Claas Arion 650-620 Cmatic (A37) Tractors Repair Manual EN

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00 0289 086 0.pdf
00 1149 440 X.pdf
XX XXXX XXX X.pdf

00 0289 086 0.pdf:

CTIC 2800CTIC
Table of contents
Introduction
General information
Validity of manual
Handling of this manual
General repair instructions
Technical specifications
Information on technically correct repairs
Self-locking bolts
Liquid locking compound
Circlips
Hydraulic hoses
Hose routing
Spare parts and technical questions
Tightening torques
Tightening torques for metric ISO screw thread
Tightening torques for metric fine thread
General information
Particularly important
Qualification of drivers and maintenance personnel
Identification of warning and danger signs
General safety and accident prevention regulations
Pressurised fluids
Pressure accumulator
Putting the machine out of operation
Raised machine parts and loads
No welding
Optional equipment and spare parts
Tyre pressure control system
Overview
Electronic box
Control valve block
Rotary coupling
Compressor
Compressor
Oil cooler
Hydraulic motor
Hydraulic motor
Flow control valve
Flow control valve
Flow control valve
Appendix
Tyre pressure control system
Circuit diagrams

00 1149 440 X.pdf:

ARION 650-620 CMATICARION 550-530 CMATIC
Table of contents
CCN (CLAAS Component Number)
Introduction
General information
Using this repair manual
Validity of this 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 02 0225 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
General information
Important
Warning and danger markings
General safety advice and accident prevention regulations
First aid measures
Leaving the tractor
Adjustment and maintenance work
Risk of injury from hydraulic fluid
Air conditioning
Accumulator
Battery isolating switch
Place the tractor on axle stands
Stopping the tractor
01 Engine
0102 Complete component
Complete engine
Coupling the engine to the chassis
Preparation for work
0110 Engine housing
Timing cover
6 cylinders
4 cylinders
Preparation for work
Special tool
Removing the timing cover
Removing the front panel
Fitting the front panel
Fitting the timing cover
Removing the oil pressure controller
6 cylinders
4 cylinders
Fitting the oil pressure controller
6 cylinders
4 cylinders
Engine flywheel housing
Preparation for work
0115 Engine unit
Connecting rod/piston assembly
Special tool
Removing the conrod / piston assembly
Dismantling the piston/conrod assembly and piston rings
Checking the piston shaft bore
Checking the piston skirt
Checking the piston height
Checking the piston / liner play
Checking the conrod bearing shells
Checking the conrod and the bearing cap
Checking the conrod shaft bore
Checking the centre-to-centre distance of the conrod bores
Removing the piston pin ring
Checking the piston rings and shafts
Fitting the piston pin rings
Checking the piston protrusion
Conrod/piston assembly and piston rings
Description
Fitting the pistons and conrods
Removing the piston cooling nozzle
Cleaning and inspecting the piston cooling nozzle
Fitting the piston cooling nozzle
Preparation for work
Special tool
Removing the liners
Honing the cylinder liners
Checking the depth of the recess for the liner flange in the block
Checking the liner flange
Refitting the liners
Reconditioning the 6-cylinder engine block
Preparation for work
Special tool
Reconditioning the 4-cylinder engine block
Preparation for work
Special tool
Balancer shaft
Preparation for work
Special tool
Changing the rings
Replacing the balancer shaft pinion
Flywheel
Dismantling
Assembly
Crankshaft torsional absorber
Preparation for work
Special tool
Crankshaft sensor target
Special tool
Crankshaft bearing seals
Special tool
Removing the rear bearing seal
With the old special tool reference
With the new special tool reference
Fitting the rear bearing seal
Removing the front bearing seal
Fitting the front bearing seal
Crankshaft and bearing shells
Special tool
Removing the crankshaft pinion
Fitting the crankshaft pinion
Removing the crankshaft
Fitting the crankshaft
0120 Cylinder head / Valves / Idler gear
6-cylinder cylinder head
Special tool
Flatness of the cylinder head
Measuring the thickness of the cylinder head
4-cylinder cylinder head
Special tool
Flatness of the cylinder head
Measuring the thickness of the cylinder head
Dimensional specifications
Special tool
Cleaning and checking the valves
Checking the valve springs
Replacing the valve guides
Removing the valve seats
Fitting the valve seats
Fitting the valves
Valve rockers and rods
Preparation for work
Special tool
Removing the rocker cover
6 cylinders
4 cylinders
Fitting the rocker cover
6 cylinders
4 cylinders
Removing the rocker arm
Dismantling
Assembly
Fitting the rocker arm
Adjusting the valve clearance
6 cylinders
4 cylinders
Camshaft and bearing shells
Special tool
Removing the camshaft
Measuring the camshaft axial play
Measuring the camshaft ring bore
Measuring the diameters of the camshaft ring and journals
Measuring the height of the cam
Removing the camshaft ring
Fitting the camshaft ring
Fitting the camshaft
Timing pinions
Special tool
Checking the clearance between the timing pinion teeth
6 cylinders
4 cylinders
Upper intermediate pinion and camshaft timing
Setting the timing for the lower intermediate pinion and balancer shafts (4-cylinder engine)
0125 Injection / Fuel system
Main tank
6 cylinders
4 cylinders
Secondary tank
High pressure pump
Preparation for work
Special tool
Removing the high-pressure pump
Dismantling
6 cylinders
4 cylinders
Assembly
6 cylinders
4 cylinders
Fitting the high-pressure pump
Injection pipes
6 cylinders
4 cylinders
Injector
Preparation for work
Special tool
Removing an injector
Checking and cleaning an injector
Fitting an injector
0130 Lubricating oil system
Oil pump
Special tool
Removing the oil pump
6 cylinders
4 cylinders
Fitting the oil pump
6 cylinders
4 cylinders
Oil cooler and filter
6 cylinders
4 cylinders
Preparation for work
Oil vapour recycling filter
0135 Cooling system
Draining the cooling circuit
Technical specifications
Draining the coolant from the radiator
Draining the coolant present in the engine
Purging the cooling circuit
Ventilation and belts
6 cylinders
4 cylinders
Special tool
Engine water radiator
Water pump
Preparation for work
Thermostat unit
6 cylinders
4 cylinders
Special tool
Checking a thermostat
0140 Exhaust system
Turbocharger
Inspecting the turbocharger
Compressor inspection
Turbine inspection
Removing the turbocharger linkage
Fitting the turbocharger linkage
Removing the turbocharger speed sensor (B226)
Fitting the turbocharger speed sensor (B226)
Exhaust manifold
Preparation for work
Exhaust gas recirculation (6 cylinders)
Preparation for work
Removing the EGR cooler
Removing the EGR cooler support
Fitting the EGR cooler support
Fitting the EGR cooler
Removing the EGR valve
Fitting the EGR valve
Removing the EGR flow meter
Disassembling the EGR flow meter
Assembling the EGR flow meter
Fitting the EGR flow meter
Removing the intake manifold
Fitting the intake manifold
Removing the air intake flap actuator M057
Fitting the air intake flap actuator M057
Exhaust gas recirculation (4 cylinders)
Preparation for work
Removing the EGR cooler
Removing the EGR cooler support
Fitting the EGR cooler support
Fitting the EGR cooler
Removing the EGR valve
Fitting the EGR valve
Removing the EGR flow meter
Disassembling the EGR flow meter
Assembling the EGR flow meter
Fitting the EGR flow meter
Removing the intake manifold
Fitting the intake manifold
Removing the air intake flap actuator M057
Fitting the air intake flap actuator M057
Checking the pulsed secondary air injection valve
Exhaust device (6 cylinders)
Preparation for work
Exhaust device (4 cylinders)
Preparation for work
0145 Air intake
Air filter
Air cooler
Pre-heater plugs
0150 Engine attachment parts
Electric starting motor
Alternator
6 cylinders
4 cylinders
0155 Engine control
6 cylinders
4 cylinders
Preparation for work
Fitting advice
ECM engine control module
Accelerator pedal
Technical specifications
0165 Exhaust gas aftertreatment
Exhaust filter
Dismantling
Inspection
Assembly
02 Gearbox / Clutch / Universal drive shaft
0202 Complete component
Overview of the gearbox
Coupling the gearbox to the engine
Coupling the gearbox to the rear axle
Preparation for work
Special tool
0210 Oscillation damper
Transport damper
Preparation for work
0218 Clutch control
Clutch pedal
Technical specifications
0228 Reverser control
Clutchless reverser lever
0230 Mechanical gearbox
Gearbox input shaft seal
Preparation for work
Special tool
Technical specifications
Technical specifications
Technical specifications
Preparation for work
Special tool
Disassembling the gearbox
Assembling the gearbox
Adjusting the gearbox output shaft play
Adjusting the output shaft towards the bevel gear
Adjusting the power take-off output shaft
0232 Hydraulical gearbox
Hydraulic module
Technical specifications
Hydraulic module cover
Technical specifications for the cover
Special tools
Preparation for work
Removing the hydraulic module
Fitting the hydraulic module
Gearbox hoses
Removing the pipes
Fitting the hoses
0238 Gearbox control
Adjustment unit
Technical specifications
Special tools
Preparation for work
Removing the adjustment unit
Fitting the adjustment unit
Valve block
Technical specifications
Removing the valve block
Removing the external components of the valve block
Fitting the external components of the valve blocks
Fitting the valve block
Control module
Technical specifications
Preparation for work
Disassembling the control module
Reassembling the control module
Control unit
Technical specifications
Preparation for work
Removing the control unit
Removing the external components of the control unit
Fitting the external components of the control unit
Removing the pressure filter
Fitting the pressure filter
Fitting the control unit
Sensors on the gearbox
Technical specifications
Removing the sensors
Fitting the sensors
Wiring harness
Technical specifications
Removing the wiring harness
Fitting the wiring harness
0240 Rear axle housing
Axle tubes
Preparation for work
Axle tube GPA 22 and GPA 22+
Preparation for work
Axle tube GPA 23 and GPA 23+
Preparation for work
Tubes connecting the gearbox housing to the rear axle
Preparation for work
Special tool
0248 Rear axle control
Rear axle sensors
0242 Differential
Drive pinion
Technical specifications
Preparation for work
Auxiliary tool
Removing the drive pinion
Adjusting the conical distance
Fitting the drive pinion
Adjusting the preload of the drive pinion bearings
Differential
Preparation for work
Special tool
Dismantling
Assembly
Calibrating the differential
Checking and adjusting the clearance between the teeth
Checking and adjusting the reach of the teeth
Differential lock sealing check
0252 Electro-hydraulical front axle drive
Four-wheel-drive shaft
Technical specifications
Special tool
Setting the roller bearing preload p
Four-wheel drive clutch
Preparation for work
Auxiliary tool
Removing the four-wheel drive clutch
Disassembling the four-wheel drive clutch
Assembling the four-wheel drive clutch
Adjusting the four-wheel drive clutch
Fitting the four-wheel drive clutch
Adjusting the four-wheel drive clutch shaft
0260 Universal drive shaft
Transmission shaft
Preparation for work
03 Chassis
0325 Front steering drive axle
Identifying the front axle
Front axle (type 2025)
Preparation for work
Coupling the chassis to the front axle
Preparation for work
Sensor (type 2025, 2025 SI, 2029)
Technical specifications
Special tool
Adjusting the steering angle sensor
Calibrating the guidance system
Wheel hubs and reducer (type 2025)
Preparation for work
Special tool
Disassembly
Assembly
Wheel pivots (type 2025)
Preparation for work
Special tool
Assembly
Bevel gear and differential (type 2025)
Preparation for work
Special tool
Dismantling
Adjustment
Adjusting the differential roller bearing preload
Miscellaneous checks (type 2025)
Checking the play in the front axle bearings (type 2025)
Checking the play in the front axle pivots and ball joints (type 2025)
Procedure for checking the play in the front axle steering tie-rods (type 2025)
Procedure for checking the play in the front axle steering ball joints (type 2025)
Procedure for checking the play in the front axle wheel pivot ball joints (type 2025).
0325 Front steering drive axle
Identifying the front axle
Front axle (type 2025 SI)
Preparation for work
Coupling the chassis to the front axle
Preparation for work
Sensor (type 2025, 2025 SI, 2029)
Technical specifications
Special tool
Adjusting the steering angle sensor
Calibrating the guidance system
Wheel hubs and reducer (type 2025 SI)
Preparation for work
Special tool
Wheel pivots (type 2025 SI)
Preparation for work
Special tool
Dismantling
Assembly
Universal drive shaft and wheel pivot support (type 2025 SI)
Preparation for work
Special tool
Dismantling
Assembly
Upper suspension arms (type 2025 SI)
Preparation for work
Lower suspension arms (type 2025 SI)
Preparation for work
Torsion bars (type 2025 SI)
Preparation for work
Adjustment
Differential (type 2025 SI)
Preparation for work
Special tool
Dismantling
Assembly
Adjustment
Checking the contact imprint of the differential teeth
Bevel gear (type 2025 SI)
Preparation for work
Special tool
Miscellaneous checks (type 2025 SI)
Checking the routing of the wiring harnesses and hydraulic hoses (type 2025 SI)
Checking the play in the front axle bearings (type 2025 SI)
Checking the play in the front axle pivots and ball joints (type 2025 SI)
Procedure for checking the play in the front axle steering tie-rods (type 2025 SI)
Procedure for checking the play in the front axle steering ball joints (type 2025 SI)
Procedure for checking the play in the front axle wheel pivot ball joints (type 2025 SI).
0325 Front steering drive axle
Identifying the front axle
Front axle (type 2029)
Preparation for work
Coupling the chassis to the front axle
Preparation for work
Sensor (type 2025, 2025 SI, 2029)
Technical specifications
Special tool
Adjusting the steering angle sensor
Calibrating the guidance system
Wheel hubs and reducer (type 2029)
Preparation for work
Special tool
Wheel pivots (type 2029)
Preparation for work
Special tool
Disassembly
Assembly
Wheel shaft (type 2029)
Preparation for work
Special tool
Differential (type 2029 SI and type 2029)
Type 2029 SI front axle
Type 2029 front axle
Preparation for work
Special tool
Dismantling
Assembly
Adjustment
Checking the contact imprint of the differential teeth
Bevel gear (type 2029 SI and type 2029)
Preparation for work
Special tool
Dismantling
Assembly
Miscellaneous checks (type 2029)
Checking the play in the front axle bearings (type 2029)
Checking the play in the front axle pivots and ball joints (type 2029)
Procedure for checking the play in the front axle steering tie-rods (type 2029)
Procedure for checking the play in the front axle steering ball joints (type 2029)
Procedure for checking the play in the front axle wheel pivot ball joints (type 2029).
0325 Front steering drive axle
Identifying the front axle
Front axle (type 2029 SI)
Preparation for work
Coupling the chassis to the front axle
Preparation for work
Sensor (type 2029 SI)
Technical specifications
Special tool
Adjusting the steering angle sensor
Calibrating the guidance system
Wheel hubs and reducer (type 2029 SI)
Preparation for work
Special tool
Disassembly
Assembly
Wheel pivots (type 2029 SI)
Preparation for work
Special tool
Disassembly
Assembly
Wheel shaft (type 2029 SI)
Preparation for work
Special tool
Disassembly
Assembly
Upper suspension arm (type 2029 SI)
Preparation for work
Special tool
Disassembly
Assembly
Lower suspension arm and torsion bar (type 2029 SI)
Preparation for work
Special tool
Disassembly
Assembly
Adjustment
Differential (type 2029 SI and type 2029)
Type 2029 SI front axle
Type 2029 front axle
Preparation for work
Special tool
Dismantling
Assembly
Adjustment
Checking the contact imprint of the differential teeth
Bevel gear (type 2029 SI and type 2029)
Preparation for work
Special tool
Dismantling
Assembly
Miscellaneous checks (type 2029 SI)
Check the routing of the wiring harnesses and hydraulic hoses (type 2029 SI)
Checking the play in the front axle bearings (type 2029 SI)
Checking the play in the front axle pivots and ball joints (type 2029 SI)
Procedure for checking the play in the front axle steering tie-rods (type 2029 SI)
Procedure for checking the play in the front axle steering ball joints (type 2029 SI)
Procedure for checking the play in the front axle wheel pivot ball joints (type 2029 SI)
04 Brake
0405 Service brake
Service brake
Preparation for work
Special tool
Auxiliary tool
Removing the service brake piston and brake disc
Fitting the service brake piston and brake disc
Bleeding the brake circuit
Special tool
Bleeding the brake circuit
Brake test
Cut-out relay
Replacing the cut-out relay filter 1033
Decompressing the brake circuit
Decompressing the circuit
Recommissioning the circuit
Accumulators and service brake sensors
Removing an accumulator or a service brake sensor.
Fitting an accumulator or a service brake sensor.
High-pressure service brake valve
Removing the high-pressure service brake valve
Fitting the high-pressure service brake valve
Front axle limit valve
0415 Parking brake
Adjusting the mechanism
Preparation for work
Adjusting the control
0420 Trailer air brake
Pneumatic brake valve
Special tool
05 Steering
0505 Steering
Steering unit and column
Preparation for work
Removing the steering gearbox
Fitting the steering unit
Steering actuator
Preparation for work
Adjusting the front axle alignment
Preparation for work
Adjusting the front axle alignment
06 Lift device
0605 Rear power lift
Rear linkage cover
Standard rear linkage cover
Reinforced rear linkage cover
Preparation for work
Removing the linkage cover
0610 Front power lift
Front linkage
0615 Front loader
Front loader frame
07 Hitch
0705 Coupling frame
Ladder hitch
Technical specifications
Forced steering ball joint(s)
Technical specifications
0720 Hitch
Pick-up hitch
Adjusting the pick-up hitch liftlinks
08 Drives
0802 Rear PTO
Rear power take-off
Technical specifications for the two-speed rear power take-off
Technical specifications for the four-speed rear power take-off
Preparation for work
Auxiliary tool
Removing the rear power take-off output shaft
Disassembling the rear power take-off brake
Assembling the rear power take-off brake
Disassembling the rear power take-off output shaft
Assembling the rear power take-off output shaft
Fitting the rear power take-off output shaft
Removing the rear power take-off clutch
Disassembling the rear power take-off clutch
Assembling the rear power take-off clutch
Fitting the rear power take-off clutch
Technical specifications
Preparation for work
Adjustment method
0804 Front PTO
Front power take-off
Front power take-off assembly
Internal parts
Preparation for work
Removing the front power take-off housing
Disassembling the front power take-off housing
Disassembling the front power take-off pump
Assembling the front power take-off pump
Disassembling the front power take-off clutch
Assembling the front power take-off clutch
Assembling the front power take-off housing
Fitting the front power take-off housing
09 Hydraulic system
0910 Pumps
Hydraulic feed pump (2060) and variable capacity hydraulic pump (2005)
Preparation for work
0920 Valves
Auxiliary hydraulic control valve assembly
Hydraulic control valve assembly support
Rear mechanical hydraulic control valves
Rear electrohydraulic control valves
Front electrohydraulic control valves
Preparation for work
10 Electrical / Electronic equipment
1005 Power supply
Electronic circuit breaker
1010 Central electrics
Primary accessories board (PSP)
Fuse and relay board (PRF)
Technical specifications
Auto 5 board (PA5)
Technical specifications
Upper cab board (HDC)
Technical specifications
UBM board
Technical specifications
Electronic adaptation board (PAE)
Technical specifications
1012 Modules / sensors
Auto 5 module
Technical specifications
UBM module
Technical specifications
Radar sensor
Technical specifications
1030 Board computer / Indicators
RHP rear linkage control panel
Technical specifications
DBD instrument panel module
Technical specifications
1035 Operation / Multifunction control lever
CEBIS multifunction armrest
Preparation for work
Cebis multifunction armrest support
Lower trim (Cebis)
Auxiliary tool
Position of the harnesses and mounting collars (Cebis)
Special tool
Position of MFA A100 connectors (Cebis)
MFA multifunction armrest module (A100) (Cebis)
Special tool
Electrohydraulic joystick (C060) (Cebis)
Special tool
CMotion multifunction handle (C001) (Cebis)
Preparation for work
Special tool
Direction lever control (B110) (Cebis)
Special tool
Hand accelerator control (B154) (Cebis)
Special tool
Control for the control valves (B341, B342, B343 and B344) (Cebis)
Preparation for work
Special tool
Dismantling
Assembly
Rear (R052) and front (R053) linkage position setting potentiometers (Cebis)
Special tool
For the rear linkage position setting potentiometer (R052).
For the front linkage position setting potentiometer (R053).
Front (S113) and rear (S114) power take-off on/off switch (Cebis)
Special tool
Cebis control panel
Special tool
Panel for switches S001, S094, S172, S178, S179, S180, S188, S189, S190, S191, S195, S229, S259 and S260 (Cebis)
Special tool
12 Cab / Operator’s platform
1205 Cab suspension
Cab mount
Preparation for work
Cab suspension
Preparation for work
1210 Cab
Complete cab
Special tool
Right-hand side of cab
Left-hand side of cab
Right-hand side of cab
Left-hand side of cab
Cab roof
Technical specifications
Removing the roof canopy
Removing the cab roof
Fitting the cab roof
Fitting the roof canopy
Windscreen
Technical specifications
Preparation for work
Auxiliary tool
Special tool
Rear hatch
Technical specifications
Preparation for work
Left-hand door
Preparation for work
Right-hand door
Preparation for work
Front wiper
Technical specifications
Rear screen wiper
Technical specifications
Cab front lower trim
Cab lower left-hand trim
Cab lower right-hand trim (CEBIS)
Steering column trim
1230 Seat
Grammer® seat
Technical specifications
Grammer® seat frame and upholstery
Technical specifications
Backrest angle adjustment handle
Control trim
Seat height adjustment handle
Seat suspension firmness adjustment lever
Ventilation and air conditioning/heating button
Lumbar pneumatic adjustment buttons
Backrest upholstery
Seat base upholstery
Head restraint
Headrest guide
M043 seat ventilation motor
M044 lumbar support compressor
Back rest adjustment
Backrest
Presence system flexible plate
Seat base angle adjustment plate
Presence sensor Z005
Seat base depth adjustment plate
Grammer® seat suspension
Technical specifications
Shock absorber
Longitudinal damper locking
Driver’s seat compressor M008
Comfort unit
Air spring
Active seaegulation module A160
Air tank
Air distributor
Sears® seat
Technical specifications
Sears® seat frame and upholstery
Technical specifications
Seat height adjustment button
Seat belt
Backrest upholstery
Lumbar pneumatic adjustment button
M044 lumbar support compressor
Backrest angle adjustment handle
Backrest
Seat base depth adjustment plate
Seat base depth adjustment handle
Seat direction adjustment lever
Seat base angle adjustment handle
Sears® seat suspension
Technical specifications
Air reservoir
M008 driver’s seat compressor
A160 active seat regulation module
Air spring
1235 Cab heater
Heating radiator
Teical specifications
Special tool
1240 Air condition
Air conditioning – General informat Preparation for work
Special tool
Drain the refrigerant fluid
Filling with refrigerant fluid
Flushing the air conditioning
Dehydrator filter
Condenser
Compressor
Special tool
Evaporator – Expansion valve
Technical specifications
80 Various components / Machine body
8005 Frame / Trough
Rear side member
Preparation for work
8025 Panellings / Hoods
Engine bonnet
Side panels
Engine bonnet grilles
Preparation for work
8030 Mud guards
Front wings
Adjustment table
Preparation for work
Special tool
Rear wings
8035 Ballast / Additional weight
Attaching t