Claas Quadrant 3200 (744) Balers Repair Manual EN

File List:

00 0292 743 0.pdf

00 0292 743 0.pdf:

QUADRANT 3200
Table of contents
Introduction
General Information
Handling of this manual
Texts and figures
Document structure based on subassemblies
Search and find
Directions
Abbreviations
Technical terms
Manual validity
General repair instructions
Technical specifications
Reason of damage
Spare parts
Welding work
Steel roller chains
Tensioning
Chain connector
Taper ring fasteners
Dismounting
Installation
Gib head key joints
Dismounting
Installation
Self-locking bolts
Liquid locking compound
Lock collar bearing
Dismounting
Installation
Adapter sleeve bearings
Dismounting
Installation
Ferrule fittings
Screwing in
Non-tight ferrule connection
Progressive ring fittings on hydraulic lines
Sealing cone fittings
Hydraulic hose lines
Hose placement
Information on economic repairs
Torque settings
Tightening torques for metric standard threads
Tightening torque for metric fine threads
Tightening torques for hydraulic screw fittings with ferrule DIN 3861
Tightening torques for hydraulic screw fittings and air conditioner screw fittings with O-ring and sealing cone DIN 3865
Tightening torques for SDS hydraulic male connectors
Tightening torques for direction-adjustable SDE hydraulic male connectors
Tightening torques for hydraulic swing fittings
Tightening torques for hollow screws DIN 7643
Tightening torques for brake line screw fittings
Tightening torques for worm drive hose clamps
Tightening torque for spring-loaded worm drive hose clamps
Wheel tightening torques
Technical specifications
Lubricants
CCN explanation
CCN (CLAAS Component Number)
Electric systems standard
Hydraulic system standard
General Information
Of special importance
Identification of warning and danger signs
General safety and accident prevention advice
Leaving the machine
Adjustment and maintenance work
Risk of injury from hydraulic fluid
Hydraulic accumulators
First aid measures
Place the machine on axle stands
Decommission the machine
Basic operations
Baling system
Baling piston at front dead centre
Tying system
Manually starting tying
02 Gearbox / Clutch / Universal drive shaft
0230 Mechanical gearbox
Main drive gearbox
Upper mounting
Lower mounting
Rotor gearbox
Removing the rotor gearbox
Fitting the rotor gearbox
Feed rake drive gearbox
Removing the coupling
Disassembling the coupling
Fitting the coupling
Assembling the coupling
Fitting the coupling
Removing the feeder gearbox
Fitting the feeder gearbox
0260 Universal drive shaft
Knotter gearbox universal drive shaft
Removing the universal drive shaft
Fitting the universal drive shaft
Special case:
Rotor gearbox universal drive shaft
Removing the universal drive shaft
Fitting the universal drive shaft
03 Chassis
Single axle
Removing a wheel hub
Fitting a wheel hub
Tandem axle
Overview of the 20 tandem axle
Overview of the 20 tandem suspension
Overview of the 17 tandem suspension
Trailing tandem axle
Trailing tandem axle checks and adjustments
Checking the wheel alignment
Adjusting the wheel alignment
Adjusting the locking cylinders
Checking and adjusting the wheel angle
Checking the play in the pivot axes
Correcting the play in the pivot axes
0410 Service brake trailed machine
Brake mechanism
Securinsingle axle braking components
andem axle braking components
Securing the 20 tandem axle braking components
Securing the trailing tandem axle braking components
Setting the brake control lever
Setting the brake control lever
Pneumatic brakes
Overview of the pneumatic brake cylinder
Technical specifications for pneumatic brake cylinders
Removing a pneumatic brake cylinder
Fitting a pneumatic brake cylinder
Overview of the pneumatic brake system – 20 axle
Overview of the pneumatic brake system – 17 axle
Hydraulic brakes
Overview of the hydraulic brake cylinder
Removing a hydraulic brake cylinder
Fitting a hydraulic brake cylinder
Overview of the hydraulic safety brake (depending on equipment)
Up to machine 74401069
Overview of the hydraulic safety brake (depending on equipment)
From machine 74401070
0415 Parking brake
Parking brake
justing the parking brake
07 Overview of the drawbar head
Removing the drawbar head
Fitting the drawbar head
Jack stand overview
09 Hydraulic system
0900 Hydraulic system – General
Damage to the hydraulic system
General rules
0905 Hydraulic oil tank
Hydraulic oil reservoir
Hydraulic oil reservoir – Overview
Removing the hydraulic oil reservoir
Fitting the hydraulic oil reservoir
0910 Pumps
Hydraulic pumps
Hydraulic pumps – Overview
0915 Hydraulic lines
Oil filter
Hydraulic oil filter – Overview
0920 Valves
Main hydraulic block
Main block – Overview
Pick-up pressure limit valve block
Pick-up pressure limit valve block – Overview
Removing the pick-up pressure limit valve
Disassembling the pick-up pressure limit valve
Assembling the pick-up pressure limit valve
Fitting the pick-up pressure limit valve
Bale chamber overpressure detector block
Bale chamber overpressure detector block – Overview
Removing the bale chamber overpressure detector block
Disassembling the bale chamber overpressure detector block
Assembling the bale chamber overpressure detector block
Fitting the bale chamber overpressure detector block
Adjusting the overpressure detector
External circuit hydraulic block – RotoFeed
External circuit hydraulic block – RotoFeed – Overview
External circuit hydraulic block – RotoCut
Inlet unit – Overview
Knife and cutting frame control blocks – Overview
Bale ejector / bale ramp control block – Overview
20 Crop feeding
2020 Pick-up
Full length auger pick-up chain
Removing the chain
Fitting the chain
Pick-up cylinders
Removing a pick-up cylinder
Fitting a pick-up cylinder
Full length auger pick-up
Removing the pick-up
Fitting the pick-up
2025 Tines / Tine bars
Tine carrier
Removing a tine
Fitting a tine
21 Feeder unit
2125 Rotor
RotoFeed with fixed floor
Removing the rotor chassis
Fitting the rotor chassis
Disassembling the rotor chassis
Removing the scraper
Fitting the scraper
Overview of the rotor
Removing the right-hand bearing
Fitting the right-hand bearing
Removing the rotor
Fitting the rotor
Removing the left-hand bearing
Fitting the left-hand bearing
FineCut with pivoting knife floor
Removing the rotor chassis
Fitting the rotor chassis
Fitting the base plate
Removing the scraper
Fitting the scraper
Overview of the rotor
Removing the right-hand bearing
Fitting the right-hand bearing
Removing the rotor
Fitting the rotor
Removing the left-hand bearing
Fitting the left-hand bearing
Knife floor position sensor
Removing the sensor
Fitting the sensor
Adjusting the sensor
Pivoting knife floor – FineCut
Removing the knife floor
Fitting the knife floor
Disassembling/assembling the knife floor
Removing the knife control shaft
Fitting the knife control shaft
Prefitting the levers
Removing the knife locking shaft
Fitting the knife locking shaft
Knife activation sensor
Removing the sensor
Fitting the sensor
Adjusting the sensor
Knife activation cylinder
Removing the knife activation cylinder
Fitting the knife activation cylinder
2130 Feed assister
Alternating feeder
Removing the feed rake
Removing the feeder arm
Disassembling the feeder arm
Assembling the feeder arm
Fitting the feeder arm
Fitting the feed rake
Alternating feeder tie bars
Removing the feeder tie bar
Disassembling the tie bar
Fitting the feeder tie bar
Assembling the tie bar
Setting the upper position of the feed rake
Alternating feeder control
Removing the feed rake control shaft
Fitting the feed rake control shaft
Feed rake control cylinder
Removing the cylinder
Disassembling the cylinder arm
Assembling the cylinder arm
Fitting the cylinder
Adjusting the feed rake control cylinder
Neutral feed rake control cylinder
Removing the cylinder
Fitting the cylinder
Feed chamber curved ribs
Removing the curved ribs
Fitting the curved ribs
Removing the cross member
Disassembling a retainer
Fitting the cross member
Assembling a retainer
Feed chamber base plate
Removing the base plate
Fitting the base plate
Removing a pocket shaft
Upper pocket shaft
Lower pocket shaft
Fitting a pocket shaft
Upper pocket shaft
Lower pocket shaft
Adjusting the pocket shaft position sensors
Basic settings for the alternating feeder
45 Baling system
4510 Baling ram
Baling piston
Removing a piston scraper
Fitting a piston scraper
Removing the lateral angle bars
Fitting the lateral angle bars
Removing the piston connecting rods
Fitting the piston connecting rods
Removing the runners
Fitting the runners
Bale chamber dimension
Piston dimension
Determining the number of shims
Removing the piston
Fitting the piston
Checking the alignment of the piston in the bale chamber
Correct alignment
Incorrect alignment
Adjusting the alignment of the piston in the bale chamber
Correct alignment
Incorrect alignment
Incorrect alignment
Removing the piston knives
Fitting the piston knives
Overview of the counter-knife
Adjusting the counter-knife
Baling piston bearing rollers
Removing a bearing roller
Fitting a bearing roller
Adjusting the bearing rollers
Adjusting a single roller
Setting several rollers
Removing a scraper plate
Fitting a scraper plate
Piston bearing channels
Checking the bearing channels
Removing the bearing channels
Fitting the bearing channels
Baling piston locking control (needle safety)
Removing the piston locking control
Fitting the piston locking control
Adjusting the piston locking control
Baling piston locking (needle safety)
Removing the piston locking
Fitting the piston locking
Adjusting the position of the safety levers
46 Tying system
4605 Tying material
Removing the twine box
Fitting the twine box
Removing the twine brake
Disassembling the twine brake
Assembling the twine brake
Fitting the twine brake
Adjusting the twine brake
Removing the twine route baffle plate
Fitting the twine route baffle plate
Adjusting the twine route baffle plate
4620 Knotter
Removing a knotter
Fitting a knotter
Setting the knotters
Knotter hook pushrod springs
Twine retainer springs
Knotter connecting rods
Twine guide pin
Knotter base plate
Removing a knotter base plate
Disassembling a knotter base plate
Assembling a knotter base plate
Fitting a knotter base plate
Knotter body
Disassembling the knotter body
Assembling the knotter body
Knotter gearbox intermediate shaft
Removing the left-hand bearing
Fitting the left-hand bearing
Removing the right-hand bearing
Fitting the right-hand bearing
Removing the piston cycle sensor
Fitting the piston cycle sensor
Adjusting the position of the piston cycle sensor
Removing the intermediate shaft
Fitting the intermediate shaft
Knotter shaft
Removing the brake
Disassembling the brake
Assembling the brake
Fitting the brake
Adjusting the brake
Removing the left-hand bearing
Fitting the left-hand bearing
Removing the right-hand bearing
Fitting the right-hand bearing
Removing the knotter shaft
Disassembling the knotter shaft
Assembling the knotter shaft
Fitting the knotter shaft
Twine guide control shaft
Removing the control shaft
Fitting the control shaft
Adjusting the twine guide pin control shaft position sensor
Twine fault indicators
Removing a twine fault indicator
Disassembling a twine fault indicator
Assembling a twine fault indicator
Fitting a twine fault indicator
Tying activation device
Disassembling the tying activation
Assembling the tying activation
Removing the gear motor assembly
Disassembling the gear motor assembly
Assembling the gear motor assembly
Fitting the gear motor assembly
Checking the control lever stroke
Removing the tying activation sensor
Fitting the tying activation sensor
Adjusting the tying activation sensor
Tying drive
Removing the tying system drive
Disassembling the activating unit
Assembling the activating unit
Disassembling the drive one-way clutch
Assembling the activating unit one-way clutch
Fitting the tying system drive
Removing a needle
Disassembling a needle
Assembling a needle
Fitting a needle
Needle settings
Position of the needles in the piston
Needle pressure on the knotter
Needle height
Needle top dead centre
Needles – piston position
Altering the position of the knotter gearbox
Altering the position of the universal drive shaft
Needle cross member
Removing the needle and cross member assembly
Fitting the needle and cross member assembly
Removing the needle cross member
Fitting the needle cross member
Needle balancers
Removing a needle brake
Disassembling a needle brake
Assembling a needle brake
Fitting a needle brake
Adjusting the needle brake
Removing a needle tie bar
Fitting a needle tie bar
Removing a needle balancer
Fitting a needle balancer
Turbofan (up to No. 74401267)
Disassembling the turbofan
Assembling the turbofan
Turbofan drive (up to No. 74401267)
Removing the turbofan drive
Fitting the turbofan drive
Turbofan (from No. 74401268)
Disassembling the turbofan
Assembling the turbofan
Turbofan drive (from No. 74401268)
Removing the turbofan drive
Fitting the turbofan drive
Tying system basic settings
60 Crop discharge / straw discharge
6040 Bale discharge
Removing the bale ramp
Disassembling the bale ramp
Disassembling the intermediate rollers
Disassembling the rear roller
Assembling the bale ramp
Assembling the rear roller
Assembling the intermediate rollers
Fitting the bale ramp
Bale ramp position sensor
Removing the sensor
Fitting the sensor
Adjusting the sensor
Bale discharge sensor
Removing the sensor
Fitting the sensor
Adjusting the sensor
Bale ramp hoses and cylinder
Removing the bale ramp cylinder
Fitting the bale ramp cylinder
Removing the bale ramp cylinder valve
Fitting the bale ramp cylinder valve
75 Central lubrication system
7505 Reservoir / Pump
Central lubrication pump
Removing the lubrication pump
Fitting the lubrication pump
7510 Distributor
Distribution diagrams
Overview of distributors – Machine with fixed axleup to 74401267
Overview of distributors – Machine with trailing tandem axleup to 74401267
Overview of distributors – Machine with fixed axlefrom 74401268
Overview of distributors – Machine with trailing tandem axlefrom 74401268
Main distributor
Machine with fixed axle
Machine with trailing tandem axle
Distributor 1 – Piston lubrication
Distributor 2 – Knotter lubricationup to 74401267
Distributor 2 – Knotter lubricationfrom 74401268
Distributor 3 – Needle lubricationup to 74401267
Distributor 3 – Needle lubricationfrom 74401268
Distributor 4 – Trailing tandem axle lubrication (depending on equipment)
80 Various components / Machine body
8025 Panellings / Hoods
Knotter cover
Removing the knotter cover
Fitting the knotter cover
Side flaps
Removing the side flaps
Fitting the side flaps