Claas Jaguar 900-830 (492) Forage Harvesters Repair Manual EN

File List:

00 0107 838 3.pdf
00 0296 338 1.pdf
00 0296 365 1.pdf
00 0298 077 0.pdf
00 0298 826 1.pdf
00 0303 966 1.pdf
00 0305 072 0.pdf
00 1106 921 9.pdf
1 183 409_e.pdf
Inspection protocol OM 502 LA OM 460 LA.pdf

00 0296 338 1.pdf:

Mercedes-Benz OM502LA
Table of contents
Introduction
General information
Validity of manual
Handling the manual
Texts and figures
Document structure based on the assembly structure
Search and find
Directions
Abbreviations
Technical terms
General repair instructions
Technical specifications
Information on proper repairs
Self-locking bolts
Liquid locking compound
Steel roller chains
Tensioning
Chain connector
Taper ring fasteners
Dismounting
Installation
Gib head key joints
Dismounting
Installation
Lock collar bearing
Dismounting
Installation
Adapter sleeve bearings
Dismounting
Installation
Chuck bushing
Dismounting
Installation
Circlips
Ferrule fittings
Screwing in
Non-tight ferrule connection
Sealing cone fittings
Hydraulic hoses
Hose placement
Treatment of sealing faces
Spare parts
Torque settings
Tightening torques for metric standard threads
Tightening torques for metric fine thread screws
Tightening torques for hydraulic screw fittings and air conditioner screw fittings with sealing cone and O-ring according to DIN 3865
Tightening torques for hydraulic screw fittings with ferrule according to DIN 3861
Tightening torques for SDS hydraulic male connectors
Tightening torques for hydraulic swivel fittings
Tightening torques for hollow screws DIN 7643
Tightening torques for direction-adjustable SDE hydraulic male connectors
Tightening torques for brake line screw fittings
Tightening torques for worm drive hose clamps
Tightening torque for spring-loaded worm drive hose clamps
CCN explanation
CCN (CLAAS Component Number)
Electric systems standard
Hydraulic system standard
CCN (CLAAS Component Number)
General information
Of special importance
Identification of warning and danger signs
Regulations for avoiding accidents with personal injuries
Testing, adjusting and repair work
Engine operation
Suspended loads
Working on piping and hoses
Working on the electric system
Working on the hydraulic system
Electric welding
Painting work
Working with urea solution
Information on how to avoid damage and premature wear
Liability limitation
Shutting down and storage
Regulations for avoiding health and environmental damage
Precautionary measures for protection against health and environmental damage
Disposal of operating utilities and auxiliary operating utilities
Information for working on the diesel engine
Accident protection
Cleanliness
Installation instructions
Engine overhaul
Putting into operation after an engine overhaul
First aid measures
01 Engine
0102 Complete component
Type design
Engine data
Engine description
Engine components
Ignition order
Cranking the engine
Special tool for built-in engine
Special tools for removed engine
Cranking the engine in built-in condition
Cranking the engine in removed condition
0105 Engine suspension
Lifting eyes
Technical specifications
0110 Engine housing
Oil sump
Special tool
Technical specifications
Installation
Crankshaft front seal
Special tool
Technical specifications
Removing the radial seal
Installing the radial seal
Removing the cassette seal
Installing the cassette seal ring
Crankshaft rear seal
Special tool
Technical specifications
Installation
Crankcase cover
Special tool
Technical specifications
Installation
Timing housing cover
Special tool
Technical specifications
Applies to design type 942.993
Installation
Applies to design type 942.993
Timing housing
Work preparation
Technical specifications
Installation
Timing housing
Work preparation
Technical specifications
Installation
0115 Engine unit
Special tool
Technical specifications
Disassembly
Checking
Assembly
Installation
Installation
Measuring the excess dimension
Connecting rod
Technical specifications
Checking
Installation
Cylinder liner
Special tool
Technical specifications
Checking
Installation
Applies to design type: 458.99x
Measuring the excess dimension
Measuring the cylinder bore
Crankshaft
Special tool
Technical specifications
Checking
Installation
Crankshaft ring
Special tool
Technical specifications
Installation
Oscillation damper
Special tool
Technical specifications
Installation
Flywheel
Special tool
Technical specifications
Checking
Installation
Replace ring gear
Replacing the ring
0120 Cylinder head / Valves / Idler gear
Valve cover
Technical specifications
Cylinder head
Special tool
Technical specifications
Checking
Disassembly
Assembly
Installation
Rocker lever
Special tool
Technical specifications
Installation instructions
Replacing the roller tappets
Special tool
Technical specifications
Installation instructions
Checking the valves
Adjusting the valve lash
Valve springs and valve stem seals
Special tool
Mercedes-Benz
Technical specifications
Installation
Valve guide
Work preparation
Special tool
Technical specifications
Checking
Installation
Camshaft
Special tool
Technical specifications
Checking
Installation
0125 Injection / Fuel system
Fuel system
Cylinder head injection line
Special tool
Technical specifications
Installation instructions
Cylinder head leakage lines
Technical specifications
Nozzle holder combination
Special tool
Technical specifications
Installation
Protective sleeve
Special tool
Technical specifications
Installation instructions
Plug-on pump
Special tool
Work preparation
Technical specifications
Installation
Fuel pump
Work preparation
Technical specifications
Installation
Fuel filter housing
Technical specifications
0130 Lubricating oil system
Lubricating oil system
Special tool
Pre-filling
Oil spray nozzle
Technical specifications
Installation instructions
Oil filter housing
Work preparation
Technical specifications
Installation
Oil cooler
Technical specifications
Installation instructions
Oil excess pressure valve
Technical specifications
Installation instructions
Oil pump
Technical specifications
Installation instructions
0135 Cooling system
Special tool
Technical specifications
Draining
Filling up
Cleaning the coolant circuit
Coolant pump
Special tool
Technical specifications
Disassembly
Assembly
Installation
Coolant thermostat
Work preparation
Technical specifications
Checking
Installation
0140 Exhaust system
Exhaust manifold
Technical specifications
Installation
Exhaust manifold
Technical specifications
Installation
Main exhaust manifold
Technical specifications
Installation instructions
Exhaust turbo charger suction tube
Technical specifications
Installation instructions
Exhaust turbo charger
Special tool
Technical specifications
Installation
Checking
Checking the axial play
Checking the radial play
Exhaust turbo charger
Special tool
Technical specifications
Installation
Checking
Checking the axial play
Checking the radial play
Catalyst
Work preparation
Technical specifications
Installation instructions
0145 Air intake
Intake housing
Technical specifications
Applies to type designs with one exhaust turbo charger
Applies to type designs with two exhaust turbo chargers
Installation
Applies to type designs with two exhaust turbo chargers
Applies to type designs with one exhaust turbo charger
0150 Engine attachment parts
Electric starting motor
Work preparation
Technical specifications
Installation
Removing the solenoid switch
Installing the solenoid switch
Removing the starter pinion
Installing the starter pinion
Alternator
Special tool
Technical specifications
Installation
Removing the pulley
Installing the pulley
Alternator
Special tool
Technical specifications
Alternator (G002)
Alternator (G002)
Alternator (G003)
Alternator (G003)
Alternator (G003)
Installation
Alternator (G002)
Alternator (G002)
Alternator (G003)
Alternator (G003)
Alternator (G003)
Removing the pulley
Installing the pulley
Alternator drive belt tensioner
Technical specifications
Installation instructions
Air compressor
Special tool
Technical specifications
Checking the oil thrown out
Removing the drive wheel
Installing the drive wheel
Removing the cylinder head
Applies to design type 942.993
Disassembling the cylinder head
Assembling the cylinder head
Installing the cylinder head
Applies to design type 942.993
Removing the piston and the cylinder liner
Installing the piston and the cylinder liner
Removing the crankshaft and the connecting rod
Installing the crankshaft and connecting rod
0155 Engine control
MR/PLD control unit
Technical specifications
Installation instructions
0165 Exhaust gas aftertreatment
Exhaust treatment system
Work preparation
Special tool
Technical specifications
Checking the urea solution (purity)
Checking the urea solution (density)
Urea heater valve
Work preparation
Special tool
Technical specifications
Installation
Urea pump
Work preparation
Special tool
Technical specifications
Installation
Removing the pressure accumulator
Installing the pressure accumulator
Removing the dump valve
Installing the dump valve
Removing the intake filter
Installing the intake filter
Checking the electric wiring loom
Filling the accumulator
Urea dosing unit
Work preparation
Special tool
Technical specifications
Installation instructions
Flushing
Urea injector
Technical specifications
Installation instructions
0190 Accessories
Engine insulation
Work preparation
Technical specifications
Engine insulation
Work preparation
Technical specifications
Installation

00 0296 365 1.pdf:

Mercedes-Benz OM460LA
Table of contents
Introduction
General information
Validity of manual
Handling the manual
Texts and figures
Document structure based on the assembly structure
Search and find
Directions
Abbreviations
Technical terms
General repair instructions
Technical specifications
Information on proper repairs
Self-locking bolts
Liquid locking compound
Steel roller chains
Tensioning
Chain connector
Taper ring fasteners
Dismounting
Installation
Gib head key joints
Dismounting
Installation
Lock collar bearing
Dismounting
Installation
Adapter sleeve bearings
Dismounting
Installation
Chuck bushing
Dismounting
Installation
Circlips
Ferrule fittings
Screwing in
Non-tight ferrule connection
Sealing cone fittings
Hydraulic hoses
Hose placement
Treatment of sealing faces
Spare parts
Torque settings
Tightening torques for metric standard threads
Tightening torques for metric fine thread screws
Tightening torques for hydraulic screw fittings and air conditioner screw fittings with sealing cone and O-ring according to DIN 3865
Tightening torques for hydraulic screw fittings with ferrule according to DIN 3861
Tightening torques for SDS hydraulic male connectors
Tightening torques for hydraulic swivel fittings
Tightening torques for hollow screws DIN 7643
Tightening torques for direction-adjustable SDE hydraulic male connectors
Tightening torques for brake line screw fittings
Tightening torques for worm drive hose clamps
Tightening torque for spring-loaded worm drive hose clamps
CCN explanation
CCN (CLAAS Component Number)
Electric systems standard
Hydraulic system standard
CCN (CLAAS Component Number)
General information
Of special importance
Identification of warning and danger signs
Regulations for avoiding accidents with personal injuries
Testing, adjusting and repair work
Engine operation
Suspended loads
Working on piping and hoses
Working on the electric system
Working on the hydraulic system
Electric welding
Painting work
Working with urea solution
Information on how to avoid damage and premature wear
Liability limitation
Shutting down and storage
Regulations for avoiding health and environmental damage
Precautionary measures for protection against health and environmental damage
Disposal of operating utilities and auxiliary operating utilities
Information for working on the diesel engine
Accident protection
Cleanliness
Installation instructions
Engine overhaul
Putting into operation after an engine overhaul
First aid measures
01 Engine
0102 Complete component
Type design
Engine data
Engine description
Engine components
Ignition order
Cranking the engine
Special tool for built-in engine
Special tools for removed engine
Cranking the engine in built-in condition:
JAGUAR double engine (A)
JAGUAR Double engine (B)
Cranking the engine in removed condition
0105 Engine suspension
Lifting eyes
Technical specifications
0110 Engine housing
Oil sump
Install special tool
Technical specifications
Installation
Crankshaft front seal
Special tool
Technical specifications
Removing the radial seal
Installing the radial seal
Removing the cassette seal
Installing the cassette seal ring
Crankshaft rear seal
Special tool
Technical specifications
Installation
Crankcase cover
Special tool
Technical specifications
Installation
Camshaft timing gear wheel cover
Technical specifications
Installation instructions
Timing housing
Work preparation
Technical specifications
Installation
Oil separator
Technical specifications
0115 Engine unit
Special tool
Technical specifications
Disassembly
Checking
Assembly
Installation
Installation
Measuring the excess dimension
Connecting rod
Technical specifications
Checking
Installation
Cylinder liner
Special tool
Technical specifications
Checking
Installation
Applies to design type: 458.99x
Measuring the excess dimension
Measuring the cylinder bore
Crankshaft
Install special tool
Technical specifications
Checking
Installation
Crankshaft ring
Special tool
Technical specifications
Installation
Oscillation damper
Technical specifications
Installation instructions
Flywheel
Special tool
Technical specifications
Checking
Installation
Replace ring gear
Replacing the ring
0120 Cylinder head / Valves / Idler gear
Valve cover
Technical specifications
Cylinder head
Special tool
Technical specifications
Checking
Disassembly
Assembly
Installation
Rocker lever
Special tool
Technical specifications
Installation instructions
Replacing the roller tappets
Special tool
Technical specifications
Installation instructions
Checking the valves
Adjusting the valve lash
Valve springs and valve stem seals
Special tool
Mercedes-Benz
Technical specifications
Installation
Valve guide
Work preparation
Special tool
Technical specifications
Checking
Installation
Camshaft
Install special tool
Technical specifications
Checking
Installation
Camshaft timing gear wheel
Technical specifications
0125 Injection / Fuel system
Fuel system
Cylinder head injection line
Special tool
Technical specifications
Installation instructions
Cylinder head leakage lines
Technical specifications
Nozzle holder combination
Special tool
Technical specifications
Installation
Protective sleeve
Special tool
Technical specifications
Installation instructions
Plug-on pump
Special tool
Work preparation
Technical specifications
Installation
Fuel pump
Work preparation
Technical specifications
Removing the bearing
Installing the bearing
Installation
Fuel filter housing
Technical specifications
0130 Lubricating oil system
Lubricating oil system
Install special tool
Pre-filling
Oil spray nozzle
Technical specifications
Installation instructions
Oil filter housing
Technical specifications
Installation
Oil cooler
Technical specifications
Installation instructions
Oil pump
Technical specifications
Installation instructions
Oil excess pressure valve
Technical specifications
Installation instructions
0135 Cooling system
Special tool
Technical specifications
Draining
Filling up
Cleaning the coolant circuit
Coolant pump
Technical specifications
Installation
Coolant thermostat
Work preparation
Technical specifications
Checking
Installation
0140 Exhaust system
Exhaust manifold
Technical specifications
Installation
Exhaust turbo charger
Special tool
Technical specifications
Installation
Checking
Checking the axial play
Checking the radial play
Flap nozzle
Technical specifications
Installation
Catalyst
Work preparation
Technical specifications
Installation instructions
0145 Air intake
Intake housing
Technical specifications
Installation
0150 Engine attachment parts
Electric starting motor
Work preparation
Technical specifications
Installation
Removing the solenoid switch
Installing the solenoid switch
Removing the starter pinion
Installing the starter pinion
Alternator
Special tool
Technical specifications
Installation
Removing the pulley
Installing the pulley
Alternator
Special tool
Technical specifications
Installation
Removing the pulley
Installing the pulley
Alternator drive belt tensioner
Technical specifications
Installation instructions
Air compressor
Technical specifications
Applies to design type 458.992
Installation
Applies to design type 458.992
Checking the oil thrown out
0155 Engine control
MR/PLD control unit
Technical specifications
Installation instructions
0165 Exhaust gas aftertreatment
Exhaust treatment system
Work preparation
Special tool
Technical specifications
Checking the urea solution (purity)
Checking the urea solution (density)
Urea heater valve
Work preparation
Special tool
Technical specifications
Installation
Urea pump
Work preparation
Special tool
Technical specifications
Installation
Removing the pressure accumulator
Installing the pressure accumulator
Removing the dump valve
Installing the dump valve
Removing the intake filter
Installing the intake filter
Checking the electric wiring loom
Filling the accumulator
Urea dosing unit
Work preparation
Special tool
Technical specifications
Installation instructions
Flushing
Urea injector

00 0298 077 0.pdf:

JAGUAR 900 – 830
Table of contents
Introduction
General Information
Validity of manual
Handling the manual
Texts and figures
Document structure based on the assembly structure
Search and find
Directions
Abbreviations
Technical terms
General repair instructions
Technical specifications
Information on proper repairs
Self-locking bolts
Liquid locking compound
Steel roller chains
Tensioning
Chain connector
Taper ring fasteners
Dismounting
Installation
Gib head key joints
Dismounting
Installation
Lock collar bearing
Dismounting
Installation
Adapter sleeve bearings
Dismounting
Installation
Chuck bushing
Dismounting
Installation
Circlips
Ferrule fittings
Screwing in
Non-tight ferrule connection
Sealing cone fittings
Hydraulic hoses
Hose placement
Treatment of sealing faces
Spare parts
Torque settings
Tightening torques for metric standard threads
Tightening torques for metric fine thread screws
Tightening torques for hydraulic screw fittings and air conditioner screw fittings with sealing cone and O-ring according to DIN 3865
Tightening torques for hydraulic screw fittings with ferrule according to DIN 3861
Tightening torques for SDS hydraulic male connectors
Tightening torques for hydraulic swivel fittings
Tightening torques for hollow screws DIN 7643
Tightening torques for direction-adjustable SDE hydraulic male connectors
Tightening torques for brake line screw fittings
Tightening torques for worm drive hose clamps
Tightening torque for spring-loaded worm drive hose clamps
Tightening torques for tyres
CCN explanation
CCN (CLAAS Component Number)
Electric systems standard
Hydraulic system standard
CCN (CLAAS Component Number)
General Information
Of special importance
Identification of warning and danger signs
General safety and accident prevention regulations
First aid measures
Danger of injury from hydraulic liquid
Leaving the machine
Putting the machine out of operation
Jacking up the machine
Adjustment and maintenance operations
Welding work
03 Chassis
0330 Driven steering axle, rear
Rear drive axle
Work preparation
Special tool
Technical specifications
Installation
Axle body
Work preparation
Special tool
Technical specifications
Disassembly
Assembly
Stub axle
Work preparation
Special tool
Technical specifications
Installation
Bevel gear drive
Work preparation
Special tool
Technical specifications
Disassembly
Assembly
Checking the backlash
Installation
Differential
Work preparation
Special tool
Technical specifications
Disassembly
Assembly
Installation
If the measured play equals the value specified for play (a), skip this work step!
If the measured rolling moment equals the specified rolling moment value (b), skip this work step!
Plug-in axles
Technical specifications
Installation
Wheel hub
Work preparation
Special tool
Technical specifications
Remove the wheel hub completely.
Installing the wheel hub completely
Disassembly
Assembly
Track rods
Technical specifications
Adjusting the track and the steering angle
05 Steering
0505 Steering
Steering hydraulic cylinder (3023)
Technical specifications
Disassembly
Assembly
Installation
0510 Automatic steering
AUTO PILOT steering angle sensor (B006)
Technical specifications

00 0298 826 1.pdf:

Table of contents
General information
Introduction
Introduction to the CLAAS Repair Manual
Picture symbol description
Safety rules
Important note
Identification of warning and danger signs
Correct use of the vehicle
General safety and accident prevention regulations
Leaving the machine
Air conditioner
Maintenance
Basic Rules
Pressure accumulator
General repair notes
Cause of damage
The repair will be quick and correct if the following is observed
Transmissions
Welding work
Three phase AC generator
Tensioning the steel roller chain
Conical ring connectors
Self-locking screws (MK-screws)
Liquid screw locking material
Clamping ring bearings (lock collar bearings)
Adapter sleeve bearing fitting
Ferrule fittings on hydraulic lines
Conical seating fittings on hydraulic/air conditioning lines
Hydraulic hoses
Tightening torques
Tightening torques screws
Tightening torques hydraulic fittings
Tightening torques brake pipe fittings
Tightening torques wheel bolts/wheel nuts
Specifications
Lubricants chart
Hydraulic pressures
Engine data
Operator’s platform
Removing front frame
Fitting the front frame
Removing the heating elements
Fitting the heating element
Removing the regulating valve
Fitting the regulating valve
Air conditioning
Air conditioning unit – filling up the refrigerant
Removing the evaporator
Air conditioner (cab side) dismantled
Fitting the evaporator
Removing the expansion valve
Fitting the expansion valve
Removing the temperature switch
Fitting the temperature switch
Removing the filter drier
Filter drier disassembled
Fitting the filter drier
Removing the condenser
Fitting the condenser
Removing the compressor coupling
Fitting the coupling compressor
Removing the compressor
Fitting the compressor
Driver’s seat
Fitting the driver’s seat
Driver’s seat dismantled (Isringhausen, pneumatically adjustable)
Driver’s seat dismantled (Grammer, pneumatically adjustable)
Fitting the driver’s seat
Operating Elements
Dismantling the traverse regulation (Mechanical-hydraulic traverse drive, up to serial no. …)
Traverse regulation dismantled (Mechanical-hydraulic ground drive, up to serial no. …)
Assembling the traverse regulation (Mechanical-hydraulic ground drive, up to serial no. …)
Dismantling the traverse regulation (Mechanical-hydraulic traverse drive, from serial no. …)
Traverse regulation dismantled (Mechanical-hydraulic ground drive, from serial no. …)
Assembling the traverse regulation (Mechanical-hydraulic ground drive, from serial no. …)
Dismantling the traverse regulation (electro-hydraulic ground drive)
Dismantled traverse regulation (electro-hydraulic ground drive)
Assembling the traverse regulation (electro-hydraulic ground drive)
Removing the traverse lever pull actuation (mechanical-hydraulic ground drive)
Fitting the traverse lever pull actuation (mechanical-hydraulic ground drive)
Steering
Removing the steering column
Dismantling the steering column
Steering column dismantled:
Assembling the steering column
Fitting the Steering Column
Removing the steering column (adjustable)
Dismantling the steering column (adjustable)
Steering column (adjustable) dismantled:
Assembling the steering column (adjustable)
Fitting the steering column (adjustable)
Removing the steering unit (fixed steering column)
Fitting the steering unit (fixed steering column)
Removing the steering unit (adjustable steering column)
Removing the steering unit (adjustable steering column)
Checking/setting the steering unit
Removing the parking brake actuation cable
Fitting the parking brake actuation cable
Removing the brake cylinder
Fitting the brake cylinder
Electrics
Central electrics
Removing the monitor (CIS)
Fitting the monitor (CIS)
Power supply
Removing the regulator
Fitting the regulator
Removing the starter
Fitting the starter
Feeder housing
Removing the feeder housing
Fitting the feeder housing
Removing the feed roller and magnetic boxes
Dismantling the lower feed roller and magnetic boxes
Lower feed roller and magnetic boxes dismantled:
Assembling the lower feed roller and magnetic boxes
Fitting the lower feed roller and magnetic boxes
Removing the upper compression roller
Dismantling the upper compression roller
Upper compression roller dismantled:
Assembling the upper compression roller
Fitting the upper compression roller
Removing the upper rear compression roller
Dismantling the upper rear compression roller
Upper rear compression roller dismantled:
Assembling the upper rear compression roller
Assembling the upper rear compression roller
Removing the lower smooth roller
Dismantling the lower smooth roller
Lower smooth roller dismantled:
Assembling the lower smooth roller
Fitting the lower smooth roller
Tensioning the tension springs for the rollers
Forage device
Drum housing
Removing the drum housing
Fitting the drum housing
Adjusting the drum disc
Shear bar
Removing the shear bar
Fitting the shear bar
Removing the shear bar support
Shear bar support dismantled