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

File List:

00 1157 720 3.pdf

00 1157 720 3.pdf:

ATOS 350-330ATOS 240-220
CCN (CLAAS COMPONENT NUMBER)
Introduction
General information
Using this repair manual
Validity of this repair manual
General repair instructions
Safety rules
General instructions
Precautions to be taken during the execution of the work
Instructions for lifting
Metal cables, slings
Technical characteristics
Cause of damage
Interchange parts
Diesel engine
Generator
Welding work
Drive belt/drive chains
Conical ring assemblies
Self-locking screws with microencapsulated glue
Thread braking
Tightening ring bearing
Tightening sleeve bearing
Threaded fittings with cutting ring in hydraulic lines
Threaded fittings with progressive ring in hydraulic lines
Biconical threaded fittings in hydraulic conduits
Hydraulic hoses
Hose route
Tips for an economical repair
Tightening torques
Tightening torques
General characteristics
Tightening classes
Coefficient of friction
Tightening torques
Class 6.8 and 8.8 screws
Screws class 10.9 and 12.9
Tightening torques for the screws and nuts of the electrical connections
Standard tightening torques
Thread locking products, adhesives, sealing and lubrication products
Threadlockers
Sealing products (for surfaces and fittings)
Silicone-based sealants
Lubricants
Tightening torques for metric threads according to standard NF E25-030-1 2007-12-01
Tightening torques for hydraulic fittings CLAAS standard CN 020 225
Tightening torques for hydraulic threaded fittings and air conditioning threaded fittings with sealing cone and O-ring DIN 3865
Tightening torques for hydraulic threaded fittings DIN 3901
Tightening torques for adjustable hydraulic threaded fittings ISO 6149-2/ISO 11926-2 (3)
Tightening torques for pivoting hydraulic threaded fittings
Tightening torques for hollow screws DIN 7643
Technical data
Lubricants
01 Engine
0102 Complete component
Introduction
General observations
special tool
Disassembly
Mounting
Water pump generator belt and air conditioner compressor
Disassembly
Versions equipped with power take-off
Mounting
Engine/transmission decoupling
Disassembly
Mounting
Engine disassembly
Preliminary operations
0110 Engine casing
Tightening torques
Disassembly
Mounting
Distribution case
special tool
Disassembly
Mounting
motor plate
Disassembly
Mounting
Brake compressor support
Disassembly
Mounting
0115 Engine propulsion
Tightening torques
Crankshaft
Disassembly
Mounting
Alignment of water pump and crankshaft pulleys
Alignment
Pistons and cylinder liners
Disassembly
Mounting
Balancing masses. Four-cylinder engines (depending on equipment)
Work preparation
Disassembly
Mounting
Checking the balancing masses
Disassembly
Mounting
motor pulley
Disassembly
Mounting
Engine flywheel. With hydraulic shuttle
Disassembly
Mounting
Engine flywheel. With mechanical inverter
Disassembly
Mounting
tone wheel
Disassembly
Mounting
0120 Cylinder head / valves / distributor wheel
Tightening torques
Cylinders
special tool
Disassembly
Mounting
Camshaft
Disassembly
Mounting
Disassembly
Mounting
Distribution
special tool
Synchronization
Distribution draft control
Pneumatic Compressor Gear Set Adjustment
0125 Fuel/injection system
Tightening torques
high pressure pump
Work preparation:
Disassembly
Mounting
common ramp
Disassembly
Mounting
Injectors
Disassembly
Mounting
Wiring harness Injectors
Disassembly
Mounting
Diesel radiator
Fuel tank
Disassembly
Mounting
0130 Lubricating oil system
Tightening torques
Oil pump
Disassembly
Mounting
Oil pump gear clearance adjustment
Engine oil filter
Disassembly
Mounting
Heat exchanger
Disassembly
Mounting
GroupBlow-By
Disassembly
Mounting
0135 Cooling system
Tightening torques
radiator block
Disassembly
Mounting
Decoupling the radiator block
Disassembly
Mounting
coolant radiator
Intercooler
Viscostatic Drive Fan
Work preparation
Disassembly
Mounting
Coolant pump
Disassembly
Mounting
Coolant collector
Disassembly
Mounting
Thermostatic valve
Disassembly
Mounting
Thermostat control
Glass of expansion
Disassembly
Mounting
Draining the cooling circuit
Draining the radiator coolant
0140 Exhaust gas system
Tightening torques
Catalyst
Preliminary operations
Disassembly
Mounting
Exhaust pipe
Disassembly
Mounting
Manifold
Disassembly
Mounting
EGR Exhaust Gas Manifold
Disassembly
Mounting
EGR exhaust gas manifold: disassembly/installation
Disassembly
Assembly
EGR exhaust gas cooling pipe
Disassembly
Mounting
EGR exhaust gas recirculation pipe
Disassembly
Mounting
EGR valve
Disassembly
Mounting
Turbocharger
Disassembly
Mounting
0145 Air suction
Tightening torques
Air filter container
Disassembly
Mounting
Intake manifold
Disassembly
Mounting
0150 Engine coupled parts
Battery terminal tightening torques
Starter motor terminal tightening torques
Alternator tightening torques
Alternators
Disassembly
Mounting
Belt tensioner bracket
Disassembly
Mounting
Belt tensioner
Mounting
0155 Engine adjustment
engine wiring
Disassembly
Mounting
Preheat relay
Disassembly
Mounting
Tightening torques
Engine speed sensor
Disassembly
Mounting
Adjustment
Camshaft phase sensor
Disassembly
Mounting
Temperature indicating sensors
Disassembly
Mounting
Fuel temperature and pressure sensors
Disassembly
Mounting
fuel pressure sensor
Disassembly
Mounting
Water in fuel sensor
Disassembly
Mounting
Boost pressure and air temperature sensor
Disassembly
Mounting
Engine oil pressure switch
Disassembly
Mounting
02 Gears / clutch / cardan shaft
0202 Complete component
Location of components
Right side
Left side
View from above
Back view
Engine flex
Preliminary operations
Disassembly
Mounting
Disassembly
Mounting
0215 Mechanical clutch
Clutch bell. Disassembly and assembly operations
Preliminary operations
Disassembly
Mounting
Clutch bell. Disassembly and assembly operations
Preliminary operations
Disassembly
Mounting
Clutch disc. Disassembly and assembly operations
Preliminary operations
Disassembly
Mounting
Clutch stop bearing: replacement operations
Preliminary operations
Substitution
0222 Hydraulic inversion
Inverter set. Disassembly and assembly operations
Preliminary operations
Disassembly
Mounting
Inverter set. Disassembly and assembly operations
Section View
ATOS 350
Disassembly
Assembly
Forward clutch assembly (ATOS 350)
Section View
Disassembly
Mounting
Forward clutch assembly (ATOS 220-340)
Section View
Disassembly
Mounting
Reverse clutch assembly (ATOS 350)
Section View
Disassembly
Mounting
Reverse clutch assembly (ATOS 220-340)
Section View
Disassembly
Mounting
0230 Mechanical gear
Input shaft and tone wheel assembly. With hydraulic shuttle
Preliminary operations
Disassembly
Mounting
Gearbox primary shaft (hydraulic shuttle)
Section View
Preliminary operations
Disassembly
Mounting
Primary shaft. With hydraulic reverser. Disassembly and assembly operations
Preliminary operations
Disassembly
Mounting
Primary shaft. Disassembly and assembly operations
Section View
Disassembly
Mounting
Secondary axis. Version with TRISHIFT (4 gears). Disassembly and assembly operations
Work preparation
Preliminary operations
Disassembly
Mounting
Secondary axis. Version with TWINSHIFT. Disassembly and assembly operations
Work preparation:
Preliminary operations
Disassembly
ATOS 350
ATOS 340-330
Mounting
Secondary axis. Version with TWINSHIFT (four gears). Disassembly and assembly operations
Preliminary operations
Disassembly
Mounting
Secondary axis. Versions with “TWINSHIFT” or “TRISHIFT” (ATOS 350). Disassembly and assembly operations
Section View
Disassembly
Mounting
Secondary axis. Version with TWINSHIFT. Disassembly and assembly operations
Section View
Disassembly
Mounting
Rear sprocket. Four range version
rear sprocket assembly
special tool
Preliminary operations
Disassembly
Mounting
Rear sprocket. Two range version
rear sprocket assembly
special tool
Preliminary operations
Disassembly
Mounting
0234 Load Switching Gear
GEARBOX ASSY AND TRISHIFT
Work preparation:
Preliminary operations
Disassembly
TRISHIFT shaft axial play adjustment
Mounting
HML Group. Disassembly and assembly (hydraulic reverser)
Work preparation:
Preliminary operations
Disassembly
TRISHIFT axial play adjustmento «TRISHIFT» group (ATOS 350 with hydraulic shuttle). Disassembly and assembly operations
Work preparation
special tool
Disassembly
Assembly
«A» and «B» clutches (ATOS 350 with hydraulic shuttle)
special tool
Disassembly
Mounting
«C» clutch (ATOS 350 with hydraulic shuttle)
special tool
Disassembly
Mounting
«A» clutch (ATOS 350 with hydraulic shuttle)
Section View
Work preparation:
Preliminary operations
Disassembly
Mounting
«TRISHIFT» epicyclic reducer (ATOS 350 with hydraulic reverser)
Work preparation
Disassembly
Mounting
«TRISHIFT» crankcase (ATOS 350 with hydraulic shuttle)
Preliminary operations
Disassembly
Mounting
«TRISHIFT» group drive shaft (ATOS 350 with hydraulic shuttle)
Section View
Disassembly
Mounting
Gearbox and inverter assembly. Version with TWINSHIFT. Disassembly and assembly operations
Mounting
Gearbox and TWINSHIFT assembly
Work preparation
Preliminary operations
Disassembly
Mounting
“TWINSHIFT” set
Work preparation
Preliminary operations
special tool
Disassembly
Mounting
ATOS 340-330
ATOS 350
Adjusting the axial play of the epicyclic group gears
Clutch bell «C» (ATOS 340-330)/«A» (ATOS 350). Disassembly and assembly operations
Section View
Work preparation:
special tool
Disassembly
Mounting
Preload adjustment of conical compression washers
«TWINSHIFT» epicyclic reducer
Section view. satellite carrier assembly
Disassembly
Mounting
TWINSHIFT assembly drive shaft (ATOS 350)
Section View
Disassembly
Mounting
TWINSHIFT Assy Drive Shaft (ATOS 340-330)
Section View
Disassembly
Mounting
0238 Gearbox control/drive
Range selection set. Disassembly and assembly operatiPreliminary operations
Mounting
Range selection set. Disassembly and assembly operations
Disassembly
Mounting
0240 Rear axle housing
ATOS trumpets 350-340-330. Disassembly and assembly operations
Work preparation
Preliminary operations
Disassembly
Mounting
ATOS Trumpets 240-230-220. Disassembly and assembly operations
Preliminary operations
Disassembly
Mounting
Trumpets. Disassembly and assembly operations
Preliminary operations
special tool
Disassembly
Satellite carrier
Specific operation for ATOS 200
Mounting
Satellite carrier
Specific operation for ATOS 200
0242 Differential
Rear differential. Disassembly and assembly operations
Preliminary operations
special tool
Disassembly
Mounting
Rear differential. Disassembly and assembly operations
Exploded views
ATOS differential 330 340 350
ATOS differential 220 230 240
Section View
Work preparation:
Disassembly
Additional operation on ATOS 330 340 350
Additional operation on ATOS 330 340 350
Mounting
Differential adjustment. conical pair
Section View
Operations prior to adjustments
Differential bearing preload adjustment
Adjusting the positioning of the drive pinion
ATOS 350
ATOS 340-330
ATOS 350-340-330
Pinion-crown play adjustment
0250 Mechanical drive of the front axle
Four-wheel drive axle in transmission
Preliminary operations
Disassembly
Mounting
Front axle drive device
Section View
Preliminary operations
Work preparation:
special tool
Disassembly
Mounting
Front axle actuation device with mechanical parking brake
Preliminary operations
special tool
Disassembly
Mounting
Four-wheel drive drive shaft. Four range version
ATOS 340-330
Preliminary operations
Disassembly
Mounting
ATOS 350
Section View
Disassembly
Mounting
Four-wheel drive drive shaft. Two range version
Section View
Preliminary operations
Disassembly
Mounting
Additional information
03 Chassis
0325 Front drive steering axle
Four-wheel drive front axle. Sections
final reducer
Differential. Differential lock
Front axle of drive wheels. Axial play adjustment
Preliminary operations
Four wheel drive axle
Disassembly on ATOS 330-340-350
Disassembly at ATOS 220-230-240
Mounting
Decoupling the front support and the engine
Preliminary operations
Disassembly
Mounting
Front axle drive wheels
Preliminary operations
Disassembly
Mounting
Front support
Preliminary operations
Disassembly
Mounting
Differential set. Disassembly and assembly operations
Preliminary operations
Disassembly
Assembly
Differential set. Disassembly and assembly operations
Preliminary operations
Disassembly
Mounting
Differential adjustment
Work preparation
Preliminary operations
Adjustment
Differential. Disassembly and assembly operations
Preliminary operations
Disassembly
Assembly
Conical pair. Disassembly and assembly operations
Preliminary operations
Disassembly
Mounting
Bevel torque adjustment
Technical characteristics
Preliminary operations
Differential pretension adjustment.
Adjustment procedure
Pinion-crown play adjustment
Directional cilindrum. Disassembly and assembly operations
Disassembly
Mounting
Steering cylinders. Disassembly and assembly operations
Work preparation
Disassembly
Assembly
Epicyclic reducer. Disassembly and assembly operations.
Disassembly
Mounting
Epicyclic reducer. Disassembly and assembly operations
Section View
Preliminary operation
Disassembly
Mounting
Steering pivot and axle shaft housing. Disassembly and assembly operations
Section View
Preliminary operation
Disassembly
Mounting
Adjusting the kingpin housing and axle shaft
Section View
Preliminary operation
Bearing pretension adjustment
Bearing preload adjustment
Front axle brake disc. Disassembly and assembly operations
Preliminary operation
Disassembly
Mounting
Brake piston for front axle. Disassembly and assembly operations
Preliminary operation
Disassembly
Mounting
0340 Front wheels
front wheels
Disassembly
Mounting
0345 Rear wheels
Rear wheels
Disassembly
Mounting
04 Brake
0405 Service brake
Braking system circuit bleeding
Brake support. Versions without hydraulic parking brake. Disassembly and assembly operations
Disassembly
Mounting
Brake support. Versions without hydraulic parking brake. Disassembly and assembly operations
Disassembly
Assembly
Brake pump. Disassembly and assembly operations
Disassembly
Mounting
0415 Parking brake
Parking brake control cable
Work preparation:
Preliminary operations
Disassembly
Mounting
Parking brake adjustment
Parking brake pads
Work preparation:
Preliminary operations
Locally manufactured special tool
Disassembly
Mounting
Parking brake pads. Traction on the four wheels
Work preparation:
Preliminary operations
Locally manufactured special tool
Disassembly
Mounting
Location of components. Hydraulic parking brake
Parking brake assembly. With hydraulic reverser. Disassembly and assembly operations
Work preparation
Preliminary operations
special tool
Disassembly
Mounting
Parking brake assembly. With hydraulic reverser. Disassembly and assembly operations
Work preparation:
Locally manufactured special tool
special tool
Disassembly
Mounting
05 Address
0505 Address
steering wheel
Work preparation:
Disassembly
Mounting
Steering column with cardan joint
Work preparation:
Preliminary operations
Disassembly
Mounting
Complete steering column
Disassembly
Mounting
steering box
Disassembly
Mounting
06 Lifting device
0605 Rear linkage
ATOS 200 Lifting set. Disassembly and assembly operations
Disassembly
Mounting
ATOS 300 Lifting set. Disassembly and assembly operation
Disassembly
Mounting
ATOS 200 Lifting set. Disassembly and assembly operations
Disassembly
Mounting
ATOS 300 Rear Linkage Assembly. Disassembly and assembly operations
Disassembly
Mounting
Detail of the assembly of the sealing gaskets
ATOS 300 Rear Linkage Distributor
Disassembly
Mounting
ATOS 200 Rear Linkage Distributor
Disassembly
Mounting
ATOS 200 Mechanical rear linkage adjustment
Flow control valve sensitivity adjustment
Position control lever adjustment
Force control lever adjustment
Checking the reaction spring
Checking the position of the inner connecting rod
ATOS 300 Mechanical rear linkage adjustment
Position control lever adjustment
Force control lever adjustment
ATOS 200 Mechanical rear linkage control cable
Mounting
ATOS 300 Mechanical rear linkage control cable
Mounting
ATOS 200 Mechanical rear linkage control
Adjustment
Position control lever
Effort control lever
Verification
Safety stop operation
Floating position operation
ATOS 300 Mechanical rear linkage control
Adjustment
Position control lever
Effort control lever
Verification
Safety stop operation
Floating position operation
ATOS 200 Mechanical rear linkage control lever
Adjustment
Position control lever
Effort control lever
ATOS 300 Mechanical rear linkage control levers
Adjustment
Position control lever
Effort control lever
effort sensor
Disassembly
Mounting
Additional lift cylinders
Disassembly
Mounting
Rear linkage bushings
Disassembly
Mounting
Three-point hitch
Disassembly
Mounting
Stabilizer fixing flange
07 Towing device
Head and shaft assembly for automatic hitch
0705 Trailer support
Coupling hook carriage
Disassembly
Mounting
08 Drives
0802 Rear PTO
Rear power take-off. Location of components
Rear PTO drive shaft. Four-speed version. Disassembly and assembly operations
Preliminary operations
special tool
Disassembly
Mounting
Rear PTO drive shaft. Four-speed version. Disassembly and assembly operations
ATOS 350
Disassembly
Mounting
ATOS 340-330
Disassembly
Mounting
Rear PTO drive shaft. Two-speed version. Disassembly and assembly operations
Preliminary operations
special tool
Disassembly
Mounting
Rear PTO drive shaft. Two-speed version. Disassembly and assembly operations
Section View
Disassembly
Mounting
PTO clutch. Disassembly and assembly operations
Preliminary operations
Disassembly
Mounting
PTO clutch. Disassembly and assembly operations
Section View
special tool
Disassembly
Mounting
Final terminal of the power take-off. Four-speed version
Sections
Section of the final terminal of the power take-off. ATOS 350
Section of the final terminal of the power take-off. ATOS 340-330
Preliminary operations
Work preparation:
special tool
Disassembly
Versions with removable terminal shaft
Mounting
Final terminal of the power take-off. Two-speed version
Section View
Preliminary operations
Work preparation:
special tool
Disassembly
Mounting
Final terminal of the power take-off proportional to the advance
special tool
Disassembly
Mounting
Power take-off drive device proportional to advance
Preliminary operations
Disassembly
Assembly
0804 Front power take-off
Front PTO primary shaft
Front power take-off. Disassembly and assembly operations
Disassembly
Mounting
Front power take-off. Disassembly and assembly operations
Technical characteristics
special tool
Disassembly
Assembly
Detail of the assembly of the retainer on the front cover
Pump group
Solenoid valve group
Clutch/brake group. Disassembly and assembly operations
Clutch/brake group. Disassembly and assembly operations
Section View
Work preparation:
special tool
Disassembly
Mounting
09 Hydraulic
0907 Hydraulic oil cooler
Transmission oil cooler
0910 Bombs
Transfer pump. Components
Complete pump block. Disassembly and assembly operations
Work preparation
Disassembly
60 l ECO pump
Steering box pump
Service pump
transfer pump
Mounting
transfer pump
Service pump
Steering box pump
60 l ECO pump
Pump drive pinion without additional pump
Preliminary operations
Disassembly
Mounting
Pump drive pinion with supplementary pump
Preliminary operations
Disassembly
Mounting
Drive of the pumps. inner gear
Preliminary operations
Section View
Drive of the pumps. inner gear
Disassembly
Mounting
0920 Valves
Location of components
Inverter control group
Services Command Group
Replacing the distributor slide with Kick-Out
Disassembly procedure for the type 367 slide
Assembly of the type 372 slide kit
Rear auxiliary services distributor
Disassembly
Mounting
Two-way distributor. Disassembly and assembly operations
Disassembly
Mounting
Auxiliary hydraulic distributor slide
Disassembly
Mounting
Two-way distributor. Disassembly and assembly operations
Disassembly
Assembly
Four-way auxiliary distributor. Disassembly and assembly operations
Disassembly
Mounting
Six-way auxiliary distributor. Disassembly and assembly operations
Disassembly
Mounting
Supplementary hydraulic pump solenoid valve block. Disassembly and assembly operations
Disassembly
Mounting
Supplementary hydraulic pump solenoid valve block. Disassembly and assembly operations
Disassembly
Mounting
Transmission solenoid valve block. Disassembly and assembly operations
Preliminary operations
Disassembly
Mounting
Transmission solenoid valve block. Disassembly and assembly operations
Preliminary operations
Disassembly
Mounting
Transmission solenoid valve block. Disassembly and assembly operations
Preliminary operations
Disassembly
Mounting
Transmission solenoid valve block. Disassembly and assembly operations
Disassembly
Mounting
Hydraulic shuttle solenoid valve block. Disassembly and assembly operations
Preliminary operations
Disassembly
Mounting
Hydraulic shuttle solenoid valve block. Disassembly and assembly operations
Disassembly
Mounting
10 Install. electrical/electronic
1005 Power supply
Battery support tray
Disassembly
Mounting
Battery support tray – Version without front PTO
Disassembly
Mounting
Disassembly
Mounting
Battery – Version without front power take-off
Disassembly
Mounting
Battery disconnect switch
Disassembly
Mounting
1012 Modules / sensors
Engine management module
Disassembly
Mounting
Transmission control unit
Disassembly
Mounting
Outdoor air temperature pr Disassembly
Mounting
utch pedal potentiometer
Disassembly
Mounting
Accelerator pedal position sensor
Disassembly
Mounting
Air conditioning control unit
Disassembly
Mounting
Inverter output speed sensor. Disassembly and assembly operations
Disassembly
Mounting
1020 Advance lighting
Pushbuttons
Disassembly
Headlight control buttons
Ceiling buttons
Mounting
Light control
Disassembly
Mounting
Cabin interior lighting
Disassembly
Cabin illumination light
Cabin illumination light located above the console
Mounting
1030 On-board computer / display devices
Instruments panel
Disassembly
Mounting
12 Driver’s cab/platform
1210 Cabin
Disassembly
In the back
On the left side of the tractor
Mounting
Cab access step
Disassembly
Mounting
Driver’s seat
Disassembly
Mounting
Right terminal
Disassembly
Mounting
Right side cabin trim
Disassembly
Mounting
1235 Cabin heating
Warmer set
Disassembly
Mounting
Heating radiator – Version with air conditioning
Disassembly
Mounting
1240 Air conditioning equipment
Climate control assembly. Disassembly and assembly operations
Disassembly
Mounting
Motor with fan
Disassembly
Mounting
Air conditioning evaporator
Disassembly
Mounting
Antifrost probe
Disassembly
Mounting
Pressure reducer
Disassembly
Mounting
Condenser. Disassembly and assembly operations
Disassembly
Mounting
Condenser. Disassembly and assembly operations
Disassembly
Assembly
Dehydrator filter
Disassembly
Mounting
Emptying and recharging the air conditioning circuit
Climate control assembly
Mounting
1290 Accessories
Cabin mat
Disassembly
Mounting
80 Attached parts, machine casing
8025 Coverings / hoods
engine hood
Disassembly
Mounting
8030 Mudguard
Front fins. Disassembly and assembly operations
Disassembly
Mounting