Claas Nexos 240 V – 210 V Stage 3B (A45) Tractors Repair Manual EN

File List:

00 1164 668 1.pdf

00 1164 668 1.pdf:

NEXOS VE 240/230/220/210NEXOS VL 250/240/230/220/210NEXOS F 250/240/230/220/210
Table of contents
CCN (CLAAS Component Number)
Introduction
General information
Using this repair manual
Scope of the 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
Advice for economical repairs
Tightening torques
Tightening torques for NF E25-030-1 2007-12-01 standard metric threads
Tightening torques for CLAAS CN 020 225 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 DIN 7643 hollow bolts
Technical specifications
Lubricants
01 Engine
0102 Complete component
Introduction
General notes
Complete engine
Technical specifications
Special tool
Preliminary operations
Coupling the engine to the chassis
Preparation for work
General specifications
Tightening torques
Disassembling the engine
Technical specifications
Preliminary operations
Disassembly
Removing the cylinder head
Fitting the engine
Technical specifications
Assembly
Checks and inspections
0110 Engine housing
Oil sump
Technical specifications
Preliminary operations
Timing gear train housing
Technical specifications
Preparation for work
Flywheel housing
Technical specifications
Preparation for work
Repairing the cylinder block
Dimensional specifications
Checks and measurements
Checking the supporting surface of the cylinder head on the cylinder block
0115 Engine unit
Crankshaft
Technical specifications
Dimensional specifications
Tolerances
Special tool
Preliminary operations
Measuring the journals and crank pins
Crankshaft journals and crank pins – Measured values
Replacing the crankshaft front pinion
Fitting the bearing half-shells
Checking the lateral play
Fitting the rear bearing seal
Fitting the timing cover
Connecting rod/piston assembly
Technical specifications
Dimensional specifications
Special tool
Dismantling
Checking the piston
Pairing the shaft and the piston
Piston rings
Checking the piston rings
Checking the links
Torsion check
Flexion check
Fitting the connecting rod/piston assembly – Coupling the connecting rod/piston
Fitting the piston rings
Fitting the connecting rod and piston into the cylinder
Fitting the connecting rod caps
Piston protrusion measurement
Balancer
Technical specifications
Special tool
0120 Cylinder head / Valves / Idler gear
Cylinder head
Technical specifications
Preliminary operations
Sealing check
Checking the cylinder head contact surface
Checking the cylinder head contact surface
Dimensional specifications
Special tool
Decarbonising, checking and rectifying the valves
Valve guide
Checking the clearance between the valve stem and guide – Checking the centring
Replacing the valve guide
Valve guide bore
Valve seats
Rectifying the valve seats
Replacing the valve seats
Checking the valve withdrawal
Checking the valve springs
Rocker cover
Technical specifications
Preliminary operations
Final assembly
Rocker arm ramp
Technical specifications
Dimensional specifications
Special tool
Preliminary operations
Final assembly
Camshaft
Technical specifications
Dimensional specifications
Special tool
Checking the cam lift and the alignment of the shaft bearings
Replacing the rings
Fitting the valve lifters
Technical specifications
Special tool
0125 Injection – / Fuel system
Main fuel tank
Preliminary operations
Auxiliary fuel tank
Low-pressure fuel pipes
Technical specifications
Connections
Fuel pre-filter and cooler
Technical specifications
Preliminary operations
Fuel pipes running from the high-pressure pump to the common rail
Technical specifications
Preliminary operations
High pressure pump
Technical specifications
Special tool
Preliminary operations
Common rail
Technical specifications
Preliminary operations
Final assembly
Injectors
Technical specifications
Preliminary operations
Final assembly
Fuel cooler
0130 Lubricating oil system
Engine oil filter
Technical specifications
Preliminary operations
Oil pump
Technical specifications
Preliminary operations
Engine oil heat exchanger
Technical specifications
Preliminary operations
Final assembly
Blow-by (Recirculation of oil vapours)
Technical specifications
Preliminary operations
0135 Cooling system
Radiator
Preliminary operations
Drive belts
Main drive belt
Preliminary operations
Checking the tension of the main drive belt
Air conditioning compressor drive belt
Preliminary operations
Final assembly
Ventilation
Preliminary operations
Water pump
Technical specifications
Preliminary operations
Thermostat
Technical specifications
Preliminary operations
0140 Exhaust system
Exhaust pipe
Removing the vertical exhaust pipe
Preliminary operations
Disassembly
Removing the horizontal exhaust pipe
Preliminary operations
Turbocharger
Technical specifications
Preliminary operations
Exhaust manifold
Technical specifications
Preliminary operations
0145 Air intake
Air filter
Preliminary operations
Intake manifold
Technical specifications
Preliminary operations
Final assembly
0150 Engine attachment parts
Alternator
Technical specifications
Preliminary operations
Electric starting motor
Preliminary operations
0155 Engine control
ECM engine control module
Technical specifications
Preliminary operations
Engine wiring harness
Technical specifications
Pre-heater plugs
Technical specifications
Preliminary operations
Final assembly
0165 Exhaust gas aftertreatment
Exhaust filter
Technical specifications
Preliminary operations
Exhaust filter support
EGR valve
Technical specifications
Preliminary operations
02 Gearbox / Clutch / Universal drive shaft
0202 Complete component
Transmission special tools
12/12 and 24/24 mechanical reverser
24/24 mechanical doubler and reverser
24/24 hydraulic doubler and mechanical reverser
24/24 and 24/12 hydraulic doubler
24/12 hydraulic reverser
Reduction gear housing
Standard version final drive
Reinforced version final drive
Hydraulic front axle clutch
Front axle hydraulic clutch
Tightening torques, sealing and lubrication
Application of lubricants and sealing products
Sealing products for seals
Threadlock
Assembly adhesive
Lubrication during assembly
Greasing the gearbox input shaft and the power take-off shaft
Front axle clutch housing with hydraulic control
Front axle clutch housing with mechanical control
12/12 transmission clutch housing
24/24 transmission clutch housing with mechanically-controlled doubler
24/24 transmission clutch housing with hydraulically-controlled doubler
24/12 transmission clutch housing
Reduction gear housing
Standard final drive
Reinforced final drive
Final drive with narrow axle tube
Final drive with short axle tube
Final drive with ultra-short axle tube (892 mm)
Brake control unit (valid for all models)
Reduction gear internal control
Reduction gear external control
Upper and lower covers
Assembly specifications
All transmission models
12/12 transmission
24/24 transmission with mechanical doubler
24/24 transmission with hydraulic doubler
24/12 transmission
Separating the engine and clutch housing with a fixed front axle
Special tool
Preliminary operations
Draining the transmission oil
Removing the pipes
Removing the first pipe
Removing the second pipe
Separating the engine and clutch housing
Installing the trolley underneath the tractor
Immobilising the front axle
Removing the mounting bolts
Separating the elements
Separating the engine and clutch housing with a suspended front axle
Special tool
Preliminary operations
Draining the transmission oil
Removing the pipes
Removing the first pipe
Removing the second pipe
Separating the engine and clutch housing
Removing the mounting bolts
Separating the elements
Upper covers and linkage
Technical specifications
Preparation for work
Disassembly
Assembly
0215 Mechanical clutch
Adjusting the clutch
11 inch clutch
Adjustment
12 inch clutch
Adjustment
Clutch for REVERSHIFT transmission with rear power take-off with mechanical clutch
Adjustment
Transmissions with hydraulic doubler – Clutch shaft
Replacing the Teflon seals – Exploded view
Replacing
Special tools
24/12 transmission
24/24 transmission with hydraulic doubler
24/12 and 24/24 transmissions with hydraulic doubler
24/12 transmission
24/24 transmission with hydraulic doubler
24/12 and 24/24 transmissions with hydraulic doubler
Air compressor – 24/12 transmission
Exploded view
Disassembly
Assembly
0218 Clutch control
Reverser and clutch controls – 12/12 transmission
Mechanical reverser without doubler – Exploded view
Disassembly
Assembly
Reverser ancrols – 24/24 transmission (Mechanical reverser and doubler)
Technical specifications
Preparation for work
Disassembly
Assembly
Adjusting the axial play
Reverser and clutch controls – 24/24 transmission (Mechanical reverser and hydraulic doubler)
Hydraulic doubler and mechanical reverser – Exploded view
Disassembly
Assembly
Adjusting the axial play of the upper shaft
Adjusting the axial play of the reverser shaft
Reverser and clutch controls – 24/12 transmission — Hydraulically controlled power take-off
Technical specifications
Preparation for work
Disassembly
Assembly
Adjusting the axial play of the upper shaft
Adjusting the axial play of the reverser shaft
Reverser and clutch controls – 24/12 transmission — Mechanically controlled power take-off
Technical specifications
Preparation for work
Preliminary operation
Disassembly
Assembly
Adjusting tof the Adjusting the axial play of the reverser shaft
0220 Mechanical reverser
Controls – Mechanical reverser
Exploded view
Disassembly
24/12 transmission
Assembly
24/12 transmission
Synchronised idle gear
Exploded view
Disassembly
Assembly
0222 Hydraulical reverser
Hydraulic reverser
Exploded view
Disassembly
Assembly
Adjusting the play
Wear to the packets of discs
Idle gear
Exploded view
Disassembly
Assembly
0228 Reverser control
Reverser controls
Adjusting the mechanical reverser
Adjustment
0230 Mechanical gearbox
Input shaft – Transmission with mechanical reverser
Technical specifications
Disassembly
Assembly
Input shaft – Transmission with hydraulic reverser
Exploded view
Disassembly
Assembly
Primary shaft – Gears – Transmissions with mechanical reverser
Exploded view
Disassembly
Primary shafGears – 24/12 transmission
Exploded view
Disassembly
Assembly
Determining the axial play
Primary shaft – Ranges
Exploded view
Disassembly
Assembly
Secondary shaft – Ranges
Exploded view
Disassembly
Assembly
Primary shaft covers
12/12 transmission – Cross-section
24/24 transmission with mechanical reverser and doubler – Cross-section
24/24 transmission with mechanical reverser and hydraulic doubler – Cross-section
24/12 transmission – Cross-section
Secondary shaft – Gears
Technical specifications
Disassembly
Assembly
Secondary shaft – Measuring the axial play
Cross-section
Mechanical doubler
Exploded view
Disassembly
Assembly
0234 Powershift gearbox
Hydraulic doubler
Exploded view
Disassembly
Assembly
Wear to the packet of discs
0238 Gearbox control
External controls
Exploded vie Assembly
Internal/12 and 24/24 transmission – Exploded view
Internal controls – 24/12 transmission
Disassembly
Forward/reverse gear:
Assembly
0240 Rear axle housing
Standard version final drives and axle tube
Exploded view
Disassembly
Assembly
Adjusting the axial play
Reinforced version final drives and axle tube 506 UP 6/1
Exploded view
Disassembly
Assembly
Tapered roller bearings preload.
Axle tube and final drives, short version (972 mm)
Exploded view
Disassembly
Assembly
Tapered roller bearings preload
Axle tube and final drives, ultra-short version (872 mm)
Exploded view
Disassembly
Assembly
Tapered roller bearings preload
0242 Differential
Differential
Exploded view
Disassembly
Assembly
Differential lock control
Exploded view
Disassembly
Assembly
0248 Rear control
Transmission sensors – Explode
Location
Sensor/transmission applicability
Disassembly
Description
Assembly
0250 Mechanical front axle drive
Hydraulic front axle clutch
Exploded view
Disassembly
Assembly
0252 Electro-hydraulical front axle drive
Front axle hydraulic clutch
Exploded view
Disassembly
Assembly
0255 Gearbox cooling system
Oil cooler
0260 Universal drive shaft
Fixed front axle transmission shaft
Suspended front axle transmission shaft
03 Chassis
0310 Axle
Recommendations – Servicing and repair
Shaft seals
Adjustment shims
Roller bearings
Caps and rivets
Plastic protections and caps
Cotter pins
Adhesives and sealing products
Oil drain
Cleaning
Ends of flanges and special tools
Using lubricants
0320 Steering axle
Tightening torques, lubric and sealing products (two-wheel drive)
Seali products for seals
Application of lubricants and sealing products
Main dimensions (mm)
Adhesives and tightening torques
Steering actuator (two-wheel drive)
Exploded view
Disassembly
Assembly
Repairing the steering actuators
Exploded view
Disassembling the steering actuator
Assembling the steering actuator
Wheel hub
Exploded view
Disassembly
Assembly
Preliminary operations
Wheel hub support
Exploded view
Disassembly
Assembly
Preliminary operations
Axle body
Exploded view
Disassembly
Preliminary operations
Assembly
Toe-in and steering angle
Exploded view
Adjusting the toe-in
Adjusting the steering angle
0325 Driven steering axle, front
Tightening torques, lubricants and sealing products (four-wheel drive)
Sealing products for seals
Threadlock
Assembly adhesive
Application of lubricants and sealing products
Technical specifications of the four-wheel drive axle – Nexos F
Main dimensions (mm)
Adhesives and tightening torques
Technical specifications of the four-wheel drive front axle – Nexos VE
Main dimensions (mm)
Adhesives and tightening torques
Technical specifications of the four-wheel drive axle – Nexos VL
Main dimensions (mm)
Adhesives and tightening torques
Characteristics of the limited slip differential discs
Steering actuator • Nexos F – VE – VL
Exploded view
Disassembling the steering actuator
Assembling the steering actuator
Epicyclic reduction unit – Nexos F
Exploded view
Disassembling the epicyclic reduction unit
Assembling the epicyclic reduction unit
Epicyclic reduction unit – Nexos VE
Exploded view
Disassembly
Preliminary operations
Assembly
Epicyclic reduction unit – Nexos VL
Exploded view
Assembly
Wheel hub • Nexos F – VL
Disassembling the wheel hub F – VL
Preliminary operations
Preliminary operations
Fitting the wheel hub • Nexos F – VL
Wheel hub • Nexos VE
Exploded view
Disassembly
Assembly
Seal – Bearing assembly – Support • Nexos F
Exploded view
Disassembly
Assembly
Flange • Nexos F – VL
Exploded view
Disassembly
Assembly
Flange • Nexos VE
Exploded view
Disassembly
Assembly
Differential casing • Nexos F – VL
Exploded view
Disassembly
Assembly
Assembly with new roller bearing
Alternative procedure after adjusting the clearance between the teeth
Checking the contact imprint of the differential teeth
Differential casing • Nexos VE
Exploded view
Disassembly
Preliminary operations
Assembly
Adjusting the clearance between the teeth
If thn replaced
If the roller bearings have been replaced
Alternativg the clearance between the teeth
Checking the contact imprint of the differential teeth
Differential • Nexos F – VL
Exploded view
Disassembling the differential • Nexos F – VL
Preliminary operations
Assembling the differential • Nexos F – VL
Additional operation on Nexos F
Differential • Nexos VE
Exploded view
Disassembling the differential • Nexos VE
Preliminary operations
Assembly
Drive pinion
Special tools
Exploded view
Disassembling the drive pinion shaft
Preliminary operations
Assembling the drive pinion shaft
Operation to be carried out on Nexos F – VL
Operation to be carried out on Nexos VE
If the roller bearings have not been replaced
If the roller bearings have been replaced
Alternative operation – Nexos VE
Alte Front axle body • Nexos F – VL
Special tools
Exploded view
Disassembling the sembling the front axle body
Front axle body • Nexos VE
Special tools
Exploded view
Disassembly
Preliminary operations
Assembly
Toe-in and steering angle
Exploded view
Adjusting the toe-in
Adjusting the steering angle
0325 Driven steering axle, front
Suspended front axle
Preliminary operations
Position sensor connecting rod
Preliminary operations
Adjustment
Suspended front axle guides
Preliminary operations
Front axle suspension cylinders
Preliminary operations
Suspended front axle position sensor
Exploded view
Preliminary operations
Suspended front axle articulated support
Preliminary operations
Suspended front axle articulated support roller bearing
Exploded view
Hydraulic suension module
Preliminary operations
Front axle suspension module
Preliminary operations
Front axle suspension calibration
Front axle suspension calibration button
Front axle suspension calibration procedure
Preliminary operations
Calibration
04 Brake
0405 Service brake
Assembly specifications
Mechanical brake
Hydraulic brake control – Tightening torques
Brake master cylinders
Slave cylinder
Exploded view
Disassembly
Assembly
Bleeding the brake circuit
Technical specifications
Preparation for work
Bleeding the brake circuit
0415 Parking brake
Parking brake
Exploded view
Preliminary operations
Disassembly
Assembly
On either side of the transmission housing
Adjting the control
Method to adjust the control
0425 Trailer hydraulic brake
Trailer hydraulic brake
05teering
0505 Steering
Steering unit
Steering angle sensor
Technical specifications
Preparation for work
Special tool
06 Lift device
0605 Rear power lift
Specifications
Identifying the product
Description
Main components of the linkage
Technical specifications
Main dimensions
Performance
Settings
Sensitivity adjustment valve
Position control lever
Draft control lever
Adjusting the force return bar
Adjusting the end of travel position sensor
Setting the shock valve pressure
Preliminary operations
Special tool
Adjustment
Assembling the reaction spring
Internal push bar
Linkage actuator and arm
Exploded view
Assembly
Rear linkage control rod linkage
Exploded view
Assembly
Rear linkage main control
Disassembly
Assembly
Rear linkage plastic ring
Exploded view
Preliminary operations
Position control lever ring
Disassembly
Assembly
Draft control lever ring
Disassembly
Assembly
Position and draft control rod linkage
Exploded view
Disassembly
Assembly
Rear linkage spool valve
Exploded view
Preliminary operations
Disassembly
Solenoid valves
Non-return valve
Pressure balance
Rear linkage shock valve
Assembly
08 Drives
0802 Rear PTO
Special tools
Rear power take-off
Tightening torques, lubricants and sealing products
Mechanical power take-off – 12/12 and 24/24 transmissions
Switches
Independent power take-off (540/540E – 540/1000)
Independent power take-off (540/540E – 540/1000) and power take-off proportional to ground speed
Hydraulic power tf – 24/12 transmission
Switches
Independent power take-off (540/540E – 540/1000)
Independent power ta0/540E – 540/1000) and power take-off proportional to ground speed
Cover and clutch
Exploded view
Disassembly
Assembly
Rear power take-off clutch
Wear to the packet of discs
Rear power take-off control mechanical control
Technical specifications
Preparation for work
Disassembly
Assembly
Rear power take-off control
Technical specifications
Disassembly
Only for 24/12 transmissions.
Assembly
Only for 24/12 transmission
All transmission types
Only for 24/12 transmission
All transmission types
Input shaft
Technical specifications
Disassembly
Only without power take-off
All power take-off types
Assembly
Only without power take-off proportional to ground speed
All power take-off types
Output shaft
hnical specifications
Disassembly
Assembly
Power take-off brake – 24/12 transmission
Technical specifications
Dassembly
Assembly
Power take-off proportional to ground speed
Hydraulically controlled power take-off – technical characteristics
Mechanically controlled power take-off – Technical characteristics
Disassembly
Assembly
Operation of the power take-off proportional to ground speed
Rear power take-off sensors
Location
09 Hydraulic system
0915 Hydraulic lines
Hydraulic oil filters
0920 Valves
Auxiliary control valves and levers
Auxiliary spool valves
Pressure limit valve
Exploded view
Preliminary operations
Disassembly
Cleaning
Assembly
Rear control valve expansion
Exploded view
Preliminary operations
Disassembly
Assembly
10 Electrical / Electronic equipment
1005 Power supply
Battery isolating switch
ON position
OFF position
Remove the battery isolating switch
1035 Operation / Multifunction control lever
Lifting control panel
12 Cab / Operator’s platform
1210 Cab
Lever trim
Removing the right-hand side control panel trim
Removing the left-hand side control panel trim
Rear screen wiper
Cab support
Preparation for work
Front cab support mounting
Rear cab support mounting
Complete cab
Special tool
1240 Air condition
Air conditioning system
Compressor
Preliminary operations
Removing the compressor
80 Various components / Machine body
8025 Panellings / Hoods
Engine bonnet
Bonnet side panels