Claas Xerion 3800-3300 (781) Tractors Repair Manual EN

File List:

00 0114 220 2.pdf
00 0288 638 1.pdf
00 0290 621 3.pdf
00 1106 921 9.pdf
1 160 241_e.pdf
1 183 409_e.pdf
Diagnostics report ECCOM 3.5.pdf
Inspection protocol XERION 3800 – 3300.pdf

00 0288 638 1.pdf:

ZF ECCOM 3.5 / 4.5
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
Converting metric units to US units
Pressure
Ground speed
Acceleration (vibration intensity)
Viscosity
Temperature
Electric system
General repair instructions
Technical specifications
Information on technically correct repairs
Self-locking bolts
Liquid locking compound
Steel roller chains
Tensioning
Chain connector
Taper ring fasteners
Dismounting
Installing
Gib head key joints
Dismounting
Installation
Lock collar bearing
Dismounting
Installing
Adapter sleeve bearings
Dismounting
Installation
Chuck bushing
Removing version A
Removing version B
Installation
Version A chuck bushing
Version B chuck bushing
Circlips
Ferrule joints
Screwing in
Leaky ferrule joints
Sealing cone joints
Hydraulic hoses
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 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-type threaded clips
Tightening torques for hose clamps with round pins
Tightening torques for tyres
General information
Important
Identification of warning and danger signs
General safety and accident prevention regulations
First aid measures
Danger of injury from hydraulic liquid
Leaving the machine
Putting the machine out of operation
Jacking up the machine
Adjustment and maintenance work
Welding work
02 Gearbox / Clutch / Universal drive shaft
0202 Complete component
Diagnostic protocol
Removing / installing the gearbox
Transmission housing
Technical specifications
Work preparation
Special tool
Separating the halves of the housing
Joining the halves of the housing
0220 Mechanical reverser
Clutch KR
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Clutch KV
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Adjusting the axial play
Special tool
Adjusting the axial play of the clutches and spur gears
0230 Mechanical gearbox
Engine input shaft
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Installing
Central shaft
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Multi-disc brake BG
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Shifter roller
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Clutches K3/K4 and planetary gear P4
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Planetary gears P1/P2/P3
Technical specifications
Work preparation
Special tool
Removing
Removing P1
Disassembling planetary gear P1
Removing planetary gear P2
Disassembling planetary gear P2
Removing planetary gear P3
Disassembling planetary gear P3
Assembling planetary gear P3
Assembling planetary gear P2
Assembling planetary gear P1
Assembling the profile tube
Clutch K1/K2
Technical specifications
Special tool
Removing
Disassembling
Assembling
Front axle output shaft (ECCOM 3.5 / 4.5)
Technical specifications
Work preparation
Special tool
Removing
Installing
Rear axle output shaft
Technical specifications
Work preparation
Special tool
Removing the output flange
Removing the output shaft
Disassembling the output shaft
Assembling the output shaft
Installing the output shaft
Installing the output flange
PTO (ECCOM 3.5 / 4.5)
Technical specifications
Work preparation
Special tool
Disconnecting the PTO from the intermediate housing
Disassembling
Disassembling the PTO clutch
Assembling
Installing
Spur gear Z4
Technical specifications
Removing the spur gear (Z4)
Installing the spur gear (Z4)
Spur gear Z5
Special tool
Removing
Removing the spur gear (Z5)
Installing the spur gear (Z5)
Spur gear Z6
Technical specifications
Work preparation
Special tool
Removing
Removing gear (Z6)
Installing gear (Z6)
Spur gear Z23
Technical specifications
Special tool
Removing
Installing
Spur gears Z2 / Z3
Technical specifications
Work preparation
Special tool
Removing
Removing gear (Z2)
Disassembling the gear (Z2)
Assembling the gear (Z2)
Installing gear (Z2)
Removing gear (Z3)
Disassembling the gear (Z3)
Installing gear (Z3)
Spur gear Z33
Technical specifications
Work preparation
Special tool
Removing
Removing gear (Z33)
Installing gear (Z33)
Intermediate gear Z24 / Z25
Technical specifications
Work preparation
Special tool
Removing (Z24) and (Z25)
Fitting Z24
Fitting Z25
Auxiliary PTO power hydraulics (ECCOM 4.5)
Technical specifications
Work preparation
Removing
Installing
0232 Hydraulical gearbox
Hydrostatic drive
Technical specifications
Work preparation
Special tool
Removing
Removing gear (Z4)
Installing gear (Z4)
Installing
0238 Gearbox control
System pressure control block
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Clutch control block
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
0242 Differential
Longitudinal differential lock clutch (ECCOM 3.5 / 4.5)
Technical specifications
Work preparation
Special tool
Removing
Installing
Differential (ECCOM 3.5 / 4.5)
Technical specifications
Work preparation
Special tool
Removing
Assembling
0255 Gearbox cooling system
Gear pump (ECCOM 3.5 / 4.5)
Technical specifications
Work preparation
Special tool
Removing
Installing
CCN (CLAAS Component Number)

00 0290 621 3.pdf:

XERION 3800-3300
Table of contents
Introduction
General information
Validity of the 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
Reason of damage
Spare parts
Diesel engine
Alternator
Welding work
Drive belts / drive chains
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 placement
Information on technically correct repairs
Torque settings
Tightening torques for metric standard threads
Tightening torque for metric fine threads
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-type threaded clips
Tightening torques for hose clamps with round pins
Tightening torques for tyres
Technical specifications
Lubricants
CCN explanation
CCN (CLAAS Component Number)
Electric system standard
Overview
Hydraulic system standard test
Overview
CCN (CLAAS Component Number)
General information
Important
Identification of warning and danger signs
General safety and accident prevention regulations
Leaving the machine
Adjusting and maintenance work
Danger of injury from hydraulic liquid
Air conditioner
Hydraulic accumulators
First aid measures
Battery isolating switch
Jacking up the machine
Putting the machine out of operation
01 Engine
0102 Complete component
Power measurement
Visual inspections
Preparations for power measurement
Performing the power measurement
Attention!
Power diagram XERION 3300
Power diagram XERION 3800
Diesel engine
Removing
On TRAC / TRAC VC
On TRAC / TRAC VC
On SADDLE TRAC
On TRAC / TRAC VC
On TRAC / TRAC VC
On TRAC / TRAC VC
Installing
On TRAC / TRAC VC
On TRAC / TRAC VC
On TRAC / TRAC VC
On SADDLE TRAC
On TRAC / TRAC VC
On TRAC / TRAC VC
0125 Injection – / Fuel system
Fuel tank
Removing
With TRAC
On TRAC VC
Installing
With TRAC
0135 Cooling system
Fan blade assembly
Removing
Only with reversing blower
Installing
Only with reversing blower
Work preparation
Special tool
Installation instructions
Rotary chaff screen
Removing
Only for SADDLE TRAC
Installing
Only for SADDLE TRAC
Engine radiator
Work preparation
Technical specifications
Removing
Installing
Coolant lines
Work preparation
Technical specifications
Thermostat
Removing
Installing
0140 Exhaust system
Silencer
Work preparation
Technical specifications
Removing
Installing
Silencer
Technical specifications
Removing
Installing
0145 Air intake
Charge air cooler
Work preparation
Technical specifications
Removing
Installing
Charge air lines
Technical specifications
0150 Engine attachment parts
Electric starting motor (M21)
Removing
Installing
Alternator (G2-1 / G2-2)
Installation instructions
Removing alternator (G2-1)
Removing alternator (G2-2)
Installing alternator (G2-2)
Installing alternator (G2-1)
Fan drive belt (R1)
Installation instructions
Air conditioner compressor drive belt (R2)
0155 Engine control
Accelerator pedal
Technical specifications
02 Gearbox / Clutch / Universal drive shaft
Diagnostic protocol
0202 Complete component
Transmission
Installation instructions / diagnostic protocol
Work preparation
Special tool
Removing
On SADDLE TRAC / TRAC VC
Opening the housing
Joining the housing
Installing
On SADDLE TRAC / TRAC VC
On TRAC VC
With TRAC
On SADDLE TRAC
0210 Oscillation damper
Torsion damper
Work preparation
Special tool
Removing
On TRAC VC
With TRAC
Installing
Torsion damper
Technical specifications
Work preparation
Removing
Installing
0218 Clutch control
Inching pedal
Technical specifications
Inching pedal
Technical specifications
0255 Gearbox cooling system
Oil cooler (109)
Removing
Installing
Oil cooler
Technical specifications
Work preparation
Special tool
Removing
Installing
0260 Universal drive shaft
Universal drive shaft main drive
Work preparation
Technical specifications
Universal drive shaft main drive
Technical specifications
Work preparation
Front axle drive universal drive shaft
Installation instructions
Front axle drive universal drive shaft
Technical specifications
Work preparation
Rear axle drive universal drive shaft
Installation instructions
Rear axle drive universal drive shaft
Technical specifications
Work preparation
03 Chassis
0325 Driven steering axle, front
Front drive axle
Removing
On TRAC / TRAC VC
Installing
On TRAC / TRAC VC
Axle bearing
Work preparation
Front driven steering axle sensor (B152)
Removing
On TRAC / TRAC VC
Installing
On TRAC / TRAC VC
Front differential drive
Front differential clutch
Front wheel hub
Front stub axles
Front track rods
Front plug-on shafts
Floating axle lock hydraulic cylinder
Technical specifications
Work preparation
Special tool
0330 Driven steering axle, rear
Rear steering drive axle
Removing
Installing
Rear driven steering axle sensor (B151)
Removing
Installing
Rear differential
Work preparation
Removing
Disassembling
Up to serial no. 78100577
Up to serial no. 78100577
Up to serial no. 78100577
Assembling
Up to serial no. 78100577
Up to serial no. 78100577
Up to serial no. 78100577
Installing
Checking the wear
Pressure testing of differential lock
Pressure testing special tool
Rear differential clutch
Work preparation
Special tool
Removing
Up to serial no. 78100577
Up to serial no. 78100577
Up to serial no. 78100577
Up to serial no. 78100577
Up to serial no. 78100577
From serial no. 78100578
From serial no. 78100578
Installing
From serial no. 78100578
From serial no. 78100578
Up to serial no. 78100577
Up to serial no. 78100577
Up to serial no. 78100577
Up to serial no. 78100577
Up to serial no. 78100577
Rear wheel hub
Work preparation
Special tool
Removing / disassembling
For axle type 576
For axle type 576
For axle type 576
For axle type 576
For axle type 576
For axle type 577
Assembling / installing
For axle type 576
For axle type 576
For axle type 576
For axle type 576
For axle type 576
For axle type 576
For axle type 576
For axle type 577
Removing the complete wheel hub
Installing the complete wheel hub
Rear stub axle
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Rear track rods
Work preparation
Adjusting the track
Rear plug-on shafts
Work preparation
Removing
Installing
Axle shaft play
Work preparation
Adjusting
04 Brake
0405 Service brake
Service brake
Technical specifications
Work preparation
Special tool
Pressure testing
Wear test
Installation instructions
Venting the service brake
Pressure testing
Wear test
Brake pedal
Removing the brake pedal up to serial no.
Installing the brake pedal up to serial no.
Brake pedal installation instructions from serial no.
0415 Parking brake
Parking brake (3108)
Adjusting
Bleeding
Changing the brake linings
Adjusting the parking brake return mechanism
0420 Trailer air brake
Compressed-air accumulator
Removing
Only on compressed-air trailer brake system
Installing
Only on compressed-air trailer brake system
Compressed-air trailer brake system valve block
05 Steering
0505 Steering
Steering column
Work preparation
Special tool
Removing up to serial no. 78100620
Disassembling up to serial no. 78100620
Removing from serial no. 78100621
Disassembling from serial no. 78100621
Assembling up to serial no. 78100620
Installing up to serial no. 78100620
Assembling from serial no. 78100620
Installing from serial no. 78100620
Steering pump (218)
Special tool
Removing
On TRAC VC
With TRAC
Installing
On TRAC VC
With TRAC
Adjusting the working pressure
Adjusting the system pressure
Steering unit
Technical specifications
Work preparation
Special tool
Removing
Installing
Emergency steering pump (245)
Special tool
Work preparation
Removing
Installing
Bleeding
Steering valve block
Installation instructions
Steering hydraulic cylinder (3023)
Work preparation
Disassembling
Assembling
Installation instructions
06 Lift device
0605 Rear power lift
Rear power lift sensor (B144)
Work preparation
Technical specifications
Removing
Installing
Rear power lift sensor (B144)
Work preparation
Technical specifications
Removing
Installing
Rear power lift position sensor (B139-2)
Technical specifications
Lift arms
Work preparation
Technical specifications
Removing
Installing
Lift arms
Work preparation
Technical specifications
Removing
Installing
Lower link
Work preparation
Technical specifications
Removing
Installing
Lower link
Work preparation
Technical specifications
Removing
Installing
Upper link
Work preparation
Installation instructions
Lift braces
Work preparation
Removing
Installing
Side braces
Work preparation
Technical specifications
Side braces valve block
Slew rear power lift valve block
Raise / lower rear power lift hydraulic cylinder (3112)
Work preparation
Special tool
Removing
Installing
Slew rear power lift hydraulic cylinder (3163)
Work preparation
Removing
Installing
0610 Front power lift
Front power lift position sensor (B139-1)
Technical specifications
Front power lift slewing position sensor (B369)
Technical specifications
Lower link
Work preparation
Technical specifications
Removing (standard lower link)
Installing (standard lower link)
Removing (slewing lower link)
Installing (slewing lower link)
Upper link
Work preparation
Technical specifications
Slew front power lift valve block
Work preparation
Special tool
Technical specifications
Raise / lower front power lift hydraulic cylinder (3013)
Work preparation
Special tool
Technical specifications
Removing
Installing
Slew front power lift hydraulic cylinder (3163)
Work preparation
Special tool
Technical specifications
07 Hitch
0705 Coupling frame
Hitch block
Work preparation
Technical specifications
Removing
Installing
0715 Towing ball and socket joint
Towing ball and socket joint lubrication system
Technical specifications
0730 Three-point frame / implement frame
Fitting frame
Technical specifications
08 Drives
0800 Drive diagram
Drive diagram
Technical specifications
Technical specifications
0802 Rear PTO
Rear PTO shaft gearbox
Work preparation
Special tool
Technical specifications
Removing
Disassembling
Assembling
Installing
Rear PTO shaft universal drive shaft
Work preparation
Technical specifications
Removing
Installing
09 Hydraulic system
0900 Hydraulic system – General
Damage to hydraulic system
Special tool
Hydraulic system – General
Work preparation
Special tool
Filling / bleeding the hydraulic system
0905 Hydraulic oil tank
Hydraulic oil tank (1010)
Special tool
Removing
Installing
Generating a vacuum
0910 Pumps
Working hydraulics pump (205)
Special tool
Removing up to serial no. 78100395
With TRAC
On TRAC VC
Removing from serial no. 78100396
With TRAC
On TRAC VC
Installing up to serial no. 78100395
With TRAC
Installing from serial no. 78100396
With TRAC
Adjusting the working pressure
With TRAC
On TRAC VC
Adjusting the system pressure
0920 Valves
Main valve block
Installation instructions
Additional control units valve block
Installation instructions
Crane operation pressure relief valve (7006)
Installation instructions
0940 Power hydraulics
Power hydraulics pump (227)
Special tool
Removing
At rear connections:
At front connections:
Installing
At front connections:
At rear connections:
Bleeding
Universal drive shaft power hydraulics drive
Work preparation
Special tool
Installing
10 Electrical / Electronic equipment
1000 General electrical system
Electric system – General
Special tool
1005 Power supply
Removing
Installing
1030 Board computer / Indicators
CEBIS (A030)
Removing
Installing
1035 Operation / Multifunction control lever
Ground speed control lever
Removing
Installing
Switch console
Removing
Removing
12 Cab / Operator’s platform
1205 Cab suspension
Lift tower
Work preparation
Special tool
Technical specifications
Removing
Disassembling
Assembling
Installing
Lift tower
Work preparation
Technical specifications
Removing
Disassembling
Assembling
Installing
Lift tower valve block
Work preparation
Special tool
Technical specifications
Unlock cab hydraulic cylinder (3111)
Work preparation
Special tool
Technical specifications
1210 Cab
Work preparation
Special tool
Technical specifications
Repair position up to serial no. 78100109
Repair position from serial no. 78100110
Technical specifications
Work preparation
Special tool
Removing
Installing
1230 Seat
Driver’s seat
Technical specifications
Removing
Disassembling and assembling
Installing
1235 Cab heater
Heat exchanger
Technical specifications
Work preparation
Special tool
Removing
Installing
Regulating valve
Technical specifications
Work preparation
Special tool
Technical specifications
Removing
Installing
1240 Air condition
Air conditioning system – General information
Special tool
Technical specifications
Discharging / topping up refrigerant
Flushing the air conditioner
A/C-MATIC sensors
Technical specifications
Removing
Installing
A/C-MATIC module
Technical specifications
Removing
Installing
Air conditioner compressor
Special tool
Technical specifications
Removing
Installing
Condenser
Special tool
Technical specifications
Removing
Installing
Evaporator
Special tool
Technical specification Removing
Installing
Expansion valve
Technical specifications
Work preparation
Special tool
Removing
Installing
Filter dryer
Special tool
Technical specifications
Removing
Installing
Thermostat
Technical specifications
Removing
Installing
80 Various components / Machine body
8005 Frame / Trough
Connecting links
Technical specifications
Work preparation
Removing
Installing
Axle bridge
Work preparation
Technical specifications
Removing
Installing
Cross member
Technical specifications
Work preparation
Removing
Installing
Work preparation
Technical specifications
Removing
Installing
8015 Access
Platform
Work preparation
Technical specifications
Removing
Installing
8025 Panellings / Hoods
Front grille
Work preparation
Technical specifications
Removing
Installing
Stowage box cover sheets
Technical specifications
Removing
Installing