Claas Avero 240 (561) Combines Repair Manual FR

File List:

00 0288 248 0.pdf
00 0300 635 1.pdf
00 0303 822 2.pdf

00 0288 248 0.pdf:

Perkins 1206F E70TA
Contents
Introduction
General instructions
Validity of the notice
Use of the instructions
Texts and illustrations
Articulated structure in the form of modules/groups
Seek and find
Steering Specifications
Abbreviations
Specialized terminology
General repair instructions
Technical characteristics
Tips for correct repair
Self-locking screws
Liquid screw brake
Steel roller chains
Chain closing link
Conical ring connections
Disassembly
Assembly
Heel pin connections
Disassembly
Assembly
Clamp ring bearing
Disassembly
Assembly
Clamp sleeve bearing
Disassembly
Assembly
Clamping sleeve
Disassembly
Assembly
Clamping sleeve version (1)
Clamping sleeve version (2)
Circlips
Screwed fittings with cutting ring
To screw
Tightness defect of connections screwed by cutting ring
Connections screwed by bicone ring
Hydraulic flexible lines
Hose routing
Treatment of sealing surfaces
Spare parts
Tightening torques
Tightening torques for metric coarse threads
Tightening torques for metric fine pitch threads
Tightening torques for hydraulic screw connections and air conditioning system screw connections with bicone ring and O-ring DIN 3865
Tightening torques for hydraulic connections with cutting ring DIN 3861
Tightening torques for SDS hydraulic screwed sleeve
Tightening torques for hydraulic swivel threaded connections
Tightening torques for hollow screws DIN 7643
Tightening torques for SDE adjustable screwed hydraulic coupling
Tightening torques for brake line screw connections
Tightening torques for tangent screw clamps
Tightening torques for hose clamps with round bolts
CCN explanation
CCN (CLAAS Component Number – CLAAS part number)
Electrical standard
Hydraulic standard
CCN (CLAAS Component Number – CLAAS part number)
Security
General instructions
To respect
Warning pictogram
Signal word
Instructions to avoid accidents and personal injury
Inspection, adjustment and repair work
Engine operation
Suspended loads
Work on tubular pipes and flexible pipes
Work on the Common Rail system
Work on the electrical system
Work on the hydraulic system
Electric welding
Paint work
Works with urea solution
Notes to avoid damage and premature wear
Limits of liability
Shutdown and storage
Instructions to avoid damage to health and the environment
Preventive measures to protect against damage to health and the environment
Disposal of operating consumables, secondary consumables
Notes for working on the diesel engine
Protection against accidents
Cleanliness
Assembly tips
Engine overhaul
Commissioning after engine overhaul
First aid measures
01 Motor
0102 Complete set
Engine characteristics
1206F-E70TA
Engine Description
Engine components
Start the engine manually
Special tool when the engine is removed
Special tool for the engine in mounted position
Start the engine manually in the up position
Start the engine manually in the disassembled position
Place the engine on ignition top dead center
Place the engine on ignition top dead center: remove
0110 Motor housing
Crankcase
Technical characteristics
Technical characteristics
Preparing for work
To set down
Oil pan gasket
Technical characteristics
Preparing for work
Special tool
To set down
Front crankshaft seal
Technical characteristics
Special tool
To set down
Rear crankshaft seal
Technical characteristics
Special tool
To set down
Front protective cover
Technical characteristics
Preparing for work
Special tool
To set down
Flywheel housing
Technical characteristics
Preparing for work
To set down
Front cover
Technical characteristics
Preparing for work
Special tool
To set down
Crankcase air bleeding
Technical characteristics
Disassemble
To assemble
To set down
0115 Powertrain
Piston and connecting rod
Technical characteristics
Special tool
Disassemble
To assemble
To set down
Crankshaft
Technical characteristics
Special tool
Disassemble
To assemble
To set down
Crankshaft main bearing
Technical characteristics
To set down
Crankshaft sprocket
Technical characteristics
To set down
Vibration damper and pulley
Technical characteristics
Preparing for work
Special tool
To set down
Flywheel
Technical characteristics
Preparing for work
To set down
0120 Cylinder head – Valves – Distribution
Upper valve cover
Technical characteristics
To set down
Camshafts
Technical characteristics
To set down
Cylinder head
Technical characteristics
Preparing for work
Special tool
To set down
Rocker arms
Technical characteristics
Special tool
Disassemble
To assemble
To set down
Technical characteristics
To set down
Check the valves
Valve Springs
Technical characteristics
Special tool
To set down
Hydraulic rod
Technical characteristics
To set down
Gear drive
Technical characteristics
Special tool
To set down
Timing gear
Technical characteristics
Special tool
To set down
Intermediate gear (gear drive)
Technical characteristics
Special tool
To set down
0125 Injection system, fuel supply
Fuel feed pump
Technical characteristics
Preparing for work
Special tool
To set down
High pressure pipes and ramp
Technical characteristics
Special tool
To set down
Rail pressure limiter
Technical characteristics
Special tool
To set down
Injectors
Technical characteristics
Preparing for work
Special tool
To set down
Glow plugs
Technical characteristics
Special tool
To set down
High pressure fuel pump
Technical characteristics
Preparing for work
Special tool
Remove the drive gear
Install the drive gear
To set down
Suction control valve
Technical characteristics
Preparing for work
Special tool
To set down
0130 Lubrication system
Piston jet
Technical characteristics
To set down
Oil cooler
Technical characteristics
Preparing for work
Disassemble
To assemble
To set down
Oil filter console
Technical characteristics
To set down
Oil pump
Technical characteristics
Preparing for work
To set down
0135 Cooling system
Cooling liquid
Drain at the radiator
Drain at the engine
Drain below the oil cooler
Clean the coolant circuit
Air conditioning compressor
Technical characteristics
To set down
Coolant pump
Technical characteristics
Preparing for work
To set down
Coolant thermostat
Technical characteristics
To set down
Fan drive
Technical characteristics
To set down
0140 Exhaust device
Exhaust gas cooler
Technical characteristics
To set down
Exhaust gas recirculation
Technical characteristics
Special tool
To set down
Differential pressure sensor and absolute pressure sensor
Technical characteristics
To set down
Magnetic coil-wastegate
Technical characteristics
Preparing for work
To set down
Exhaust back pressure valve
Technical characteristics
Preparing for work
To set down
Exhaust gas recirculation valve
Technical characteristics
To set down
Flexible exhaust pipe
Technical characteristics
Disassemble
To assemble
To set down
Exhaust gas manifold and turbocharger
Technical characteristics
Preparing for work
Special tool
To set down
0145 Air suction
Intake Manifold
Technical characteristics
0150 Engine assembly parts
Technical characteristics
To set down
Generator
Technical characteristics
Preparing for work
Disassemble
To assemble
To set down
0155 Engine controls
Control device
Technical characteristics
Special tool
To set down
Control block mounting bracket
Technical characteristics
To set down
0165 Exhaust gas aftertreatment
Catalyst support arm
Technical characteristics
To set down

00 0303 822 2.pdf:

Repair instructions
Contents
Introduction
General instructions
Validity of the notice
Copyright Notice
Use of the instructions
Texts and illustrations
Plan with module structure
Seek and find
Steering Specifications
Abbreviations
Specialized terminology
General repair instructions
Technical characteristics
General informations
General cleaning instructions
Treatment of sealing surfaces
Tightening torques
Tightening torques for hexagonal or hexagon socket screws/nuts, head without collar or flange (man factory standard M 3059)
Tightening torques for metric ISO threads
Tightening torques for metric fine pitch threads
Tightening torques for screw connections with bicone connection and hydraulic connections with flexible sealing gasket
Tightening torques for hydraulic connections with cutting ring
Tightening torques for hydraulic screwed coupling SDS form B and E
Tightening torques for hydraulic swivel screw connections
Tightening torques for hollow screws (with copper seal)
Tightening torques for hydraulic screwed coupling SDE form H, adjustable
Tightening torques for brake line screw connections
Tightening torques for tangent screw clamps
Tightening torques for hose clamps with round bolts
CCN explanation
CCN (CLAAS Component Number – CLAAS part number)
Electrical standard
Hydraulic standard
CCN (CLAAS Component Number – CLAAS part number)
Security
Foreword
Explanation of symbols
Working environment
Good practices
Personal protective equipment
Power generation applications
Exhaust aftertreatment
Common substances
Hazardous Material
Electrical components
General risks
Work safety assessment
Welding work on a vehicle with an electronically controlled fuel system
01 Motor
0102 Complete set
Engine characteristics
Engine Description
Engine components
Exhaust aftertreatment system
Start the engine manually
Special tool when the engine is removed
Special tool for the engine in mounted position
Start the engine manually in the up position
Start the engine manually in the disassembled position
0105 Engine suspension
0110 Motor housing
Front crankshaft seal (001-023)
Technical characteristics
Special tool
To set down
Rear crankshaft seal (001-024)
Technical characteristics
Preparing for work
Special tool
Clean and check
To set down
Front Gable Cover (001-031)
Technical characteristics
To set down
Rear Gable Cover (001-034)
Technical characteristics
To set down
Flywheel housing (016-006)
Technical characteristics
Special tool
Disassemble
Clean and check
To assemble
To set down
0115 Powertrain
Connecting rod bearing (001-005)
Technical characteristics
To set down
Main bearing (001-006)
Technical characteristics
To set down
Connecting rod (001-014)
Technical characteristics
Piston (001-043)
Technical characteristics
Special tool
Disassemble
To assemble
To set down
Piston injection cooling (001-046)
Technical characteristics
To set down
Crankshaft (001-016)
Technical characteristics
To set down
Crankshaft wear sleeve (001-067)
Technical characteristics
Special tool
To set down
Crankshaft speed ring (001-071)
Technical characteristics
Crankshaft sprocket (001-019)
Technical characteristics
To set down
Vibration damper (001-052)
Technical characteristics
To set down
Flywheel (016-005)
Technical characteristics
Special tool
Clean and check
To set down
Flywheel ring gear (016-008)
Technical characteristics
To set down
0120 Cylinder head – Valves – Distribution
Cylinder head (002-004)
Technical characteristics
Special tool
Disassemble
To assemble
To set down
Cylinder block (001-026)
Technical characteristics
Cylinder block reinforcement plate (001-089)
Technical characteristics
To set down
Rocker arm caliper (002-001)
Technical characteristics
To set down
Camshaft (001-008)
Technical characteristics
Disassemble
To assemble
To set down
Camshaft sprocket (001-012)
Technical characteristics
To set down
Camshaft bushing (001-010)
Technical characteristics
To set down
Cylinder head with valve guide gasket (002-016)
Technical characteristics
Preparing for work
Special tool
Clean and check
To set down
Head gasket (002-021)
Technical characteristics
Clean and check
To set down
Rocker arm (003-008)
Technical characteristics
Disassemble
Clean and check
To assemble
To set down
Rocker cover / valve cover (003-011)
Technical characteristics
Clean and check
To set down
Rocker cover (003-013)
Technical characteristics
Clean and check
To set down
Crankcase vent line (003-018)
Technical characteristics
Clean and check
To set down
Crankcase Air Bleed (Internal) (003-002)
Technical characteristics
To clean
To set down
Cylinder head group (003-004)
Technical characteristics
Special tool
Preliminary activities
Final work
Pusher (004-015)
Technical characteristics
Preparing for work
Special tool
Clean and check
To set down
Pushrods and tubes (004-014)
Technical characteristics
Clean and check
To set down
Camshaft sensor (019-363)
Technical characteristics
Clean and check
To set down
Crankshaft Position Sensor (019-365)
Technical characteristics
Clean and check
To set down
Crankcase Pressure Sensor (019-445)
Technical characteristics
Clean and check
To set down
0125 Injection system, fuel supply
Fuel preheater, electric (005-008)
Technical characteristics
Clean and check
To set down
Fuel Pump Actuator (019-117)
Technical characteristics
To set down
Fuel pump (005-016)
Technical characteristics
Preparing for work
Special tool
Disassemble
Clean and check
To assemble
To set down
High pressure accumulator (ramp) (006-60)
Technical characteristics
Clean and check
To set down
High Pressure Fuel Lines to Rail (006-071)
Technical characteristics
Clean and check
To set down
Pressure limiter (006-061)
Technical characteristics
To set down
Injector (006-026)
Technical characteristics
Special tool
Clean and check
To set down
High pressure feed lines to injectors (006-051)
Technical characteristics
To set down
Fuel line fitting (installed on cylinder head) (006-052)
Technical characteristics
Special tool
Clean and check
To set down
Fuel filter head (006-017)
Technical characteristics
Disassemble
Clean and check
To assemble
To set down
Fuel Filter Head Attachment (006-018)
Technical characteristics
Clean and check
To set down
Fuel Discharge Lines (006-013)
Technical characteristics
Clean and check
To set down
Fuel Supply Lines (006-024)
Technical characteristics
Clean and check
To set down
Rail pressure sensor (019-115)
Technical characteristics
Clean and check
To set down
Intake Manifold Pressure/Temperature Sensor (019-159)
Technical characteristics
To set down
0130 Lubrication system
Lubricating Oil Cooler (007-003)
Technical characteristics
Clean and check
To set down
Oil level gauge (007-009)
Technical characteristics
Calibrate
Oil dipstick tube (007-011)
Technical characteristics
To set down
Lubricating Oil Filter Bypass Valve (007-014)
Technical characteristics
Clean and check
To set down
Lubricating Oil Filter Head (007-015)
Technical characteristics
Clean and check
To set down
Lubricating Oil Filter Head Adapter (007-018)
Technical characteristics
Clean and check
To set down
Engine Oil Preheater (007-001)
Technical characteristics
Clean and check
To set down
Oil Suction Tube (Cylinder Block Mounted) (007-035)
Technical characteristics
Clean and check
To set down
Oil pan (007-025)
Technical characteristics
Preparing for work
Clean and check
To set down
Engine Oil Pressure Regulator (Main Channel) (007-029)
Technical characteristics
Clean and check
To set down
Oil pump (007-031)
Technical characteristics
Clean and check
To set down
Engine Oil Filler Tube (007-065)
Technical characteristics
Clean and check
To set down
Lubricating Oil Lines (007-092)
Technical characteristics
To set down
Turbocharger Oil Supply Line (010-046)
Technical characteristics
Clean and check
To set down
Turbocharger oil drain line (010-045)
Technical characteristics
Clean and check
To set down
Lubricating Oil Level Sensor (019-056)
Technical characteristics
Clean and check
To set down
Engine Oil Pressure Sensor and Switch (019-066)
Technical characteristics
Clean and check
To set down
0135 Cooling system
Coolant thermostat (008-013)
Technical characteristics
To set down
Coolant Air Purge Lines (008-017)
Technical characteristics
To set down
Fan Hub (Belt Drive) (008-036)
Technical characteristics
Disassemble
To assemble
To set down
Spacer and Fan Pulley (008-039)
Technical characteristics
Clean and check
To set down
Fan Belt Tensioner (008-087)
Technical characteristics
Clean and check
To set down
Water pump (008-062)
Technical characteristics
Clean and check
To set down
Turbocharger (010-041)
Technical characteristics
Clean and check
To set down
Inlet fitting (008-082)
Technical characteristics
Preparing for work
Clean and check
To set down
Coolant lines (008-124)
Technical characteristics
Preparing for work
Clean and check
To set down
Coolant Level Sensor (019-017)
Technical characteristics
To set down
Coolant Level Sensor (019-019)
Technical characteristics
Clean and check
To set down
Ambient Air Temperature Sensor (019-134)
Technical characteristics
To set down
0140 Exhaust device
Turbocharger (010-033)
Technical characteristics
Special tool
Clean and check
To set down
Turbocharger thermal protection plate (010-076)
Technical characteristics
Clean and check
To set down
Exhaust Manifold, Dry (011-007)
Technical characteristics
Clean and check
To set down
Exhaust Gas Pressure Sensor Line (011-027)
Technical characteristics
To set down
Thermal protection plate (011-032)
Technical characteristics
Clean and check
To set down
Exhaust Gas Pressure Sensor (019-376)
Technical characteristics
To set down
Turbocharger RPM Sensor (019-390)
Technical characteristics
Preparing for work
Clean and check
To set down
0145 Air suction
Restrictor Actuator (010-140)
Technical characteristics
To set down
Air Intake Fitting (010-080)
Technical characteristics
Special tool
To set down
Air Intake Manifold (010-023)
Technical characteristics
To set down
0150 Engine assembly parts
Auxiliary Drive Cover (009-039)
Technical characteristics
Clean and check
To set down
Alternator (generator) (013-001)
Technical characteristics
To set down
Charging System Alternator Attachment (013-003)
Technical characteristics
Clean and check
To set down
Alternator pulley (013-006)
Technical characteristics
To set down
Starter (013-020)
Technical characteristics
Preparing for work
Clean and check
To set down
0155 Engine controls
Engine Management Module (019-031)
Technical characteristics
To set down
Engine management motor mounting plate
Technical characteristics
To set down
0165 Exhaust gas aftertreatment
Preparing for work
Special tool
Check the urea solution (purity)
Check the urea solution (density)
95 Overview of maintenance parts
9599 Maintenance work
Silencer/catalyst
Technical characteristics
Preparing for work
Remove the SCR catalyst (011-36)
Clean and check the SCR catalyst (011-36)
Install the SCR catalyst (011-36)
Remove the diesel particulate filter (DPF) (011-41)
Clean and check the diesel particulate filter (DPF) (011-41)
Install the diesel particulate filter (DPF) (011-41)
Remove the diesel particulate filter differential pressure sensor lines (011-47)
Clean and check the lines of the diesel particulate filter differential pressure sensor (011-47)
Install the diesel particulate filter differential pressure sensor lines (011-47)
Remove Exhaust Aftertreatment System Inlet and Outlet (011-36)
Clean and check the inlet and outlet of the exhaust gas aftertreatment system (011-36)
Install the inlet and outlet of the exhaust gas aftertreatment system (011-36)
Remove Diesel Oxidation Catalyst (DOC) (011-49)
Disassemble Diesel Oxidation Catalyst (DOC) (011-49)
Clean and Check Diesel Oxidation Catalyst (DOC) (011-49)
Assemble Diesel Oxidation Catalyst (DOC) (011-49)
Install Diesel Oxidation Catalyst (DOC) (011-49)
Remove decomposition reactor tube (011-62)
Clean and check the decomposition reactor tube (011-62)
Install decomposition reactor tube (011-62)
Urea Dosing Unit (011-059)
Technical characteristics
Preparing for work
Remove urea dosing unit (011-059)
Disassemble Urea Dosing Unit (011-059)
Clean and check the urea dosing unit (011-059)
Assemble Urea Dosing Unit (011-059)
Install the urea dosing unit (011-059)
Urea pump (011-058)
Technical characteristics
Preparing for work
Remove urea pump (011-058)
Disassemble the urea pump (011-058)
Clean and check the urea pump (011-058)
Assemble the urea pump (011-058)
Install the urea pump (011-058)