Claas Lexion 8800-8500 (C89) Combines Repair Manual FR

File List:

00 0300 668 8.pdf
00 0302 852 1.pdf
00 0303 060 6.pdf
00 0303 463 1.pdf
00 0305 753 1.pdf
00 0305 843 0.pdf

00 0300 668 8.pdf:

Repair instructions
Contents
Introduction
Notes on the instructions
Validity of the notice
Repair manual information
Use of the instructions
Classification in module/group structure
Seek and find
Directions
General repair instructions
Technical characteristics
Tips for correct repair
Self-locking screws
Liquid screw brake
Steel roller chains
Quick hitch
Type E quick coupler with spring
Type G quick coupler with wire
Type S quick coupler with pins
Assemblies using conical ring
Disassembly
Assembly
Heel pin assemblies
Assembly
Clamp ring bearing
Disassembly
Assembly
Clamp sleeve bearing
Assembly
Clamping sleeve
Removing version A
Removing version B
To set down
Clamping sleeve version A
Clamping sleeve version B
Circlips
Lip rings with spring
Hose clamps
Tightening torque
Tightening torques
Collar Alignment
Auxiliary mounting means
Assembly tools
Cutting ring fittings
To screw
Leaky cutting ring fittings
Sealing Cone Fittings
Hydraulic flexible lines
Passage of hoses
Diaphragm accumulator (pressure accumulator) according to factory standard CLAAS CN 24 0403
Features
Means of exploitation
Service and assembly
Modification of gas filling
Special tool
Treatment of sealing surfaces
Spare parts
Operating consumables
Welding work
ESD protective measures
Special tool
ESD protective measures
Inspection and repair advice
Tightening torques
Screw types according to CLAAS factory standard CN 02 5000
Description of the screw type
Tolerance class
Tightening instruction
Tightening torques for metric ISO thread
Tightening torques for metric precision threads
Tightening torques for hydraulic screw connections with cutting ring
Tightening torques for pipe fittings with conical sealing fitting and hydraulic fittings with soft sealing gasket
Tightening torques for nuts for feed-through fitting, straight and angular
Tightening torques for hydraulic screwed coupling SDS form B and E
Tightening torques for hydraulic screwed socket SDS form F and sealing screw
Tightening torques for hydraulic screwed coupling SDS form H
Tightening torques for form E cover screws
Tightening torques for hydraulic screwed coupling form C, conical thread
Tightening torques for hydraulic screwed coupling SDE form F, adjustable
Tightening torques for hydraulic screwed coupling SDE form H, adjustable
Tightening torques for hydraulic swivel screw connections
Tightening torques for hollow screws (with copper seal)
Tightening torques for brake line screw connections
Tightening torques for tubular structures with O-ring and union nuts
Tightening torques for threaded rods / calibrated holes
Tightening torques for threaded bolts and special screws
Tightening torques for hydraulic components
Tightening torques for hexagonal sealing nuts
Hose clamp tightening torques
Assembly tips
Tangent screw clamps
Tangent screw clamps with spring washers
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 for avoiding accidents causing bodily harm
Inspection, adjustment and repair work
Engine operation
Suspended loads
Work on tubular 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
Rated motor characteristic data
OM 470 LA
OM 471 LA
OM 473 LA
Engine Description
Engine components
Lighting order
Start the engine manually
Special tool
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
0105 Engine suspension
Fixing eyelets
Technical characteristics
Fixing eyelets
Technical characteristics
0110 Motor housing
Technical characteristics
Special tool
To set down
Front crankshaft seal
Technical characteristics
Special tool
Install the cassette seal
Rear crankshaft seal
Technical characteristics
Special tool
To set down
Crankcase cover
Technical characteristics
To set down
Steering cover
Technical characteristics
To set down
Oil separator
Technical characteristics
Disassemble
To assemble
To set down
Oil separator
Technical characteristics
Disassemble
To assemble
To set down
Oil separator
Technical characteristics
Disassemble
To assemble
To set down
0115 Powertrain
Technical characteristics
Special tool
Disassemble
To assemble
To set down
Measure the projection
Check compression pressure
Connecting rod
Technical characteristics
Special tool
To set down
Cylinder liner
Technical characteristics
Special tool
To set down
Measure the projection
Measure the cylinder bore
Crankshaft
Technical characteristics
Special tool
Remove the crankshaft
Check the crankshaft
Install the crankshaft
Crankshaft main bearing
Technical characteristics
Special tool
Replace the main bearing of the adjustment bearing cover
Replace the main bearing of the adjustment bearing cover
Replace the crankshaft main bearing
To set down
Replace the crankshaft main bearing
Replace the main bearing of the adjustment bearing cover
Vibration damper
Technical characteristics
Special tool
To set down
Flywheel
Technical characteristics
Special tool
To set down
0120 Cylinder head – Valves – Distribution
Upper valve cover
Technical characteristics
To set down
Subframe
Technical characteristics
To set down
Camshaft housing
Technical characteristics
Special tool
Valid for: OM 470 LA
Valid for: OM 470 LA
To set down
Valid for: OM 470 LA
Valid for: OM 470 LA
Camshafts
Technical characteristics
Special tool
To set down
Cylinder head
Technical characteristics
Special tool
To set down
To clean
Cylinder head
Technical characteristics
Preparing for work
Special tool
To set down
To clean
Cylinder head
Technical characteristics
Preparing for work
Special tool
To set down
To clean
Intake rocker arms
Technical characteristics
Disassemble
To assemble
To set down
Exhaust rocker arms
Technical characteristics
Special tool
Disassemble
To assemble
To set down
Technical characteristics
Special tool
To set down
Check the valves
Adjust valve clearance
Engine brake valves
Technical characteristics
Special tool
Adjust engine brake valve clearance
Valve Springs and Valve Stem Seals
Technical characteristics
Special tool
To set down
Gear drive
Technical characteristics
Special tool
To set down
Gear drive
Technical characteristics
Special tool
To set down
Gear drive
Technical characteristics
Special tool
To set down
0125 Injection system, fuel supply
High pressure pipes and ramp
Technical characteristics
Special tool
To set down
Rail pressure limiter
Technical characteristics
To set down
Injectors
Technical characteristics
Preparing for work
Special tool
To set down
Injector power block
Technical characteristics
Preparing for work
To set down
Protective sleeve
Technical characteristics
Special tool
To set down
High pressure fuel pump
Technical characteristics
Preparing for work
Special tool
OM470 LA, OM471 LA from 032691, OM473 LA
If the high pressure fuel pump gear (OM471 LA to 032690) is damaged
Remove the drive gear
OM470 LA from 168338, OM471 LA from 168338, OM473 LA from 168338
OM470 LA from 168338, OM471 LA from 168338, OM473 LA from 168338
OM470 LA from 168338, OM471 LA from 168338, OM473 LA from 168338
Install the drive gear
OM470 LA from 168338, OM471 LA from 168338, OM473 LA from 168338
To set down
OM470 LA from 168338, OM471 LA from 168338, OM473 LA from 168338
OM470 LA from 168338, OM471 LA from 168338, OM473 LA from 168338
2-stage valve
Technical characteristics
Assembly tips
Fuel feed pump
Technical characteristics
Preparing for work
Special tool
Valid for: OM470 / 471 LA
To set down
Valid for: OM 470/471 LA
Pressure limiter
Technical characteristics
Assembly tips
Debit regulator
Technical characteristics
Preparing for work
To set down
Debit regulator
Technical characteristics
Preparing for work
To set down
Debit regulator
Technical characteristics
Preparing for work
To set down
Fuel Filter Module
Technical characteristics
Preparing for work
Mounting pins for installing the fuel filter module
Special tool
To set down
0130 Lubrication system
Lubricating oil system
Technical characteristics
Special tool
Oil injection nozzle
Technical characteristics
To set down
Oil-coolant module
Technical characteristics
Preparing for work
To set down
Oil cooler
Technical characteristics
Assembly tips
Oil cooler
Technical characteristics
Assembly tips
Oil pump
Technical characteristics
Disassemble
To assemble
To set down
Oil pump
Technical characteristics
Disassemble
To assemble
To set down
Oil pump
Technical characteristics
Disassemble
To assemble
To set down
Oil thermostat
Technical characteristics
Special tool
To set down
0135 Cooling system
Cooling liquid
Technical characteristics
Special tool
Clean the coolant circuit
Coolant pump
Technical characteristics
Preparing for work
To set down
Coolant thermostat
Technical characteristics
To set down
0140 Exhaust device
Exhaust gas recirculation radiator
Technical characteristics
Special tool
To set down
Exhaust gas recirculation radiator
Technical characteristics
Special tool
To set down
Exhaust gas recirculation radiator
Technical characteristics
Special tool
To set down
Exhaust gas recirculation radiator support
Technical characteristics
Preparing for work
Dismantle the exhaust gas recirculation radiator support
Install the exhaust gas recirculation radiator support
Exhaust gas recirculation actuator
Technical characteristics
To set down
Exhaust gas recirculation actuator
Technical characteristics
Special tool
To set down
Exhaust gas recirculation valve
Technical characteristics
To set down
Differential pressure sensor
Technical characteristics
Exhaust manifold
Technical characteristics
Preparing for work
To set down
Exhaust manifold
Technical characteristics
Preparing for work
To set down
Exhaust manifold
Technical characteristics
Preparing for work
To set down
Turbocharger
Technical characteristics
Preparing for work
To set down
Turbocharger
Technical characteristics
Preparing for work
To set down
Turbocharger
Technical characteristics
Preparing for work
To set down
TURBO-COMPOUND Turbine
Technical characteristics
Preparing for work
To set down
TURBO-COMPOUND Gearbox
Technical characteristics
Preparing for work
To set down
0145 Air suction
Charge air housing
Technical characteristics
To set down
Charge air housing
Technical characteristics
To set down
0150 Engine assembly parts
Technical characteristics
To set down
Generator
Technical characteristics
Special tool
Remove the generator
Install the generator
Resonance box
Technical characteristics
Assembly tips
Resonance box
Technical characteristics
Assembly tips
Air compressor
Technical characteristics
Preparing for work
Special tool
To set down
Remove the drive gear
Install the drive gear
Air compressor
Technical characteristics
Preparing for work
Special tool
To set down
Remove the drive gear
Install the drive gear
0155 Engine controls
Control device
Technical characteristics
Only if the control device is replaced
OM470 LA and OM471 LA with air suction from the front
To set down
0165 Exhaust gas aftertreatment
Exhaust aftertreatment system
Technical characteristics
Preparing for work
Special tool
Check the urea solution (cleanliness)
Check the urea solution (density)
Exhaust gas aftertreatment diesel particulate filter
Technical characteristics
Install the DPF
Install the profiled collar
Install the flat collar
Install the maintenance hatch
Urea heating valve
Technical characteristics
Preparing for work
Special tool
To set down
Urea pump
Technical characteristics
Preparing for work
Special tool
Remove the urea pump
Install the urea pump
Remove the filter from the inlet fitting
Install the inlet connection filter
Remove the pressure relief valve
Install the pressure limiter
Remove the antifreeze protection element
Install the frost protection element
Urea Dosing Unit (A089/A67-MB)
Technical characteristics
Preparing for work
Special tool
Remove the flexible pipe (flexible pipes only)
Remove the dosing unit
Install the dosing unit
Remove the filter
Install the filter
0190 Accessories
Motor insulation
Technical characteristics
Preparing for work
To set down

00 0302 852 1.pdf:

MAN D2676
Contents
Introduction
General instructions
Validity of the 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
Tips for correct repair
Self-locking screws
Liquid screw brake
Steel roller chains
Quick hitch
Type E quick coupler with spring
Type G quick coupler with wire
Type S quick coupler with pins
Assemblies using conical ring
Assembly
Heel pin assemblies
Assembly
Clamp ring bearing
Disassembly
Assembly
Clamp sleeve bearing
Assembly
Clamping sleeve
Removal of version A
Submission of version B
To set down
Clamping sleeve version A
Clamping sleeve version B
Circlips
Cutting ring fittings
To screw
Leaky cutting ring fittings
Sealing Cone Fittings
Hydraulic flexible lines
Passage of hoses
Treatment of sealing surfaces
Spare parts
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
Staffing Requirements
Instructions to avoid accidents and personal injury
Instructions to avoid damage to health and the environment
Limitation of liability for spare parts and accessories
Notes to avoid damage and premature wear to the engine
Emergency driving program on engines with electronic control device
Tips for working on common rail system
Use of AdBlue® / DEF
Engine overhaul
Assembly tips
01 Motor
0102 Complete set
Start the engie manually
Special tool when the engine is removed
Start the engine in the parked psition
LEXION C8X
Run the engine in the stored position
0105 Engine suspension
0110 Motor housing
Technical characteristics
Preparing for work
Disassemble
To assemble
To set down
Crankcase air bleeding
Technical characteristics
Preparing for work
Remove the air bleeder from the crankcase
Install the crankcase air bleeder
Front crankshaft seal
Technical characteristics
Special tool
To set down
Rear crankshaft seal
Technical characteristics
Special tool
To set down
Front cover
Technical characteristics
Preparing for work
To set down
Flywheel housing
Technical characteristics
Preparing for work
Disassemble
To assemble
To set down
0115 Powertrain
Piston with connecting rod
Technical characteristics
Special tool
Disassemble
To assemble
To set down
Measure the projection
Cylinder liner
Technical characteristics
Special tool
To set down
Crankshaft
Technical characteristics
Special tool
Check axial play
Check radial clearance
To set down
Vibration damper
Technical characteristics
Special tool
Disassemble
To assemble
To set down
Flywheel
Technical characteristics
Special tool
To set down
Replace the ring gear
Camshaft intermediate gear
Technical characteristics
Special tool
Preparing for work
To set down
Crankcase intermediate gear
Technical characteristics
To set down
Large intermediate gear
Technical characteristics
To set down
High pressure pump intermediate gear
Technical characteristics
To set down
Crankshaft sprocket (front)
Technical characteristics
Special tool
To set down
Crankshaft sprocket (rear)
Technical characteristics
Special tool
To set down
Crankshaft sensor
Technical characteristics
Preparing for work
To set down
Piston cooling
Technical characteristics
Remove the lubrication nozzle
Install the lubrication nozzle
0120 Cylinder head – Valves – Distribution
Upper valve cover
Technical characteristics
To set down
Cylinder head
Technical characteristics
Special tool
To set down
Rocker arm
Technical characteristics
Disassemble
To assemble
To set down
Check rocker arm radial clearance
Camshaft speed sensor
Technical characteristics
Preparing for work
To set down
Technical characteristics
Special tool
Check the valves
Check valve removal
Check/adjust valve clearance
Valve Springs and Valve Stem Seals
Technical characteristics
Special tool
To set down
Camshaft
Technical characteristics
Preparing for work
To set down
Valve timing
Technical characteristics
0125 Injection system, fuel supply
Fuel Service Center
Technical characteristics
Preparing for work
Disassemble
To assemble
To set down
Fuel Lines
Technical characteristics
Preparing for work
Special tool
To set down
Injector return line – KSC
Technical characteristics
Preparing for work
Special tool
To set down
High pressure pipes
Technical characteristics
Preparing for work
Special tool
To set down
Technical characteristics
Preparing for work
Remove the ramp
Install the ramp
Common-Rail pressure relief valve
Technical characteristics
Preparing for work
Special tool
To set down
Injector with nozzle (Common-Rail)
Technical characteristics
Preparing for work
Special tool
To set down
High pressure line from high pressure pump – rail
Technical characteristics
Preparing for work
Special tool
To set down
High pressure pump
Technical characteristics
Preparing for work
Special tool
Remove the high pressure pump
Disassemble the high pressure pump
Assemble the high pressure pump
Install the high pressure pump
High pressure pump drive housing
Technical characteristics
Preparing for work
Special tool
Disassemble
To assemble
To set down
Fuel pressure sensor
Technical characteristics
Special tool
To set down
Rail pressure sensor
Technical characteristics
Preparing for work
Special tool
To set down
Injector wiring harness
Technical characteristics
Preparing for work
To set down
0130 Lubrication system
Oil module
Technical characteristics
Preparing for work
Special tool
Disassemble
To assemble
To set down
Oil pump
Technical characteristics
Special tool
To set down
Oil pressure sensor
Technical characteristics
To set down
Oil fill port
Technical characteristics
To set down
0135 Cooling system
Coolant elbow (coolant pump)
Technical characteristics
To set down
Coolant elbow on crankcase
Technical characteristics
To set down
Coolant elbow (EGR module)
Technical characteristics
To set down
Coolant elbow (crankcase-EGR module)
Technical characteristics
To set down
Coolant elbow (thermostat housing)
Technical characteristics
To set down
Coolant elbow (thermostat housing)
Technical characteristics
To set down
Coolant elbow (thermostat housing)
Technical characteristics
To set down
Thermostat housing
Technical characteristics
To set down
Thermostat Trim
Technical characteristics
To set down
Coolant pump distribution box
Technical characteristics
To set down
Coolant pump
Technical characteristics
To set down
Coolant temperature sensor
Technical characteristics
Preparing for work
To set down
0140 Exhaust device
Exhaust gas turbocharger
Technical characteristics
To set down
Turbocharger exhaust manifold
Technical characteristics
To set down
Turbocharger suction elbow
Technical characteristics
To set down
Exhaust gas collector
Technical characteristics
Disassemble
To assemble
To set down
Exhaust manifold line – shut-off valve
Technical characteristics
To set down
Housing with EGR module shut-off valve
Technical characteristics
To set down
Housing with EGR check valve
Technical characteristics
To set down
EGR module (exhaust gas recirculation)
Technical characteristics
Disassemble
To assemble
To set down
EGR temperature sensor
Technical characteristics
To set down
Raw emission NOx sensor
Technical characteristics
Preparing for work
Special tool
To set down
Lambda probe
Technical characteristics
Special tool
To set down
0145 Air suction
Charge air elbow (cylinder head)
Technical characteristics
Preparing for work
To set down
Air flow meter
Technical characteristics
To set down
Charge air temperature sensor
Technical characteristics
To set down
Intake pressure sensor/intake pressure probe
Technical characteristics
To set down
0150 Engine assembly parts
Generator
Technical characteristics
Preparing for work
Special tool
To set down
Remove the pulley
Install the pulley
Ribbed V-Belt Pulley
Technical characteristics
To set down
Belt tensioner for generator drive belt
Technical characteristics
To set down
Compressor
Technical characteristics
Preparing for work
Special tool
Disassemble
To assemble
To set down
Compressor closing plate
Technical characteristics
Preparing for work
To set down
0155 Engine controls
Control device console
Technical characteristics
To set down
Motor control device
Technical characteristics
To set down
Overvoltage protection relay
Technical characteristics
Assembly tips
To set down
Engine wiring harness
Technical characteristics
Assembly tips
To set down
0165 Exhaust gas aftertreatment

00 0303 463 1.pdf:

D4276 LE121BD4276 LE121CD4276 LE122BD4276 LE122CD4276 LE122D
Contents
Introduction
General instructions
Validity of the 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
Tips for correct repair
Self-locking screws
Liquid screw brake
Steel roller chains
Quick hitch
Type E quick coupler with spring
Type G quick coupler with wire
Type S quick coupler with pins
Assemblies using conical ring
Disassembly
Assembly
Heel pin assemblies
Assembly
Clamp ring bearing
Disassembly
Assembly
Clamp sleeve bearing
Assembly
Clamping sleeve
Removal of version A
Submission of version B
To set down
Clamping sleeve version A
Clamping sleeve version B
Circlips
Cutting ring fittings
To screw
Leaky cutting ring fittings
Sealing Cone Fittings
Hydraulic flexible lines
Passage of hoses
Treatment of sealing surfaces
Spare parts
Tightening torques
Tightening torques for hexagonal or hexagon socket screws/nuts, head without collar or flange (man factory standard M 3059)
Screws / nuts with external hexagon or hexagon socket, head with collar or flange
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