Claas Trion 630-520 (L53) Combines Repair Manual EN

File List:

00 0305 035 3.pdf
00 0305 365 0.pdf
00 0305 843 0.pdf

00 0305 365 0.pdf:

Cummins L9 CM2350 L133CCummins QSL9 CM2350 L120C
Table of contents
Introduction
Notes on the manual
Validity of manual
Copyright note
Information about this Repair Manual
Using the manual
Document structure based on subassemblies
Search and find
Directions
General repair instructions
Technical specifications
Information on technically correct repairs
Self-locking bolts
Liquid locking compound
Steel roller chains
Tensioning
Chain connector
Chain connector type E with spring
Chain connector type G with wire
Chain connector type S with cotter pins
Taper ring fasteners
Dismounting
Installing
Gib head key connections
Dismounting
Installing
Lock collar bearing
Dismounting
Installing
Adapter sleeve bearing
Dismounting
Installing
Chuck bushing
Dismounting of version A
Dismounting of version B
Installing
Chuck bushing version A
Chuck bushing version B
Radial shaft seals
Hose clamps
Tightening torques
Alignment of clamps
Installation aids
Assembly tools
Ferrule fittings
Screwing in
Leaky ferrule fittings
Sealing cone fittings
Hydraulic hoses
Hose placement
Diaphragm accumulator (pressure accumulator) according to CLAAS works standard CN 24 0403
Operating utilities
Service and assembly
Change of gas filling
Special tool
Treatment of sealing faces
Spare parts
Operating materials
Welding work
ESD protection measures
Special tool
ESD protection measures
Notes on inspection and repair
Tightening torques
Threaded assemblies according to CLAAS works standard CN 02 5000
Description of threaded assembly
Tolerance class
Tightening specifications
Tightening torques for metric ISO screw thread
Tightening torques for metric fine thread
Tightening torques for hydraulic fittings with ferrule
Tightening torques for screwed pipe connections with sealing cone joint and hydraulic threaded joints with soft core seal
Tightening torques for bulkhead union nuts, straight and angled
Tightening torques for hydraulic male connectors SDS shape B and E
Tightening torques for hydraulic male connectors SDS shape F and screw plug
Tightening torques for SDS shape H hydraulic male connectors
Tightening torques for screw plugs shape E
Tightening torque for hydraulic male connectors shape C, conical thread
Tightening torques for hydraulic male connectors SDE shape F, adjustable direction
Tightening torques for hydraulic male connectors SDE shape H, with adjustable direction
Tightening torques for hydraulic swivel screw fittings
Tightening torque for hollow screws (with copper sealing ring)
Tightening torques for brake line screw fittings
Tightening torque for tubes with O-ring and union nuts
Tightening torques for threaded pins / orifice plates
Tightening torque for studs and special screws
Tightening torques for hydraulic components
Tightening torques for hex. sealing nuts
Tightening torques for hose clamps
Installation instructions
Worm drive hose clamps
Hose clamps with round pins
Identifying warnings
Hazard signs
Signal word
Safety rules
Safety signs and warnings
Requirement made on technical staff
Children in danger
Hazard areas of the machine
Instructors travelling along during fieldwork
Risk of injury due to rotating shafts
Structural alterations of the machine
Optional equipment and spare parts
Control of running machine
Technical condition
Respecting technical limit values
Danger from machine parts that continue rotating
Keeping safety devices functional
Personal protective equipment
Wearing suitable clothing
Removing dirt and loose objects
Parking the machine safely
Unsuitable operating utilities
Safe handling of service fluids and auxiliary utilities
Environmental protection and disposal
Keeping the cab free of chemicals
Avoiding fires
Potentially fatal electric shock from overhead lines and lightning strike
Electric shock from electric system
Noise may damage your health
Pre-loaded machine parts
Liquids under pressure
Compressed air
Toxic exhaust gases
Hot surfaces
Safe access and leaving
Working only on the stopped machine
Hazards during repairs
Raised machine parts and loads
Danger from welding work
Checking and charging the battery
Preparations for cases of emergency
CCN explanation
CCN (CLAAS Component Number)
Electric systems standard
Hydraulic system standard
CCN (CLAAS Component Number)
0102 Complete component
Specifications
Specifications
Diesel engine overview
Overview of exhaust gas aftertreatment
Diesel engine overview
Disassembling the engine
Overview (304-999)
Disassembling (304-001)
Assembling the engine
Overview (305-999)
Assembling (305-001)
Cranking the engine (000-017)
Special tool
Half-round plug (017-002)
Cleaning and checking
Installing
Screw plug (017-007)
Cleaning and checking
Installing
Screw plug (017-007)
Cleaning and checking
Oil sump, centre
Installing
Screw plug with cylindrical thread (017-011)
Cleaning and checking
Installing
Screw plug with cylindrical thread (017-011)
General information
Cleaning and checking
Installing
Necked-down bolt (017-015)
Cleaning and checking
Installing
0110 Engine housing
Front crankshaft seal (001-023)
Special tool
Cleaning and checking
Installing
Front crankshaft seal (001-023)
Special tool
Cleaning and checking
Installing
Rear crankshaft seal (001-024)
Special tool
General information
Multi-part seal
Multi-part seal
Cleaning and checking
Installing
Front gearwheel cover (001-031)
Cleaning and checking
Installing
Front gearwheel housing (001-033)
Cleaning and checking
Installing
Oil sump seal – repair
Crankcase ventilation (external) (003-001)
Cleaning and checking
Installing
Crankcase ventilation (internal) (003-002)
General information
Installing
Crankcase ventilation (internal) (003-002)
Cleaning and checking
Installing
Crankcase vent line (003-018)
Cleaning and checking
Installing
Crankcase vent line (003-018)
Crankcase ventilation mounted on the block
Crankcase ventilation mounted on the rocker assembly cover
Cleaning and checking
Installing
Crankcase ventilation mounted on the block
Crankcase ventilation mounted on the rocker assembly cover
Oil sump (007-025)
Work preparation
Cleaning and checking
Only oil sump made of composite material
Installing
Flywheel housing (016-006)
Special tool
Disassembling
Cleaning and checking
Assembling
Measurements
Mating surface alignment
Bore alignment
Installing
Applications with a wet flywheel
Flywheel housing (016-006)
Special tool
Disassembling
Cleaning and checking
Assembling
Measurements
Mating surface alignment
Bore alignment
Installing
Applications with a wet flywheel
Applications with a wet flywheel
Crankcase pressure sensor (019-445)
General information
Cleaning and checking
Installing
0115 Engine unit
Connecting rod bearings (001-005)
Cleaning and checking
Installing
Main bearing (001-006)
Special tool
Cleaning and checking
Installing
Upper main bearings
Lower main bearings
Main bearing (001-006)
Special tool
Cleaning and checking
Installing
Upper main bearings
Lower main bearings
Connecting rod (001-014)
Cleaning and checking
Bending and torsion test
Calibration process
Installing
Connecting rod (001-014)
General information
Cleaning and checking
Bending and torsion test
Calibration process
Installing
Crankshaft (001-016)
Special tool
Cleaning and checking
Installing
Rotation test
Crankshaft (001-016)
Special tool
General information
Cleaning and checking
Installing
Rotation test
Front crankshaft gear (crankshaft removed) (001-019)
Cleaning and checking
Installing
Crankshaft pulley (001-022)
Installing
Front crankshaft wear bushing (001-025)
Special tool
Cleaning and checking
Installing
Piston (001-043)
Work preparation
General information
Cleaning and checking
Fault analysis / inspection
Measurements
Installing
Piston cooling nozzle (001-046)
Cleaning and checking
Installing
Piston cooling nozzle (001-046)
Cleaning and checking
Installing
Piston rings (001-047)
Work preparation
Fault analysis / inspection
Rubber vibration damper (001-051)
Installing
Viscose vibration damper (001-052)
Installing
Piston/connecting rod sub-assembly (001-054)
Special tool
Engines with horizontally split connecting rods
Disassembling
Cleaning and checking
Assembling
One-piece piston
Multi-piece piston
Installing
Engines with pins and nuts on the connecting rods
Engines with cap screws on the connecting rods
Piston/connecting rod sub-assembly (001-054)
Special tool
Engines with horizontally split connecting rods
Engines with diagonally split connecting rods
Disassembling
Cleaning and checking
Assembling
One-piece piston
Multi-piece piston
Installing
Engines with pins and nuts on the connecting rods
Engines with cap screws on the connecting rods
Crankshaft wear sleeve, rear (001-067)
Special tool
Initial check
Cleaning and checking
Installing
Crankshaft speed ring (001-071)
Cleaning and checking
Installing
Crankshaft seal carrier, rear (001-104)
Special tool
Cleaning and checking
Installing
Maintenance tip
Ring gear disc (016-004)
Initial check
Electric system
Check for reusability
Installing
Flywheel (016-005)
Special tool
Initial check
Electric system
Disassembling
Cleaning and checking
Assembling
Installing
Measurements
Eccentricity of the bore
Side run out
Flywheel ring gear (016-008)
General information
Initial check
Installing
Crankshaft position sensor (019-365)
General information
Cleaning and checking
Installing
0120 Cylinder head / Valves / Idler gear
Camshaft (001-008)
Cleaning and checking
Installing
Camshaft (001-008)
Cleaning and checking
Installing
Camshaft bushings (001-010)
General information
Cleaning and checking
Installing
Camshaft gear (camshaft installed) (001-012)
Special tool
Cleaning and checking
Installing
Camshaft gear (camshaft removed) (001-013)
Cleaning and checking
Installing
Cylinder block (001-026)
Work preparation
Initial check
Cleaning and checking
Measurements
Cylinder liner (001-028)
Special tool
General information
Initial check
Cleaning and checking
Installation
Cylinder block liner seat (001-058)
Initial check
Cylinder block reinforcement plate (001-089)
General information
Cleaning and checking
Installing
Valve bridge (002-001)
Cleaning and checking
Installing
Valve bridge (002-001)
Cleaning and checking
Installing
Cylinder head (002-004)
Special tool
Disassembling
Cleaning and checking
Assembling
Installing
Cylinder head (002-004)
Special tool
Disassembling
Cleaning and checking
Assembling
Installing
Cylinder head valve guide seal (002-016)
Work preparation
Special tool
General information
Cleaning and checking
Installing
Cylinder head valve guide seal (002-016)
Work preparation
Special tool
General information
Cleaning and checking
Installing
Cylinder head gasket (002-021)
Installing
Cylinder head group (003-004)
Technical specifications
Special tool
Preparatory work
Final tasks
Rocker arm (003-008)
Technical specifications
Disassembling
Cleaning and checking
Assembling
Installing
Rocker arm cover (003-011)
Cleaning and checking
Installing
Rocker arm cover (003-011)
Cleaning and checking
Rocker assembly cover, bolted at the outer edge
Installing
Rocker assembly cover, bolted in the middle
Rocker assembly cover, bolted at the outer edge
Rocker arm housing (003-013)
Work preparation
Cleaning and checking
Installing
Push rods and tubes (004-014)
Cleaning and checking
Installing
Tappet (004-015)
Work preparation
Special tool
Cleaning and checking
Installing
Tappet (004-015)
Work preparation
Special tool
Sliding tappet
Roller tappets
Cleaning and checking
Sliding tappet
Roller tappets
Installing
Sliding tappet
Roller tappets
Camshaft sensor (019-363)
General information
Cleaning and checking
Installing
0125 Injection / Fuel system
Fuel pump (005-016)
Technical specifications
Special tool
Preparatory measures
Installing
Fuel pump (005-016)
Technical specifications
Special tool
Preparatory measures
Installing
Fuel pump (005-025)
Preparatory measures
Cleaning and checking
Installing
Fuel pump adjustment (005-037)
Cleaning and checking
Installing
Fuel feed pump (005-045)
General information
Preparatory measures
Installing
Output fitting on fuel pump head (005-226)
Preparatory measures
Removing a flat sealing washer
Cleaning and checking
Installing
Fuel pump heads (005-227)
Special tool
Preparatory measures
Cleaning and checking
Installing
Fuel pump heads (005-227)
Special tool
Preparatory measures
Cleaning and checking
Steel piston
Ceramic piston
Reconditioning
Installing
Plastic pump actuator housing (005-228)
Preparatory measures
Cleaning and checking
Installing
Engine Control Module (ECM) cooling plate, fuel-cooled (006-006)
Preparatory measures
Initial check
Disassembling
Assembling
Installing
Fuel return lines (006-013)
Preparatory measures
Initial check
Installing
Fuel manifold (006-019)
Preparatory measures
Disassembling
Assembling
Fuel manifold with threaded fittings
Fuel manifold with threaded fittings
Installing
Fuel supply lines (006-024)
Preparatory measures
Initial check
Installing
Injection nozzle (006-026)
Special tool
Preparatory measures
Cleaning and checking
Installing
High-pressure supply lines to the injection nozzles (006-051)
Preparatory measures
Initial check
Cleaning and checking
Installing
High-pressure supply lines to the injection nozzles (006-051)
Preparatory measures
Initial check
Installing
Fuel line connection (installed on cylinder head) (006-052)
Special tool
Preparatory measures
Cleaning and checking
Installing
High-pressure accumulator (rail) (006-060)
Technical specifications
Preparatory measures
Initial check
Cleaning and checking
Installing
Pressure relief valve (006-061)
Technical specifications
Preparatory measures
Installing
Pressure relief valve (006-061)
Technical specifications
Preparatory measures
Installing
Fuel manifold high-pressure valve (006-067)
Technical specifications
Preparatory measures
Initial check
Installing
Pressure relief in the high-pressure fuel system (006-081)
Preparatory measures
Relieving pressure
Rail pressure sensor (019-115)
Technical specifications
Preparatory measures
Cleaning and checking
Installing
Fuel pump actuator (019-117)
Technical specifications
Preparatory measures
Initial check
Installing
0130 Lubricating oil system
Engine oil preheater (007-001)
Cleaning and checking
Installing
Lubricating oil cooler (007-003)
Cleaning and checking
Leak check
Installing
Oil cooler without cavity
Oil cooler with cavity
Lubricating oil cooler (007-003)
Cleaning and checking
Leak check
Installing
Oil dipstick (007-009)
Calibrating
Oil dipstick tube (007-011)
Installing
Oil dipstick tube (007-011)
Installing
Lubricating oil filter (007-013)
Lubricating oil filter bypass valve (007-014)
Cleaning and checking
Installing
Lubricating oil filter head (007-015)
Cleaning and checking
Installing
Lubricating oil filter head (separately installed) (007-017)
Disassembling
Cleaning and checking
Assembling
Installing
Lubricating oil filter head adapter (007-018)
Cleaning and checking
Installing
Lubricating oil high-pressure drain valve (007-021)
Installing
Lubricating oil pressure regulator (main duct) (007-029)
Cleaning and checking
Installing
Oil pump (007-031)
Disassembling
Cleaning and checking
Measurements
Assembling
Installing
Oil suction tube (fitted on cylinder block) (007-035)
Cleaning and checking
Installing
Oil thermostat (007-039)
Cleaning and checking
Installing
Lubricating oil lines (007-092)
Installing
Turbocharger oil return line (010-045)
Disassembling
Cleaning and checking
Assembling
Installing
Turbocharger oil return line (010-045)
Cleaning and checking
Installing
Turbocharger oil supply (010-046)
Cleaning and checking
Installing
Turbocharger oil supply (010-046)
Installing
Engine oil pressure sensor and switch (019-066)
Cleaning and checking
Installing
0135 Cooling system
Coolant thermostat (008-013)
Cleaning and checking
Installing
Coolant vent lines (008-017)
General information
Cleaning and checking
Installing
Water pump (008-062)
Cleaning and checking
Installing
Water inlet connection (008-082)
Work preparation
Cleaning and checking
Installing
Coolant lines (008-124)
Work preparation
Cleaning and checking
Installing
Turbocharger coolant hoses (010-041)
Work preparation
Cleaning and checking
Installing
Turbocharger coolant hoses (010-041)
Work preparation
Cleaning and checking
Installing
Coolant temperature sensor (019-019)
General information
Cleaning and checking
Installing
0140 Exhaust system
Turbocharger (010-033)
Work preparation
Special tool
Checking if correct component is used
Disassembling
Cleaning and checking
Assembling
Installing
Turbocharger (010-033)
Work preparation
Cleaning and checking
Check the axial play
Checking the radial play
Installing
Charge pressure control valve (010-050)
Initial check
Cleaning and checking
Installing
Outlet connection of turbocharger compressor (010-132)
Special tool
Cleaning and checking
Installing
VTG turbocharger actuator, electric (010-134)
Cleaning and checking
Installing
Calibrating
Calibration instructions
Turbocharger exhaust gas connection adapter (010-141)
Cleaning and checking
Installing
Exhaust manifold, dry (011-007)
General information
Disassembling
Cleaning and checking
Assembling
Installing
Exhaust manifold, dry (011-007)
Disassembling
Cleaning and checking
Only multi-piece:
Installing
Exhaust pressure sensor line (011-027)
Initial check
Cleaning and checking
Installing
Exhaust pressure sensor (019-376)
Installing
0145 Air intake
Air intake manifold (010-023)
Cleaning and checking
Installing
Cold weather starting aid (010-029)
General information
Cold weather starting aid (010-029)
Cleaning and checking
Installing
Air intake connection (010-080)
Special tool
General information
Cleaning and checking
Installing
Air intake connection (010-080)
Cleaning and checking
Installing
Cover, air intake manifold (010-108)
Cleaning and checking
Installing
FIPG seal at the joint between intake manifold cover and cylinder head
Standard seal at the joint between intake manifold cover and cylinder head
Air intake connection adapter (010-131)
General information
Cleaning and checking
Installing
Air intake connection adapter (010-131)
Cleaning and checking
Installing
Intake manifold pressure/temperature sensor (019-159)
Cleaning and checking
Installing
0150 Engine attachment parts
Coolant lines, air compressor (012-004)
Installing
Air compressor cylinder head, single cylinder (012-007)
Initial check
Cleaning and checking
Disassembling
Assembling
Installing
Air compressor cylinder head, single cylinder (012-007)
Initial check
Cleaning and checking
Disassembling
Assembling
Installing
Air compressor (012-014)
Special tool
Cleaning and checking
Synchronising
Installing
Air compressor (012-014)
Work preparation
Special tool
Cleaning and checking
Synchronising
Wabco��� air compressor
Knorr-Bremse��� air compressor
Installing
Air compressor intake line (012-109)
General information
Cleaning and checking
Installing
Oil supply line, air compressor (012-110)
Cleaning and checking
Installing
Alternator (013-001)
Initial check
Installing
Chator bracket (013-003)
Installing
Starter (013-020)
Work preparation
Special tool
Rotation test
Cleaning and checking
Measurements
Installing
Starter motor made by Cummins:
Starter motor not made by Cummins:
0155 Engine control
Engine control module (019-031)
Installing
Engine wiring loo19-043)
Installing
Wiring loom, internal actuator (019-063)
Installing
Delphi 96-way connector for the engine control module (019-505)
Special tool
General information
Replacing a pin
Removing the clamps
Inserting the pin
Installing
0165 Exhaust gas aftertreatment
SCR catalytic converter (011-036)
General information
Cleaning and checking
Installing
Diesel particulate filter (011-041)
General information
Cleaning and checking
Installing
Lines of the diesel particle filter differential pressure sensor (011-047)
General information
Cleaning and checking
Installing
Diesel oxidation catalytic converter (011-049)
General information
Cleaning and checking
In case of side-in configurations
In case of end-in configurations
Installing
Exhaust gas aftertreatment system (011-050)
General information
Installing
Atomiser tube of exhaust gas aftertreatment system (011-062)
General information
Initial check
Cleaning and checking
Installing
Bracket of diesel particulate filter sensor sub-assembly (011-141)
General information
Cleaning and checking
Installing
Bracket of atomiser tube sensor sub-assembly (011-142)
General information
Cleaning and checking
Installing
Diesel particulate filter differential pressure sensor (019-443)
General information
Cleaning and checking
Installing
Exhaust gas temperature sensor of exhaust gas aftertreatment system (019-449)
General information
Initial check
Installing
NOx sensor at the outlet of the exhaust gas aftertreatment system (019-451)
General information
Cleaning and checking
Installing
NOx sensor at the inlet of the exhaust gas aftertreatment system (019-463)
General information
Cleaning and checking
Installing

00 0305 843 0.pdf:

LEXION 8900-5300TRION 750-520
Table of contents
00 2998 428 0
Safety rules
Package list
Shipping package of repair kit 00 2998 428 0
Work preparation
Job preparation for repair kit 00 2998 428 0
Assembling
Replacing the shaft and the bearing