Claas Variant 485 480 385 380 Rc Rf (752) Balers Repair Manual EN

File List:

00 0292 253 1.pdf

00 0292 253 1.pdf:

VARIANT 380 / 385 / 480 / 485VARIANT 360 / 365 / 460 / 465VARIANT 370 / 370 POWER / 470VARIANT 350 / 450
Table of contents
Introduction
General information
Using the manual
Text and figures
Document structure based on sub-assemblies
Search and find
Directions
Abbreviations
Technical terms
Manual validity
General repair instructions
Technical specifications
Reason of damage
Spare parts
Welding work
Steel roller chains
Tensioning
Chain connector
Taper ring fasteners
Dismounting
Installing
Gib head key joints
Dismounting
Installation
Self-locking bolts
Liquid locking compound
Lock collar bearing
Dismounting
Installing
Adapter sleeve bearings
Dismounting
Installation
Ferrule joints
Screwing in
Leaky ferrule joints
Progressive ring fittings on hydraulic lines
Sealing cone joints
Hydraulic hoses
Hose routing
Information on technically correct repairs
Tightening torques
Tightening torques for metric standard threads
Tightening torques for metric fine thread
Tightening torques for hydraulic screw fittings with ferrule according to DIN 3861
Tightening torques for hydraulic screw fittings and air conditioner screw fittings with sealing cone and O-ring according to DIN 3865
Tightening torques for SDS hydraulic male connectors
Tightening torques for direction-adjustable SDE hydraulic male connectors
Tightening torques for hydraulic swivel fittings
Tightening torques for hollow screws DIN 7643
Tightening torques for brake line screw fittings
Tightening torques for worm drive hose clamps
Tightening torques for hose clamps with round pins
Wheel tightening torques
Technical specifications
Lubricants
CCN explanation
CCN (CLAAS Component Number)
Electric system standard
Overview
Hydraulic system standard
Overview
General information
Important
Identification of warning and danger signs
General safety and accident prevention advice
Leaving the machine
Adjustment and maintenance work
Danger of injury from hydraulic liquid
Hydraulic accumulators
First aid measures
Place the machine on axle stands
Decommission the machine
Basic operations
Baling system
Locking the tailgate
Slackening the baling belts
Moving the tensioning arms
02 Gearbox / Clutch / Universal drive shaft
0230 Mechanical gearbox
540 rpm drive gearbox
Overview
Removing the drive gearbox
Removing the drive gearbox bearing
Fitting the drive gearbox
Fitting the drive gearbox bearing
1000 rpm drive gearbox
Overview
03 Chassis
0310 Axle
Overview
Removing a wheel hub
Fitting a wheel hub
Removing a non-braked axle
Fitting a non-braked axle
Removing a braked axle
Pneumatic brake
Hydraulic brakes
Fitting a braked axle
Pneumatic brake
Hydraulic brakes
04 Brake
0405 Service brake
Brake mechanism
Overview
Removing a brake
Fitting a brake
Pneumatic brakes
Hydraulic brakes and active hydraulic brakes
Setting the brake control lever
Pneumatic membrane cylinder
Overview
Removing a membrane cylinder
Fitting a membrane cylinder
Pneumatic braking system
Overview
Removing the compressed air tank
Fitting the compressed air tank
Hydraulic cylinder
Overview
Removing a hydraulic brake cylinder
Fitting a hydraulic brake cylinder
0415 Parking brake
Parking brake
Overview
Setting the parking brake
07 Hitch
0725 Drawbar
Overview
Removing the drawbar
Fitting the drawbar
Adjusting the position of the hitch eye
08 Drives
0800 Drive diagram
Drive chains
0808 Main drive
Rotor drive
Overview
Removing the rotor drive chain
Fitting the rotor drive chain
Removing the rotor drive chain tensioner
Disassembling the rotor drive chain tensioner
Assembling the rotor drive chain tensioner
Fitting the rotor drive chain tensioner
Tailgate drive
Overview
Removing the tailgate drive chain
Fitting the tailgate drive chain
Tensioning the chains
Removing the tailgate drive chain tensioner
Fitting the tailgate drive chain tensioner
Disassembling the tailgate drive chain tensioner
Assembling the tailgate drive chain tensioner
Roller No.5 drive
Overview
Removing the drive chain from roller No.5
Fitting the drive chain for roller No.5
Disassembling the roller No.5 drive chain tensioner
Assembling the roller No.5 drive chain tensioner
Removing the roller No.5 chain drive
Fitting the roller No.5 chain drive
Removing the drive gear from roller No.5
Fitting the drive gear for roller No.5
Roller No.3 drive
Overview
Removing the drive chain from roller No.3
Fitting the drive chain to roller No.3
Removing the drive clutch on roller No.3
Disassembling the drive gear on roller No.3
Assembling the drive gear on roller No.3
Disassembling the clutch gear on roller No.3
Assembling the clutch gear on roller No.3
Fitting the drive clutch on roller No.3
0821 Feeder unit drive
Rotor cut-out clutch
Overview
Removing the rotor cut-out clutch
Disassembling the rotor cut-out clutch hydraulic control
Assembling the rotor cut-out clutch hydraulic control
Fitting the rotor cut-out clutch
09 Hydraulic system
0900 Hydraulic system – General
General rules
Risk of damage to the hydraulic system
General rules
Before any operation on the machine’s hydraulic circuit:
When dismantling a cap or a hydraulic block component:
When fitting a cap or a hydraulic block component:
Special tools
Special tool
Checking the operation of the hydraulic circuit
Measuring hydraulic pressure
Connecting a device to a Minimess socket
Removing the components from the hydraulic block
Removing the seals and sealing rings
0915 Hydraulic lines
Oil filter
0920 Valves
Main hydraulic block – VARIANT 450 / 460 / 465 / 470 / 480 / 485
Main hydraulic block – VARIANT 350 / 360 / 365 / 370 / 380 / 385
Main hydraulic block – VARIANT 360 / 365 / 380 / 385
Main hydraulic block – VARIANT 350 / 370
RotoCut control block and pivoting rotor chassis
RotoCut control block and pivoting rotor chassis
RotoFeed control block and pivoting rotor chassis
2/3 control valve for RotoCut knives
Tensioning arm unlockable non-return valves
Tailgate cylinder unlockable non-return valves
0930 Cylinders
Hydraulic cylinder control for roller No.3
Overview
Disassembling the hydraulic cylinder control for roller No.3
Assembling the hydraulic cylinder control for roller No.3
0932 Rotary coupling
Rotating hydraulic connection
Disassembling a rotating hydraulic connection
Assembling a rotating hydraulic connection
0980 Hydraulic circuit diagram
VARIANT main hydraulic diagram with pivoting rotor chassis
VARIANT main hydraulic diagram without pivoting rotor chassis
Main hydraulic diagram VARIANT 350 / 370
Main hydraulic diagram – VARIANT 360 / 365 / 380 / 385
Hydraulic diagram of pick-up without fixed chassis RotoCut
Hydraulic diagram of pick-up and fixed chassis RotoCut knives
RotoFeed pivoting chassis hydraulic diagram
RotoCut pivoting chassis hydraulic diagram
20 Crop feeding
2020 Pick-up
Overview
Removing the pick-up
Fitting the pick-up
2025 Tines / Tine bars
Tine carrier
Overview
Removing a tine
Fitting a tine
21 Feeder unit
2125 Rotor
Rotor chassis – fixed RotoFeed
Overview
Availability of this option:
Removing the rotor chassis
Fitting the rotor chassis
Disassembling the rotor chassis
Removing the scraper
Removing the toothed wheel from the pick-up drive
Removing the rotor drive chain wheel
Removing the right-hand bearing
Removing the left-hand bearing
Removing the cylinders from the pick-up
Assembling the rotor chassis
Fitting the cylinders on the pick-up
Left- and right-hand deflectors
Fitting the right-hand bearing
Fitting the left-hand bearing
Fitting the scraper
Fitting the rotor drive chain wheel
Fitting the toothed wheel of the pick-up drive
Rotor chassis – Pivoting RotoFeed
Overview
Availability of this option:
Rotor chassis – standard fixed RotoCut
Overview
Availability of this option:
Rotor chassis – Heavy Duty fixed RotoCut
Overview
Availability of this option:
Rotor chassis – standard pivoting RotoCut
Overview
Availability of this option:
Rotor chassis – Heavy Duty pivoting RotoCut
Overview
Availability of this option:
Floor – Heavy Duty pivoting RotoCut / standard pivoting RotoCut
Overview
Disassembling the cutting floor
Fitting the cutting floor
Knife position sensor (B111)
Removing the knife position sensor (B111)
Fitting the knife position sensor (B111)
45 Baling system
4505 Baling chamber
Belt guide panel
Overview
Removing the belt guide panel
Fitting the belt guide panel
Tailgate
Removing the tailgate
Fitting the tailgate
Tailgate hooks without eccentrics
Overview
Removing the hooks
Fitting the hooks
Tailgate hooks with eccentrics
Overview
Removing the hooks
Fitting the hooks
Adjusting the eccentric rings
4520 Compression rollers / Guide rollers
Roller identification
Roller No.1
Overview
Removing the scraper on roller No.1
Fitting the scraper on roller No.1
Removing roller No.1
Left-hand side
Fitting roller No.1
Left-hand side
Roller No.2
Overview
Removing the scraper on roller No.2
Fitting the scraper on roller No.2
Adjusting the scraper play
Removing roller No.2
VARIANT type 752 / 771
VARIANT type 751 / 770
VARIANT type 751 / 770
Fitting roller No.2
VARIANT type 751 / 770
VARIANT type 751 / 770
VARIANT type 752 / 771
Roller No.3
Removing roller No.3
Right-hand side – VARIANT 370 POWER and type 751 / 752
Left- and right-hand sides – VARIANT type 770 / 771
Left-hand side – VARIANT 370 POWER and type 751 / 752 equipped with standard tying
Left-hand side – VARIANT type 751 / 752 equipped with comfort tying
Removing the scraper from roller No.3
Fitting roller No.3
Left-hand side – Machine fitted with standard tying
Left-hand side – VARIANT type 751 752 equipped with comfort tying
Right-hand side – VARIANT type 770 / 771
Right-hand side – VARIANT 370 POWER and type 751 / 752
Fitting the scraper on roller No.3
Left- and right-hand sides – VARIANT type 770 / 771
Left-hand side – VARIANT 370 POWER and type 751 / 752 equipped with standard tying
Left-hand side – VARIANT type 751 / 752 equipped with comfort tying
Adjusting the sensor
Right-hand side – VARIANT 370 POWER and type 751 / 752
Roller No.4
Overview
Removing roller No.4
Fitting roller No.4
Roller No.5
Overview
Removing the scraper on roller No.5
Fitting the scraper on roller No.5
Removing roller No.5
Fitting roller No.5
Scraper control for roller No.5: Spring preload
Roller No.6
Overview
Removing roller No.6
Fitting roller No.6
Roller No.7
Overview
Removing the scraper on roller No.7
Fitting the scraper on roller No.7
Adjusting the scraper play
Removing roller No.7
Fitting roller No.7
Roller No.8
Overview
Removing roller No.8
Fitting roller No.8
Roller No.9
Overview
Removing roller No.9
VARIANT type 752 / 771
VARIANT type 751 / 770
Fitting roller No.9
VARIANT type 752 / 771
VARIANT type 751 / 770
Roller No.10
Overview
Removing roller No.10
Fitting roller No.10
Replacing the bearings in rollers with cast aluminium baffle plates
Overview
Disassembling the roller
Assembling the roller
Replacing the bearings in rollers with plastic baffle plates
Overview
Disassembling the roller
Assembling the roller
4525 Belt conveyors
Baling belts
Overview
Removing the baling belts
Fitting the baling belts
Baling belt replacement kit
Tensioning and aligning the baling belts
Adjusting the bottom tensioning arm
Adjusting the top tensioning arm
Adjusting roller No.7
Checking the tension of the baling belts
Replacing a baling belt
Repairing the baling belts
4530 Tensioning device
Bottom tensioning arm
Overview
Removing the bottom tensioning arm
Right-hand draw spring
Left-hand side – VARIANT type 751 / 752 and VARIANT 400 series
Left-hand side – VARIANT 350 / 370 / 370 POWER
Right- and left-hand cylinder rod
Left- and right-hand bearings
Fitting the bottom tensioning arm
Right-hand bearings
Left-hand bearing
Right- and left-hand cylinder rod
Left-hand side – VARIANT 350 / 370 / 370 POWER
Left-hand side – VARIANT type 751 / 752 and VARIANT 400 series
Right-hand draw spring
Adjusting the end of travel sensor – VARIANT 350 / 370 / 370 POWER
Adjusting the bale diameter indicator – VARIANT 350 / 370 / 370 POWER
Adjusting the bale diameter indicator – VARIANT type 751 / 752 and VARIANT 400 series
Top tensioning arm
Overview
Removing the top tensioning arm
Right-hand side cylinder rod
Left-hand draw spring
Fitting the top tensioning arm
Right-hand side cylinder rod
Left-hand draw spring
46 Tying system
4605 Tying material
Twine box
Overview
Removing the twine box
Twine box/net support
Fitting the twine box
Twine box/net support
Tying drive
Overview
Removing the electromagnetic tying clutch
Disassembling the electromagnetic tying clutch
Assembling the electromagnetic tying clutch
Fitting the electromagnetic tying clutch
Tying drive belt
Removing the tying drive belt
Fitting the tying drive belt
Tying feed lips
Overview
Removing the tying feed lips
Procedure for a bonded rear guide plate
Fitting the tying feed lips
Bonding the rear guide plate
Tying feed plate
Overview
Removing the tying feed plate
Fitting the tying feed plate
Bonding the rear guide plate
Adjusting the position of the tying feed plate
Testing operation
Adjusting during work
4610 Twine wrapping
Standard tying – Twine slide drive
Overview
Removing the twine slide drive
Fitting the twine slide drive
Comfort tying – Twine slide drive
Overview
Removing the twine slide drive
Fitting the twine slide drive
Disassembling the twine slide drive
Assembling the twine slide drive
4615 Net wrapping
Standard net tying – Tying chassis
Overview
Removing the net tying chassis
Fitting the net tying chassis
Net tying – Net brake
Overview
Removing the net brake
Fitting the net brake
Net tying – Cam net brake
Overview
Removing the cam net brake
Fitting the cam net brake
Removing the net brake lock
Fitting the net brake lock
Standard tying / comfort tying – Rubber roller and net cutter
Overview
Disassembling the rubber roller and net cutter assembly
Assembling the rubber roller and net cutter assembly
Removing the ratchet wheel on the rubber roller
Machine equipped with comfort tying
Machine equipped with standard tying
Fitting the ratchet wheel on the rubber roller
Machine equipped with comfort tying
Machine equipped with standard tying
Disassembling the ratchet wheel on the rubber roller
Machine equipped with comfort tying
Machine equipped with standard tying
Assembling the ratchet wheel on the rubber roller
Machine equipped with standard tying
Machine equipped with comfort tying
Net tying – Net cutter resetting lever
Overview
Removing the net cutter resetting lever
Fitting the net cutter resetting lever
Adjusting the net cutter resetting lever
Net tying – Net cutter control hook stop
Overview
Position of the net cutter control hook stop
Edge to edge comfort tying
Extra wide comfort tying
60 Crop discharge / straw discharge
6040 Bale discharge
Bale ramp
Overview
Removing the bale ramp
Fitting the bale ramp
75 Central lubrication system
7505 Reservoir / Pump
Central lubrication pump (M025)
Overview
Removing the lubrication pump
Fitting the lubrication pump
Continuous chain lubrication pump
Overview
Removing the pump
Fitting the pump
Adjusting the position of the pump
Connecting the pump
Removing the eccentric control disc
Machine equipped with a pivoting floor
Machine equipped with an unblocking key
Fitting the eccentric control disc
Machine equipped with a pivoting floor
Machine equipped with an unblocking key
Removing the reservoir assembly
Fitting the reservoir assembly
Commissioning
Adjusting the pump flow rate
Changing the filter
Intermittent chain lubrication pump – 6-litre reservoir
Overview
Removing the pump
Fitting the pump
Intermittent chain lubrication pump – 3-litre reservoir
Overview
Removing the pump
Fitting the pump
7510 Distributor
Central lubrication distributors
Overview
Distributor 1
Distributor 2
Distributor (depending on the equipment)
Continuous chain lubrication circuit
Overview
Lubrication ducts
Distributor/pump hose
Disconnecting
Connecting
Distributor hose
Disconnecting
Disassembling a nozzle
Fitting a nozzle
Connecting
Chain lubrication points
Hose for the lubrication points
Disconnecting
Connecting
Removing a brush
Fitting a brush
Removing the brushes from the tailgate chain
Fitting the brushes for the tailgate chain
7515 Lubrication system / Lines
Wiring harness for the continuous chain lubrication hoses
Removing the wiring harness for the lubrication hoses
Fitting the wiring harness for the lubrication hoses
Wiring harness for the intermittent chain lubrication hoses
Removing the wiring harness for the lubrication hoses
Fitting the wiring harness for the lubrication hoses
80 Various components / Machine body
8005 Frame / Trough
Jack stand – Fitting on the right
Overview
Removing the stand
Fitting the jack stand
8025 Panellings / Hoods
Plastic bodywork
Overview
Removing the side flaps
Fitting the side flaps
Adjusting the opening height (VARIANT 400 series)
Removing the upper covers
Fitting the upper covers
Removing the upper rear cover
Fitting the upper rear cover
Removing the lower rear cover
Fitting the lower rear cover
Steel bodywork
Overview
Removing the side flaps
Fitting the side flaps
Removing the upper rear cover
Fitting the upper rear cover
Removing the lower rear cover
Fitting the lower rear cover