Claas Lexion 7700-7400 (C85) Combines Repair Manual EN

File List:

00 0296 400 0.pdf
00 0300 667 6.pdf
00 0302 784 5.pdf
00 0302 851 1.pdf
00 0303 709 0.pdf
00 0305 843 0.pdf
Test protocol LEXION and TUCANO.pdf
Threshing drum reduction gearbox Hydraulic shifting.pdf
Threshing drum reduction gearbox Manual shifting.pdf

00 0296 400 0.pdf:

TERRA TRAC track roller unitGeneration II
Table of contents
Introduction
General information
Validity of manual
Handling of this manual
Texts and figures
Document structure based on subassemblies
Search and find
Directions
Abbreviations
Technical terms
General repair instructions
Technical specifications
Information on economic repairs
Self-locking bolts
Liquid locking compound
Ferrule fittings
Screwing in
Non-tight ferrule connection
Sealing cone fittings
Hydraulic hose lines
Hose placement
Spare parts
Torque settings
Tightening torques for metric standard threads
Tightening torque for metric fine threads
Tightening torques for hydraulic screw fittings with ferrule DIN 3861
Tightening torques for hydraulic screw fittings and air conditioner screw fittings with O-ring and sealing cone DIN 3865
Tightening torques for SDS hydraulic male connectors
Tightening torques for direction-adjustable SDE hydraulic male connectors
Tightening torques for hydraulic swing fittings
Tightening torques for hollow screws DIN 7643
Tightening torques for brake line screw fittings
CCN explanation
CCN (CLAAS Component Number)
Electric systems standard
Hydraulic system standard
CCN (CLAAS Component Number)
General information
Of special importance
Identification of warning and danger signs
General safety and accident prevention regulations
First aid measures
Risk of injury from hydraulic fluid
Leaving the machine
Putting the machine out of operation
Jacking up the machine
Adjustment and maintenance operations
Hydraulic accumulators
Battery isolating switch
Welding work
03 Chassis
0355 Track roller unit
Overview of TERRA TRAC track roller unit
Removal/Installation
Overview of TERRA TRAC track roller unit
Removal/Installation
TERRA TRAC track roller unit rubber tracks
Work preparation
Installation
TERRA TRAC track roller unit rubber tracks
Work preparation
Special tool
Installation
TERRA TRAC track roller unit support wheels
Work preparation
Disassembly
Installation
TERRA TRAC track roller unit support wheels
Work preparation
Disassembly
Installation
TERRA TRAC track roller unit bearing unit
Work preparation
Installation
TERRA TRAC track roller unit rocker arm
Work preparation
Disassembly
Installation
TERRA TRAC track roller unit gearbox
Work preparation
Special tool
Disassembly
Installation
Rubber track tension hydraulic cylinder (3071)
Work preparation
Special tool
Removing the hydraulic cylinder
Installing the hydraulic cylinder

00 0300 667 6.pdf:

Mercedes-Benz OM470LAMercedes-Benz OM471LAMercedes-Benz OM473LA
Table of contents
Introduction
General information
Validity of manual
Using the manual
Text and figures
Document structure based on sub-assemblies
Search and find
Directions
Abbreviations
Technical terms
General repair instructions
Technical specifications
Information on technically correct repairs
Self-locking bolts
Liquid locking compound
Steel roller chains
Tensioning
Chain connector
Chain connector type E with spring
Chain connector type G with wire
Chain connector type S with cotter pins
Taper ring fasteners
Dismounting
Installation
Gib head key connections
Dismounting
Installation
Lock collar bearing
Dismounting
Installing
Adapter sleeve bearing
Dismounting
Installation
Chuck bushing
Dismounting of version A
Dismounting of version B
Installing
Chuck bushing version A
Chuck bushing version B
Ferrule fittings
Screwing in
Leaky ferrule fittings
Sealing cone fittings
Hydraulic hoses
Hose placement
Treatment of sealing faces
Spare parts
Tightening torques
Tightening torques for metric ISO screw thread
Tightening torques for metric fine thread
Tightening torques for screwed pipe connections with sealing cone joint and hydraulic threaded joints with soft core seal
Tightening torques for hydraulic fittings with ferrule
Tightening torques for hydraulic male connectors SDS shape B and E
Tightening torques for hydraulic swivel screw fittings
Tightening torque for hollow screws (with copper sealing ring)
Tightening torques for hydraulic male connectors SDE shape H, with adjustable direction
Tightening torques for brake line screw fittings
Tightening torques for worm drive hose clamps
Tightening torques for hose clamps with round pins
CCN explanation
CCN (CLAAS Component Number)
Electric systems standard
Hydraulic system standard
CCN (CLAAS Component Number)
General information
Hazard signs
Signal word
Regulations for avoiding accidents with personal injuries
Testing, adjusting and repair work
Engine operation
Suspended loads
Working on piping and hoses
Work on the Common Rail System
Working on the electric system
Working on the hydraulic system
Electric welding
Painting work
Working with urea solution
Information on how to avoid damage and premature wear
Liability limitation
Shutting down and storage
Regulations for avoiding health and environmental damage
Precautionary measures for protection against health and environmental damage
Disposal of operating utilities and auxiliary operating utilities
Information for working on the diesel engine
Accident protection
Cleanliness
Installation instructions
Engine overhaul
Putting into operation after an engine overhaul
First aid measures
0102 Complete component
Type design
Engine data
Engine description
Engine components
Ignition order
Cranking the engine
Special tool
Special tool for built-in engine
Cranking the engine in built-in condition
Cranking the engine in removed condition
Setting the engine to ignition TDC
Setting the engine to ignition TDC: Removing
0105 Engine suspension
Lifting eyes
Technical specifications
Lifting eyes
Technical specifications
0110 Engine housing
Technical specifications
Special tool
Installation
Crankshaft front seal
Technical specifications
Special tool
Installing the cassette seal ring
Crankshaft rear seal
Technical specifications
Special tool
Installation
Housing cover
Technical specifications
Installation
Timing housing
Technical specifications
Installation
Oil separator
Technical specifications
Disassembly
Installation
Oil separator
Technical specifications
Disassembly
Installation
Oil separator
Technical specifications
Disassembly
Installation
0115 Engine unit
Technical specifications
Special tool
Disassembly
Installation
Measuring the excess dimension
Checking the combustion pressure
Connecting rod
Technical specifications
Special tool
Installation
Cylinder liner
Technical specifications
Special tool
Installation
Measuring the excess dimension
Measuring the cylinder bore
Crankshaft
Technical specifications
Special tool
Removing the crankshaft
Checking the crankshaft
Installing the crankshaft
Crankshaft main bearings
Technical specifications
Special tool
Installation
Oscillation damper
Technical specifications
Special tool
Installation
Technical specifications
Special tool
Installation
0120 Cylinder head / Valves / Idler gear
Valve cover
Technical specifications
Installation
Reinforcing frame
Technical specifications
Installation
Camshaft housing
Technical specifications
Special tool
Applies to: OM 470 LA
Applies to: OM 470 LA
Installation
Applies to: OM 470 LA
Applies to: OM 470 LA
Technical specifications
Special tool
Installation
Cylinder head
Technical specifications
Special tool
Installation
Cylinder head
Technical specifications
Work preparation
Special tool
Installation
Cylinder head
Technical specifications
Work preparation
Special tool
Installation
Inlet rocker arm mechanism
Technical specifications
Disassembly
Installation
Outlet rocker arm mechanism
Technical specifications
Special tool
Disassembly
Installation
Technical specifications
Special tool
Installation
Checking the valves
Adjusting the valve lash
Valve springs and valve stem seals
Technical specifications
Special tool
Installation
Gear drive
Technical specifications
Special tool
Installation
Adjustment
Gear drive
Technical specifications
Special tool
Installation
Adjustment
Gear drive
Technical specifications
Special tool
Installation
Adjustment
0125 Injection – / Fuel system
High-pressure lines and rail
Technical specifications
Special tool
Installation
Rail pressure relief valve
Technical specifications
Installation
Technical specifications
Work preparation
Special tool
Installation
Injectors line kit
Technical specifications
Work preparation
Installation
Protective sleeve
Technical specifications
Special tool
Installation
Fuel high-pressure pump
Technical specifications
Work preparation
Special tool
Removing the drive gearwheel
Installing the drive gearwheel
Installation
2-step valve
Technical specifications
Installation instructions
Technical specifications
Work preparation
Special tool
Applies to: OM 470/471 LA
Installation
Applies to: OM 470/471 LA
Pressure relief valve
Technical specifications
Installation instructions
Fuel controller valve
Technical specifications
Work preparation
Installation
Fuel controller valve
Technical specifications
Work preparation
Installation
Fuel controller valve
Technical specifications
Work preparation
Installation
Fuel filter module
Technical specifications
Work preparation
Special tool
Installation
0130 Lubricating oil system
Lubricating oil system
Technical specifications
Special tool
Pre-filling
Oil spray nozzle
Technical specifications
Installation
Oil/coolant module
Technical specifications
Work preparation
Installation
Oil cooler
Technical specifications
Installation instructions
Oil cooler
Technical specifications
Installation instructions
Technical specifications
Disassembly
Installation
Technical specifications
Disassembly
Installation
Technical specifications
Disassembly
Installation
Oil thermostat
Technical specifications
Special tool
Installation
0135 Cooling system
Technical specifications
Special tool
Filling up
Cleaning the coolant circuit
Coolant pump
Technical specifications
Work preparation
Installation
Coolant thermostat
Technical specifications
Installation
0140 Exhaust system
Exhaust recirculation cooler
Technical specifications
Special tool
Installation
Exhaust recirculation cooler
Technical specifications
Special tool
Installation
Exhaust recirculation cooler
Technical specifications
Special tool
Installation
Exhaust gas recirculation cooler bracket
Technical specifications
Work preparation
Removing the exhaust gas recirculation cooler bracket
Installing the exhaust gas recirculation cooler bracket
Exhaust recirculation actuator
Technical specifications
Installation
Exhaust recirculation actuator
Technical specifications
Special tool
Installation
Exhaust recirculation valve
Technical specifications
Installation
Differential pressure sensor
Technical specifications
Exhaust manifold
Technical specifications
Work preparation
Installation
Exhaust manifold
Technical specifications
Work preparation
Installation
Exhaust manifold
Technical specifications
Work preparation
Installation
Turbocharger
Technical specifications
Work preparation
Installation
Turbocharger
Technical specifications
Work preparation
Installation
Turbocharger
Technical specifications
Work preparation
Installation
TURBO-COMPOUND turbine
Technical specifications
Work preparation
Installation
TURBO-COMPOUND transmission
Technical specifications
Work preparation
Installation
0145 Air intake
Charge air housing
Technical specifications
Installation
Charge air housing
Technical specifications
Installation
0150 Engine attachment parts
Electric starting motor
Technical specifications
Installation
Alternator
Technical specifications
Special tool
Removing the alternator
Installing the alternator
Resonance vessel
Technical specifications
Installation instructions
Resonance vessel
Technical specifications
Installation instructions
Air compressor
Technical specifications
Work preparation
Special tool
Installation
Removing the drive gearwheel
Installing the drive gearwheel
Air compressor
Technical specifications
Work preparation
Special tool
Installation
Removing the drive gearwheel
Installing the drive gearwheel
0155 Engine control
Control unit
Technical specifications
Installation
0165 Exhaust gas aftertreatment
Exhaust gas aftertreatment system
Technical specifications
Work preparation
Special tool
Checking the urea solution (purity)
Checking the urea solution (density)
Urea heater valve
Technical specifications
Work preparation
Special tool
Installation
Technical specifications
Work preparation
Special tool
Removing the urea pump
Installing the urea pump
Removing the inlet nozzle filter
Installing the inlet nozzle filter
Removing the pressure relief valve
Installing the pressure relief valve
Removing the frost protection element
Installing the frost protection element
Urea dosing unit (A089 / A67-MB)
Technical specifications
Work preparation
Special tool
Removing the dosing unit
Installing the dosing unit
Removing the filter
Installing the filter
0190 Accessories
Engine insulation
Technical specifications
Work preparation
Installing

00 0302 851 1.pdf:

Table of contents
Introduction
General information
Validity of manual
Using the manual
Text and figures
Document structure based on sub-assemblies
Search and find
Directions
Abbreviations
Technical terms
General repair instructions
Technical specifications
Information on technically correct repairs
Self-locking bolts
Liquid locking compound
Steel roller chains
Tensioning
Chain connector
Chain connector type E with spring
Chain connector type G with wire
Chain connector type S with cotter pins
Taper ring connections
Dismounting
Installation
Gib head key connections
Dismounting
Installation
Lock collar bearing
Dismounting
Installing
Adapter sleeve bearing
Dismounting
Installation
Chuck bushing
Removing version A
Removing version B
Installation
Version A chuck bushing
Version B chuck bushing
Ferrule fittings
Screwing in
Leaky ferrule fittings
Sealing cone fittings
Hydraulic hoses
Hose routing
Treatment of sealing faces
Spare parts
Tightening torques
Tightening torques for hex. or hex. socket bolts / nuts, head without collar or flange (MAN company standard M 3059)
Tightening torques for metric ISO screw thread
Tightening torques for metric fine thread
Tightening torques for screwed pipe connections with sealing cone joint and hydraulic threaded joints with soft core seal
Tightening torques for hydraulic fittings with ferrule
Tightening torques for hydraulic male connectors SDS shape B and E
Tightening torques for hydraulic swivel screw fittings
Tightening torque for hollow screws (with copper sealing ring)
Tightening torques for hydraulic male connectors SDE shape H, with adjustable direction
Tightening torques for brake line screw fittings
Tightening torques for worm drive hose clamps
Tightening torques for hose clamps with round pins
CCN explanation
CCN (CLAAS Component Number)
Electric systems standard
Hydraulic system standard
CCN (CLAAS Component Number)
Explanation of symbols
Personnel requirements
Regulations for avoiding accidents with personal injuries
Regulations for avoiding health and environmental damage
Limitation of liability for spare parts and accessories
Information on how to avoid damage and premature wear on the engine
Emergency driving program of engine with electronic control unit
Notes regarding work on the common rail system
Handling of AdBlue�� / DEF
Engine overhaul
Installation instructions
0102 Complete component
Cranking the engine
Special tool for when the engine is removed
Cranking the engine in built-in condition
LEXION C8X
Cranking the engine in removed condition
0105 Engine suspension
0110 Engine housing
Technical specifications
Work preparation
Disassembly
Installation
Crankcase bleeding
Technical specifications
Work preparation
Removing the crankcase ventilation
Installing the crankcantilation
Crankshaft front seal
Technical specifications
Special tool
Iation
Crankshaft rear seal
Technical specifications
Special tool
Installation
Face-end lid
Technical specifications
Work preparation
Installation
Flywheel housing
Technical specifications
Work preparation
Disassembly
Installation
0115 Engine unit
Piston with connecting rod
Technical specifications
Special tool
Disassembly
Installation
Measuring the excess dimension
Cylinder liner
Technical specifications
Special tool
Installation
Crankshaft
Technical specifications
Special tool
Checking the axial play
Checking the radial play
Installation
Oscillation damper
Technical specifications
Special tool
Disassembly
Installation
Technical specifications
Special tool
Installation
Replacing the ring gear
Camshaft intermediate gear wheel
Technical specifications
Special tool
Work preparation
Installation
Crankcase intermediate gear wheel
Technical specifications
Installation
Large intermediate gear wheel
Technical specifications
Installation
High-pressure pump intermediate gear wheel
Technical specifications
Installation
Crankshaft gear wheel (front)
Technical specifications
Special tool
Installation
Crankshaft gear wheel (rear)
Technical specifications
Special tool
Installation
Crankshaft sensor
Technical specifications
Work preparation
Installation
Piston spray cooling
Technical specifications
Removing the oil spray nozzle
Installing the oil spray nozzle
0120 Cylinder head / Valves / Idler gear
Valve cover
Technical specifications
Installation
Cylinder head
Technical specifications
Special tool
Installation
Rocker lever
Technical specifications
Disassembly
Installation
Checking the rocker arm radial play
Camshaft speed sensor
Technical specifications
Work preparation
Installation
Technical specifications
Special tool
Checking the valves
Checking the valve depth
Checking / adjusting the valve clearance
Valve springs and valve stem seals
Technical specifications
Special tool
Installation
Technical specifications
Work preparation
Installation
Valve timing
Technical specifications
0125 Injection / Fuel system
Fuel service centre
Technical specifications
Work preparation
Disassembly
Installation
Fuel lines
Technical specifications
Work preparation
Special tool
Installation
Return line from injector to fuel service centre
Technical specifications
Work preparation
Special tool
Installation
High-pressure lines
Technical specifications
Work preparation
Special tool
Installation
Technical specifications
Work preparation
Removing the rail
Installing the rail
Common rail pressure relief valve
Technical specifications
Work preparation
Special tool
Installation
Injector with nozzle (common rail).
Technical specifications
Work preparation
Special tool
Installation
High-pressure pump high-pressure line – Rail
Technical specifications
Work preparation
Special tool
Installation
High-pressure pump
Technical specifications
Work preparation
Special tool
Removing the high-pressure pump
Disassembling the high-pressure pump
Assembling the high-pressure pump
Installing the high-pressure pump
High-pressure pump drive housing
Technical specifications
Work preparation
Special tool
Disassembly
Installation
Fuel pressure sensor
Technical specifications
Special tool
Installation
Rail pressure sensor
Technical specifications
Work preparation
Special tool
Installation
Injector wiring loom
Technical specifications
Work preparation
Installation
0130 Lubricating oil system
Oil module
Technical specifications
Work preparation
Special tool
Disassembly
Installation
Technical specifications
Special tool
Installation
Oil pressure sensor
Technical specifications
Installation
Oil filler neck
Technical specifications
Installation
0135 Cooling system
Coolant manifold (coolant pump)
Technical specifications
Installation
Coolant manifold on the crankcase
Technical specifications
Installation
Coolant manifold (EGR module)
Technical specifications
Installation
Coolant manifold (crankcase EGR module)
Technical specifications
Installation
Coolant manifold (thermostat housing)
Technical specifications
Installation
Coolant manifold (thermostat housing)
Technical specifications
Installation
Coolant manifold (thermostat housing)
Technical specifications
Installation
Thermostat housing
Technical specifications
Installation
Thermostat cartridge
Technical specifications
Installation
Coolant pump distributor housing
Technical specifications
Installation
Coolant pump
Technical specifications
Installation
Coolant Temperature Sensor
Technical specifications
Work preparation
Installation
0140 Exhaust system
Turbocharger
Technical specifications
Installation
Turbocharger exhaust manifold
Technical specifications
Installation
Exhaust turbocharger inlet manifold
Technical specifications
Installation
Exhaust manifold
Technical specifications
Disassembly
Installation
Exhaust manifold – closing flap line
Technical specifications
Installation
Housing with closing flap EGR module
Technical specifications
Installation
Housing with non-return valve EGR
Technical specifications
Installation
EGR module (exhaust gas recirculation)
Technical specifications
Disassembly
Installation
EGR temperature sensor
Technical specifications
Installation
NOx raw emission sensor
Technical specifications
Work preparation
Special tool
Installation
Lambda sensor
Technical specifications
Special tool
Installation
0145 Air intake
Charge air elbow (cylinder head)
Technical specifications
Work preparation
Installation
Air flow meter
Technical specifications
Installation
Charge air temperature sensor
Technical specifications
Installation
Charge pressure sensor / charge pressure pick-up
Technical specifications
Installation
0150 Engine attachment parts
Alternator
Technical specifications
Work preparation
Special tool
Installation
Removing the pulley
Installing the pulley
Multigroove V-belt pulley
Technical specifications
Installation
Alternator drive belt tensioner
Technical specifications
Installation
Air compressor
Technical specifications
Work preparation
Special tool
Disassembly
Installation
Air compressor cap
Technical specifications
Work preparation
Installation
0155 Engine control
Control unit holder
Technical specifications
Installation
Engine control unit
Technical specifications
Installation
Voltage load protection relay
Technical specifications
Installation instructions
Installation
Engine wiring loom
Technical specifications
Installation instructions
Installation
0165 Exhaust gas aftertreatment

00 0303 709 0.pdf:

Crawler track unit TERRA TRACGeneration IIIon wheels with bolted joints
Table of contents
Introduction
General information
Validity of manual
Handling of this manual
Abbreviations
General repair instructions
Technical specifications
Information on technically correct repairs
Self-locking bolts
Liquid locking compound
Hydraulic hoses
Hose placement
Spare parts and technical questions
Tightening torques
Tightening torques for metric ISO screw thread
Tightening torques for metric fine thread
CCN explanation
CCN (CLAAS Component Number)
Electric system standard
Hydraulic system standard
CCN (CLAAS Component Number)
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
Leaving the machine
Putting the machine out of operation
Raised machine parts and loads
No welding
Optional equipment and spare parts
Crawler track unit