Claas Axion 850-800 (A60) Tractors Repair Manual EN

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00 0289 086 0.pdf
00 1165 102 X.pdf

00 0289 086 0.pdf:

CTIC 2800CTIC
Table of contents
Introduction
General information
Validity of manual
Handling of this manual
General repair instructions
Technical specifications
Information on technically correct repairs
Self-locking bolts
Liquid locking compound
Circlips
Hydraulic hoses
Hose routing
Spare parts and technical questions
Tightening torques
Tightening torques for metric ISO screw thread
Tightening torques for metric fine thread
General information
Particularly important
Qualification of drivers and maintenance personnel
Identification of warning and danger signs
General safety and accident prevention regulations
Pressurised fluids
Pressure accumulator
Putting the machine out of operation
Raised machine parts and loads
No welding
Optional equipment and spare parts
Tyre pressure control system
Overview
Electronic box
Control valve block
Rotary coupling
Compressor
Compressor
Oil cooler
Hydraulic motor
Hydraulic motor
Flow control valve
Flow control valve
Flow control valve
Appendix
Tyre pressure control system
Circuit diagrams

00 1165 102 X.pdf:

AXION 850-840-830-810-800HEXASHIFT
Table of contents
CCN (CLAAS Component Number)
Introduction
General information
Using this repair manual
Validity of this repair manual
General repair instructions
Technical specifications
Cause of damage
Spare parts
Diesel engine
Alternator
Welding work
Drive belt/drive chains
Tapered ring assemblies
Self-locking bolts with microencapsulated glue
Threadlock
Lock collar bearing
Collet bearing
Threaded unions with cutting rings on the hydraulic hoses
Threaded unions with progressive rings on the hydraulic hoses
Threaded double flare unions on the hydraulic hoses
Flexible hydraulic pipes
Pipe routing
Pneumatic pipes
Advice for economical repairs
Tightening torques
Tightening torques for CN02-0220 2002-09-26 factory standard metric threads
Tightening torque for bolts
Tightening torque for DRH lock nuts
Tightening torque for Nylstop lock nuts
Tightening torques for CLAAS CN 02 0225 standard hydraulic connections
Tightening torques for hydraulic threaded unions and air conditioning threaded unions with sealing cone and DIN 3865 O-ring
Tightening torques for DIN 3901 hydraulic threaded unions
Tightening torques for ISO 6149-2/ISO 11926-2 (3) adjustable hydraulic threaded unions
Tightening torques for hydraulic swivel threaded unions
Tightening torques for quick connection cartridges
Tightening torques for DIN 8434 hydraulic threaded bulkhead connectors
Tightening torques for DIN 7643 hollow bolts
Technical specifications
Lubricants
General information
Important
Warning and danger markings
General safety advice and accident prevention regulations
First aid measures
Leaving the tractor
Adjustment and maintenance work
Risk of injury from hydraulic fluid
Air conditioning
Accumulator
Battery isolating switch
Place the tractor on axle stands
Stopping the tractor
01 Engine
0102 Complete component
Complete engine
Technical specifications
Special tool
Adjusting the engine and the front axle chassis
Technical specifications
Calculation of shim thickness a
0110 Engine housing
Cylinder block
Technical specifications
Dimensional specifications
Preparation for work
Timing cover
Technical specifications
Preparation for work
Special tool
Technical specifications
0115 Engine unit
Connecting rod and piston assembly
Technical specifications
Dimensional specifications
Special tool
Removing the conrod and piston assembly
Dismantling
Checks and measurements
Cylinder block
Piston pin
Piston rings
Connecting rod and half-shells
Assembly
Fitting the connecting rod and piston assembly
Checking the piston protrusion
Crankshaft and bearing shells
Technical specifications
Dimensional specifications
Removing the crankshaft
Checks and measurements
Journals and crank pins
Crankshaft bearings
Lubrication clearance
Fitting the crankshaft
Replacing the oil pump drive pinion
Checking the crankshaft lateral play
Flywheel
Technical specifications
Crankshaft pulley
Technical specifications
Crankshaft bearing seals
Technical specifications
Special tool
Removing the crankshaft rear bearing seal
Fitting the crankshaft rear bearing seal
Removing the crankshaft front bearing seal
Fitting the crankshaft front bearing seal
0120 Cylinder head / Valves / Idler gear
Cylinder head
Technical specifications
Special tool
Flatness of the cylinder head
Measuring the thickness of the cylinder head
Flatness of the cylinder block
Rocker cover and oil vapour filter
Technical specifications
Preparation for work
Removing the rocker cover
Removing the oil vapour filter
Fitting the oil vapour filter
Fitting the rocker cover
Dimensional specifications
Special tool
Cleaning and checking the valves
Checking the clearance between the valve stems and the housings in the cylinder head and centring the valves
Checking the valve springs
Checking and replacing the valve seats
Fitting the valves
Checking the valve withdrawal
Valve rockers – Rods
Technical specifications
Special tool
Adjusting the valve clearance
Camshaft and bearing shells
Technical specifications
Dimensional specifications
Special tool
Removing the camshaft
Checks and measurements
Bearing journals
Cam operating height
Ring and journal housings in the cylinder block
Pushrods and pushrod housings in the cylinder block
Replacing the camshaft ring
Fitting the camshaft
Timing pinions
Technical specifications
Camshaft and crankshaft timing
0125 Injection / Fuel system
Main tank
Technical specifications
Secondary tank
Technical specifications
Supply pump
Technical specifications
High pressure pump
Technical specifications up to engine number 001653110
Technical specifications from engine number 001653111
Special tool
Removing the high-pressure pump
Disassembling the high-pressure pump
Assembling the high-pressure pump
Fitting the high-pressure pump
Removing the Y489 fuel pressure solenoid valve
Fitting the Y489 fuel pressure solenoid valve
Fuel pre-filter and cooler
Technical specifications
Injection pipes
Technical specifications
Injector
Technical specifications
Preparation for work
Special tool
Removing an injector
Fitting an injector
0130 Lubricating oil system
Oil pump
Technical specifications
Special tool
Oil cooler and filter
Technical specifications
0135 Cooling system
Fan support
Technical specifications
Fan and belts
Technical specifications
Special tool
Removing the pneumatic brake compressor belt
Remove the engine accessory belts
Fitting the engine accessory belts
Fitting the pneumatic brake compressor belt
Checking the belts
Preliminary operations
Inspection of the belt
Inspection of the fixed rollers, tensioner and pulley
Checking the alignment of the pulleys
Method for adjusting the alignment of the pulleys
Refitting operations
Engine water radiator
Technical specifications
Water pump
Technical specifications
Water reservoir
Technical specifications
Thermostat
Technical specifications
Engine coolant heater
Technical specifications
0140 Exhaust system
Turbocharger
Technical specifications
Preparation for work
Removing the turbocharger
Inspecting the turbocharger
Compressor inspection
Turbine inspection
Fitting the turbocharger
Removing the turbocharger actuator (M037)
Fitting the turbocharger actuator (M037)
Removing the turbocharger speed sensor (B226)
Fitting the turbocharger speed sensor (B226)
Removing the exhaust gas flap
Fitting the exhaust gas flap
Exhaust manifold
Technical specifications
Preparation for work
0145 Air intake
Air filter
Technical specifications
Air cooler
Technical specifications
Preheating
Technical specifications
Intake manifold
Technical specifications
Preparation for work
0150 Engine attachment parts
Electric starting motor
Technical specifications
Alternator
Technical specifications
Fitting a new alternator
0155 Engine control
Technical specifications
Fitting advice
ECM engine control module
Technical specifications
Accelerator pedal
Technical specifications
0165 Exhaust gas aftertreatment
Sensors and modules
Technical specifications
Preparation for work
Urea tank
Technical specifications
Special tool
Metering unit
Technical specifications
Preparation for work
Special tool
Cleaning
SCR catalyst
Technical specifications
Preparation for work
Special tool
Removing the SCR catalyst
Fitting the SCR catalyst
DOC diesel oxidation catalyst
Technical specifications
Preparation for work
Special tool
Removing the DOC diesel oxidation catalyst
Fitting the DOC diesel oxidation catalyst
02 Gearbox / Clutch / Universal drive shaft
0202 Complete component
Removal stage
Coupling the transmission to the engine
Technical specifications
Coupling the HEXASHIFT module to the range module
Technical specifications
Preparation for work
Coupling the range module to the rear axle
Technical specifications
Preparation for work
0210 Oscillation damper
Transport damper
Technical specifications
0218 Clutch control
Clutch pedal
Technical specifications up to serial number A6002297
Technical specifications from serial number A6002298
0222 Hydraulical reverser
Hydraulic reverser
Technical specifications
Preparation for work
Special tool
Removing the REVERSHIFT module
Disassembling the REVERSHIFT module
Disassembling the reverse gear clutch
Disassembling the forward gear clutch
Assembling the forward gear clutch
Forward gear clutch
Assembling the reverse gear clutch
Assembling the REVERSHIFT module
Fitting the REVERSHIFT module
Repairing the forward gear clutch without removing the cab
0228 Reverser control
Clutchless reverser lever
0230 Mechanical gearbox
Robotised ranges
Technical specifications
Technical specifications
Preparation for work
Special tool
Removing the robotised range module
Removing the primary and secondary lines
Removing the primary line
Adjusting the conical bearings
Adjusting the synchroniser cover with shims
Fitting the primary line
Removing the secondary line
Fitting the secondary line
Adjusting the conical bearings
Adjusting the shafts in the housing
Fitting the range module
Fitting the range module
Operation of the control unit on the robotised ranges
Special tool
Locally produced tool
Slow range
Technical specifications
Preparation for work
Removing the slow range
Dismantling the reducer assembly
Refitting the reducer assembly
Fitting the slow range
Adjusting the control device
Adjusting the slow range lever
0234 Powershift gearbox
HEXASHIFT
Technical specifications
Technical specifications
Technical specifications
Preparation for work
Removing the HEXASHIFT module
Disassembling the HEXASHIFT module
Assembly
Fitting the HEXASHIFT module
0238 Gearbox control
Transmission solenoid valves and sensors
Technical specifications
Preparation for work
Instructions when performing work
Range control guide rod
Technical specifications
Preparation for work
Special tool
Auxiliary tool
Removing/fitting a range control guide rod assembly
Adjusting the guide rods
0240 Rear axle housing
Axle tubes GPA 41
Technical specifications
Preparation for work
Adjusting the conical bearings
Axle tubes GPA 42
Technical specifications
Preparation for work
Adjusting the conical bearings
Axle tubes GPA 44
Technical specifications
Preparation for work
Dismantling
Assembly
Fitting the axle tube
Adjusting the conical bearings
Axle tubes GPA 45
Technical specifications
Preparation for work
Adjusting the conical bearings
0242 Differential
Drive pinion
Technical specifications
Preparation for work
Special tool
Removing the drive pinion
Adjusting the preload of the drive pinion bearings
Adjusting the drive pinion’s conical distance
Fitting the drive pinion
Differential
Differential technical specifications (GPA 41 and GPA 42)
Differential technical specifications (GPA 44 and GPA 45)
Preparation for work
Special tool
Removing the differential
Dismantling
Assembly
Fitting the differential
Calibrating the differential roller bearings
Checking and adjusting the reach of the teeth
Differential lock sealing check
0248 Rear axle control
Rear axle sensors
0252 Electro-hydraulical front axle drive
Four-wheel-drive clutch
Technical specifications
Special tool
Adjusting the clutch play J1
Adjusting the shaft play J2
Four-wheel-drive shaft
Technical specifications
Special tool
Setting the roller bearing preload p
0260 Universal drive shaft
Transmission shaft
Technical specifications
Preparation for work
03 Chassis
0325 Front steering drive axle
Coupling the chassis to the front axle
Technical specifications
Decompressing the CARRARO front axle suspension hydraulic circuit
Technical specifications
Decompressing the circuit
Recommissioning the circuit
CARRARO front axle
CARRARO front axle technical specifications
Steering angle sensor (CARRARO type 2043, 2043 S, 2055 and 2055 S)
Technical specifications
Preparation for work
Special tool
Adjustment
Front axle position sensor (CARRARO type 2043 S and 2055 S)
Technical specifications
Special tool
Adjustment
Wheel hubs and reducer (Carraro type 2043 and 2043 S)
Technical specifications
Preparation for work
Special tool
Wheel hubs and reducer (CARRARO type 2055 and 2055 S)
Technical specifications
Preparation for work
Special tool
Dismantling
Assembly
Wheel pivots (CARRARO type 2043, 2043 S, 2055 and 2055 S)
Technical specifications
Preparation for work
Special tool
Assembly with steering angle sensor
Dismantling
Assembly
Adjustment
Assembly with steering angle sensor
Upper suspension arms (CARRARO type 2043 S and 2055 S)
Technical specifications
Preparation for work
Adjustment
Lower suspension arms (CARRARO type 2043 S and 2055 S)
Technical specifications
Preparation for work
Adjustment
Suspension cylinder (CARRARO type 2043 S and 2055 S)
Technical specifications
Preparation for work
Dismantling
Assembly
Bevel gear (Carraro type 2043, 2043 S, 2055 and 2055 S)
Technical specifications
Preparation for work
Special tool
Adjustment
Differential (Carraro type 2043, 2043 S, 2055 and 2055 S)
Technical specifications
Preparation for work
Special tool
Dismantling
Assembly
Adjustment
Checking the contact imprint of the differential teeth
04 Brake
0405 Service brake
Service brake
Technical specifications
Preparation for work
Auxiliary tool
Adjusting the brake piston return springs
Cut-out relay
Technical specifications
Replacing the cut-out relay filter 1033
Decompressing the braking circuit
Technical specifications
Decompressing the circuit
Recommissioning the circuit
Accumulators and service brake sensors
Technical specifications with a braked front axle
Technical specifications with a non-braked front axle
Removing an accumulator or a service brake sensor
Fitting an accumulator or a service brake sensor.
Brake pedals
Technical specifications for double pedal
Technical specifications for single pedal with a braked front axle
Technical specifications for single pedal with a non-braked front axle
Adjusting the brake pedal upper stops
Adjusting the brake pedal travel
High-pressure service brake valve
Technical specifications with a non-braked front axle
Technical specifications with a braked front axle
Front axle limit valve
Technical specifications
Bleeding the brake circuit
Technical specifications
Bleeding the brake circuit
Brake test
0415 Parking brake
Handbrake control
Technical specifications
Adjusting the handbrake clearance
Parking brake mechanism
Removing and refitting the parking brake mechanism
Parking brake mechanism control
Technical specifications
Preparation for work
Adjusting the brake release play
Automatic parking brake mechanism control
Technical specifications
Preparation for work
0420 Trailer air brake
Single-cylinder compressor
Technical specifications
Special tool
Pneumatic braking circuit
Technical specifications up to serial number A6002210
Technical specifications from serial number A6002211
0425 Trailer hydraulic brake
Brake valve
05 Steering
0505 Steering
Steering unit and column
Technical specifications
Preparation for work
Removing the steering gearbox
Fitting the steering unit
Steering actuator (CARRARO)
Technical specifications
Preparation for work
Dismantling
Assembly
Adjusting the front axle alignment (CARRARO)
Technical specifications
Preparation for work
Adjusting the front axle alignment
06 Lift device
0605 Rear power lift
Technical specifications
Preparation for work
Special tool
Instructions when performing work
Linkage arm
Technical specifications
Preparation for work
Rear linkage control valve on 150 and 110 l/min circuit
Technical specifications
Preparation for work
Special tool
Lift cylinder
Technical specifications
Preparation for work
Stabiliser
Technical specifications
Technical specifications
0610 Front power lift
Front linkage
Technical specifications up to serial number A6000733
Technical specifications from serial number A6000734
Preparation for work
Lift cylinder
Technical specifications
Preparation for work
Repairing the cylinder
Front linkage position sensor
Technical specifications
07 Hitch
0705 Coupling frame
Ladder hitch
Technical specifications
Forced steering ball joint(s)
Technical specifications
0720 Hitch
Pick-up hitch
Technical specifications
08 Drives
0802 Rear PTO
Rear power take-off
Technical specifications
Preparation for work
Special tool
Auxiliary tool
On the right
On the left
Dismantling
Assembly
Shaft adjustment
Adjustment of the 540/1 000 rpm fork
Adjustment of the prevention system
On the right
On the left
Rear power take-off clutch
Technical specifications
Preparation for work
Dismantling
Auxiliary tool
Assembly
Technical specifications
Preparation for work
Adjustment method
0804 Front PTO
Front power take-off
Technical specifications
Preparation for work
Removing the front power take-off
Disassembling the front power take-off
Disassembling the front power take-off pump
Assembling the front power take-off pump
Disassembling the front power take-off clutch
Assembling the front power take-off clutch
Assembling the front power take-off
Fitting the front power take-off
Front power take-off shaft
Technical specifications
Replacing the toothed rings
09 Hydraulic system
0910 Pumps
Feed pump on 150 and 110 l/min circuit
Technical specifications
Preparation for work
Special tool
Variable capacity hydraulic pump 150 and 110 l/min
Technical specifications
Preparation for work
Special tool
0920 Valves
Priority valve on 150 and 110 l/min circuit
Technical specifications
Booster feed plate on 150 and 110 l/min circuit
Technical specifications
Preparation for work
Special tool
Feed plate for the variable capacity pump on the 150 and 110 l/min circuit
Technical specifications
Preparation for work
Special tool
Rear electrohydraulic control valves
Technical specifications
Instructions when performing work
Front electrohydraulic control valves
Technical specifications
Preparation for work
Instructions when performing work
Rear mechanical control valves
Technical specifications
Preparation for work
Control valve control
Technical specifications
Adjustment method
0990 Accessories
Power Beyond system
Technical specifications
Preparation for work
10 Electrical / Electronic equipment
1005 Power supply
Technical specifications
Battery tray and primary accessories board (PSP) support
Technical specifications
1010 Central electrics
Primary accessories board (PSP)
Technical specifications
Fuse and relay board (PRF)
Technical specifications
Auto 5 board (PA5)
Technical specifications
UBM board
Technical specifications
Electronic adaptation board (PAE)
Technical specifications
Cab weights board (PMC)
Technical specifications
1012 Modules / sensors
Auto 5 module
Technical specifications
Replacing
UBM module
Technical specifications
Replacing
Radar sensor
Technical specifications
1030 Board computer / Indicators
RHP rear linkage control panel
Technical specifications
Dashboard module
Technical specifications
1035 Operation / Multifunction control lever
CEBIS multifunction armrest
Multifunction armrest module technical specifications
Multifunction armrest support technical specifications
Preparation for work
CEBIS multifunction armrest support
Technical specifications
CEBIS terminal
Technical specifications
Lower trim (CEBIS)
Technical specifications
Auxiliary tool
Position of the harnesses and mounting collars (CEBIS)
Special tool
Position of A100 module connectors (CEBIS)
C060 electrohydraulic joystick (CEBIS)
Technical specifications
Special tool
CMOTION C001 multifunction handle (CEBIS)
Technical specifications
Preparation for work
Special tool
B110 Direction lever position sensor – CEBIS
Technical specifications
Special tool
B154 Engine speed adjustment sensor (CEBIS)
Technical specifications
Special tool
Control valve B341, B342, B343 and B344 controls (CEBIS)
Technical specifications
Preparation for work
Special tool
Dismantling
Assembly
Rear (R052) and front (R053) linkage position setting potentiometers (CEBIS)
Technical specifications
Special tool
For the rear linkage position setting potentiometer R052
For the front linkage position setting potentiometer R053
Front (S113) and rear (S114) power take-off on/off switches (CEBIS)
Technical specifications
Special tool
CEBIS terminal control panel
Technical specifications
Special tool
Panel for switches S001, S094, S172, S178, S179, S180, S188, S189, S190, S191, S195, S229, S233 and S259 (CEBIS)
Technical specifications
Special tool
CIS + multifunction armrest
Multifunction armrest module technical specifications
Multifunction armrest support technical specifications
Preparation for work
CIS + multifunction armrest support
Technical specifications
CIS multifunction armrest
Multifunction armrest module technical specifications
Multifunction armrest support technical specifications
Preparation for work
CIS multifunction armrest support
Technical specifications
12 Cab / Operator’s platform
1205 Cab suspension
Left-hand step
Technical specifications
Right-hand step
Technical specifications
Cab support (GPA 41/42/44 axle tubes)
Technical specifications
Preparation for work
Cab support (GPA 45 axle tubes)
Technical specifications
Preparation for work
Cab suspension
Technical specifications
Preparation for work
Shock absorber and cab suspension checks
Technical specifications
Checking the cab shock absorbers
Parts to check
Examples of wear
Checking the longitudinal and transverse bars
Parts to check
Examples of wear
Checking the connecting rods and flanges
Parts to check
Checking the bearings
Parts to check
Checking the rubber studs
Parts to check
Example of wear
1210 Cab
Complete cab
Technical specifications
Special tool
Cab roof
Technical specifications
Removing the roof canopy
Removing the cab roof
Fitting the cab roof
Fitting the roof canopy
Windscreen
Technical specifications
Special tool
Rear hatch
Technical specifications
Preparation for work
Left-hand door
Technical specifications
Preparation for work
Right-hand door
Technical specifications
Front wiper
Technical specifications
Rear screen wiper
Technical specifications
Side wiper
Technical specifications
Cab front lower trim
Technical specifications
Cab lower left-hand trim
Technical specifications
Cab lower right-hand trim (CEBIS)
Technical specifications
Cab lower right-hand trim (CIS)
Technical specifications
Steering column trim
Technical specifications
1230 Seat
Sears® seat
Technical specifications
Sears® seat frame and upholstery
Technical specifications
Seat height adjustment button
Seat belt
Backrest upholstery
Lumbar pneumatic adjustment button
M044 lumbar support compressor
Backrest angle adjustment handle
Backrest
Seat base depth adjustment plate
Seat base depth adjustment handle
Seat direction adjustment lever
Seat base angle adjustment handle
Sears® seat suspension
Technical specifications
Air reservoir
M008 driver’s seat compressor
A160 active seat regulation module
Air spring
Grammer® seat
Technical specifications of the Grammer® mechanical seat
Technspecifications of the Grammer® pneumatic seat
Grammer® seat frame and upholstery
Technical specifi
Backrest angle adjustment handle
Control trim
Seat height adjustment handle
Seat suspension firmness adjustment lever
Ventilation and air conditioning/heating button
Lumbar pneumatic adjustment buttons
Backrest upholstery
Seat base upholstery
Head restraint
Headrest guide
M043 seat ventilation motor
M044 lumbar support compressor
Back rest adjustment
Backrest
Presence system flexible plate
Seat base angle adjustment plate
Presence sensor Z005
Seat base depth adjustment plate
Grammer® seat suspension
Technical specifications
Shock absorber
Longitudinal damper locking
Driver’s seat compressor M008
Comfort unit
Air spring
Activeat regulation module A160
Air tank
Air distributor
1235 Cab heater
Heating radiator
Technical specificaions
Special tool
1240 Air condition
Air conditioning – General information
Technical specifications
Preparation for work
Drain the refrigerant fluid
Filling with refrigerant fluid
Condenser and dehydrator filter
Technical specifications
Removing the dehydrator filter
Fitting the dehydrator filter
Compressor
Technical specifications
Evaporator – Expansion valve
Technical specifications
Air conditioning control module
Technical specifications
80 Various components / Machine body
8025 Panellings / Hoods
Engine bonnet
Technical specifications