Claas Axion 900 (A23) Tractors Repair Manual EN

File List:

00 0289 086 0.pdf
00 1144 527 X.pdf
ZF-Tractor Transmission ECCOM 3.0 – Repair Level III.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 1144 527 X.pdf:

AXION 950-920
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
Screwed connectors with cutting rings on the hydraulic pipes
Progressive ring bolt connectors on hydraulic pipes
Double flare unions screwed onto the hydraulic pipes
Flexible hydraulic hoses
Pipe routing
Advice for economical repairs
Torque settings
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 screw connections and air conditioning screw connections with sealing cone and DIN 3865 O-ring
Tightening torques for DIN 3901 threading hydraulic flanges
Tightening torques for ISO 6149-2/ISO 11926-2 (3) adjustable hydraulic screw connections
Tightening torques for hydraulic swivel screw connections
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
Introduction
General notes
General features
Tightening torques
Complete engine
Special tool
Chassis – engine – gearbox coupling
0110 Engine housing
Stiffener panel
Preparation for work
Preparation for work
Special tool
Auxiliary tool
Centrifuge oil vapour filter
Preparation for work
0115 Engine unit
Dimensional specifications
General engine service
Repairing the cylinder block
Checks and measurements of the liners
Replacing the liners
Special tool
Assembly and checking clearance
Crankshaft
Procedure for selecting connecting rod and bearing half-shells
Measuring the journals and crank pins
Defining the diameter class of the housings for the bearing half-shells on the engine block
Selecting the bearing and connecting rod shells
Definition of the diameter class of journals and crank pins (with nominal or standard diameter)
Selecting the colour of the bearing half-shells (nominal or standard diameter journals)
Selecting the colour of the bearing half-shells (journals modified to – 0.127 mm)
Selecting the colour of the connecting rod half-shells (nominal or standard diameter crank pins)
Selecting the colour of the connecting rod bearing half-shells (modified crank pins to – 0.127 mm)
Replacing the control pinions for the timing and the oil pump
Fitting the crankshaft
Fitting the bearing half-shells
Checking the crankshaft lateral play
Crankshaft bearing seal
Preparation for work
Special tool
Removing the crankshaft rear bearing seal
Fitting the crankshaft rear bearing seal
Connecting rod/piston assembly
Dismantling
Pairing the shaft and the piston
Checking the piston
Piston rings
Connecting rods
Refitting the connecting rod/piston assembly
Fitting the piston rings
Fitting the connecting rod and piston into the cylinder
Checking the piston clearance
Checking the play of the crank pins
0120 Cylinder head / Valves / Idler gear
Dimensional specifications
Valves – Cylinder head
Camshaft – Rocker arms
Timing pinions
Single intermediate pinion shaft
Simple intermediate pinion
Double intermediate pinion
Camshaft – Shell – Camshaft housing (metrology)
Special tool
Removing the camshaft rings
Fitting the camshaft rings
Checking the cam lift
Checking the runout
Checking the play between the camshaft and the cylinder head
Setting the play between timing pinion teeth
Preparation for work
Special tool
Adjusting the clearance between the teeth on the high pressure pump
Adjusting the clearance between the teeth on the intermediate pinion
Setting the timing
Preparation for work
Special tool
Setting the timing
Fitting the camshaft timing tool
Fitting the crankshaft timing tool
Fitting the timing tool for the sensor B054 target
Removing the timing setting tools
Cylinder head
Preparation for work
Special tool
For tractors equipped with pneumatic brakes
For tractors equipped with pneumatic brakes
Overhauling the cylinder head
Removing the valves
Cleaning and checking the valves
Checking the support surfaces of the cylinder head on the cylinder group
Replacing the valve guides
Replacement – Reboring the valve seats
For tractors equipped with pneumatic brakes
For tractors equipped with pneumatic brakes
Adjusting the valve clearance
0125 Injection – / Fuel system
Main fuel tank
Special tool
Secondary fuel tank
High pressure pump
Removing the high pressure pump
Fitting the high pressure pump
Removing the supply pump
Fitting the supply pump
Removing the Y489 fuel pressure solenoid valve
Fitting the Y489 fuel pressure solenoid valve
Injector
Preparation for work
Special tool
Removing an injector
Auxiliary tool
Fitting an injector
Removing all injectors
Fitting all of the injectors
Common rail
0130 Lubricating oil system
Oil pump
Oil pressure regulation valve
0135 Cooling system
Draining the coolant
Radiator
Thermostat and casing
Auxiliary tool
0140 Exhaust system
Exhaust device
Checking
Cleaning
Turbocharger
0145 Air intake
Air filter
Air hose support
Intake manifold
0150 Engine attachment parts
Alternator G002
0155 Engine control
Engine sensors (B043, B044, B045, B053, B054, B048, B364, C077, C078)
Fitting advice
ECM A015 engine management module
Engine control B231
0165 Exhaust gas aftertreatment
Catalytic converter
Urea tank
AdBlue® gauge
Special tool
02 Gearbox / Clutch / Universal drive shaft
0202 Complete component
Overview of the gearbox
Preparation for work
Special tool
Engine – gearbox coupling
Gearbox – rear axle coupling
Preparation for work
0210 Oscillation damper
Transport damper
Preparation for work
0218 Clutch conrol
Clutch pedal
Technical specifications
0222 Hydraulical reverser
Brake “BG”
Preparation for work
Special tool
Dismantling
Assembly
Adjusting the de-clutching play
Adjusting the clutch KV using shims
Clutch “KR”
Special tool
Dismantling
Assembly
Adjusting the de-clutching play
Clutch “KV”
Preparation for work
Special tool
Dismantling
Assembly
Adjusting the de-clutching play
0228 Reverser control
Clutchless reverser lever
0230 Mechanical gearbox
Primary line
Preparation for work
Special tool
Removing the input shaft
Intermediate housing
Preparation for work
Special tool
Summing mechanism
Preparation for work
Special tool
Dismantling
Assembly
Adjustingching play of clutch K1
Adjusting the de-clutching play of clutch K2
Secondary line
Special tool
Dismantling
Assembly
Adjusting the play of the output shaft
Adjusting the rotation torque of the counter shaft
Adjusting the intermediate pinion play
0232 Hydraulical gearbox
Hydrostatic module
Preparation for work
Special tool
0238 Gearbox control
Gearbox sensors
Preparation for work
System control unit
Special tool
Disassembly
Assembly
Clutch control unit
Special tool
Dismantling
Assembly
0240 Rear axle housing
Wheel hub
Rear axle tube GPA 37
Preparation for work
Special tool
For tractors equipped with pneumatic brakes
Disassembly
For the left-hand axle tube
To remove the planet gears
Assembly
Auxiliary tool
Auxiliary tool
For the left-hand axle tube
Fitting the axle tube seal
For tractors equipped with pneumatic brakes
Rear axle tube GPA 36
Preparation for work
Special tool
For tractors equipped with pneumatic brakes
Disassembly
For the left-hand axle tube
For the left-hand axle tube
Assembly
For the left-hand axle tube
For the left-hand axle tube
For tractors equipped with pneumatic brakes
For tractors equipped with pneumatic brakes
Fitting the axle tube seal
For tractors equipped with a smooth shaft
0242 Differential
Drive pinion
Preparation for work
Special tools
Removing the transfer case
Removing the drive pinion
Adjusting the drive pinion’s conical distance
Preloading the drive pinion bearings
Checking the drive pinion drag torque
Fitting the drive pinion
Fitting the transfer case
Differential
Preparation for work
Removing the differential
Adjusting the clearance between teeth on the crown gear
Setting the differential bearing preload
Shim setting checks
Fitting the differential
0248 Rear axle control
Rear axle sensors
Preparation for work
0252 Electro-hydraulical front axle drive
Four wheel drive shaft
Special tool
Setting the c bearing preload
Front axle clutch
Preparation for work
Special tool
Removing the front axle clutch
Disassembling the front axle clutch
Auxiliary tool
Assembling the front axle clutch
Adjusting the play b
Fitting the front axle clutch
Removing the inlet ring
Auxiliary tool
Fitting the inlet ring
Auxiliary tool
0255 Gearbox cooling system
Booster pump 2084
Cooler circuit
0260 Universal drive shaft
Transmission shaft
Preparation for work
03 Chassis
0325 Driven steering axle, front
Decompressing the front axle suspension circuit
Decompressing the circuit
Recommissioning the circuit
Complete front axle
Preparation for work
B117 steering angle sensor
Preparation for work
Disassembly
Assembly
Wheel pivots
Preparation for work
Disassembly
Assembly
Wheel and reducer hubs
Preparation for work
Special tool
Disassembly
Assembly
Drive pinion
Preparation for work
Auxiliary tool
Special tool
Disassembly
Adjustment
Differential
Preparation for work
Special tool
Disassembly
Assembly
Adjustment
04 Brake
0405 Service brake
Service brake
Preparation for work
Auxiliary tool
Removing the service brake piston
Fitting the service brake piston
Adjusting the service brake piston play compensation system
Service brake sealing test
Bleeding the brake circuit
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
Service brake pressure accumulator
Front and rear wheels
Rear left- and right-hand wheels
High pressure service brake valve
Removing the high pressure service brake valve
Refitting the high pressure service brake valve
0415 Parking brake
Handbrake control
Adjusting the handbrake clearance
Parking brake mechanism
Parking brake mechanism control
Preparation for work
Adjusting the brake release play
For tractors equipped with pneumatic brakes
For tractors equipped with pneumatic brakes
0420 Trailer air brake
Single-cylinder compressor
05 Steering
0505 Steering
Steering unit – Steering unit rotary distributor 6009
Special tool
Steering cylinder 3023
Preparation for work
Disassembly
Assembly
Emergency steering block
Emergency steering pump 2045
Preparation for work
Adjusting the front axle alignment
Preparation for work
Adjusting the front axle alignment
Steering column
06 Lift device
0605 Rear power lift
Rear linkage spool valve
Rear power lift left B335 and right B336 force sensors
Linkage arms
0610 Front power lift
Front linkage
Preparation for work
Front power lift hydraulics
07 Hitching device
0705 Coupling frame
Ladder hitch
08 Drives
0802 Rear PTO
Rear power take-off
Preparation for work
Disassembly
Output shaft timing
Input shaft timing
0804 Front PTO
Front power take-off
Preparation for work
09 Hydraulic system
0910 Pumps
Booster pump 2060
Preparation for work
Variable capacity hydraulic pump 220 l/min 2005
Preparation for work
Variable capacity hydraulic pump 150 l/min 2005
Preparation for work
0920 Valves
Feed plate of the left-hand cover of the booster pump
Special tool
Priority valve on 220 l/min circuit
Priority valve on 150 l/min circuit
Feed plate for the variable capacity pump on the 220 l/min circuit
Preparation for work
Special tool
For tractors equipped with pneumatic brakes
For tractors equipped with pneumatic brakes
Feed plate for the variable capacity pump on the 150 l/min circuit
Preparation for work
Special tool
Rear auxiliary control valves
Front auxiliary control valves
10 Electrical / Electronic equipment
1005 Power supply
Electronic circuit breaker
12/24 volt converter
1010 Central electrics
Primary accessories board (PSP)
Fuse and relay board (PRF)
Auto 5 board (PA5)
Upper cab board (HDC)
UBM board
Electronic adaptation board (EAB)
1012 Modules / sensors
Auto 5 module
UBM module
1035 Operation / Multifunction control lever
Cebis multifunction armrest
Preparation for work
Lower trim (Cebis)
Auxiliary tool
Position of the harnesses and mounting collars (Cebis)
Special tool
Position of MFA A100 connectors (Cebis)
MFA A100 multifunction armrest module (Cebis)
Special tool
C060 electrohydraulic joystick (Cebis)
Special tool
CMotion C001 multifunction handle (Cebis)
Preparation for work
Special tool
B110 direction lever control (Cebis)
Special tool
B154 hand accelerator control (Cebis)
Special tool
Control valve B341, B342, B343 and B344 controls (Cebis)
Preparation for work
Special tool
Disassembling
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
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
Windscreen
Special tool
Cab front lower trim
Cab lower left-hand trim
Cab lower right-hand trim
Steering column trim
1230 Seat
Grammer® seat
Sears® seat
1235 Cab heater
Radiator
Special tool
1240 Air condition
Air conditioning – General information
Preparation for work
Drain the refrigerant fluid
Filling with refrigerant fluid
ushing the air conditioning
Special tool
Dehydrator filter
Condenser
Compressor
Evaporator – Expansion valve
80 Various components / Machine body
8025 Panellings / Hoods
Engine bonnet
Removing the engine bonnet
Fitting the engine bonnet
Removing the engine bonnet support
In front of the engine bonnet support
Behind the engine bonnet support
Fitting the engine bonnet support
Behind the engine bonnet support
In front of the engine bonnet support

ZF-Tractor Transmission ECCOM 3.0 – Repair Level III.pdf:

ZF – TRACTOR TRANSMISSION ECCOM 3.0 Repair Level III
Contents
Conversion table
Denomination of standard dimensions
Tightening torques for screws
Special tools
Commercial tools
1. Speed sensor, speed transmitter, pressure sensor, induktive sensor and pump
2. Hydraulic control unit (clutch control block)
3. Control unit
4. Separate central shaft and clutch housing from intermediate housing
5. Spur gear, planetary drive P1/P2/P3
5.1 Planetary drive P1
5.2 Planetary drive P2
5.3 Planetary drive P3
6. Clutch K1/K2
7. Clutch K3/K4 and planetary drive P4
8. Brake BG
9. Clutch KR
10. Clutch KV
11. Intermediate gear
12. Input
13. Output
14. Hydrostatic unit and wiring harness
15. Output
16. Input
17. Intermediate gear
18. Clutch KV and central shaft
19. Clutch KR
20. Brake BG and bearing clearance clutch KV/KR
21. Clutch K3/K4 and planetary drive P4
22. Clutch K1/K2
23. Insert planetary drive P3/P2/P1, splined tube and preassembled components into the intermediate housing
23.1 Planetary drive P3
23.2 Planetary drive P2
23.3. Planetary drive P1
23.4 Insert splined tube and preassembled components into the intermediate housing
24. Wiring harness and hydrostatic unit
25. Housing and central shaft
26. Hydrostatic control unit (clutch control block)
27. Control unit
28. Pump, speed sensor, speed transmitterand inductive sensor
29. Closing components
Sans titre