Claas Atos 240-220 (A78) Tractors Repair Manual EN

File List:

00 1157 719 3.pdf

00 1157 719 3.pdf:

ATOS 350-330ATOS 240-220
Table of contents
CCN (CLAAS Component Number)
Introduction
General information
Using this repair manual
Validity of this repair manual
General repair instructions
Safety advice
General instructions
Precautions to be taken when carrying out work
Instructions for lifting
Metal cables – slings
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
General points
Tightening classes
Friction coefficient
Tightening torques
Bolt class 6.8 and 8.8
Bolt class 10.9 and 12.9
Tightening torques for nuts and bolts for electrical connections
Standard tightening torques
Threadlocker products, adhesives, lubrication and sealing products
Threadlocker
Sealing products (for joint faces and unions)
Silicone-based sealant pastes
Lubricants
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
Special tool
Alternator, water pump and A/C compressor belt
Versions equipped with power take-off
Refitting
Separating the engine and transmission
Refitting
Disassembling the engine
Preliminary operations
0110 Engine housing
Tightening torques
Oil sump
Refitting
Timing cover
Special tool
Engine plate
Refitting
Brake compressor support
Refitting
0115 Engine unit
Tightening torques
Crankshaft
Refitting
Alignment of coolant pump and crankshaft pulleys
Alignment
Pistons and cylinder liners
Disassembly
Assembly
Balance weights – 4-cylinder engines (depending on the equipment)
Preparation for work
Refitting
Overhauling the balance weights
Disassembly
Reassembling
Engine pulley
Refitting
Engine flywheel – With hydraulic reverser
Refitting
Flywheel – With mechanical reverser
Refitting
Phonic wheel
Refitting
0120 Cylinder head / Valves / Idler gear
Tightening torques
Cylinder heads
Special tool
Camshaft
Refitting
Refitting
Special tool
Checking the timing setting
Adjusting the air compressor gear backlash
0125 Injection – / Fuel system
Tightening torques
High pressure pump
Preparation for work
Refitting
Common rail
Refitting
Injectors
Refitting
Injector wiring harness
Refitting
Diesel radiator
Fuel tank
Refitting
0130 Lubricating oil system
Tightening torques
Oil pump
Refitting
Adjusting the oil pump gear backlash
Engine oil filter
Refitting
Heat exchanger
Refitting
Blow-By assembly
Refitting
0135 Cooling system
Tightening torques
Radiator assembly
Refitting
Disassembling the radiator assembly
Refitting
Coolant fluid radiator
Intercooler
Viscostatic clutch fan
Preparation for work
Refitting
Coolant pump
Refitting
Coolant manifold
Refitting
Thermostatic valve
Refitting
Checking the thermostat
Expansion chamber
Draining the cooling circuit
Draining the coolant from the radiator
0140 Exhaust system
Tightening torques
Catalytic converter
Preliminary operations
Refitting
Exhaust pipe
Refitting
Exhaust manifold
Refitting
EGR exhaust gas manifold
Refitting
EGR exhaust gas manifold – Removal/Refitting
Disassembly
Reassembly
EGR exhaust gas cooling pipe
Refitting
EGR exhaust gas recirculation pipe
Refitting
EGR valve
Refitting
Turbocharger
Refitting
0145 Air intake
Tightening torques
Air filter container
Refitting
Intake manifold
Refitting
0150 Engine attachment parts
Battery terminal tightening torques
Electric starting motor terminal tightening torques
Alternator tightening torques
Alternators
Belt tensioner support
Belt tensioner
0155 Engine control
Engine wiring harness
Preheating relay
Tightening torques
Engine speed sensor
Disassembly
Assembly
Adjustment
Camshaft phase sensor
Temperature indicator sensors
Fuel pressure and temperature sensors
Fuel pressure sensor
Water in fuel sensor
Air temperature and turbocharging pressure sensor
Engine oil pressure switch
02 Gearbox / Clutch / Universal drive shaft
0202 Complete component
Location of components
Right-hand side
Left-hand side
Top view
Rear view
Engine torsional spring plate
Preliminary operations
Refitting
Cover assembly
Refitting
0215 Mechanical clutch
Clutch bell housing – Removal and fitting operations
Preliminary operations
Clutch bell housing – Removal and refitting operations
Preliminary operations
Refitting
Clutch disc – Removal and refitting operations
Preliminary operations
Refitting
Clutch release bearing – Replacement operations
Preliminary operations
Replacing
0222 Hydraulical reverser
Reverser assembly – Removal and refitting operations
Preliminary operations
Refitting
Reverser assembly – Disassembly and reassembly operations
Cross-sectional view
ATOS 350
Disassembly
Reassembly
Forward gear clutch assembly (ATOS 350)
Cross-sectional view
Forward gear clutch assembly (ATOS 220-340)
Cross-sectional view
Reverse gear clutch assembly (ATOS 350)
Cross-sectional view
Reverse gear clutch assembly (ATOS 220-340)
Cross-sectional view
0230 Mechanical gearbox
Phonic wheel and input shaft assembly – With hydraulic reverser
Preliminary operations
Refitting
Gearbox input shaft (hydraulic reverser)
Cross-sectional view
Preliminary operations
Refitting
Primary shaft – With hydraulic reverser – Removal and fitting operations
Preliminary operations
Primary shaft – Disassembly and assembly operations
Cross-sectional view
Disassembly
Assembly
Secondary shaft – Version with “TRISHIFT” (4-speed) – Removal and refitting operations
Preparation for work
Preliminary operations
Refitting
Secondary shaft – Version with TWINSHIFT – Removal and fitting operations
Preparation for work
Preliminary operations
ATOS 350
ATOS 340-330
Secondary shaft – Version with TWINSHIFT (four-speed) – Removal and fitting operations
Preliminary operations
Fitt econdary shaft – Versions with TWINSHIFT or with TRISHIFT (ATOS 350) – Disassembly and reassembly operations
Cross-sectional view
Disassembly
Assembly
Secondary shaft – Version with TWINSHIFT – Disassembly and reassembly operations
Cross-sectional view
Rear pinion – Four-range version
Rear pinion assembly
Special tool
Preliminary operations
Rear pinion – Two-range version
Rear pinion assembly
Special tool
Preliminary operations
0234 Powershift gearbox
Gearbox and TRISHIFT assembly
Preparation for work
Preliminary operations
Adjusting the TRISHIFT shaft axial play
HML assembly – Removal/Refitting (hydraulic reverser)
Preparation for work
Preliminary operations
Adjusting the TRISHIFT axial play
Refitting
“TRISHIFT” assembly (ATOS 350 with hydraulic reve) – Dsembly and reassembly operations
Preparation for work
Special tool
Disassembly
Reassembly
“A” and “B” clutches (ATOS 350 with hydraulic reverser)
Special tool
Refitting
“C” clutch (ATOS 350 with hydraulic reverser)
Special tool
Refitting
Clutch “A” (ATOS 350 with hydraulic reverser)
Cross-sectional view
Preparation for work
Preliminary operations
Refitting
“TRISHIFT” epicyclic reduction gear (ATOS 350 with hydraulic reverser)
Preparation for work
Refitting
“TRISHIFT” housing (ATOS 350 with hydraulic reverser)
Preliminary operations
Refitting
“TRISHIFT” assembly output shaft (ATOS 350 with hydraulic reverser)
Cross-sectional view
Refitting
Gearbox and reverser assembly – Version with TWINSHIFT – Disassembly and assembly operations
Preliminary operationg
Gea Preparation for work
Preliminary operations
Refitting
TWINSHIFT assembly
Preparation for work
Preliminary operations
Special tool
Refitting
ATOS 340-330
ATOS 350
Adjusting the axial play of epicyclic unit gears
C (ATOS 340-330) / A (ATOS 350) clutch bell housing – Disassembly and reassembly operations
Cross-sectional view
Preparation for work
Special tool
Adjusting the preload for the Belleville washers
“TWINSHIFT” epicyclic reduction gear
Cross-sectional view – Planet carrier assembly
Refitting
TWINSHIFT assembly output shaft (ATOS 350)
Cross-sectional view
TWINSHIFT assembly output shaft (ATOS 340-330)
Cross-sectional view
0238 Gearbox control
Range selector assembly – Removal and fitting operations
Prinary operations
Range selector assembly – Disassembly and assembly operations
Disassembly
Assembly
0240 Rear axle housing
ATOS 350-340-330 axle tubes – Removal and refitting operations
Preparation for work
Preliminary operations
Refitting
ATOS 240-230-220 axle tubes – Removal and refitting operations
Preliminary operations
Refitting
Axle tubes – Disassembly and assembly operations
Preliminary operations
Special tool
Disassembly
Axle tube
Planet carrier
Operation specific to the ATOS 200
Assembly
Planet carrier
Operation specific to the ATOS 200
Axle tube
0242 Differential
Rear differential – Removal and refitting operations
Preliminary operations
Special tool
Refitting
Rear differential – Disassembly and assembly operations
Exploded views
Differential for ATOS 330 340 350
Differential for ATOS 220 230 240
Cross-sectional view
Preparation for work
Disassembly
Additional operation on ATOS 330 340 350
Additional operation on ATOS 330 340 350
Assembly
Adjusting the differential – Bevel gear
Cross-sectional view
Preliminary operations before adjustment
Setting the differential bearing preload
Adjusting the drive pinion positioning
ATOS 350
ATOS 340-330
ATOS 350-340-330
Adjusting the pinion – crown wheel play
0250 Mechanical front axle drive
4-wheel drive shaft in the transmission
Preliminary operations
Refitting
Device for engaging the front axle
Cross-sectional view
Preliminary operations
Preparation for work
Special tool
Front axle engagement device with mechanical parking brake
Preliminary operations
Special tool
Four-wheel drive output shaft – Four-range version
ATOS 340-330
Preliminary operations
ATOS 350
Cross-sectional view
Four-wheel drive output shaft – Two-range version
Cross-sectional view
Preliminary operations
Additional instructions
03 Chassis
0325 Driven steering axle, front
Four-wheel drive front axle – Cross sections
Final drive
Differential – Differential lock
Drive wheel front axle – Adjusting the axial play
Preliminary operations
Four-wheel drive shaft
Removal on ATOS 330-340-350
Removal on ATOS 220-230-240
Separating the front carrier and engine
Preliminary operations
Refitting
Drive wheel front axle
Preliminary operations
Refitting
Front carrier
Preliminary operations
Refitting
Differential assembly – Disassembly and reassembly operation
Preliminary operations
Reassembly
Differential assembly – Removal and refitting operation
Preliminary operations
Refitting
Adjusting the differential
Preparation for work
Preliminary operations
Adjustment
Differential – Disassembly and reassembly operation
Preliminary operations
Disassembly
Reassembly
Bevel gear – Disassembly and assembly operations
Preliminary operations
Disassembly
Assembly
Adjusting the bevel gear
Technical specifications
Preliminary operations
Adjusting the differential preload.
Adjustment procedure
Adjusting the pinion-crown wheel play
Steering actuator – Removal and refitting operations
Refitting
Steering actuators – Disassembly and reassembly operations
Preparation for work
Disassembly
Reassembly
Epicyclic reduction gear – Removal and refitting operation.
Refitting
Epicyclic reduction gear – Disassembly and assembly operation
Cross-sectional view
Preliminary operation
Disassembly
Assembly
Axle shaft and stub axle pivot unit – Removal and refitting operation.
Cross-sectional view
Preliminary operation
Refitting
Adjusting the axle shaft and stub axle pivot unit.
Cross-sectional view
Preliminary operation
Adjusting the bearing preload
Setting the bearing preload
Front axle brake disc – Removal and fitting operations
Preliminary operation
Braking piston for front axle – Disassembly and assembly operations
Preliminary operation
Disassembly
Assembly
0340 Front wheels
Front wheels
Refitting
0345 Rear wheels
Rear wheels
Refitting
04 Brake
0405 Service brake
Bleeding the braking circuit
Brake carrier – Versions without hydraulic parking brake – Removal and refitting operations
Refitting
Brake carrier – Versions without hydraulic parking brake – Disassembly and reassembly operations
Disassembly
Reassembly
Brake pump – Removal and refitting operations
Refitting
0415 Parking brake
Parking brake control cable
Preparation for work
Preliminary operations
Refitting
Adjusting the parking brake
Parking brake pads
Preparation for work
Preliminary operations
Locally produced special tool
Parking brake pads – Four-wheel drive
Preparation for work
Preliminary operations
Locally produced special tool
Refitting
Location of components – Hydraulic parking brake
Parking brake assembly – With hydraulic reverser – Removal and refitting operations
Preparation for work
Preliminary operations
Special tool
Refitting
Parking brake assembly – With hydraulic reverser – Disassembly and assembly operations
Preparation for work
Locally produced special tool
Special tool
Disassembly
Assembly
05 Steering
0505 Steering
Steering wheel
Preparation for work
Steering column with universal joint
Preparation for work
Preliminary operations
Complete steering column
Refitting
Steering gearbox
Refitting
06 Lift device
0605 Rear power lift
ATOS 200 Linkage assembly – Removal and fitting operations
ATOS 300 Linkage assembly – Removal and fitting operations
ATOS 200 Linkage assembly – Disassembly and assembly operations
Disassembly
Assembly
ATOS 300 Rear linkage assembly – Disassembly and assembly operations
Disassembly
Assembly
Detail of procedure for installing the seals
ATOS 300 Rear linkage control valve
ATOS 200 Rear linkage control valve
ATOS 200 Adjusting the mechanical rear linkage
Adjusting the sensitivity of the flow control valve
Adjusting the position control lever
Adjusting the draft control lever
Checking the reaction spring
Checking the position of the internal conrod
ATOS 300 Adjusting the mechanical rear linkage
Adjusting the position control lever
Adjusting the draft control lever
ATOS 200 Mechanical rear linkage control cable
ATOS 300 Mechanical rear linkage control cable
ATOS 200 Mechanical rear linkage control
Adjustment
Position control lever
Draft control lever
Safety stop operation
Operation in floating position
ATOS 300 Mechanical rear linkage control
Adjustment
Position control lever
Draft control lever
Safety stop operation
Operation in floating position
ATOS 200 Mechanical rear linkage control levers
Adjustment
Position control lever
Draft control lever
ATOS 300 Mechanical rear linkage control levers
Adjustment
Position control lever
Draft control lever
Force sensor
Auxiliary linkage cylinders
Rear linkage bushes
3-point hitch
Stabiliser mounting bracket
07 Hitch
Assembling the head and pin for automatic hitching
0705 Coupling frame
Tow hook sled
Refitting
08 Drives
0802 Rear PTO
Rear power take-off – Location of components
Rear power take-off output shaft – Four-speed version – Removal and fitting operations
Preliminary operations
Special tool
Rear power take-off output shaft – Four-speed version – Disassembly and assembly operations
ATOS 350
Disassembly
Assembly
ATOS 340-330
Disassembly
Assembly
Rear power take-off output shaft – Two-speed version – Removal and fitting operations
Preliminary operations
Special tool
Rear power take-off output shaft – Two-speed version – Disassembly and assembly operations
Cross-sectional view
Disassembly
Assembly
Power take-off clutch – Removal and fitting operations
Preliminary operations
Power take-off clutch – Disassembly and assembly operations
Cross-sectional view
Special tool
Disassembly
Assembly
Power take-off final end fitting – Four-speed version
Cross-sectional views
Power take-off final end fitting cross section – ATOS 350
Power take-off final end fitting cross section – ATOS 340-330
Preliminary operations
Preparation for work
Special tool
Disassembly
Versions with removable end fitting
Assembly
Power take-off final end fitting – Two-speed version
Cross-sectional view
Preliminary operations
Preparation for work
Special tool
Disassembly
Assembly
Drive-proportional power take-off final end fitting
Special tool
Disassembly
Assembly
Drive-proportional power take-off engagement device
Preliminary operations
Disassembly
Reassembly
0804 Front PTO
Front power take-off input shaft
Front power take-off – Removal and fitting operations
Refitting
Front power take-off – Disassembly and reassembly operations
Technical specifications
Special tool
Disassembly
Reassembly
Detail of the position of the seal on the front cover
Pump assembly
Solenoid valve block
Brake/clutch group – Removal and fitting operations
Brake/clutch group – Disassembly and assembly operation
Cross-sectional view
Preparation for work
Special tool
Disassembly
Assembly
09 Hydraulic system
0907 Hydraulic oil cooler
Transmission oil radiator
0910 Pumps
Transfer pump – Components
Complete pump assembly – Removal and refitting operations
Preparation for work
60 l ECO pump
Steering gearbox pump
Services pump
Transfer pump
Refitting
Transfer pump
Services pump
Steering gearbox pump
60 l ECO pump
Pump drive pinion without additional pump
Preliminary operations
Disassembly
Assembly
Pump drive pinion with additional pump
Preliminary operations
Disassembly
Assembly
Pump drive – Inner gear
Preliminary operations
Cross-sectional view
Pump drive – Inner gear
Disassembly
Assembly
0920 Valves
Location of components
Reverser control assembly
Services command unit
Replacing the slide valve for the control valve with Kick-Out
Procedure for removing slide valve type 367
Assembling slide valve kit type 372
Auxiliary services rear control valve
Refitting
2-way control valve – Removal and refitting operations
Refitting
Auxiliary hydraulic control valves slide valve
Refitting
2-way control valve – Disassembly and reassembly operations
Disassembly
Reassembly
4-way auxiliary control valve – Removal and refitting operations
Refitting
6-way auxiliary control valve – Removal and refitting operations
Refitting
Additional hydraulic pump solenoid valve block – Removal and fitting operations
Additional hydraulic pump solenoid valve block – Disassembly and assembly operations
Disassembly
Assembly
Transmission solenoid valve block – Removal and fitting operations
Preliminary operations
Transmission solenoid valve block – Disassembly and assembly operations
Preliminary operations
Disassembly
Assembly
Transmission solenoid valve block – Removal and fitting operations
Preliminary operations
Transmission solenoid valve block – Disassembly and assembly operations
Disassembly
Assembly
Hydraulic reverser solenoid valve block – Removal and fitting operations
Preliminary operations
Hydraulic reverser solenoid valve block – Disassembly and assembly operations
Disassembly
Assembly
10 Electrical / Electronic equipment
1005 Power supply
Battery mount
Refitting
Battery mount – Version without front power-take off
Refitting
Refitting
Battery – Version without front power-take off
Refitting
Battery isolating switch
Refitting
1012 Modules / sensors
Engine control module
Transmission ECU
External air temperature sensor
Refitting
Clutch pedal potentiometer
Accelerator pedal position sensor
Refitting
Air conditioning system ECU
Reverser output speed sensor – Removal and refitting operation.
Refitting
1020 Driving lights
Button panels
Light control buttons
Headliner button panel
Refitting
Steering column stalk
Refitting
Cab interior lights
Courtesy light
Courtesy light above console
Refitting
1030 Board computer / Indicators
Instrument panel
Refitting
12 Cab / Operator’s platform
1210 Cab
Working from the rear
Working from the left-hand side of the tractor
Refitting
Cab access steps
Refitting
Driver’s seat
Right-hand console
Refitting
Right hand side cab trim
Refitting
1235 Cab heater
Heater assembly
Refitting
Heater radiator – Version with air conditioner
Refitting
1240 Air condition
Air conditioning assembly – Removal and fitting operations
Motor with fans
Refitting
Air conditioner evaporator
Refitting
Anti-frost sensor
Refitting
Expansion valve
Refitting
Condenser – Removal and refitting operations
Refitting
Condenser – Disassembly and reassembly operations
Disassembly
Reassembly
Dehydrator filter
Refitting
Draining and recharging the air conditioning circuit.
Air conditioning assembly
1290 Accessories
Refitting
80 Various components / Machine body
8025 Panellings / Hoods
Engine bonnet
Refitting
8030 Mud guards
Front wings – Removal and refitting operation.
Refitting