 171 Engine Sensor (coolant temperature) W 170 CLAAS display Fuel gauge W 169 Fitted to fuel tank Sensor (fuel tank) W 168 Not used W 153.....W 167 Starter motor W 152 Engine pre-heat W 151 Ìgnition key W 150 Left hand trailer brakes Pin 54 (7 pin connector) W 142 Right hand trailer brakes Pin 54 (7 pin connector) W 141 Brake lights (left) W 140 Brake lights (right) W 139 Fitted in the brake ram line (front axle) Oil pressure switch (brake lights) W 138 Fitted to steering ram Wheel position sensor (rear axle) W 137 Wheels straight = light on Wheel position display (rear axle) W 136 Fitted to steering ram Wheel position sensor (front axle) W 135 Wheels straight = light on Wheel position display (front axle) W 134 Comments Description Pos Electrics TARGO K CLAAS ACADEMY 10-10 11/2001 Notes CLAAS ACADEMY TARGO K Electrics 11/2001 10-11 2.2 Fuse Iegends Positioned behind cab roof (air conditioning) Thermo fuse (red press switch) F 25 7.5 Amp. CLAAS display F 24 10 Amp. Headlight flashers F 23 15 Amp. Horn \ front washers \ wiper and washer F 22 10 Amp. Beacons \ inner lighting \ socket (cab) F 21 10 Amp. Travel direction switch (F,N,R lever) \ gearbox module (APC) \ brake clutch switch F 20 10 Amp. Hazard lights F 19 7.5 Amp. LHS head lights F 18 7.5 Amp. RHS head lights F 17 7.5 Amp. LHS high beam F 16 7.5 Amp. RHS high beam F 15 5 Amp. LHS side lights F 14 5 Amp. RHS side lights F 13 10 Amp. Brake lights \ parking brakes \ steering position display F 12 10 Amp. Engine stop solenoid F 11 15 Amp. Front work lights F 10 15 Amp. Rear work lights F 9 10 Amp. Fog lights F 8 3 Amp. Load indicator \ load sensor \ steering solenoid F 7 K12 \ K15 \ K13 individually protected 5 Amp. Danfoss solenoid valve control unit F 6 25 Amp. Cab fan \ air conditioning (option) F 5 10 Amp. Ìndicators \ radio F 4 10 Amp. Road travel switch (hydraulic) F 3 K16 \ K8 individually protected. 7.5 Amp Working lights (front, rear, side, boom) F 2 7.5 Amp. Front and rear windscreen wiper and washer F 1 Comments Fuse Pos E-MV = Solenoid valve Electrics TARGO K CLAAS ACADEMY 10-12 11/2001 CLAAS ACADEMY TARGO K Electrics 11/2001 10-13 2.3 ReIays Iegends Separate, near fuse box K8 on terminal 85 Working lights (front, rear side and boom) K 16 Separate, behind load indicator Hydraulic (road travel switch), load indicator and steering K 15 Positioned near battery isolator switch Pre-heater K 14 Separate, behind load indicator Front and rear quick release couplings or Hitch K 13 Separate, behind load indicator front attachment crowd K 12 Not used K 11a Separate, near fuse box Starting lock (control lever in the neutral position) K 11 Positioned near the battery isolator switch Starting relay K 10 Positioned over the condenser (behind cab roof) Air conditioning K 9 Main lights K 8 Side work lights K 7 Rear work lights K 6 Front work lights K 5 Not used K 4 Ìndicator relay K 3 Ìgnition +15 K 2 Boom work lights K 1 Comment ReIay Pos Electrics TARGO K CLAAS ACADEMY 10-14 11/2001 3.0 Targo K without gearbox moduIe (APC) CLAAS ACADEMY TARGO K Electrics 11/2001 10-15 1RWHV Electrics TARGO K CLAAS ACADEMY 10-16 09/2001 CLAAS ACADEMY TARGO K Electrics 11/2001 10-17 4.0 Legends 4.1 Circuit Iegends Not used W 41 Not used W 40 Switch in the left hand console Switch (work lights boom) W 39 Work lights (boom) W 38 Work lights (boom) W 37 Side work lights W 36 Switch in the left hand console switch (side work lights) W 35 Side work lights W 34 Rear work lights W 33 Rear work lights W 32 Not used W 31 Switch in the left hand console Switch (rear work lights) W 30 CLAAS display Control light (rear working lights) W 29 Front working lights W 28 Front working lights W 27 Not used W 26 Switch (working lights) W 25 CLAAS display Control light (front work lights) W 24 Fog light switch W 23 Fog light W 22 CLAAS display Control light (high beam) W 21 Left hand high beam W 20 Right hand high beam W 19 Left hand head lights W 18 Right hand head lights W 17 Ìntegrated in the Multifunction lever Switch for high beam/head lights W 16 Not used W 15 Not used W 14 Not used W 13 On boom (optional) Pin 58L (7 pin connector) W 12 Trailer (optional) Pin 58L (7 pin connector) W 11 Rear left side light W 10 Front left side light W 9 Switch mounted in the left hand console Light switch W 8 On boom (optional) Pin 58R (7 pin connector) W 7 Trailer (optional) Pin 58R (7 pin connector) W 6 Ìnstrument illumination W 5 Rear right side light W 4 Front right side light W 3 Switch mounted in the left hand console Light switch W 2 Battery W 1 Comments Description Pos Electrics TARGO K CLAAS ACADEMY 10-18 11/2001 Cab, and fitted in the side console Connector (internal) W 44a Control light in switch Control light (beacons) W 44 Switch (beacons) W 43 Fitted on the rear cab wall Connector (beacons) W 42 Comments Description Pos Switch in windscreen wiper motor Switch (end position of the front wiper motor) W64a Ìntegrated in the multifunction lever Switch for the front windscreen wiper motor W 64 front windscreen wiper motor W 63 Ìntegrated in the multifunction lever Horn switch W 62 Horn W 61 Control light in switch Control light (hazard lights) W 60 CLAAS display Control light (LHS indicators) W 59 Fitted to boom (optional) Pin L (7 pin connector) W 58 Trailer (optional) Pin L (7 pin connector) W 57 LHS indicator (rear) W 56 LHS indicator (front) W 55 RHS indicator (front) W 54 RHS indicator (rear) W 53 Trailer (optional) Pin R (7 pin connector) W 52 Fitted to the boom (optional) Pin R (7 pin connector) W 51 CLAAS display Control light (RHS indicator) W 50 Ìntegrated in the multifunction lever Switch (indicators) W 49 CLAAS display Control light (trailer indicators) W 48 Switch (hazard lights) W 47 Not used W 46 Switch on the inner lighting Switch and inner lighting W 45 CLAAS ACADEMY TARGO K Electrics 11/2001 10-19 The solenoid valve controls various clutches in the gearbox Solenoid valve S W 99 The solenoid valve controls various clutches in the gearbox Solenoid valve 1 W 98 The solenoid valve controls various clutches in the gearbox Solenoid valve 2 W 97 Power is either broken or switched Oil pressure switch (brakes) W 96 Ìn side console Switch with control light (brake clutch) W95 Not used W84...W94 behind the cab roof Axial fan, condenser (air conditioning) W 83 behind the cab roof Axial fan, condenser (air conditioning) W 82 Not used W 81 Not used W 80 Compressor (air conditioning) W 79 Monitors pressure in the high pressure circuit Pressure safety switch (Trinary) W 78 Switch dependent on temperature near condenser Thermostat (air conditioning) W 77 Ìn side console Switch (air conditioning) W 76 Not used W 75 resister in cab fan motor resistance (cab fan motor) W 74 Ìn side console Switch (cab fan) W 73 3 steps Cab fan motor W 72 Not used W 71 Rear washer motor W 70 Rear windscreen wiper motor W 69 Fitted in side console Switch (rear windscreen wiper motor) W 68 Switch in windscreen wiper motor Switch (end position of the rear wiper motor) W 67a Ìntegrated in the Multifunction lever Switch (front windscreen wiper motor) W 67 Front windscreen motor W 66 Ìntegrated in the Multifunction lever Switch (front windscreen wiper motor) W 65 Switch in windscreen wiper motor Switch end position of the front wiper motor W64a Ìntegrated in the Multifunction lever Switch (front windscreen wiper motor) W 64 Comments Description Pos Electrics TARGO K CLAAS ACADEMY 10-20 11/2001 Fitted near Orbitrol Solenoid valve (steering mode rear axle) W 133 Ìn side console Rotary switch (steering mode) W 132 Fitted near Orbitrol Solenoid valve (steering mode front axle) W 131 Fitted to rear axle Load sensor W 130 Load indicator W 129 Not used W 128 Switches from the front quick release couplings to the rear quick release or the hitch Change over valve (way valve) W 127 Ìn side console Switch, activating the change over valve W 126 Not used W 122....W 125 Rotary switch positioned in the side console Road travel switch W 121 Solenoid valve Valve (additional hydr. functions) W 120 Solenoid valve Valve, front and rear couplings or hitch W 119 Solenoid valve Valve , boom raise / lower W 118 Solenoid valve Valve, boom extend / retract W 117 Solenoid valve Valve, front attachment crowd W 116 Joystick (optional) Switch (additional hydr. functions) W 115 Joystick Switch for front/ rear or hitch couplings W 114 Joystick Boom raise / lower W 113 Joystick Boom extend / retract control W 112 Joystick Front attachment crowd W 111 Signal horn (reverse) W 110 reversing light W 109 Not used W 108 Not used W 107 The solenoid valve controls various clutches in the gearbox Solenoid valve F W 106 Solenoid valve reverse W 105 Near the battery isolator switch Potentiometer (parking brake) W 104b Near the battery isolator switch Solenoid valve (parking brake) W 104a Switch in left hand console Switch with control light (parking brake) W 104 Not used W 103 From company Britax gear selection switch (control lever) W 102 Switch, travel direction (F,N,R) W 101 Not used W 100 Comments Description Pos CLAAS ACADEMY TARGO K Electrics 11/2001 10-21 Regulator (alternator) W 203 Alternator W 202 Fitted in the fuel injection pump. Active until the temp reaches 47°C Fuel adjustment W 201 positioned near the fuel injection pump solenoid (engine) W 200 Not used W 186....W 199 Terminal W (alternator) Signal from alternator (speed display) W 185 CLAAS display Display (speed, km/h) W 184 Screwed into gearbox Switch (gearbox temp) W 183 CLAAS display Control light (gearbox temp) W 182 Fitted to hydraulic filter Switch (hydraulic filter) W 181 CLAAS display Control light (hydraulic filter) W 180 Ìnstalled in the parking brake line (front axle) oil pressure switch (parking brake) W 179 CLAAS display Control light (parking brake) W 178 positioned near air filter Switch (air filter) W 177 CLAAS display Control light (air filter) W 176 Oil pressure switch (engine) W 175 CLAAS display Control light (engine oil pressure) W 174 Fitted to alternator Regulator (alternator) W 173 CLAAS display Control light (battery charging) W 172 CLAAS display Display (coolant temperature) W 171 Engine Sensor (coolant temperature) W 170 CLAAS display Fuel gauge W 169 Fitted to fuel tank Sensor (fuel tank) W 168 Not used W 153.....W 167 Starter motor W 152 Engine pre-heat W 151 Ìgnition key W 150 Left hand trailer brakes Pin 54 (7 pin connector) W 142 Right hand trailer brakes Pin 54 (7 pin connector) W 141 Brake lights (left) W 140 Brake lights (right) W 139 Fitted in the brake ram line (front axle) Oil pressure switch (brake lights) W 138 Fitted to steering ram Wheel position sensor (rear axle) W 137 Wheels straight = light on Wheel position display (rear axle) W 136 Fitted to steering ram Wheel position sensor (front axle) W 135 Wheels straight = light on Wheel position display (front axle) W 134 Comments Description Pos Electrics TARGO K CLAAS ACADEMY 10-22 11/2001 Notes CLAAS ACADEMY TARGO K Electrics 11/2001 10-23 4.2 Fuse Iegends Positioned behind cab roof (air conditioning) Thermo fuse (red press switch) F 25 7.5 Amp. Claas display F 24 10 Amp. Headlight flashers F 23 15 Amp. Horn \ front washers \ wiper and washer F 22 10 Amp. Beacons \ inner lighting \ socket (cab) F 21 10 Amp. Travel direction switch (F,N,R lever) gearbox module (APC) \ brake clutch switch F 20 10 Amp. Hazard lights F 19 7.5 Amp. LHS head lights F 18 7.5 Amp. RHS head lights F 17 7.5 Amp. LHS high beam F 16 7.5 Amp. RHS high beam F 15 5 Amp. LHS side lights F 14 5 Amp. RHS side lights F 13 10 Amp. Brake lights \ parking brakes \ steering position display F 12 10 Amp. Engine stop solenoid F 11 15 Amp. Front work lights F 10 15 Amp. Rear work lights F 9 10 Amp. Fog lights F 8 3 Amp. Load indicator \ load sensor \ steering solenoid F 7 K12 \ K15 \ K13 individually protected 5 Amp. Danfoss solenoid valve control units F 6 25 Amp. Cab fan \ air conditioning (option) F 5 10 Amp. Ìndicators \ radio F 4 10 Amp. Road travel switch (hydraulic) F 3 K16 \ K8 individually protected 7.5 Amp Working lights (front, rear, side boom) F 2 7.5 Amp. Front and rear windscreen wiper and washer F 1 Comments Fuse Pos E-MV = Solenoid valve Electrics TARGO K CLAAS ACADEMY 10-24 11/2001 CLAAS ACADEMY TARGO K Electrics 11/2001 10-25 4.3 ReIay Iegends Separate, near fuse box also K8 terminal 85 Working lights (front, rear side and boom) K 16 Separate, behind load indicator Hydraulic (road travel switch), load indicator and steering K 15 Positioned near battery isolator switch Pre-heater K 14 Separate, behind load indicator Front and rear quick release couplings or hitch K 13 Separate, behind load indicator front attachment crowd K 12 Separate, near fuse box Starting lock (control lever in the neutral position) K 11a Separate, near fuse box Starting lock (control lever in the neutral position) K 11 Positioned near the battery isolator switch Starting relay K 10 Positioned over the condenser (behind cab roof) Air conditioning K 9 Main lights K 8 Side work lights K 7 Rear work lights K 6 Front work lights K 5 Separate, near fuse box Brake clutch circuit K 4 Ìndicator relay K 3 Ìgnition +15 K 2 Boom work lights K 1 Comments ReIay Pos Electrics TARGO K CLAAS ACADEMY 10-26 11/2001 Notes CLAAS ACADEMY TARGO K Electrics 11/2001 10-27 This diagram has been taken from the main circuit diagram in chapter 3.0. The reason is for the starting lock and the brake circuit. 5.0 TraveI cIutch Electrics TARGO K CLAAS ACADEMY 10-28 11/2001 Starter motor W 152 Engine pre-heat W 150 The solenoid valve controls various clutches in the gearbox Solenoid valve F W 106 Solenoid valve reverse W 105 Near the battery isolator switch Potentiometer (parking brake) W 104b Near the battery isolator switch Solenoid valve (parking brake) W 104a Switch in left hand console Switch with control light (parking brake) W 104 From company Britax Gear selection switch (control lever) W 102 Switch, travel direction (F,N,R) W 101 The solenoid valve controls various clutches in the gearbox Solenoid valve S W 99 The solenoid valve controls various clutches in the gearbox Solenoid valve 1 W 98 The solenoid valve controls various clutches in the gearbox Solenoid valve 2 W 97 Power is either broken or switched Oil pressure switch (brakes) W 96 Ìn side console Switch with control light (Brake clutch) W 95 Positioned near battery isolator switch Pre-heater K 14 separate, near fuse box Starting lock (control lever in the reverse position) K 11a separate, near fuse box Starting lock (control lever in the forward position) K 11 Positioned near the battery isolator switch Starting relay K 10 Separate, not in fuse box Brake clutch circuit K 4 Ìgnition +15 K 2 10 Amp. travel direction switch (F,N,R lever) gearbox module (APC) \ brake clutch switch) F 20 10 Amp. Brake lights \ parking brake\ steering display F 12 Comments ReIay Pos Not used 12 Power supply from K4 Blue 11 ÷ Not used 10 ÷ Not used 9 W105 (Solenoid reverse) White/Green 8 W106 (Solenoid F) Blue/Yellow 7 Not used Brown 6 Switch (travel direction F/N/R) Power supply from K4 Red 5 W99 Solenoid S White 4 Not used Green 3 W97 Solenoid 2 Yellow 2 W98 Solenoid 1 Grey 1 Comment Wire coIour Pin Iayout W101 + W102 (traveI Iever) Pin Iayout W101+W102 (traveI Iever) CLAAS ACADEMY TARGO K Electrics 11/2001 10-29 From the operators book 319 565.3 15.0 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2 15.1 Maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . 15-2 - As required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2 - Every 10 operating hours or daily . . . . . . . . . . . 15-2 - Every 20 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3 - After the first 50 operating hours . . . . . . . . . . . 15-3 - After the first 100 operating hours . . . . . . . . . . 15-3 - Every 50 hours or weekly . . . . . . . . . . . . . . . . . 15-3 - Every 500 operating hours . . . . . . . . . . . . . . . . 15-4 - Every 1000 operating hours or yearly . . . . . . . 15-4 - Every 15000 operating hours or yearly . . . . . . 15-4 - Every 2000 operating hours . . . . . . . . . . . . . . . 15-4 - Additional maintenance . . . . . . . . . . . . . . . . . . . 15-5 - For storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5 Contents CLAAS ACADEMY TARGO K Maintenance and care 11/2001 15-1 15.0 Maintenance CAUTION Maintenance section page Warning lights / displays carry out regardless 15.1 Maintenance pIan 3.15 Air filter Check: Secondary and outer air filter 3.7 Wheels / tyres Check: Wheel nuts 3.20 Hydraulic system Check: hydraulic filter 3.21 Hydraulic system Check: hydraulic oil level 3.17 Gearbox Check: gearbox oil level 3.15 Air filter Check: Air prefilter 3.12 Fuel system Check: Fuel tank 3.10 Cooling system Check: Sealing and bleeding of the cooling system 3.10 Cooling system Check: coolant level 3.8 Engine oil Check: oil level Every 10 operating hours or daiIy 3.15 Air filter Clear: Air prefilter 3.15 Air filter Replace / Clear: Secondary and if necessary outer air filter 3.15 Air filter Replace primery and if necessary inner air filter As required Hydraulic system Warning light, (yellow): Change the hydraulic filter Air filter Warning light: clean air filter Brakes Warning light ¨on¨, check system (only qualified mechanics) Page in Operator´s manuaI Section Maintenance Maintenance and care TARGO K CLAAS ACADEMY 15-2 11/2001 3.19 Axle Check: Oil level in the Front and rear axle 3.16 Engine Check: Fan belt tension 3.22 Battery Check: Battery level 3.7 Tyres Check: Tyre condition and 3.7 Tyres Check: Tyre pressure and 3.21 Hydraulic system Clean: Hydraulic tank and breather filter After 50 operating hours or weekIy 3.18 Gearbox Change: Gearbox oil and Oil filter After the first 100 operating hours 3.17 Gearbox Check: Drive shaft fixings Check: Ìdle speed (only qualified personnel, see engine hand book) Every the first 50 operating hours 3.24 Front attachment Grease: Trailer coupling from Rockinger 3.24 Front attachment Grease: Auto hitch Lock and bowden cable 3.13 Fuel system Empty: Fuel pre filter 3.6 Grease point Grease: Blank metal and Rotary shafts 3.6 Grease point Grease: All drive shafts 3.6 Grease point Grease: Axle pins Every 20 operating hours Check the operation of the brakes. Ìf the travel of the brake is too short then the machine will stop abruptly, Ìf its long or the brakes are not responsive enough then have them adjusted. Check: Brake pedal travel Check the operation of the parking brake and if necessary adjust. CLAAS ACADEMY TARGO K Maintenance and care 11/2001 15-3 Check: brakes, braking system to be checked by the local agent. 3.11 Cooling system Check: Coolant pipes Every 2000 operating hours 3.21 Hydraulic Replace: Hydraulic oil 3.15 Air filter Replace: Air filter outer element Every 15000 operating hours or yearIy 3.11 Cooling system Clean: Oil cooler 3.11 Cooling system Check: Cooling pipes 3.19 Axles Replace: Oil in front and rear axles 3.11 Cooling system Check: Coolant quality 3.18 Gearbox Change: Gearbox oil and oil filter 3.16 Engine Clean: Alternator fan 3.16 Engine Check: valve clearance 3.16 Engine Check: Fuel ÷ injectors Every 1000 operating hours 3.15 Air filter Replace: Air filter inner element 3.15 Air filter Replace: Air filter outer element 3.16 Engine Check: belt tensions 3.20 Hydraulic system Check: hydraulic filter Ìnsert 3.13 Fuel system Change: Fuel filter insert 3.13 Fuel system Replace: Fuel ÷ filter Plate housing 3.16 Engine Check: Ìdle speed 3.8 Engine and filter Change: Engine oil And filter Check all the bolts and nuts are tight, in particular in relation to the drive train and steering. Every 500 operating hours Maintenance and care TARGO K CLAAS ACADEMY 15-4 11/2001 Where conditions are either very dirty, hot or cold then the maintenance schedule has to be carried out more frequently especially the cleaning of the cooling system and the greasing of the machine. When the machine is being left for a long period without use, then give the battery to workshop personnel, close all the openings such as air intake and exhaust. Grease all bare metal components , protect all rubbers from direct sunshine, fill the fuel tank, check the tyre pressures and release the pressure in the hydraulic system. AdditionaI maintenance For storage CLAAS ACADEMY TARGO K Maintenance and care 11/2001 15-5 Following the policy of the CLAAS KGaA mbH to improve their products as technical developments continue, CLAAS reserve the right to make alterations which must not necessarily correspond to text and illustrations contained in this publication, and without incurring obligation to alter any machines previously delivered. Technical data, dimensions and weights are given as an indication only. Responsibility for errors or omissions not accepted. Reproduction or translation of this publication, in whole or part, is not permitted without the written consent of the CLAAS KGaA mbH. All rights under the provision of the Copyright Act reserved. CLAAS KGaA mbH 33426 Harsewinkel Germany Our contribution to the environment: CLAAS have printed this manual on 100 % chlorine free paper. 298 657.0 Academy TT Targo K50, K60, K70 - GB - 11.01 - 50 - BEV Printed in Germany