Claas Xerion 5000-4000 (782) Tractors Repair Manual EN

File List:

00 0114 220 2.pdf
00 0288 638 1.pdf
00 0288 705 0.pdf
00 0292 473 4.pdf
00 0303 706 0.pdf
00 1106 921 9.pdf
1 160 241_e.pdf
1 183 409_e.pdf
Diagnostics report ECCOM 4.5.pdf
Diagnostics report ECCOM 5.0.pdf
Inspection protocol XERION 5000 – 4500.pdf
Special Tool List LEXION 770-650 XERION 5000-4000.pdf
WORKSHOP HANDBOO FRONT AND REAR AXLE GRAZIANO SFA15-SRA15.pdf

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 0288 705 0.pdf:

Perkins 2206D-E13TA
Table of contents
Introduction
General information
Validity of manual
Using the manual
Text and figures
Layout with assembly group structure
Search and find
Directional indicators
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
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
Treatment of sealing faces
Spare parts
Torque settings
Tightening torques for metric standard threads
Tightening torque for metric fine threads
Tightening torques for hydraulic screw fittings and air conditioner screw fittings with sealing cone and O-ring according to DIN 3865
Tightening torques for hydraulic screw fittings with ferrule according to DIN 3861
Tightening torques for SDS hydraulic male connectors
Tightening torques for hydraulic swivel fittings
Tightening torques for hollow screws DIN 7643
Tightening torques for direction-adjustable SDE hydraulic male connectors
Tightening torques for brake line screw fittings
Tightening torques for worm-type threaded clips
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
PERKINS 2206D
Engine description
Engine components
Ignition order
Cranking the engine
Special tools for removed engine
Special tool for built-in engine
Cranking the engine in built-in condition
Setting the engine to Top Center Position for No.1 Piston
0105 Engine suspension
Engine support
Technical specifications
Work preparation
Removing
Installing
0110 Engine housing
Cylinder block
Technical specifications
Cylinder liner
Technical specifications
Work preparation
Special tools
Removing
Installing
Checking
Technical specifications
Work preparation
Removing
Removing the oil strainer
Installing the oil strainer
Installing
Front housing
Technical specifications
Work preparation
Removing
Installing
Crankshaft front seal
Technical specifications
Removing
Installing
Crankshaft rear seal
Technical specifications
Work preparation
Removing
Installing
Front cover
Technical specifications
Work preparation
Removing
Installing
Flywheel housing
Technical specifications
Work preparation
Removing
Installing
Crankcase breather
Technical specifications
Removing
Installing
0115 Engine unit
Pistons and connecting rods
Technical specifications
Special tool
Removing
Disassembling
Assembling
Installing
Crankshaft
Technical specifications
Special tool
Removing
Installing
Crankshaft main bearings
Technical specifications
Special tool
Removing
Installing
Vibration damper and pulley
Technical specifications
Work preparation
Removing
Installing
Flywheel
Technical specifications
Special tool
Work preparation
Removing
Installing
Checking
0120 Cylinder head / Valves / Idler gear
Valve mechanism cover
Technical specifications
Removing
Installing
Valve mechanism cover base
Technical specifications
Removing
Installing
Camshaft
Technical specifications
Special tool
Removing
Installing
Removing the camshaft gear
Installing the camshaft gear
Removing the camshaft bearings
Installing the camshaft bearings
Cylinder head
Technical specifications
Work preparation
Removing
Installing
Rocker Shaft and Pushrod
Technical specifications
Removing
Disassembling
Assembling
Installing
Lifter group
Technical specifications
Removing
Disassembling
Assembling
Installing
Valve springs
Technical specifications
Special tool
Removing
Installing
Valves and Valves Guides
Technical specifications
Special tool
Removing
Installing
Adjusting valve lash
Valve seat inserts
Technical specifications
Special tool
Removing
Installing
Gear drive
Technical specifications
Special tool
Removing
Installing
0125 Injection / Fuel system
Fuel Priming Pump
Technical specifications
Removing
Installing
Fuel Filter Base
Technical specifications
Removing
Disassembling
Assembling
Installing
Fuel Transfer Pump
Technical specifications
Removing
Installing
Fuel Pressure Regulator
Technical specifications
Removing
Installing
Injectors
Technical specifications
Work preparation
Special tools
Removing
Installing
Adjusting
Injector sleeve
Technical specifications
Special tool
Removing
Installing
0130 Lubricating oil system
Piston cooling jets
Technical specifications
Work preparation
Removing
Installing
Checking
Oil pump
Technical specifications
Work preparation
Removing
Disassembling
Assembling
Installing
Oil cooler
Technical specifications
Work preparation
Removing
Installing
Oil Filter Base
Technical specifications
Work preparation
Removing
Disassembling
Assembling
Installing
0135 Cooling system
Water pump
Technical specifications
Work preparation
Special tools
Removing
Disassembling
Assembling
Installing
Water temperature regulator housing
Technical specifications
Work preparation
Special tools
Removing
Installing
0140 Exhaust system
Turbocharger
Technical specifications
Work preparation
Removing
Installing
Exhaust manifold
Technical specifications
Work preparation
Removing
Installing
0145 Air intake
Inlet manifold
Technical specifications
Work preparation
Removing
Installing
0150 Engine attachment parts
Electric starting motor
Technical specifications
Removing
Installing
Alternator (G002)
Technical specifications
Removing
Installing
Alternator drive belt tensioner
Technical specifications
Installation instructions
Air compressor
Technical specifications
Removing
Installing
Front plate
Technical specifications
Removing
Installing
0155 Engine control
Electronic control module
Technical specifications
Removing
Installing

00 0292 473 4.pdf:

XERION 5000-4000
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
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
CCN explanation
CCN (CLAAS Component Number)
Electric system standard
Overview
Hydraulic system standard
Overview
CCN (CLAAS Component Number)
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
Adjusting and maintenance work
Welding work
01 Engine
0102 Complete component
Power measurement
Visual inspections
Preparations for power measurement
Performing the power measurement
Attention!
Power diagram XERION 5000
XERION 4500 power diagram
XERION 4000 power diagram
Diesel engine
Work preparation
Special tool
Technical specifications
Removing
Installing
0125 Injection – / Fuel system
Fuel tank
Work preparation
Special tool
Technical specifications
Removing
On TRAC VC
With TRAC
Installing
With TRAC
Additional fuel tank
Work preparation
Special tool
Technical specifications
Removing
On TRAC VC
With TRAC
Installing
With TRAC
0135 Cooling system
Radiator air intake
Work preparation
Technical specifications
Removing
Installing
Fan blade
Technical specifications
Installing
Radiator
Work preparation
Technical specifications
Removing
Installing
Fan drive motor (2082)
Work preparation
Special tool
Technical specifications
Removing
Installing
Fan drive pump (2083)
Work preparation
Special tool
Technical specifications
Removing
Installing
Bleeding
Fan reversing solenoid valve (Y244)
Work preparation
Special tool
Technical specifications
0140 Exhaust system
Silencer
Work preparation
Technical specifications
Removing
Installing
0145 Air intake
Air filter
Technical specifications
Installing
Charge air cooler
Work preparation
Technical specifications
Installing
0150 Engine attachment parts
Electric starting motor (M021)
Technical specifications
Removing
Installing
Alternator (G002 / G003)
Technical specifications
Removing the alternator (G002)
Installing the alternator (G002)
Removing the alternator (G003)
Installing the alternator (G003)
0155 Engine control
Accelerator pedal
Technical specifications
02 Gearbox / Clutch / Universal drive shaft
0202 Complete component
Diagnostic protocol
Transmission
Work preparation
Technical specifications
Removing
Installing
On TRAC VC
With TRAC
0210 Oscillation damper
Torsion damper
Work preparation
Technical specifications
On TRAC VC
With TRAC
Installing
With TRAC
0218 Clutch control
Inching pedal
Technical specifications
0255 Gearbox cooling system
Oil cooler (1009 / 1031)
Work preparation
Special tool
Technical specifications
Removing
Installing
0260 Universal drive shaft
Universal drive shaft main drive
Work preparation
Technical specifications
Front axle drive universal drive shaft
Work preparation
Technical specifications
Rear axle drive universal drive shaft
Work preparation
Technical specifications
03 Chassis
0325 Driven steering axle, front
Identifying the front drive axle
Technical specifications
Front drive axle
Work preparation
Special tool
Technical specifications
Removing
Disassembling
Assembling
Installing
Front drive axle
Work preparation
Special tool
Technical specifications
Removing
Installing
Floating axle lock hydraulic cylinder
Technical specifications
Work preparation
Special tool
Steering angle sensor
Technical specifications
Removing
Installing
Front pressure sensor
Front temperature sensor
Front axle body
Front stub axle
Front bevel gear drive
Front differential
Front floating axle
Front wheel hub
Front track rods
Swing axle thermostatic valve
Technical specifications
Work preparation
Removing
Installing
Swing axle pressure filter
Technical specifications
Work preparation
Removing
Installing
Front axle oil cooler
Technical specifications
Work preparation
Removing
Installing
Front lubricating pump
0330 Driven steering axle, rear
Identifying the rear drive axle
Technical specifications
Rear steering drive axle
Work preparation
Special tool
Technical specifications
Removing
Disassembling
Assembling
Installing
Rear steering drive axle
Work preparation
Special tool
Technical specifications
Removing
Installing
Steering angle sensor
Technical specifications
Removing
Installing
Pressure sensor
Technical specifications
Removing
Installing
Temperature sensor
Technical specifications
Removing
Installing
Axle body
Technical specifications
Work preparation
Auxiliary tool
Special tool
Removing
Disassembling
Assembling
Installing
Stub axle
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Checking the pin bearing
Bevel gear drive
Differential
Technical specifications
Work preparation
Auxiliary tool
Special tool
Installation instructions
Removing the differential housing
Disassembling the differential housing
Assembling the differential housing
Installing the differential housing
Checking the differential lock
Venting the differential lock
Removing the bevel gear drive
Disassembling the bevel gear drive
Assembling the bevel gear drive
Installing the bevel gear drive
Adjusting
Floating axle
Technical specifications
Removing
Disassembling
Assembling
Installing
Wheel hub
Technical specifications
Work preparation
Special tool
Installation instructions
Removing the outer planetary gear
Disassembling the outer planetary gear
Removing the inner planetary gear
Disassembling the inner planetary gear
Removing the ring gear
Disassembling the ring gear
Removing the wheel hub housing
Disassembling the wheel hub housing
Assembling the wheel hub housing
Installing the wheel hub housing
Assembling the ring gear
Installing the ring gear
Assembling the inner planetary gear
Installing the inner planetary gear
Assembling the outer planetary gear
Installing the outer planetary gear
Checking the rolling moment
Repairing the wheel bolt bore thread
Track rods
Technical specifications
Work preparation
Removing
Disassembling
Assembling
Installing
Adjusting the toe-in
Rigid axle thermostatic valve
Technical specifications
Work preparation
Removing
Installing
Rigid axle pressure filter
Technical specifications
Work preparation
Removing
Installing
Rear axle oil cooler
Technical specifications
Work preparation
Removing
Installing
Lubrication pump
Technical specifications
Work preparation
Removing
Disassembling
Assembling
Installing
04 Brake
0405 Service brake
Brake lines
Work preparation
Special tool
Technical specifications
Brake pedal
Work preparation
Special tool
Technical specifications
Service brake
Technical specifications
Work preparation
Auxiliary tool
Special tool
Installation instructions
Removing the brake disc
Removing the brake piston
Installing the brake piston
Installing the brake discs
Checking the pressure
Bleeding
Checking the brake wear
0415 Parking brake
Parking brake
Technical specifications
Work preparation
Special tool
Removing the brake calliper
Disassembling the brake calliper
Assembling the brake calliper
Installing the brake calliper
Bleeding
Adjusting
Replacing the brake disc
Changing the brake linings
0420 Trailer air brake
Compressed-air trailer brake system valve block
Work preparation
Special tool
Technical specifications
Compressed-air treatment
Work preparation
Special tool
Technical specifications
Compressed-air accumulator
Work preparation
Special tool
Technical specifications
0425 Trailer hydraulic brake
Hydraulic trailer brake valve block
Work preparation
Special tool
Technical specifications
05 Steering
0505 Steering
Steering column (from serial no. …)
Work preparation
Technical specifications
Disassembly
Assembly
Installing
Steering hydraulics pump (2018)
Work preparation
Special tool
Technical specifications
Removing
On TRAC VC
With TRAC
Installing
On TRAC VC
With TRAC
Adjusting the working pressure
Adjusting the system pressure
Emergency steering pump (2045)
Work preparation
Special tool
Technical specifications
Removing
Installing
Bleeding
Steering unit
Technical specifications
Work preparation
Special tool
Removing
Installing
Steering hydraulics valve block (from serial no. …)
Work preparation
Special tool
Technical specifications
Steering hydraulic cylinder
Technical specifications
Work preparation
Removing
Installing
06 Lift device
0605 Rear power lift
Rear power lift tractive force sensors (B335 / B336)
Work preparation
Technical specifications
Installing
Rear power lift position sensor (B334)
Technical specifications
Lift arms
Work preparation
Technical specifications
Installing
Lower link
Technical specifications
Upper link
Work preparation
Technical specifications
Lift braces
Work preparation
Technical specifications
Side braces
Work preparation
Technical specifications
Side braces valve block
Work preparation
Special tool
Technical specifications
Rear power lift hydraulic cylinder (3182 / 3183)
Work preparation
Special tool
Technical specifications
Removing
Installing
0610 Front power lift
Front power lift position sensor (B333)
Technical specifications
Front power lift pressure sensors (B339 / B340)
Work preparation
Technical specifications
Lower link
Work preparation
Technical specifications
Upper link
Work preparation
Technical specifications
Rocker arm
Work preparation
Technical specifications
Front power lift hydraulic cylinder (3184 / 3185)
Work preparation
Special tool
Technical specifications
Removing
Installing
07 Hitch
0705 Coupling frame
Hitch block
Work preparation
Technical specifications
Installation
0710 Swinging drawbar
Swinging drawbar
Work preparation
Technical specifications
08 Drives
0800 Drive diagram
Drive diagram
Technical specifications
Technical specifications
0802 Rear PTO
PTO shaft clutch
Special tool
Technical specifications
Rear PTO shaft gearbox
Work preparation
Special tool
Technical specifications
Disassembly
Assembly
Installing
Rear PTO shaft universal drive shaft
Work preparation
Technical specifications
Removing
Installing
09 Hydraulic system
0900 Hydraulic system – General
Hydraulic system – General
Work preparation
Special tool
Filling / bleeding the hydraulic system
0905 Hydraulic oil tank
Hydraulic oil tank (1010)
Work preparation
Special tool
Technical specifications
Removing
On TRAC VC
With TRAC
Installing
Creating a vacuum in the hydraulic oil tank (1010)
0910 Pumps
Working hydraulics pump (2005)
Work preparation
Special tool
Technical specifications
Removing
On TRAC VC
With TRAC
Installing
Adjusting the working pressure
With TRAC
On TRAC VC