Claas Xerion 5000-4200 (784) Tractors Repair Manual EN

File List:

00 0288 549 3.pdf
00 0288 638 1.pdf
00 0300 667 6.pdf
00 0303 522 2.pdf
1 183 409_e.pdf
Diagnostics report ECCOM 5.0.pdf
Inspection protocol XERION 5000 – 4500.pdf

00 0288 549 3.pdf:

ZF ECCOM 5.0
Table of contents
Introduction
General information
Validity of manual
Using the manual
Text and figures
Document structure based on sub-assemblies
Search and find
Directions
Abbreviations
Technical terms
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
Installation
Gib head key connections
Dismounting
Installation
Lock collar bearing
Dismounting
Installing
Adapter sleeve bearing
Dismounting
Installation
Chuck bushing
Removing
Dismounting of version A
Dismounting of version B
Installing
Chuck bushing version A
Chuck bushing version B
Circlips
Ferrule fittings
Screwing in
Leaky ferrule fittings
Sealing cone fittings
Hydraulic hoses
Hose placement
Radial shaft seals
Treatment of sealing faces
Drive belts / drive chains
Diesel engine
Alternator
Spare parts
Reason of damage
Tightening torques
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 hydraulic male connectors SDS shape B and E
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 worm drive hose clamps
Tightening torques for hose clamps with round pins
Technical specifications
Operating materials
CCN explanation
CCN (CLAAS Component Number)
Electric system standard
Overview
Hydraulic system standard
Overview
CCN (CLAAS Component Number)
General information
Important
Hazard signs
Signal word
General safety and accident prevention regulations
Combine-harvester safety and accident prevention regulations
First aid measures
Leaving the machine
Adjusting and maintenance work
Danger of injury from hydraulic liquid
Hydraulic accumulators
Battery isolating switch
Jacking up the machine
Putting the machine out of operation
Welding work
02 Gearbox / Clutch / Universal drive shaft
0202 Complete component
Diagnostic protocol
Removing / installing the gearbox
Separating / joining the gearbox housing
Technical specifications
Work preparation
Special tool
Special tool
Separating
0220 Mechanical reverser
Clutch KR
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Clutch KV
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
0230 Mechanical gearbox
Engine input shaft
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Installing
Central shaft
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Brake BG
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Shifter roller
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Clutches K3/K4 and planetary gear P4
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Planetary gears P1/P2/P3
Technical specifications
Work preparation
Special tool
Removing planetary gear P1
Disassembling planetary gear P1
Removing planetary gear P2
Disassembling planetary gear P2
Removing planetary gear P3
Disassembling planetary gear P3
Assembling planetary gear P3
Assembling planetary gear P2
Assembling planetary gear P1
Assembling the profile tube
Installing P3
Installing P2
Installing P1
Clutch K1/K2
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Front axle output shaft
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Rear axle output shaft
Technical specifications
Work preparation
Special tool
Removing
Installing
PTO shaft
Technical specifications
Work preparation
Special tool
Removing the output flange
Removing the PTO shaft
Disassembling the PTO shaft
Assembling the PTO shaft
Installing the PTO shaft
Installing the output flange
PTO shaft clutch
Technical specifications
Work preparation
Special tool
Removing the PTO shaft housing
Removing the PTO shaft clutch
Disassembling the PTO clutch
Assembling the PTO shaft clutch
Disassembling the housing
Assembling the housing
Installing the PTO shaft clutch
Adjusting the PTO shaft axial play
Calculating the axial play:
Spur gear Z6
Technical specifications
Work preparation
Special tool
Removing
Installing
Spur gear Z23
Technical specifications
Special tool
Removing
Installing
Assembling
Spur gear Z2, Z3 and pump drive
Technical specifications
Work preparation
Special tool
Removing
Oil tubes
Spur gear Z2, Z3 and pump drive
Installing
Spur gear Z3
Spur gear Z2 and pump drive
Oil tubes
Spur gear Z33
Technical specifications
Work preparation
Special tool
Removing
Installing
Intermediate gear wheel Z24
Technical specifications
Work preparation
Special tool
Removing
Installing
0232 Hydraulical gearbox
Hydrostatic drive
Technical specifications
Work preparation
Special tool
Removing
Installing
0238 Gearbox control
System pressure control block
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Clutch control block
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Sensors / valves / filters
Technical specifications
Work preparation
Removing
Installing
0255 Gearbox cooling system
Gearbox pump (ECCOM 5.0)
Technical specifications
Work preparation
Removing
Installing

00 0288 638 1.pdf:

ZF ECCOM 3.5 / 4.5
Table of contents
Introduction
General information
Validity of manual
Handling of this manual
Texts and figures
Document structure based on subassemblies
Search and find
Directions
Abbreviations
Technical terms
Converting metric units to US units
Pressure
Ground speed
Acceleration (vibration intensity)
Viscosity
Temperature
Electric system
General repair instructions
Technical specifications
Information on technically correct repairs
Self-locking bolts
Liquid locking compound
Steel roller chains
Tensioning
Chain connector
Taper ring fasteners
Dismounting
Installing
Gib head key joints
Dismounting
Installation
Lock collar bearing
Dismounting
Installing
Adapter sleeve bearings
Dismounting
Installation
Chuck bushing
Removing version A
Removing version B
Installation
Version A chuck bushing
Version B chuck bushing
Circlips
Ferrule joints
Screwing in
Leaky ferrule joints
Sealing cone joints
Hydraulic hoses
Hose placement
Spare parts
Torque settings
Tightening torques for metric standard threads
Tightening torque for metric fine threads
Tightening torques for hydraulic screw fittings with ferrule according to DIN 3861
Tightening torques for hydraulic screw fittings and air conditioner screw fittings with sealing cone and O-ring according to DIN 3865
Tightening torques for SDS hydraulic male connectors
Tightening torques for direction-adjustable SDE hydraulic male connectors
Tightening torques for hydraulic swivel fittings
Tightening torques for hollow screws DIN 7643
Tightening torques for brake line screw fittings
Tightening torques for worm-type threaded clips
Tightening torques for hose clamps with round pins
Tightening torques for tyres
General information
Important
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 work
Welding work
02 Gearbox / Clutch / Universal drive shaft
0202 Complete component
Diagnostic protocol
Removing / installing the gearbox
Transmission housing
Technical specifications
Work preparation
Special tool
Separating the halves of the housing
Joining the halves of the housing
0220 Mechanical reverser
Clutch KR
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Clutch KV
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Adjusting the axial play
Special tool
Adjusting the axial play of the clutches and spur gears
0230 Mechanical gearbox
Engine input shaft
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Installing
Central shaft
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Multi-disc brake BG
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Shifter roller
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Clutches K3/K4 and planetary gear P4
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Planetary gears P1/P2/P3
Technical specifications
Work preparation
Special tool
Removing
Removing P1
Disassembling planetary gear P1
Removing planetary gear P2
Disassembling planetary gear P2
Removing planetary gear P3
Disassembling planetary gear P3
Assembling planetary gear P3
Assembling planetary gear P2
Assembling planetary gear P1
Assembling the profile tube
Clutch K1/K2
Technical specifications
Special tool
Removing
Disassembling
Assembling
Front axle output shaft (ECCOM 3.5 / 4.5)
Technical specifications
Work preparation
Special tool
Removing
Installing
Rear axle output shaft
Technical specifications
Work preparation
Special tool
Removing the output flange
Removing the output shaft
Disassembling the output shaft
Assembling the output shaft
Installing the output shaft
Installing the output flange
PTO (ECCOM 3.5 / 4.5)
Technical specifications
Work preparation
Special tool
Disconnecting the PTO from the intermediate housing
Disassembling
Disassembling the PTO clutch
Assembling
Installing
Spur gear Z4
Technical specifications
Removing the spur gear (Z4)
Installing the spur gear (Z4)
Spur gear Z5
Special tool
Removing
Removing the spur gear (Z5)
Installing the spur gear (Z5)
Spur gear Z6
Technical specifications
Work preparation
Special tool
Removing
Removing gear (Z6)
Installing gear (Z6)
Spur gear Z23
Technical specifications
Special tool
Removing
Installing
Spur gears Z2 / Z3
Technical specifications
Work preparation
Special tool
Removing
Removing gear (Z2)
Disassembling the gear (Z2)
Assembling the gear (Z2)
Installing gear (Z2)
Removing gear (Z3)
Disassembling the gear (Z3)
Installing gear (Z3)
Spur gear Z33
Technical specifications
Work preparation
Special tool
Removing
Removing gear (Z33)
Installing gear (Z33)
Intermediate gear Z24 / Z25
Technical specifications
Work preparation
Special tool
Removing (Z24) and (Z25)
Fitting Z24
Fitting Z25
Auxiliary PTO power hydraulics (ECCOM 4.5)
Technical specifications
Work preparation
Removing
Installing
0232 Hydraulical gearbox
Hydrostatic drive
Technical specifications
Work preparation
Special tool
Removing
Removing gear (Z4)
Installing gear (Z4)
Installing
0238 Gearbox control
System pressure control block
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Clutch control block
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
0242 Differential
Longitudinal differential lock clutch (ECCOM 3.5 / 4.5)
Technical specifications
Work preparation
Special tool
Removing
Installing
Differential (ECCOM 3.5 / 4.5)
Technical specifications
Work preparation
Special tool
Removing
Assembling
0255 Gearbox cooling system
Gear pump (ECCOM 3.5 / 4.5)
Technical specifications
Work preparation
Special tool
Removing
Installing
CCN (CLAAS Component Number)

00 0300 667 6.pdf:

Mercedes-Benz OM470LAMercedes-Benz OM471LAMercedes-Benz OM473LA
Table of contents
Introduction
General information
Validity of manual
Using the manual
Text and figures
Document structure based on sub-assemblies
Search and find
Directions
Abbreviations
Technical terms
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
Installation
Gib head key connections
Dismounting
Installation
Lock collar bearing
Dismounting
Installing
Adapter sleeve bearing
Dismounting
Installation
Chuck bushing
Removing
Dismounting of version A
Dismounting of version B
Installing
Chuck bushing version A
Chuck bushing version B
Circlips
Ferrule fittings
Screwing in
Leaky ferrule fittings
Sealing cone fittings
Hydraulic hoses
Hose placement
Treatment of sealing faces
Spare parts
Tightening torques
Tightening torques for metric ISO screw thread
Tightening torques for metric fine thread
Tightening torques for screwed pipe connections with sealing cone joint and hydraulic threaded joints with soft core seal
Tightening torques for hydraulic fittings with ferrule
Tightening torques for hydraulic male connectors SDS shape B and E
Tightening torques for hydraulic swivel screw fittings
Tightening torque for hollow screws (with copper sealing ring)
Tightening torques for hydraulic male connectors SDE shape H, with adjustable direction
Tightening torques for brake line screw fittings
Tightening torques for worm drive hose clamps
Tightening torques for hose clamps with round pins
CCN explanation
CCN (CLAAS Component Number)
Electric systems standard
Hydraulic system standard
CCN (CLAAS Component Number)
General information
Important
Hazard signs
Signal word
Regulations for avoiding accidents with personal injuries
Testing, adjusting and repair work
Engine operation
Suspended loads
Working on piping and hoses
Work on the Common Rail System
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
OM 470 LA
OM 471 LA
OM 473 LA
Engine description
Engine components
Actuators
Ignition order
Cranking the engine
Special tool
Special tool for built-in engine
Cranking the engine in built-in condition
Cranking the engine in removed condition
Setting the engine to ignition TDC
Setting the engine to ignition TDC: Removing
0105 Engine suspension
Lifting eyes
Technical specifications
Lifting eyes
Technical specifications
0110 Engine housing
Technical specifications
Special tool
Installation
Crankshaft front seal
Technical specifications
Special tool
Installing the cassette seal ring
Crankshaft rear seal
Technical specifications
Special tool
Installation
Housing cover
Technical specifications
Installation
Timing housing
Technical specifications
Installation
Oil separator
Technical specifications
Disassembly
Assembly
Installation
Oil separator
Technical specifications
Disassembly
Assembly
Installation
Oil separator
Technical specifications
Disassembly
Assembly
Installation
0115 Engine unit
Technical specifications
Special tool
Disassembly
Checking
Assembly
Installation
Measuring the excess dimension
Checking the combustion pressure
Connecting rod
Technical specifications
Special tool
Checking
Installation
Cylinder liner
Technical specifications
Special tool
Checking
Installation
Measuring the excess dimension
Measuring the cylinder bore
Crankshaft
Technical specifications
Special tool
Removing the crankshaft
Checking the crankshaft
Installing the crankshaft
Crankshaft main bearings
Technical specifications
Special tool
Installation
Oscillation damper
Technical specifications
Special tool
Installation
Flywheel
Technical specifications
Special tool
Checking
Installation
0120 Cylinder head / Valves / Idler gear
Valve cover
Technical specifications
Installation
Reinforcing frame
Technical specifications
Installation
Camshaft housing
Technical specifications
Special tool
Applies to: OM 470 LA
Applies to: OM 470 LA
Installation
Applies to: OM 470 LA
Applies to: OM 470 LA
Camshaft
Technical specifications
Special tool
Installation
Checking
Cylinder head
Technical specifications
Special tool
Installation
Cleaning
Checking
Cylinder head
Technical specifications
Work preparation
Special tool
Installation
Cleaning
Checking
Cylinder head
Technical specifications
Work preparation
Special tool
Installation
Cleaning
Checking
Inlet rocker arm mechanism
Technical specifications
Disassembly
Assembly
Installation
Outlet rocker arm mechanism
Technical specifications
Special tool
Disassembly
Assembly
Installation
Technical specifications
Special tool
Installation
Checking the valves
Adjusting the valve lash
Valve springs and valve stem seals
Technical specifications
Special tool
Installation
Gear drive
Technical specifications
Special tool
Installation
Checking
Adjustment
Gear drive
Technical specifications
Special tool
Installation
Checking
Adjustment
Gear drive
Technical specifications
Special tool
Installation
Checking
Adjustment
0125 Injection – / Fuel system
High-pressure lines and rail
Technical specifications
Special tool
Installation
Rail pressure relief valve
Technical specifications
Installation
Injectors
Technical specifications
Work preparation
Special tool
Installation
Injectors line kit
Technical specifications
Work preparation
Installation
Protective sleeve
Technical specifications
Special tool
Installation
Fuel high-pressure pump
Technical specifications
Work preparation
Special tool
Removing the drive gearwheel
Installing the drive gearwheel
Installation
2-step valve
Technical specifications
Installation instructions
Fuel pump
Technical specifications
Work preparation
Special tool
Applies to: OM 470/471 LA
Installation
Applies to: OM 470/471 LA
Pressure relief valve
Technical specifications
Installation instructions
Fuel controller valve
Technical specifications
Work preparation
Installation
Fuel controller valve
Technical specifications
Work preparation
Installation
Fuel controller valve
Technical specifications
Work preparation
Installation
Fuel filter module
Technical specifications
Work preparation
Special tool
Installation
0130 Lubricating oil system
Lubricating oil system
Technical specifications
Special tool
Pre-filling
Oil spray nozzle
Technical specifications
Installation
Oil/coolant module
Technical specifications
Work preparation
Installation
Oil cooler
Technical specifications
Installation instructions
Oil cooler
Technical specifications
Installation instructions
Oil pump
Technical specifications
Disassembly
Assembly
Installation
Oil pump
Technical specifications
Disassembly
Assembly
Installation
Oil pump
Technical specifications
Disassembly
Assembly
Installation
Oil thermostat
Technical specifications
Special tool
Installation
0135 Cooling system
Technical specifications
Special tool
Draining
Filling up
Cleaning the coolant circuit
Coolant pump
Technical specifications
Work preparation
Installation
Coolant thermostat
Technical specifications
Installation
0140 Exhaust system
Exhaust recirculation cooler
Technical specifications
Special tool
Installation
Checking
Exhaust recirculation cooler
Technical specifications
Special tool
Installation
Checking
Exhaust recirculation cooler
Technical specifications
Special tool
Installation
Checking
Exhaust gas recirculation cooler bracket
Technical specifications
Work preparation
Removing the exhaust gas recirculation cooler bracket
Installing the exhaust gas recirculation cooler bracket
Exhaust recirculation actuator
Technical specifications
Installation
Exhaust recirculation actuator
Technical specifications
Special tool
Installation
Exhaust recirculation valve
Technical specifications
Installation
Differential pressure sensor
Technical specifications
Exhaust manifold
Technical specifications
Work preparation
Installation
Exhaust manifold
Technical specifications
Work preparation
Installation
Exhaust manifold
Technical specifications
Work preparation
Installation
Turbocharger
Technical specifications
Work preparation
Installation
Turbocharger
Technical specifications
Work preparation
Installation
Turbocharger
Technical specifications
Work preparation
Installation
TURBO-COMPOUND turbine
Technical specifications
Work preparation
Installation
TURBO-COMPOUND transmission
Technical specifications
Work preparation
Installation
0145 Air intake
Charge air housing
Technical specifications
Installation
Charge air housing
Technical specifications
Installation
0150 Engine attachment parts
Electric starting motor
Technical specifications
Installation
Alternator
Technical specifications
Special tool
Removing the alternator
Installing the alternator
Resonance vessel
Technical specifications
Installation instructions
Resonance vessel
Technical specifications
Installation instructions
Air compressor
Technical specifications
Work preparation
Special tool
Installation
Removing the drive gearwheel
Installing the drive gearwheel
Air compressor
Technical specifications
Work preparation
Special tool
Installation
Removing the drive gearwheel
Installing the drive gearwheel
0155 Engine control
Control unit
Technical specifications
Installation
0165 Exhaust gas aftertreatment
Exhaust gas aftertreatment system
Technical specifications
Work preparation
Special tool
Checking the urea solution (purity)
Checking the urea solution (density)
Urea heater valve
Technical specifications
Work preparation
Special tool
Installation
Urea pump
Technical specifications
Work preparation
Special tool
Removing the urea pump
Installing the urea pump
Removing the inlet nozzle filter
Installing the inlet nozzle filter
Removing the pressure relief valve
Installing the pressure relief valve
Removing the frost protection element
Installing the frost protection element
Urea dosing unit (A089 / A67-MB)
Technical specifications
Work preparation
Special tool
Removing the dosing unit
Installing the dosing unit
Removing the filter
Installing the filter
0190 Accessories
Engine insulation
Technical specifications
Work preparation
Installing

00 0303 522 2.pdf:

XERION 5000-4200
Table of contents
Introduction
Notes on the manual
Validity of manual
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
Installation
Chuck bushing
Removing
Dismounting of version A
Dismounting of version B
Installing
Chuck bushing version A
Chuck bushing version B
Circlips
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 threads
Tightening torques for metric fine thread screws