Claas Rollant 540 Rc Rf (J03) Balers Repair Manual EN

File List:

00 0302 176 1.pdf

00 0302 176 1.pdf:

ROLLANT 540 RFROLLANT 540 RC
Table of contents
Introduction
General information
Manual validity
Information about this Repair Manual
Using the manual
Text and illustrations
Plan with structure of modules
Search and find
Direction specifications
Abbreviations
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
Installing
Chuck bushing
Removing
Dismounting of version A
Dismounting of version B
Installing
Chuck bushing version A
Chuck bushing version B
Radial shaft seals
Ferrule fittings
Screwing in
Leaky ferrule fittings
Sealing cone fittings
Hydraulic hoses
Hose placement
Treatment of sealing faces
Spare parts
Operating materials
ESD protection measures
Special tool
ESD protection measures
Notes on inspection and repair
Reason of damage
Welding work
Progressive ring fittings on hydraulic lines
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 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 bulkhead union nuts, straight and angled
Tightening torques for hydraulic male connectors SDS shape B and E
Tightening torques for hydraulic male connectors SDS shape F and screw plug
Tightening torques for SDS shape H hydraulic male connectors
Tightening torques for screw plugs shape E
Tightening torque for hydraulic male connectors shape C, conical thread
Tightening torques for hydraulic male connectors SDE shape F, adjustable direction
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 threaded pins / orifice plates
Tightening torque for studs and special screws
Tightening torques for hydraulic components
Tightening torques for hex. sealing nuts
Tightening torques for hose clamps
Installation instructions
Worm drive hose clamps
Hose clamps with round pins
Bolt tightening torques
Technical specifications
Operating materials
Identifying warnings
Hazard signs
Signal word
Safety rules
Safety signs and warnings
Requirement made on technical staff
Children in danger
Hazard areas of the machine
Instructors travelling along during fieldwork
Risk of injury from rotating shafts
Structural alterations of the machine
Optional equipment and spare parts
Control of running machine
Technical condition
Respecting technical limit values
Danger from machine parts that continue rotating
Keeping safety devices functional
Personal protective equipment
Wearing suitable clothing
Removing dirt and loose objects
Parking the machine safely
Unsuitable operating utilities
Safe handling of service fluids and auxiliary utilities
Environmental protection and disposal
Avoiding fires
Potentially fatal electric shock from overhead lines and lightning strike
Electric shock from electric system
Noise may damage your health
Pre-loaded machine parts
Liquids under pressure
Compressed air
Hot surfaces
Safe access and leaving
Working only on the stopped machine
Hazards during repairs
Raised machine parts and loads
Danger from welding work
Preparations for cases of emergency
General information
Adjustment and maintenance work
First-aid measures
Place the machine on axle stands
Decommission the machine
CCN explanation
CCN (CLAAS Component Number)
Electric system standard
Overview
Hydraulic system standard
Overview
CCN (CLAAS Component Number)
02 Gearbox / Clutch / Universal drive shaft
0230 Mechanical gearbox
Drive gearbox
Overview
Removing the chain wheel
Removing the bearing
Removing the drive gearbox
Fitting the drive gearbox
Fitting the bearing
Fitting the chain wheel
03 Chassis
0310 Axle
Non-braked axle
Overview
Removing a non-braked axle
Fitting a non-braked axle
Braked axle
Overview
Removing a braked axle
Fitting a braked axle
Wheel hub
Overview
Checking the play
Lubricating the wheel bearings
Wheel hub yoke
Removing a wheel hub
Fitting a wheel hub
Adjusting a wheel bearing
04 Brake
0405 Service brake
Brake mechanism
Removing a brake
Fitting a brake
Setting the brake control lever
Cylinder travel
Checking the brake shoe linings
Determining the brake type-approval
Securing the braking components – Type-approval A
Adjusting the length of the cylinder rod
Securing the braking components – Type-approval B
Adjusting the length of the cylinder rod
Pneumatic brake*
Removing the compressed air tank
Fitting the compressed air tank
Draining the compressed air tank
Cleaning the filters
Pneumatic brake cylinder*
Removing a pneumatic brake cylinder
Fitting a pneumatic brake cylinder
Checking the pneumatic brake cylinder
Hydraulic brakes*
Removing a hydraulic brake cylinder
Fitting a hydraulic brake cylinder
Hydraulic safety brake*
0415 Parking brake
Parking brake
Adjusting the parking brake
07 Hitch
0725 Drawbar
Overview
Removing the drawbar
Adapting the universal drive shaft support
Fitting the drawbar
Adjusting the position of the hitch eye
Jack stand
Overview
Removing the jack stand
Fitting the jack stand
Removing the ladder
Fitting the ladder
Removing the ladder / jack stand support
Fitting the ladder / jack stand support
08 Drives
0800 Drive diagram
Drive chains
Machine without MPS
Machine with MPS
09 Hydraulic system
0900 Hydraulic system – General
General rules
Special tools
Special tool
Checking the operation of the hydraulic circuit
Creating hydraulic pressure
Measuring hydraulic pressure
Connecting a device to a Minimess socket
Removing the components from the hydraulic block
Removing the seals and sealing rings
0915 Hydraulic lines
Oil filter
Overview
0920 Valves
Hydraulic block – Baling pressure*
Overview
Identifying connections
Hydraulic block – pivoting ROTO FEED*
Overview
Identifying connections
Adjustment of the pressure limit valve 7187
Hydraulic block – pivoting ROTO CUT*
Overview
Identifying connections
Adjustment of the pressure limit valve 7187
Hydraulic block – Baling pressure*
Overview
Identifying connections
Adjusting the pressure of the solenoid valve Y050
Hydraulic block – ROTO CUT pivoting floor*
Overview
Identifying connections
Adjusting the pressure limit valve
Hydraulic block – pivoting ROTO CUT*
Overview
Identifying connections
Hydraulic block – Film tying*
Overview
Identifying connections
0980 Hydraulic circuit diagrams
Standard hydraulics diagram – Baling pressure
Standard hydraulics diagram – ROTO FEED
Standard hydraulics diagram – ROTO CUT
Comfort hydraulics diagram – Baling pressure
Comfort hydraulics diagram – Pivoting floor
Comfort hydraulics diagram – ROTO CUT
Comfort hydraulics diagram – Film tying
Pick-up hydraulic diagram
10 Electrical / Electronic equipment
1000 Electrical / Electronic equipment general
Special tools
1012 Modules / sensors
Electronic module (A019)
Overview
Removing the electronic module (A019)
Fit the electronic module (A019)
Electronic module (A023)
Overview
Removing the electronic module (A023)
Fitting the electronic module (A023)
1020 Driving lights
Rear indicator lights
Overview
Removing the rear indicator lights
Fitting the rear indicator lights
Removing the rear indicator lights wiring harness
Fitting the rear indicator lights wiring harness
1025 Working lights
Work lighting*
Overview
Removing the side flap work lighting
Fitting the side flap work lighting
Removing the work lighting from the tying cover
Fitting the work lighting for the tying cover
20 Crop feeding
2020 Pick-up
Overview
Removing the pick-up
Fitting the pick-up
Pick-up lift
Overview
Removing the pick-up lift
Fitting the pick-up lift
Adjusting the pick-up lift
Removing the lift tie rods
Fitting the lift tie rods
Curved profile and tine
Overview
Removing a curved profile
Fitting a curved profile
Removing a tine
Fitting a tine
2.10 m pick-up main drive
Overview
Removing the main drive
Fitting the main drive
Removing the chain tensioner
Fitting the chain tensioner
Removing the left-hand protective cover
Fitting the left-hand protective cover
Pick-up cut-out clutch
Overview
Removing the pick-up cut-out clutch
Fitting the pick-up cut-out clutch
Pick-up free wheel
Overview
Removing the free wheel
Disassembling the free wheel
Assembling the free wheel
Fitting the free wheel
Pick-up right-hand feed auger drive
Overview
Removing the drive from the right-hand feed auger
Fitting the drive of the right-hand feed auger
Remove the right-hand protective cover
Fit the right-hand protective cover
21 Feeder unit
2125 Rotor
Rotor drive
Overview
Removing the chain
Fitting the chain
Fitting the lubrication brush
Tensioning the chain
Removing the chain tensioner
Disassembling the chain tensioner
Assembling the chain tensioner
Fitting the chain tensioner
Removing the chain wheels
Fitting the chain wheels
Rotor chassis
Overview
Removing the rotor chassis
Fitting the rotor chassis
ROTO FEED pivoting floor*
Overview
Removing the ROTO FEED pivoting floor
Fitting the ROTO FEED pivoting floor
ROTO CUT pivoting floor*
Overview
Removing the ROTO CUT pivoting floor
Disassembling the ROTO CUT pivoting floor
Assembling the ROTO CUT pivoting floor
Fitting the ROTO CUT pivoting floor
Connecting the standard hydraulics
Connecting the comfort hydraulics
Overview
Removing the rotor
Disassembling the rotor
Assembling the rotor
Adjusting the position of the rotor
Fitting the rotor
Overview
Removing the scraper
Fitting the scraper
Removing the scraper flap
Fitting the scraper flap
Adjusting the scraper flap
Knife locking shaft*
Overview
Removing the knife locking shaft
Fitting the knife locking shaft
Knife tilting shaft*
Overview
Removing the knife tilting shaft
Fitting the knife tilting shaft
Knife activation shaft*
Overview
Removing the knife activation shaft
Fitting the knife activation shaft
Knife activation shafts*
Overview
Removing the knife activation shafts
Disassembling the knife activation shafts
Assembling the knife activation shafts
Fitting the knife activation shafts
Knife position sensor (B111)*
Overview
Removing the sensor (B111)
Fitting the sensor (B111)
Adjusting the knife position sensor (B111)
Knife activation cylinder (3036)*
Overview
Removing the knife activation cylinder
Fitting the knife activation cylinder
Connecting the left-hand cylinder
Connecting the right-hand cylinder
Pivoting floor position sensor (B067)*
Overview
Removing the sensor connecting rod (B067)
Removing the sensor (B067)
Fitting the sensor (B067)
Fitting the sensor connecting rod (B067)
Adjusting the pivoting floor position sensor (B067)
Pivoting floor cylinder (3042)*
Overview
Removing the pivoting floor cylinders
Fitting the pivoting floor cylinders
Connecting the left-hand cylinder
Connecting the right-hand cylinder – Standard hydraulics
Connecting the right-hand cylinder – Comfort hydraulics
45 Baling system
4505 Baling chamber
Tailgate
Overview
Removing the tailgate
Disassembling the tailgate
Fitting the tailgate
Fitting the tailgate
Tailgate sensor – closed position (B135)
Overview
Removing the tailgate sensor (B135)
Fitting the tailgate sensor (B135)
Adjusting the tailgate sensor (B135)
Tailgate sensor – open position (B136)
Overview
Removing the tailgate sensor (B136)
Fitting the tailgate sensor (B136)
Adjusting the tailgate sensor (B136)
Tailgate angle sensor (B206)*
Overview
Removing the tailgate sensor (B206)
Fitting the tailgate sensor (B206)
Adjusting the tailgate sensor (B206)
Tailgate cylinder (3018)
Overview
Removing the tailgate cylinders
Fitting the tailgate cylinders
4520 Compression rollers / Guide rollers
Drive for rollers 1, 2 and 11 to 15
Overview
Removing the chain
Fitting the chain
Fitting the lubrication brush
Tensioning the chain
Removing the chain tensioner
Disassembling the chain tensioner
Assembling the chain tensioner
Fitting the chain tensioner
Removing the chain wheels
Return chain wheel
Fitting the chain wheels
Return chain wheel
Drive for rollers 3 to 10
Overview
Removing the chain
Fitting the chain
Fitting the lubrication brush
Tensioning the chain
Removing the chain tensioner
Disassembling the chain tensioner
Assembling the chain tensioner
Fitting the chain tensioner
Removing the chain wheels
Return chain wheel
Fitting the chain wheels
Return chain wheel
Removing the chain guide
Fitting the chain guide
Drive for rollers 3 to 10
Overview
Removing the chain
Fitting the chain
Fitting the lubrication brush
Tensioning the chain
Removing the chain tensioner
Disassembling the chain tensioner
Assembling the chain tensioner
Fitting the chain tensioner
Removing the chain wheels
Fitting the chain wheels
Removing the chain guide
Fitting the chain guide
Main drive
Overview
Removing the chain
Fitting the chain
Fitting the lubrication brush
Tensioning the chain
Removing the chain tensioner
Disassembling the chain tensioner
Assembling the chain tensioner
Fitting the chain tensioner
Removing the chain wheels
Return chain wheel
Fitting the chain wheels
Return chain wheel
Chain wheels
Overview
Chain wheel adjustment configuration
Removing the chain wheels
Removing the chain wheel from roller 10
Fitting the chain wheels
Fitting the chain wheels – except roller 10
Fitting the chain wheels – only roller 10
Roller identification
Rollers 1, 4 to 9 and 11 to 14
Overview
Roller assembly configuration
Removing the rollers
Removing the left-hand bearing
Removing the right-hand bearing
Disassembling the rollers
Assembling the rollers
Fitting the rollers
Fitting the left-hand bearing
Fitting the right-hand bearing
Rollers 2, 3 and 15
Overview
Removing the rollers
Removing the left-hand bearing
Removing the right-hand bearing
Disassembling the rollers
Assembling the rollers
Fitting the rollers
Fitting the left-hand bearing
Fitting the right-hand bearing
Roller 10
Overview
Removing the roller
Removing the left-hand bearing
Removing the right-hand bearing
Disassembling the roller
Assembling the roller
Fitting the roller
Fitting the right-hand bearing
Fitting the left-hand bearing
Overview
Roller assembly configuration – left-hand side
Roller assembly configuration – right-hand side
Disassembling the rollers
Assembling the rollers
MPS (Maximum Pressure System or oscillating segment)
Overview
Removing the MPS
Fitting the MPS
MPS – Left-hand wall
Overview
Disassembling the left-hand wall
Assembling the MPS
MPS – Right-hand wall
Overview
Disassembling the right-hand wall
Assembling the right-hand wall
MPS – Springs
Overview
Removing the springs
Fitting the springs
Rotation speed sensor (B009)*
Overview
Removing the sensor (B009)
Fitting the sensor (B009)
Adjusting the sensor (B009)
46 Tying system
4605 Tying material
Twine box*
Overview
Pivoting the twine box into the maintenance position
Pivoting the twine box into the working position
Removing the twine box
Fitting the twine box
Spare net storage mounting*
Overview
Removing the spare net storage mounting
Disassembling the spare net storage mounting
Assembling the spare net storage mounting
Fitting the spare net storage mounting
Spare film / net storage mounting*
Overview
Removing the spare film / net storage mounting
Disassembling the spare film / net storage mounting
Disassembling the retractable stop
Assembling the retractable stop
Assembling the spare film / net storage mounting
Fitting the spare film / net storage mounting
4610 Twine wrapping
Electromagnetic tying clutch (Y039)
Overview
Removing the clutch belt
Fitting the clutch belt
Removing the electromagnetic tying clutch (Y039)
Disassembling the electromagnetic tying clutch (Y039)
Assembling the electromagnetic tying clutch (Y039)
Fitting the electromagnetic tying clutch (Y039)
Removing the clutch belt tensioner
Fitting the clutch belt tensioner
Removing the pulley on roller 13
Fitting the pulley on roller 13
Twine tying drive
Overview
Removing the twine tying belt
Fitting the twine tying belt
Removing the twine tying pulley
Fitting the twine tying pulley
Removing the tying belt tensioner
Fitting the tying belt tensioner
Twine tying
Overview
Removing the twine tying system
Fitting the twine tying system
Step-down gear
Overview
Removing the step-down gear
Fitting the step-down gear
Removing the step-down gear drive
Fitting the step-down gear drive
Removing the cam switch (Z035)
Fitting the cam switch (Z035)
Adjusting the cam switch (Z035)
Twine guide tube
Overview
Removing the twine guide tube
Disassembling the twine guide tube
Assembling the twine guide tube
Fitting the twine guide tube
Adjusting the twine guide tube control
Twine tensioner
Overview
Removing the twine tensioner
Fitting the twine tensioner
Setting the twine tensioner
Twine knives
Overview
Removing the twine knives
Fitting the twine knives
Removing the knife control cables
Fitting the knife control cables
Removing the cable control lever
Fitting the cable control lever
Adjusting the cables of the twine knives
Deflectors
Overview
Removing the deflector
Disassembling the deflector
Assembling the deflector
Fitting the deflector
Adjusting the deflector
4615 Net wrapping / film wrapping
Net tying drive*
Overview
Removing the net tying drive belt
Fitting the net tying drive belt
Removing the belt brake
Fitting the belt brake
Removing the net tying pulley
Fitting the net tying pulley
Removing the lower return pulley
Fitting the lower return pulley
Removing the upper return pulley
Fitting the upper return pulley
Removing the tying belt tensioner
Fitting the tying belt tensioner
Net tying*
Overview
Removing the net tying
If the machine is equipped with net / twine tying:
If the machine is equipped with standard net tying:
If the machine is equipped with comfort net tying:
If the machine is equipped with comfort film / net tying:
Disassembling the net tying system
Assembling the net tying system
Fitting the net tying system
If the machine is equipped with net / twine tying:
If the machine is equipped with standard net tying:
If the machine is equipped with comfort net tying:
If the machine is equipped with comfort film / net tying:
Right-hand side panel
Overview
Disassembling the right-hand side panel
Assembling the right-hand side panel
Pressure roller
Overview
Disassembling the pressure roller
Assembling the pressure roller
Adjusting the pressure roller springs
Left-hand side panel
Overview
Disassembling the left-hand side panel
Standard tying
Comfort tying
Assembling the left-hand side panel
Standard tying
Comfort tying
Knife and rubber roller
Overview
Disassembling the knife and the rubber roller
Assembling the knife and the rubber roller
Rubber roller speed sensor (B022)
Overview
Removing the rubber roller sensor (B022)
Fitting the rubber roller sensor (B022)
Adjusting the rubber roller sensor (B022)
Knife resetting system
Overview
Removing the knife resetting system
Disassembling the knife resetting system
Assembling the knife resetting system
Fitting the knife resetting system
Adjusting the knife resetting system
Checking
Knife resetting hook
Overview
Removing the hook
Standard tying
Comfort tying
Fitting the hook
Standard tying
Comfort tying
Knife motor (M011)*
Overview
Removing the knife motor (M011)
Fitting the knife motor (M011)
Net brake*
Overview
Removing the net brake
Fitting the net brake
Removing the net brake pulleys
Fitting the net brake pulleys
Adjusting the net brake
Net roller brake and box*
Overview
Removing the net box
Disassembling the net roller brake
Assembling the net roller brake
Fitting the net box
Adjusting the net roller brake
Film tying drive*
Overview
Removing the film tying belt
Fitting the film tying belt
Removing the film / net tying pulley
Fitting the film / net tying pulley
Removing the pulley ratchet
Fitting the pulley ratchet
Removing the tying belt tensioner
Fitting the tying belt tensioner
Film tying*
Overview
Removing the film tying system
Disassembling the film tying system
Assembling the film tying system
Fitting the film tying system
Disconnecting the hydraulics
Connecting the hydraulics
Removing the diverter roller
Fitting the diverter roller
Removing the hydraulics from the film tying system
Fitting the hydraulics on the film tying system
Film tying cylinders (3353 and 3354)*
Overview
Removing the cylinder from the left-hand film guiding roller
Removing the cylinder from the right-hand film guiding roller
Disassembling the guiding roller
Assembling the guiding roller
Fitting the cylinder of the left-hand film guiding roller
Fitting the cylinder of the right-hand film guiding roller
Film / net roller pressure arm*
Overview
Removing the pressure arm
Disassembling the pressure arm
Assembling the pressure arm
Fitting the pressure arm
Removing the pressure arm lock
Disassembling the lock
Assembling the lock
Fitting the pressure arm lock
Film / net roller tipper box*
Overview
Removing the tipper box
Disassembling the tipper box
Disassembling the connecting rods
Disassembling the rollers
Disassembling the carriage
Assembling the tipper box
Assembling the carriage
Assembling the rollers
Assembling the connecting rods
Adjusting the connecting rods
Fitting the tipper box
Film / net roller brake*
Overview
Removing the roller brake
Disassembling the roller brake
Assembling the roller brake
Fitting the roller brake
Film / net roller speed sensor (B095)
Overview
Removing the film / net roller sensor (B095)
Fitting the film / net roller sensor (B095)
Adjusting the film / net roller sensor B095
Film / net knife position sensor (B663)
Overview
Removing the film tying position sensor (B663)
Fitting the film tying position sensor (B663)
Adjusting the film / net knife sensor (B663)
Film tying position sensor (B664)
Overview
Removing the film tying position sensor (B664)
Fitting the film tying position sensor (B664)
Adjusting the film tying position sensor (B664)
60 Crop discharge / straw discharge
6040 Bale discharge
Bale ramp
Overview
Removing the bale ramp
Fitting the bale ramp
Adjusting the bale ramp position sensor (B128)
Checking
75 Central lubrication system
7505 Reservoir / Pump
Chain lubrication pump
Overview
Removing the oil pump
Fitting the oil pump
Removing the eccentric disc
Fitting the eccentric disc
Adjusting the position of the oil pump
Priming the oil pump
Replacing the filter
Central lubrication pump (M025)
Overview
Removing the lubrication pump
Fitting the lubrication pump
7510 Distributor
Chain lubrication distributor
Overview
Removing the distributor
Fitting the distributor
Central lubrication distributors
Overview
Removing the main distributor and distributors 1 to 3
Fitting the main distributor and distributors 1 to 3
Removing distributor 4
Fitting distributor 4
7515 Lubrication system / Lines
Chain lubrication lines
Pump / distributor line
Disconnecting
Connecting
Distributor line
Disconnecting
Disassembling a nozzle
Assembling a nozzle
Connecting
Lines for the lubrication points
Disconnecting
Connecting
Removing the pump / distributor line
Fitting the pump / distributor line
Removing the lubrication line for rollers 3 to 10
Fitting the lubrication line for rollers 3 to 10
Removing the pick-up lubrication lines
Fitting the pick-up lubrication lines
Removing the wiring harness for the lubrication lines
Fitting the wiring harness for the lubrication lines
Lubrication lines
Distributor lines
Main distributor*
Distributor 1
Distributor 2
Distributor 3
Distributor 4
Main distributor / pump line
Pump side
Distributor side
Lines with plug-in connectors
Disconnecting
Connecting
7590 Accessories
Chain lubrication points
Overview
Left-hand side
Overview
Right-hand side
Removing a double brush
Fitting a double brush
Removing a drip feed
Fitting a drip feed
80 Various components / Machine body
8025 Panellings / Hoods
Side flap
Overview
Removing the side flap
Fitting the side flap
Tying cover
Overview
Removing the tying cover
Fitting the tying cover
Side covers
Overview
Removing the front left-hand side cover
Fitting the front left-hand side cover
Removing the rear left-hand side cover
Fitting the rear left-hand side cover
Removing the front right-hand side cover
Fitting the front right-hand side cover
Tailgate side covers
Overview
Removing the right-hand side cover
Fitting the right-hand side cover
Removing the left-hand side cover
Fitting the left-hand side cover
Tailgate covers
Overview
Removing the tailgate covers
Fitting the tailgate covers