Claas Vario 1380-1080 (823) Combines Repair Manual EN

File List:

00 0305 933 0.pdf

00 0305 933 0.pdf:

VARIO 1380VARIO 1230VARIO 1080
Table of contents
Introduction
Notes on the manual
Validity of manual
Information about this Repair Manual
Using the manual
Document structure based on subassemblies
Search and find
Directions
General repair instructions
Technical specifications
Information on professional 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
Installing
Gib head key connections
Dismounting
Installing
Lock collar bearing
Dismounting
Installing
Adapter sleeve bearing
Dismounting
Installing
Chuck bushing
Removing
Dismounting of version A
Dismounting of version B
Installing
Chuck bushing version A
Chuck bushing version B
Circlips
Radial shaft seals
Hose clamps
Tightening speed
Tightening torques
Alignment of clamps
Installation aids
Assembly tools
Ferrule fittings
Screwing in
Leaky ferrule fittings
Sealing cone fittings
Hydraulic hoses
Hose placement
Diaphragm accumulator (pressure accumulator) according to CLAAS works standard CN 24 0403
Operating utilities
Service and assembly
Change of gas filling
Special tool
Treatment of sealing faces
Spare parts
Operating materials
Welding work
ESD protection measures
Special tool
ESD protection measures
Notes on inspection and repair
Tightening torques
Threaded assemblies according to CLAAS works standard CN 02 5000
Description of threaded assembly
Tolerance class
Tightening specifications
Tightening torques for metric ISO screw threads
Tightening torques for metric fine thread screws
Tightening torques for hydraulic screw fittings with ferrule
Tightening torques for pipe fittings with sealing cone joints and hydraulic fittings with soft ring seals
Tightening torques for bulkhead union nuts, straight and angled
Tightening torques for hydraulic male connectors SDS shape B and E
Tightening torques for hydraulic male connectors SDS shape F and screw plug
Tightening torques for SDS shape H hydraulic male connectors
Tightening torques for screw plugs shape E
Tightening torque for hydraulic male connectors shape C, conical thread
Tightening torques for hydraulic male connectors SDE shape F, adjustable direction
Tightening torques for hydraulic male connectors SDE shape H, with adjustable direction
Tightening torques for hydraulic swivel screw fittings
Tightening torque for hollow screws (with copper sealing ring)
Tightening torques for brake line screw fittings
Tightening torque for tubes with O-ring and union nuts
Tightening torques for threaded pins / orifice plates
Tightening torque for studs and special screws
Tightening torques for hydraulic components
Tightening torques for hex. sealing nuts
Tightening torques for hose clamps
Installation instructions
Worm drive hose clamps
Worm-type hose clamps with disc springs
Hose clamps with round pins
Identifying warnings
Hazard signs
Signal word
Safety rules
Safety signs and warnings
Requirement made on technical staff
Children in danger
Hazard areas of the machine
Instructors travelling along during fieldwork
Risk of injury from rotating shafts
Structural alterations of the machine
Optional equipment and spare parts
Control of running machine
Technical condition
Respecting technical limit values
Danger from machine parts that continue rotating
Keeping safety devices functional
Personal protective equipment
Wearing suitable clothing
Removing dirt and loose objects
Parking the machine safely
Unsuitable operating utilities
Safe handling of service fluids and auxiliary utilities
Environmental protection and disposal
Keeping the cab free of chemicals
Avoiding fires
Potentially fatal electric shock from overhead lines and lightning strike
Electric shock from electric system
Noise may damage your health
Pre-loaded machine parts
Liquids under pressure
Compressed air
Toxic exhaust gases
Hot surfaces
Safe access and leaving
Working only on the stopped machine
Hazards during repairs
Raised machine parts and loads
Danger from welding work
Checking and charging the battery
Preparations for cases of emergency
CCN explanation
CCN (CLAAS Component Number)
Electric systems standard
Hydraulic system standard
CCN (CLAAS Component Number)
02 Gearbox / Clutch / Universal drive shaft
0215 Mechanical clutch
Cam-type cut-out clutch
Technical specifications
Work preparation
Removing
Disassembling
Assembling
Installing
0230 Mechanical gearbox
Cylindrical angle gear
Technical specifications
Work preparation
Installation instructions
Auxiliary tool
Special tool
Removing
Disassembling
Assembling
Installing
0260 Universal drive shaft
Main drive universal drive shaft
Technical specifications
Work preparation
Removing
Disassembling
Assembling
Installing
05 Steering
0510 Automatic steering
LASER PILOT bracket
Technical specifications
Work preparation
Installation instructions
Removing
Installing
08 Drives
0800 Drive diagram
Drive diagram
Technical specifications
Installation instructions
0814 Intermediate drive shaft
Intermediate drive shaft
Technical specifications
Work preparation
Removing
Disassembling
Assembling
Installing
09 Hydraulic system
0900 Hydraulic system – General
Hydraulic system – General
Work preparation
Special tool
Damage of hydraulic system
Checking the pressure accumulator
0915 Hydraulic lines
Multi-coupler
Technical specifications
Work preparation
Repair kit
Auxiliary tool
Removing the male coupling
Disassembling the male coupling
Assembling the male coupling
Installing the male coupling
0920 Valves
Valve block
Technical specifications
Installation instructions
Before removing any valve
After installing any valve
0930 Cylinders
Bleeding the hydraulic cylinder
Intake auger
Horizontal reel adjustment
Reel height adjustment
Cutterbar table adjustment
10 Electrical / Electronic equipment
1000 Electrical / Electronic equipment general
Electrical / electronic equipment – General
Special tool
Preparing welding work
1012 Modules / sensors
Technical specifications
Removing
Installing
1020 Driving lights
Road lighting
Technical specifications
Installation instructions
1025 Working lights
Work lights
Technical specifications
1035 Operation / multifunction handle
Technical specifications
Removing
Installing
20 Crop feeding
2010 Cutterbar table
Cutterbar table
Technical specifications
Removing
Installing
Stone deflectors
Technical specifications
Removing
Installing
Feed plates
Technical specifications
Removing
Installing
Intermediate plates
Technical specifications
Removing
Installing
Outer cutterbar table adjustment hydraulic cylinder
Technical specifications
Work preparation
Removing
Installing
Inner cutterbar table adjustment hydraulic cylinder
Technical specifications
Work preparation
Installation instructions
Inner cutterbar table adjustment hydraulic cylinder with sensor
Technical specifications
Work preparation
Installation instructions
Dismounting
Assembly
2015 Reel / Crop guard
Reel, left
Technical specifications
Work preparation
Removing the left reel
Installing the left reel
Reel, right
Technical specifications
Work preparation
Removing the right reel
Installing the right reel
Left control spider
Technical specifications
Removing
Installing
Right control spider
Technical specifications
Installation instructions
Left roller bearing
Technical specifications
Work preparation
Removing
Disassembling
Assembling
Installing
Right roller bearing
Technical specifications
Work preparation
Removing
Disassembling
Assembling
Installing
Left cam rollers
Technical specifications
Removing
Installing
Right cam rollers
Technical specifications
Installation instructions
Reel spider
Technical specifications
Removing
Installing
Tine tubes
Technical specifications
Technical specifications
Removing
Installing
Replacing the pull-in nut
Left reel bearing
Technical specifications
Work preparation
Removing
Disassembling
Assembling
Installing
Centre reel bearing
Technical specifications
Work preparation
Removing
Disassembling
Assembling
Installing
Right reel bearing
Technical specifications
Removing
Disassembling
Assembling
Installing
Left reel support arm
Technical specifications
Work preparation
Removing
Installing
Centre reel support arm
Technical specifications
Work preparation
Removing
Installing
Right reel support arm
Technical specifications
Work preparation
Removing
Installing
Reel drive gear
Technical specifications
Work preparation
Removing
Installing
Reel drive shaft
Technical specifications
Work preparation
Removing
Installing
Horizontal reel position sensor
Technical specifications
Installation instructions
Left reel height position sensor
Technical specifications
Installation instructions
Centre reel height position sensor
Technical specifications
Installation instructions
Right reel height position sensor
Technical specifications
Installation instructions
Reel drive hydraulic motor
Technical specifications
Work preparation
Removing
Installing
Left reel height adjustment hydraulic cylinder
Technical specifications
Work preparation
Removing
Installing
Centre reel height adjustment hydraulic cylinder
Technical specifications
Work preparation
Removing
Installing
Right reel height adjustment hydraulic cylinder
Technical specifications
Work preparation
Installation instructions
Left horizontal reel adjustment hydraulic cylinder
Technical specifications
Work preparation
Removing
Installing
Centre horizontal reel adjustment hydraulic cylinder
Technical specifications
Work preparation
Removing
Installing
Right horizontal reel adjustment hydraulic cylinder
Technical specifications
Work preparation
Installation instructions
Basic reel adjustment
Technical specifications
Checking
2030 Oilseed rape equipment
Metal guide / guard
Technical specifications
Installation instructions
Removing
Installing
Overload clutch
Technical specifications
Work preparation
Installation instructions
Removing
Installing
Coupling rods / guide rails
Technical specifications
Work preparation
Installation instructions
Removing the coupling rods
Disassembling the coupling rods
Assembling the coupling rods
Installing the coupling rods
Removing the guide rails
Installing the guide rails
Technical specifications
Work preparation
Installation instructions
Removing
Disassembling the rocker arm
Disassembling the console
Disassembling the coupling rod
Assembling the coupling rod
Assembling the console
Assembling the rocker arm
Installing
21 Feeder unit
2140 Intake auger
Centre intake auger sensor
Technical specifications
Installation instructions
Left intake auger
Technical specifications
Work preparation
Installation instructions
Removing
Installing
Right intake auger
Technical specifications
Installation instructions
Outer intake auger bearing
Technical specifications
Work preparation
Special tool
Installation instructions
Removing
Disassembling
Determining the installation dimension
Assembling
Installing
Centre intake auger bearing
Technical specifications
Work preparation
Removing
Disassembling
Assembling
Installing
Intake auger drive shaft
Technical specifications
Installation instructions
Removing
Disassembling
Assembling
Installing
Adjusting shaft
Technical specifications
Work preparation
Special tool
Installation instructions
Removing
Installing
Control shafts
Technical specifications
Removing
Installing
Intake auger finger
Technical specifications
Installation instructions
Driven sprocket (K01 / K03)
Technical specifications
Work preparation
Special tool
Installation instructions
Removing
Disassembling
Assembling
Installing
Tensioning device of chain (K01)
Technical specifications
Work preparation
Removing
Disassembling
Assembling
Installing
Tensioning device of chain (K03)
Technical specifications
Removing
Disassembling
Assembling
Installing
Intake auger hydraulic cylinder
Technical specifications
Work preparation
Removing
Installing
23 Mower unit
2305 Cutter bar
Mower bar – General
Installation instructions
Planetary gear
Technical specifications
Work preparation
Removing
Disassembling
Assembling
Checking the gearbox play
Installing
Knife drive universal drive shaft
Technical specifications
Removing
Disassembling
Assembling
Installing
26 Ground guidance
2605 AUTO CONTOUR
Left AUTO CONTOUR sensing band sensor
Technical specifications
Adjusting
Centre AUTO CONTOUR sensing bands sensor
Technical specifications
Work preparation
Removing
Installing
Adjusting
Right AUTO CONTOUR sensing band sensor
Technical specifications
Adjusting
Left AUTO CONTOUR sensing bands
Technical specifications
Removing
Disassembling
Assembling
Installing
Centre AUTO CONTOUR sensing bands
Technical specifications
Work preparation
Removing
Disassembling
Assembling
Installing
Right AUTO CONTOUR sensing bands
Technical specifications
Installation instructions
80 Various components / Machine body
8005 Frame / Trough
Stabiliser wheels
Technical specifications
Work preparation
Removing the hydraulic cylinder
Removing the swivel arm
Removing the lift arm
Installing the lift arm
Installing the swivel arm
Installing the hydraulic cylinder
Disassembling the wheel bearing
Assembling the wheel bearing
Hydraulic cylinders of stabiliser wheels
Technical specifications
Work preparation
Installation instructions
Accumulator blocks of stabiliser wheels
Technical specifications
Installation instructions
Prior to installation work
After the installation work
Filling / bleeding the accumulator blocks of stabiliser wheels
Work preparation
Special tool
Filling / venting
Deflector plates
Technical specifications
Technical specifications
Removing
Installing
Adjusting
8010 Locking
Front attachment lock
Technical specifications
Installation instructions
8025 Panellings / Hoods
Protective flap / sliding protection
Technical specifications
Installation instructions
Removing
Installing
Protective flap
Technical specifications
Installation instructions
Sliding protection
Technical specifications
Installation instructions