Claas Atos 240 – 220 Stage Iiib T2 (A98) Tractors Repair Manual EN

File List:

00 1166 916 X.pdf

00 1166 916 X.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 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
01 Engine
0102 Complete component
Introduction
General notes
Engine – Removal and fitting operations
Special tool
Air conditioning compressor belt
Disassembling the engine
Preliminary operations
0110 Engine housing
Tightening torques
Oil sump
Timing cover
Special tool
Engine plate
Brake compressor support
Refitting
Rear flange
Refitting
Support brackets
Refitting
0115 Engine unit
Tightening torques
Crankshaft
Refitting
Crankshaft (4-cylinder engine)
Refitting
Alignment of coolant pump and crankshaft pulleys
Special tool
Alignment
Checking the belts
Preliminary operations
Inspection of the belt
Inspection of the fixed rollers, tensioner and pulley
Checking the alignment of the pulleys
Method for adjusting the alignment of the pulleys
Pistons and conrods (three-cylinder engine)
Disassembly
Assembly
Pistons and conrods (four-cylinder engine)
Disassembly
Assembly
Cooling sprayers (3-cylinder engine)
Refitting
Cooling sprayers (4-cylinder engine)
Refitting
Cylinder liners (3-cylinder engine)
Refitting
Cylinder liners (4-cylinder engine)
Refitting
Balance weights – 4-cylinder engines (depending on the equipment)
Preparation for work
Refitting
Overhauling the balance weights
Disassembly
Reassembling
Crankshaft pulley
Refitting
Engine pulley
Refitting
Flywheel with revershift
Flywheel with mechanical reverser
Rear bearing seal
Technical specifications
Preparation for work
Special tool
Removing the rear bearing lip seal
Removing the rear bearing cassette seal
Phonic wheel
Refitting
0120 Cylinder head / Valves / Idler gear
Tightening torques
Cylinder head cover
Refitting
Pushrods
Refitting
Cylinder heads
Special tool
Refitting
Refitting
Camshaft
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
Injectors and common rail (3-cylinder engine)
Refitting
Injectors and common rail (4-cylinder engine)
Refitting
Injector wiring harness (3-cylinder engine)
Refitting
Injector wiring harness (4-cylinder engine)
Refitting
Diesel radiator
Fuel tank
Fuel filter
Diesel pre-filter
Manual fuel pump
Fuel tank
0130 Lubricating oil system
Tightening torques
Oil pump
Refitting
Adjusting the oil pump gear backlash
Engine oil filter
Refitting
Heat exchanger
Refitting
Blow-by oil vapour recirculation pipe
Refitting
Blow-By assembly
Refitting
Blow-by oil vapour pipe
Refitting
0135 Cooling system
Tightening torques
Radiator assembly
Disassembling the radiator assembly
Refitting
Coolant radiator
Intercooler, transmission oil radiator and fuel radiator
Engine air inlet fan
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 exhaust silencer
Exhaust pipe
Refitting
Exhaust manifold (3-cylinder engine)
Refitting
Exhaust manifold (4-cylinder engine)
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 lubrication pipe
Refitting
Turbocharger
Refitting
0145 Air intake
Tightening torques
Air filter
Air filter rigid pipe
Inlet manifold (3-cylinder engine)
Refitting
Inlet manifold (4-cylinder engine)
Refitting
0150 Engine attachment parts
Battery terminal tightening torques
Electric starting motor terminal tightening torques
Alternator tightening torques
Tightening torques
Belt tensioner
Fitting the tensioner support
Fitting the alternator
Fitting and aligning the air conditioning compressor
Calculating the transmission ratio
Fitting the belt tensioner
0155 Engine control
Engine wiring harness
Preheating relay
Tightening torques
Engine speed sensor
Disassembly
Assembly
Adjustment
Camshaft phase sensor
Temperature indicator sensor
Engine oil temperature sensor
Fuel pressure and temperature sensors
Fuel pressure sensor
Water in fuel sensor
Air temperature and turbocharging pressure sensor
Refitting
Engine oil pressure switch
02 Gearbox / Clutch / Universal drive shaft
0202 Complete component
Rear axle – Removal and fitting operations
Location of components
Right-hand side
Left-hand side
Top view
Rear view
Engine torsional spring plate
Preliminary operations
Refitting
0215 Mechanical clutch
Clutch bell housing – Removal and fitting operations
Preliminary operations
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 assembly operations
Cross-sectional view
Disassembly
Assembly
Reverser cover assembly
Disassembly
Assembly
Forward gear clutch assembly
Cross-sectional view
Reverse gear clutch assembly
Cross-sectional view
Reverser shaft
0230 Mechanical gearbox
Gearbox assembly
Preparation for work
Preliminary operations
Gearbox and reverser assembly – Version with TWINSHIFT – Disassembly and assembly operations
Preliminary operations
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 (four-speed) – Removal and fitting operations
Preliminary operations
Secondary shaft – Version with TWINSHIFT – Removal and fitting operations
Preparation for work
Preliminary operations
Secondary sha Cross-sectional view
Disassembly
Assembly
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
TRISHIFT – Removal and fitting operations (hydraulic reverser)
Preparation for work
Preliminary operations
Adjusting the TRISHIFT axial play
TRISHIFT – Disassembly and assembly operations (hydraulic reverser)
Preparation for work
Special tool
Disassembly
Assembly
“C” clutch (hydraulic reverser)
Special tool
A and B clutches (hydraulic reverser)
Special tool
“A” clutch (hydraulic reverser)
Cross-sectional view
Preparation for work
Preliminary operations
TRISHIFT epicyclic reduction gear (hydraulic reverser)
Preparation for work
TRISHIFT housing (hydraulic reverser)
Preliminary operations
TRISHIFT assembly output shaft
Cross-sectional view
Gearbox and TWINSHIFT assembly
Preparation for work
Preliminary operations
Refitting
TWINSHIFT assembly
Preparation for work
Preliminary operations
Special tool
Adjusting the axial play of the epicyclic unit gears
TWINSHIFT assembly – Disassembly and assembly operations
Cross-sectional view
Preparation for work
Special tool
Disassembly
Assembly
Adjusting the preload for the Belleville washers
TWINSHIFT epicyclic ction gea Cross-sectional view – Planet carrier assembly
TWINSHIFT output shaft
Cross-sectional view
Disassembly
Assembly
0238 Gearbox control
Range selector assembly – Removal and fitting operations
Preliminary operations
Range selector assembly – Disassembly and assembly operations
Disassembly
Assembly
Gear lever
0240 Rear axle housing
Right-hand axle tube – Removal and fitting operations
Preliminary operations
Left-hand axle tube – Removal and fitting operations
Preliminary operations
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 roller bearing preload
Adjusting the drive pinion positioning
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
Special tool
Four-wheel drive output shaft – Two-range version
Cross-sectional view
Preliminary operations
Additional instructions
Four-wheel drive output shaft – Four-range version
Preliminary operations
03 Chassis
0325 Front steering drive axle
Four-wheel drive front axle – Cross sections
Final drive
Differential – Differential lock
Front axle axial play
Adjustment
Four-wheel-drive shaft
Front axle (four-wheel drive)
Preliminary operations
Front axle support (four-wheel drive)
Differential assembly – Removal and fitting operations
Differential assembly – Disassembly and assembly operations
Disassembly
Assembly
Differential – Disassembly and assembly operations
Disassembly
Assembly
Adjusting the differential
Preparation for work
Preliminary operations
Adjustment
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 tie-rod
Steering cylinders
Steering cylinders – Disassembly and assembly operation
Disassembly
Assembly
Epicyclic reduction gear – Removal and fitting operations
Epicyclic reduction gear – Disassembly and assembly operation
Cross-sectional view
Preliminary operation
Disassembly
Assembly
Axle half-shaft and stub axle pivot unit
Adjusting the half-shaft and stub axle pivot unit
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
0345 Rear wheels
Rear wheels
04 Brake
0405 Service brake
Brake block
Bleeding the brake circuit
Brake carrier – Removal and fitting operations
Brake carrier – Disassembly and assembly operations
Disassembly
Assembly
Brake pedals
Preliminary operations
Master cylinders
Front axle brake shuttle valve
0415 Parking brake
Parking brake control cable
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
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
0420 Trailer air brake
Air braking compressor
Trailer air braking compressor
Assembly
Compressed air pressure gauge
Air tank
Trailer air brake valves
0425 Trailer hydraulic brake
Trailer hydraulic brake
Auxiliary tool
Bleeding the trailer hydraulic braking circuit
0497 Testing / measuring / adjusting
Post-operation checks on the braking circuit
Check the brake fluid level
Pressure tests on the braking circuit
Brake test
05 Steering
0505 Steering
Steering wheel
Preparation for work
Steering column
Steering unit
06 Lift device
0605 Rear power lift
Rear linkage – Removal and fitting operations
Electrohydraulic rear linkage – Disassembly and assembly operations
Preliminary operations
Preparation for work
Disassembly
Assembly
Mechanical rear linkage – Disassembly and assembly operations
Preliminary operations
Preparation for work
Cross-sectional view
Disassembly
Assembly
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
Mechanical rear linkage control cable
Mechanical rear linkage control
Adjustment
Position control lever
Draft control lever
Safety stop operation
Operation in floating position
Mechanical rear linkage control levers
Adjustment
Position control lever
Draft control lever
Rear linkage bushes
Auxiliary linkage cylinders
Rear linkage spool valve
Force sensor
3-point hitch
Replacing the rear linkage traction force rod
Refitting
Mechanical rear linkage operating faults
Electronic rear linkage operating faults
0610 Front power lift
Front linkage
Front linkage lower support
Front linkage arms
Front linkage hydraulic valve
Front linkage cylinders
07 Hitching device
0705 Coupling frame
Rear hitch
Assembling the head and pin for automatic hitching
Assembly procedure
Stabiliser mounting bracket
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
Power take-off output shaft – Four-speed version – Disassembly and assembly operations
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
Rear power take-off clutch – Removal and fitting 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 view
Power take-off final end fitting cross-section
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
Pump drive pinion – External gear
0804 Front PTO
Front power take-off control shaft
Front power take-off – Removal and fitting operations
Front power take-off – Disassembly and assembly operations
Cross-sectional view
Special tool
Disassembly
Assembly
Fitting detail concerning 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
0915 Hydraulic lines
Transmission oil filter
Noise reducer
0910 Pumps
Transfer pump
Preliminary operations
Steering hydraulic pump
Preliminary operations
Auxiliary hydraulic pump
Additional auxiliary hydraulic 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
Rear auxiliary control valves
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
Hydraulic reverser solenoid valve block – Removal and fitting operations
Hydraulic reverser solenoid valve block – Disassembly and assembly operations
Disassembly
Assembly
TRISHIFT module solenoid valve block
10 Electrical / Electronic equipment
1005 Power supply
Battery support
Alternator
Front lighting
Battery isolating switch
Work lights
Trailer connection
Electric starting motor
Key-operated ignition
1012 Modules / sensors
Air conditioning system ECU
Transmission control module
Transmission ECU
Accelerator pedal – Removal and fitting operation
Accelerator pedal position sensor
Preliminary operations
Accelerator pedal – Disassembly and assembly operation
Disassembly
Assembly
Engine air temperature sensor
Reverser output speed sensor
Starting switch
Engine control module
Clutch pedal
Clutch pedal potentiometer
Steering angle sensor
Reverser pressure monitoring pressure switch
TRISHIFT output speed sensor
Suction circuit switch
Low pressure circuit switch
Rear linkage position sensor
Theoretical ground speed sensor
1020 Driving lights
Button panels
Light control buttons
Headliner button panel
Refitting
Steering column stalk – Removal and fitting operations
Steering column stalk – Disassembly and assembly operations
Disassembly
Assembly
Cab interior lights
Courtesy light
Courtesy light above console
Refitting
Front indicators
1030 Board computer / Indicators
Instrument panel
Refitting
12 Cab / Operator’s platform
1210 Cab
Cab access step
Driver’s seat
Passenger seat
Right-hand console
Right-hand cab trim
Left-hand cab trim
Cab pillar trims
Dashboard trim
Dashboard trim
Sun visor blind
Screen washer reservoir
Wiper motor
Tailgate
Door lock
Rear-view mirrors
1235 Cab heater
Heater assembly
Heating radiator
1240 Air condition
Air conditioning assembly – Removal and fitting operations
Air conditioning assembly – Disassembly and assembly operations
Disassembly
Assembly
Air conditioning condenser
Preliminary operations
Dehydrator filter
Preliminary operations
Evaporator
Expansion valve
Motor with fans
Anti-frost sensor
Air conditioning circuit
Draining
Air conditioning compressor
Preliminary operations
1290 Accessories
80 Various components / Machine body
8025 Panellings / Hoods
Engine bonnet
Engine bonnet – Disassembly and assembly operations
Disassembly
Assembly
Lower engine cover
8030 Mud guards
Front wings