Claas Talos 240-210 (A39) Tractors Repair Manual ES

File List:

00 1156 119 1.pdf

00 1156 119 1.pdf:

TALOS 240-230-220-210
Introduction
General information
Using this repair manual
Validity of the repair manual
General repair instructions
Technical characteristics
Cause of damage
Interchange parts
Diesel engine
Generator
Welding work
Drive belt/drive chains
Conical ring assemblies
Self-locking screws with microencapsulated glue
Thread braking
Tightening ring bearing
Tightening sleeve bearing
Threaded fittings with cutting ring in hydraulic lines
Threaded fittings with progressive ring in hydraulic lines
Biconical threaded fittings in hydraulic conduits
Hydraulic hoses
Tips for an economical repair
Tightening torques
Tightening torques for metric threads according to standard NF E25-030-1 2007-12-01
Technical data
Lubricants
CCN Explanation
CCN (CLAAS Component Number)
General indications
Electrical regulations
Hydraulic regulations
CCN Index
Security
General information
Especially important
Signage of warning and danger indications
General safety measures and accident prevention rules
Leave the machine
Adjustment and maintenance work
Risk of injury from hydraulic fluid
Air conditioning equipment
pressure accumulator
First aid measures
Battery separator switch
security routines
Put the machine out of service
01 Engine
0102 Complete component
Introduction
Assistance operation
General observations
General observations about the electrical circuit
Mass and shielding
Conversions between the main units of measurement of the international system and the derived units in common use
General information
Views of the engine. TALOS 240
Views of the engine. TALOS 230
Views of the engine. TALOS 220
Views of the engine. TALOS 210
General engine inspection
special tool
General characteristics
Assembly kits
Tightening torques
TALOS 230-220-210
TALOS 240
Engine disassembly
Disassembly of the cabin
Disassembly of the fuel tank
Right side engine
Left side engine
Left side
Front of
Disassembly of engine peripherals
Radiator disassembly
Disassembly of the engine frame
Engine separation
Engine peripherals. TALOS 230-220-210
Versions with or without EGR
Finding the top dead center of cylinder 1
Timing Gear Train Case
Assembling the rear face components
Steering wheel assembly
Assembly of front face components
Synchronization
Piston protrusion measurement
Version without EGR
Version with EGR
Engine peripherals. TALOS 240
Disassembly/assembly of engine peripherals
Introduction
Special tools
Disassembly of engine peripherals
Assembly of engine peripherals
Adjusting the rocker arm play
Disassembly and assembly of the injection pump
Top dead center location
0115 Engine propulsion
Cylinder block repair
Checks and measurements
Checking the contact surface of the cylinder head on the cylinder block
Disassembly of connecting rods/pistons/crankshaft and camshafts
Crankshaft
Measuring the journals and journals
Tables of measured values
Main crankshaft tolerances
Replacing the oil pump drive sprocket
Installing the crankshaft bushings
Trunnion clearance measurement
Checking the crankshaft axial play
Connecting rod-piston assembly
special tool
Main dimensions of the piston, axles and segments
piston shaft
Necessary conditions for a correct shaft-piston coupling
Segments
Assembly of the connecting rod-piston assembly. Connecting rod-piston coupling
TALOS 240
TALOS 230-220-210
Assembly of the segments
Assembly of the connecting rod-piston assemblies in the liners
Measuring the axial play of the connecting rods
Piston protrusion measurement
0120 Cylinder head / valves / distributor wheel
Distribution
Special tools
Camshaft
Main dimensions of the camshaft bearings
Checking cam lift and shaft cylinder alignment
Main dimensions of the camshaft bearings and their seats
Replacing the rings
Assembly of the pushers. Camshaft
Special tools
Valve disassembly
Checking the tightness of the cylinder head
Checking the cylinder head bearing surface
Main dimensions of the intake and exhaust valves
Stripping, checking and grinding of valves
Checking the clearance between valve stem and valve guide – valve centering
valve guide
Replacing valve guides
Valve seats
Main dimensions of the valve seats – in mm
Rectification. Replacing valve seats
Valve springs
Cylinder head assembly
0125 Fuel/injection system
Fuel supply. TALOS 210220230
General information
Principle scheme
Duct diagram
Operating principle
injection pump
Feeding phase
Exit phase
End of exit phase
Engine stop
LDA device (load-dependent flow adaptation)
priming pump
Fuel filter
Injection system. TALOS 210-220-230
Special tools
Disassembly/assembly of the injection pump
Preliminary operations
BOSCH VE 4/12 F pump
Disassembly
Mounting
Control of the static advance of the engine injection pump at the top dead center of cylinder 1
Preliminary conditions
Fuel supply. TALOS 240
General information
Duct diagram
Operating principle
injection pump
priming pump
Fuel filter
Injection system. TALOS 240
Special tools
Disassembly/assembly of the injection pump
Preliminary operations
Disassembly
Top dead center location
Mounting
0130 Lubricating oil system
Engine lubrication. TALOS 230-220-210
Oil pump
Oil filter
Recycling of oil vapors
Removing the blowby from the cylinder head cover
Blow-by assembly
Oil pressure switch
Engine lubrication. TALOS 240
Recycling of oil vapors
Oil pressure switch
Characteristics
0135 Cooling system
Refrigeration system. TALOS 210220230
Description
Water Pump
Thermostat
Coolant temperature sensor
Coolant temperature sensor for the cold advance system.
Heat exchanger
Refrigeration system. TALOS 240
Description
Coolant temperature sensor
Characteristics
Coolant temperature sensor for the cold advance system.
Characteristics
Feed pump solenoid
0145 Air suction
Overfeeding. TALOS 210-220-230
Overfeeding. TALOS 240
Help for starting in cold temperatures. TALOS 240
Preheating resistance
Characteristics
0165 Exhaust gas aftertreatment
External EGR. TALOS 210-220-230
Functioning
Temperature and air pressure sensor
EGR solenoid valve
02 Gears / clutch / cardan shaft
0202 Complete component
Technical characteristics
Transmission. General information
Transmission with mechanical shuttle. Section
Transmission with Power Shuttle System. Section
Tightening torques
Transmission inspection
Transmission disassembly/assembly
Incidents and solutions
Disassembly of the clutch housing
Disassembly of the central crankcase
Disassembly of the elevator casing
0215 Mechanical clutch
Clutch inspection and repair
Special tools
Description
Clutch. Section View
Incidents and solutions
Clutch disassembly/assembly
Mounting
mechanical clutch
Clutch and brake fluid level
clutch bleed
0218 Clutch control/operation
Master cylinder and clutch lever
Clutch fork and stop
Clutch pedal
Clutch pedal clearance adjustment (mechanical clutch)
Adjusting the force to press the clutch pedal
0220 Mechanical investment
0222 Hydraulic inversion
PSS inverter. Functioning
Disassembly of the PSS module
reverse clutch
Disassembly
Disassembly of the Power Shuttle System reverse clutch elements
Slow/fast clutch
Disassembly
0228 Reversing command/drive
Mechanical reverse control
Mechanical inverter control. Section
kinematic chain
forward march
View of the inverter synchro and associated parts
Disassembly of the mechanical reverser synchro
Inverter synchro wear check
PSS hydraulic shuttle control
Description
kinematic chain
forward march
0230 Mechanical gear
Gearbox. Section View
range box
Box of ranges. Section views
Tortoise gait (depending on equipment)
Turtle walking set. Section View
Transmission. Disassembly of the central crankcase elements
Transmission. Disassembly of the bridge crankcase elements
0238 Gearbox control/drive
Gear shift lever
Description
Gear shift lever. Section View
kinematic chain
Range control
Functioning
Section View
Range shift lever. Section View
kinematic chain
Turtle gear control
Functioning
Section View
kinematic chain
0240 Rear axle housing
Repair of trumpets
Trumpet. Sections
Trumpet disassembly
0242 Differential
Rear differential locking system
Special tools
Rear differential lock. General view
Description
Rear differential disassembly
Hydraulic rear differential lock device
Disassembly of the drive pinion shaft
Drive pinion shaft assembly
Adjustment of tooth clearance and resistance torque
0252 Electrohydraulic drive of the front axle
Four-wheel drive transmission
kinematic chain
Functioning
Four Wheel Drive Transmission Components
03 Chassis
0325 Front drive steering axle
Taesan Machinery Front Bridge
View of the front bridge
Description
Tightening torques
Disassembly/assembly of the front axle
Front axle separation
View of complete tie rod
Adjustment and assembly of tie rods
Wheel reducer repair
Wheel reducer. Section
Description
Wheel hub components
Wheel hub repair
Adjusting the play between teeth (between the crown and the spindle)
Pivot repair
Adjusting the backlash (between the 17-tooth bevel pinion and the wheel axle)
Front axle differential
Front axle differential and drive pinion. Section
Adjusting the position of the drive pinion shaft
Drive pinion bearing preload
Front axle differential repair
Adjusting the backlash (between the drive pinion shaft and the ring gear)
0325 Front drive steering axle
Carraro front axle
View of the front bridge
Description
Features of Limited Displacement Differential Discs
Front bridge
Disassembly
Mounting
Wheel hubs and reduction
Exploded view
special tool
Preliminary operations
Disassembly
Mounting
wheel pivots
Exploded view
Work preparation:
special tool
Preliminary operations
Disassembly
Mounting
Exploded view
Preliminary operations
Disassembly
Mounting
Drive pinion sealing ring
Exploded view
special tool
Disassembly
Mounting
wheel axles
Exploded view
Work preparation:
special tool
Preliminary operations
Disassembly
Mounting
Differential. Disassembly and assembly operations
Exploded view
Work preparation:
special tool
Preliminary operations
Disassembly
Mounting
Adjustment
Checking the contact mark of the differential teeth
Differential (LS). Disassembly and assembly operations
Exploded view
Preliminary operations
Disassembly
Mounting
Differential (ML). Disassembly and assembly operations
Exploded view
Preliminary operations
Disassembly
Mounting
Differential lock
Exploded view
Preliminary operations
Disassembly
Mounting
attack pinion
Exploded view
Work preparation:
Special tools
Preliminary operations
Disassembly
Mounting
04 Brake
0405 Service brake
Service brakes. General information
Characteristics
Incidents and solutions
Service brakes
Disassembling the service brakes
Master cylinder
Bleeding the brake hydraulic circuit
Adjusting the brake pedal clearance
0415 Parking brake
Hand brake
Handbrake components
Handbrake disassembly
Disassembly of the handbrake elements
05 Address
0505 Address
Direction system. General information
Steering system components
Description
Tightening torques
Steering operation diagrams
neutral position
Right/left turn
Right turn (1)
Left turn (2)
Incidents and solutions
steering box
Disassembly/assembly of the steering box
Disassembly/assembly of the steering box
Directional cilindrum. Taesan Machinery Front Bridge
Disassembly of the steering cylinder
Steering cylinder assembly
Directional cilindrum. Carraro front axle
Exploded view of the steering cylinder
Preliminary operations before intervening on the steering cylinder
Disassembly of the steering cylinder
Steering cylinder repair
Steering cylinder assembly
Fixed front axle parallelism adjustment
Work preparation:
Fixed front axle parallelism adjustment
06 Lifting device
0605 Rear linkage
Description of Mechanical Control Hydraulic Lift
Operating principle
Description
oil flow
neutral position
Rise position
Lowering position
elevator distributor
Hydraulic diagram of the elevator distributor
Characteristics
Connections
elevator controls
Rear linkage raising
Rear linkage lowering
Effort control
Automatic lifting
Disassembly/assembly of mechanical control hydraulic lifter crankcase
Mechanical Control Hydraulic Lift Distributor
Description of electronic control hydraulic lift
CAN bus scheme
Sensors of the electronic control system of the rear hydraulic linkage
Electronic control of the rear hydraulic lift (multifunction armrest)
User controls
Working depth control
Elevator casing. Items
Description
Hydraulic diagram
Flow adjustment
elevator distributor
oil flow
neutral position
Rise position
Lowering position
Proportional solenoid valves
Flow adjustment
Disassembly/assembly of the electronically controlled hydraulic lifter crankcase
Electrohydraulic elevator distributor
Rear hydraulic lift. Incidents and solutions
Elevator bottom stop calibration
Upper crank adjustment
Calibration of the lower limit of the position control lever
Adjustment of the automatic deactivation point of the power take-off
08 Drives
0802 Rear PTO
rear power take off system
PTO proportional to forward speed
User controls
Disassembly of the power take-off proportional to the forward speed
Rear power take-off system. Component view
Rear PTO speed selection lever
Selection of power take-off regimes. Section
Disassembly of the rear power take-off
Disassembly of the power take-off clutch
09 Hydraulic
0910 Bombs
Hydraulic bombs. General information
Characteristics
Hydraulic bombs. Disassembly
Assembly
0915 Hydraulic pipes
Description of the hydraulic system
Special tools
Components of hydraulic circuits
Mechanical control elevator
Electrohydraulic control elevator
Hydraulic system diagram
Mechanical control elevator and mechanical inverter
Electro-hydraulic control elevator and mechanical inverter
Electrohydraulic Control Elevator and Power Shuttle System
Independent PTO clutch
Section View
Hydraulic diagram
PTO deactivation (lubrication)
PTO activation
Disassembly/assembly
0920 Valves
Oil cooler and priority valve
oil cooler valve
Priority valve
Disassembly/assembly
transmission distributor
Components
Hydraulic circuit
Disassembly/assembly
Power Shuttle System Distributor
Components
Pressure control points
Hydraulic circuit
Disassembly/assembly
Auxiliary distributors
Auxiliary distributor control levers
Quick fittings
Hydraulic circuit diagram
Disassembly/assembly
Front electrohydraulic block and controls (depending on equipment)
charger distributor
Multi-function lever and electro-hydraulic block assembly
Hydraulic diagram
Distributor disassembly/assembly
10 Install. electrical/electronic
1000 General electrical installation
Electric system. General information
Technical characteristics
Special tools
Troubleshooting
Legend of function diagrams and implementation diagrams
Bulb replacement
Front lights
Turn signals and position lights
Taillights
Front/rear work lights
Interior cabin lighting
1005 Power supply
Electrical power supply
starter relay
Preheat relay
Safety contactor at start
relay box
Flashing switchboard
Control of the signal lights and the acoustic warning
Rear PTO switch
1012 Modules / sensors
A164 Rear Linkage and Transmission Modules
Connectors
instrument panel module A101;
Tachometer
Hours of service counter
Fuel level indicator
Coolant temperature
EGR module. A165
TALOS 230-220-210
Electric scheme
Engine speed sensor. TALOS 230-220-210
Engine speed sensor. TALOS 240
Preheating device controller (air heating)
Air heating relay
starter contactor
Fuel level indicator
Transmission sensors
Transmission speed sensor
Oil temperature sensor
range sensor
clutch pedal sensor
Electrohydraulic transmission controller
Power Shuttle System Contactor
brake sensors
Brake light contactors
Decoupled pedal contactor
handbrake sensor
steering sensor
Steering angle detection sensor
Elevator
Rear electro-hydraulic linkage control panel A 147
Effort and position sensors
Working depth sensor
1015 Cable sets
Wiring identification
Wiring 1. Motor wiring
TALOS 210 and 230 engines
TALOS 220 engine
TALOS 240 engine
Starting in cold temperatures
Wiring 2. Front lighting wiring
Wiring 3. Internal EGR wiring
Wiring of the injection pump (Bosch pump). TALOS 230-220-210
Definition of KSB
Wiring 4. Main wiring
Main wiring. Cabin version
Main wiring. Platform version
Wiring 5. Elevator wiring
With mechanical control elevator
With electrohydraulic control lift
Wiring 6. Cabin wiring
Air-conditioning
Wiring 8. Transmission and electrohydraulic lift wiring (optional)
Electrohydraulic lift
PSS inverter and electrohydraulic range
12 Driver’s cab/platform
1210 Cabin
Disassembly of the cabin
Right terminal
Disassembly
Mounting
Refrigerated compartment
Disassembly
Mounting
rear wiper motor
Disassembly
Mounting
Front wiper motor
Disassembly
Mounting
Disassembly
Mounting
Audio equipment
Disassembly
Mounting
Disassembly
Mounting
1240 Air conditioning equipment
Description of the air conditioning/heating system
Components
Heating/air conditioning circuit
Specifications. Air conditioning
Maintenance of the air conditioning system
Periodic maintenance operations
Semi-annually
Annually
Every 2 years
Controls and adjustments
Refrigerant
Condenser and radiator wiring
V-belt tension
Duct fittings
Air conditioning and heating. Incidents and solutions
Troubleshooting
Air conditioning/heating controls
Disassembly
Mounting
Air conditioning block
Preliminary operations
Cab roof opening
Disassembly of the air conditioning block
Mounting
Disassembly of the air conditioning block
Assembly of the air conditioning block
Condenser
Disassembly
Mounting
Compressor
Disassembly
Mounting
Diagnosis according to fault codes
Error codes
Location of components
Electrical installation
Location of components
Location of components in the engine
TALOS 240
TALOS 230-220-210
Location of components in the transmission
Main fuse
B229 Intermediate gearbox speed sensor
B144 Effort sensor potentiometer
B334 Rear linkage position sensor potentiometer/B407 Working depth sensor potentiometer
range sensor
B123 Transmission Oil Temperature Sensor
Preheating device controller
Air heating relay
Location of instrument panel components
B361 Clutch pedal sensor
Safety contactor at start
starter relay
Preheat relay
Flashing switchboard
Electrohydraulic transmission controller
C073 Inverter lever under torque
Z126 and Z127 Brake Light Contactors
Fuses and relays
Location of components in the cabin
A147 Rear Linkage Control Panel (RHP)
S114 Rear power take-off “on/off” contactor
A164 Rear Linkage and Transmission Module/A058 Rear Linkage Module (REH)
S064 Key contactor
S015 Driving lights switch/S048 Horn switch
Location of components. Several
R035 Fuel level resistance
Decoupled pedal contactor
Z012 Parking brake contactor
B117 Rotation angle sensor
Hydraulic installation
Location of components
2005 Hydraulic pump
7070 Priority Valve/1031 Transmission Oil Cooler
Power Shuttle System Distributor
charger distributor
transmission distributor