Claas C540-C450 Folding Lexion (713) Combines Repair Manual EN

File List:

00 0299 211 0.pdf

00 0299 211 0.pdf:

Contents
Introduction
Introduction
Introduction to the CLAAS Repair Manual
Key to symbols
Safety Rules
Important information
Identification of warning and danger signs
Correct use of the cutterbar
General safety and accident prevention regulations
Leaving the machine
Basic rule
Hydraulic accumulators
General repair information
Reason of damage
Spare parts
Transmission
Tensioning the steel roller chains
Taper ring fasteners
Self-locking bolts
Liquid locking compound
Correct installation of lock collar bearings
Correct installation of adapter sleeve bearings
Ferrule fittings on hydraulic lines
Progressive ring fittings on hydraulic lines
Taper fittings on hydraulic lines
Some advice for speedy and correct repair work:
Tightening torques
Hydraulic screw fittings
Specifications
Lubricants chart
Drive diagram
General information on drives
Drive diagram, left-hand
Drive diagram, right-hand
Crop dividers
Crop dividers
Removing the long / short crop dividers
Installing the long / short crop dividers
Removing the special crop dividers
Special crop divider, disassembled
Installing the special crop divider
Cutterbar trough – Cutter bar
Cutter bar
Removing the knife
Installing the knife
Adjusting the knife height
Cutterbar lock (mechanical)
Removing the mechanical cutterbar lock
Mechanical cutterbar lock, disassembled
Installing the mechanical cutterbar lock
Rotating arm
Removing the rotating arm
Rotating arm, disassembled
Installing the rotating arm
Folding unit
Removing the cutterbar fold hydraulic cylinder rack
Cutterbar fold hydraulic cylinder rack, disassembled
Installing the cutterbar fold hydraulic cylinder rack
Intermediate drive
Removing the left-hand intermediate drive shaft
Left-hand intermediate drive, disassembled
Installing the left-hand intermediate drive shaft
Removing the right-hand intermediate drive shaft
Right-hand intermediate drive, disassembled
Installing the right-hand intermediate drive shaft
Main drive universal drive shaft
Removing the main drive universal drive shaft
Disassembling the main drive universal drive shaft
Main drive universal drive shaft, disassembled:
Assembling the main drive universal drive shaft
Mounting the main drive universal drive shaft
Knife drive
Removing the knife drive belt (44)
Installing and adjusting the knife drive belt (44)
Removing the knife drive belt (51)
Installing and adjusting the knife drive belt (51)
Removing the jockey pulley of knife drive belt (44) and/or (51)
Knife drive belt (44), disassembled
Knife drive belt (51), disassembled
Installing the jockey pulley of knife drive belt (44) and/or (51)
Removing the deflection pulley of knife drive belt (44) and/or (51)
Installing the deflection pulley of knife drive belt (44) and/or (51)
Wobble transmission
Removing the wobble transmission (Part nos. 643 686.2 and 643 656.2)
Disassembling the wobble transmission (Part nos. 643 686.2 and 643 656.2)
Wobble transmission, disassembled: (Part no. 643 686.2)
Wobble transmission, disassembled: (Part no. 643 656.2)
Assembling the wobble transmission (Spare part nos. 643 686.2 and 643 656.2)
Installing the wobble transmission (Spare part nos. 643 686.2 and 643 656.2)
Intake auger
Intake auger drive
Removing the feed drive chain (40)
Installing and adjusting the feed drive chain (40)
Removing and disassembling the jockey sprocket of feed drive chain (40) and/or (50)
Installing the jockey sprocket of feed drive chain (40) and /or (50)
Removing and installing the double sprocket of feed drive chain (40) and/or (50)
Removing the intake auger slip clutch
Intake auger slip clutch, disassembled (left-hand machine side)
Installing the intake auger slip clutch
Removing the feed drive chain (50)
Installing and adjusting the feed drive chain (50)
Intake auger slip clutch, disassembled (right-hand machine side)
Intake auger
Removing the left-hand (outside) and/or right-hand (outside) intake auger bearing
Left-hand (outside) and/or right-hand (outside) intake auger bearing, disassembled:
Installing the left-hand (outside) and/or right-hand (outside) intake auger bearing
Removing the left-hand and/or right-hand intake auger drive shaft
Installing the left-hand and/or right-hand intake auger drive shaft
Removing the left-hand (centre) and/or right-hand (centre) intake auger bearing
Left-hand (centre) and/or right-hand (centre) intake auger bearing, disassembled
Installing the left-hand (centre) and/or right-hand (centre) intake auger bearing
Left-hand intake auger, disassembled:
Right-hand intake auger, disassembled:
Removing the intake auger finger
Installing the intake auger finger
Removing the control shafts
Removing the control shafts (up to serial no. )
Control shafts, disassembled: (up to serial no. )
Removing the control shafts (from serial no. )
Control shafts, disassembled: (from serial no. 🙂
Installing the control shafts (from serial no. , up to serial no. )
Reel drive
Removing the drive chain (41)
Installing and adjusting the drive chain (41)
Removing the top sprocket of drive chain (41)
Installing the top sprocket of drive chain (41)
Removing the reel drive belt (42)
Installing and adjusting the reel drive belt (42)
Removing the variable-speed pulleys of reel drive (42)
Installing the variable-speed pulleys of reel drive (42)
Removing the drive chain (43)
Installing and adjusting the drive chain (43)
Removing the top sprocket of drive chain (43)
Installing sprocket of drive chain (43)
Installing the bottom sprocket of drive chain (43)
Removing the sprocket of drive chain (43)
Installing the sprocket of drive chain (43)
Removing the reel drive slip clutch
Disassembling the reel drive slip clutch
Reel drive slip clutch, disassembled: (up to serial no. )
Reel drive slip clutch, disassembled: (from serial no. )
Assembling the reel drive slip clutch
Installing the reel drive slip clutch
Removing the reel drive shaft (17)
Installing the reel drive shaft (17)
Removing the reel drive dog clutch
Reel drive dog clutch, disassembled
Installing the reel drive dog clutch
Reel drive universal drive shaft
Removing the reel drive universal drive shaft
Disassembling the reel drive universal drive shaft
Reel drive universal drive shaft, disassembled:
Assembling the reel drive universal drive shaft
Mounting the reel drive universal drive shaft
Reel drive e drivhe rear angle drive
Disassembling the rear angle drive
Assembling the rear angle drive
Mounting the rear angle drive
Removing the front angle drive
Disassembling the front angle drive
Front angle drive, disassembled:
Assembling the front angle drive
Mounting the front angle drive
Reel speed adjustment
Removing the electric reel variable-speed pulley
Reel variable-speed drive, disassembled
Mounting the electric reel variable-speed pulley
Removing the spring-loaded reel variable-speed pulley
Spring-loaded reel variable-speed pulley, disassembled
Mounting the spring-loaded reel variable-speed pulley
Removing the reel variable-speed drive bearing tube
Reel variable-speed drive bearing tube, disassembled
Installing the reel variable-speed drive bearing tube
Removing the electric reel speed adjustment
Disassembling the electric reel speed adjustment
Electric reel speed adjustment, disassembled:
Assembling the electric reel speed adjustment
Mounting the electric reel speed adjustment
Left-hand reel
Removing the left-hand reel
Left-hand reel, disassembled
Installing the left-hand reel
Removing the left-hand reel bearing (Left-hand reel)
Installing the left-hand reel bearing (Left-hand reel)
Removing the control rollers (Left-hand reel)
Installing the control rollers (Left-hand reel)
Removing the control spider (Left-hand reel)
Installing the control spider (Left-hand reel)
Removing the left-hand reel spider (Left-hand reel)
Installing the left-hand reel spider (Left-hand reel)
Removing the right-hand reel bearing (Left-hand reel)
Installing the right-hand reel bearing (Left-hand reel)
Checking the reel lock setting
Removing the right-hand reel spider (Left-hand reel)
Installing the right-hand reel spider (Left-hand reel)
Removing the centre reel spider (Left-hand reel)
Installing the centre reel spider (Left-hand reel)
Right-hand reel
Removing the right-hand reel
Right-hand reel, disassembled
Installing the right-hand reel
Checking the pawl setting (Reel lock)
Removing the right-hand reel bearing (Right-hand reel)
Installing the right-hand reel bearing (Right-hand reel)
Removing the control rollers (Right-hand reel)
Installing the control rollers (Right-hand reel)
Removing the control spider (Right-hand reel)
Installing the control spider (Right-hand reel)
Removing the right-hand reel spider (Right-hand reel)
Installing the right-hand reel spider (Right-hand reel)
Removing the left-hand reel bearing (Right-hand reel)
Installing the left-hand reel bearing (Right-hand reel)
Removing the left-hand reel spider (Right-hand reel)
Installing the left-hand reel spider (Right-hand reel)
Removing the centre reel spider (Right-hand reel)
Installing the centre reel spider (Right-hand reel)
Hydraulic system / Electric system
Control valves
Removing the reel raise / lower valve block with check valve
Reel raise / lower valve block with check valve, disassembled
Assembling and installing the reel raise / lower valve block with check valve
Removing the reel raise 3/2-way valve (Y22)
Reel raise 3/2-way valve (Y22), disassembled
Installing the reel raise 3/2-way valve (Y22)
Removing the 2/2-way check valve (Y69)
Installing the 2/2-way check valve (Y69)
Removing the reel lower 2/2-way valve (Y23)
Reel lower 2/2-way valve (Y23), disassembled
Installing the reel lower 2/2-way valve (Y23)
Removing the reel forward / backward and cutterbar fold valve block
Reel forward / backward and cutterbar fold valve block, disassembled:
Assembling and installing the reel forward / backward and cutterbar fold valve block
Disassembling the reel forward / backward and cutterbar fold valve block
Removing the lock-up valve unit of reel backward valve (Y25)
Disassembling the lock-up valve unit of reel backward valve (Y25)
Lock-up valve unit of reel backward valve (Y25), disassembled:
Assembling the lock-up valve unit of reel backward valve (Y25)
Installing the lock-up valve unit of reel backward valve (Y25)
Removing the pilot controlled non-return valve
Disassembling the pilot controlled non-return valve
Pilot controlled non-return valve, disassembled:
Assembling the pilot controlled non-return valve
Installing and adjusting the pilot controlled non-return valve
Hydraulic cylinders
Removing the cutterbar fold hydraulic cylinder
Disassembling the cutterbar fold hydraulic cylinder
Cutterbar fold hydraulic cylinder, disassembled:
Assembling the cutterbar fold hydraulic cylinder
Installing the cutterbar fold hydraulic cylinder
Adjusting the cutterbar fold hydraulic cylinder
Removing the working position lock hydraulic cylinder
Disassembling the working position lock hydraulic cylinder
Working position lock hydraulic cylinder, disassembled:
Assembling the working position lock hydraulic cylinder
Installing the working position lock hydraulic cylinder
Removing the transport position lock hydraulic cylinder
Disassembling the transport position lock hydraulic cylinder
Transport position lock hydraulic cylinder, disassembled:
Assembling the transport position lock hydraulic cylinder
Installing the transport position lock hydraulic cylinder
Removing the left-hand single-acting reel height adjustment hydraulic cylinder
Disassembling the left-hand single-acting reel height adjustment hydraulic cylinder
Left-hand single-acting reel height adjustment hydraulic cylinder, disassembled:
Assembling the left-hand single-acting reel height adjustment hydraulic cylinder
Installing the left-hand single-acting reel height adjustment hydraulic cylinder
Removing the right-hand double-acting reel height adjustment hydraulic cylinder
Disassembling the right-hand double-acting reel height adjustment hydraulic cylinder
Right-hand double-acting reel height adjustment hydraulic cylinder, disassembled:
Assembling the right-hand double-acting reel height adjustment hydraulic cylinder
Installing the right-hand double-acting reel height adjustment hydraulic cylinder
Removing the left-hand fore and aft reel adjustment hydraulic cylinder
Disassembling the left-hand fore and aft reel adjustment hydraulic cylinder
Left-hand fore and aft reel adjustment hydraulic cylinder, disassembled:
Assembling the left-hand fore and aft reel adjustment hydraulic cylinder
Installing the left-hand fore and aft reel adjustment hydraulic cylinder
Removing the centre fore and aft reel adjustment hydraulic cylinder
Disassembling the centre fore and aft reel adjustment hydraulic cylinder
Centre fore and aft reel adjustment hydraulic cylinder, disassembled:
Assembling the centre fore and aft reel adjustment hydraulic cylinder
Installing the centre fore and aft reel adjustment hydraulic cylinder
Removing the right-hand fore and aft reel adjustment hydraulic cylinder
Disassembling the right-hand fore and aft reel adjustment hydraulic cylinder
Right-hand fore and aft reel adjustment hydraulic cylinder, disassembled:
Assembling the right-hand fore and aft reel adjustment hydraulic cylinder
Installing the right-hand fore and aft reel adjustment hydraulic cylinder
Potentiometers
Replacing the CAC sensing band potentiometer
Adjusting the CAC potentiometer
Replacing the automatic reel height adjustment potentiometer
Adjusting the automatic reel height adjustment potentiometer
Adjusting the cutterbar lock limit switch
Adjusting the reel drive universal drive shaft limit switch
Adjusting the reel limit switch
Folding procedure (Description of function)
Folding from transport position to working position
Folding from working position to transport position