PDF Technical System Manual CLAAS Ares 806 Tractor - 13 MB
Delve into the complex systems of the CLAAS Ares 806 tractor with this technical system manual.
This guide is designed for advanced technicians, providing in-depth information on the tractor's various systems, including hydraulics and electronics.
It is an essential tool for troubleshooting complex issues and performing high-level repairs.
Understanding these systems is key to keeping the Ares 806 performing at its best.
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--- Page 1 ---
A0 ā INJECTION SHEET CHECKING
PROCEDURE
A1 ā INJECTION FEED
A2 ā ENGINE TIER II
Chapter A
Ares 806 60 05 030 493 ā 09.2004 publication
--- Page 3 ---
Measurement sheet
This sheet is intended to be duplicated and completed for each operation on the tractor. If you have to send it to the
manufacturer's after sales service, it is essential to indicate:
Tractor type: ...........................................................................................................................................................................
Serial nĀ°: ................................................................................................................................................................................
Engine serial nĀ°: .....................................................................................................................................................................
Total operating hours: ............................................................................................................................................................
Date of operation: ..................................................................................................................................................................
Transmission type: .................................................................................................................................................................
Start of test End of test Reference values (bar)
Hydraulic pressure in HP circuit
See appendix
Hydraulic pressure in LP circuit
Outside temperature ā
Transmission temperature 60 Ā°C Ć 65 Ā°C
Engine temperature > 87 Ā°C
Diesel temperature
Engine speed 1 000 1 100 1 200 1 300 1 400 1 500 1 600 1 700 1 800 1 900 2 000 2 100 2 200
Measurement (kW)
Measurement (N.m).
(power take-off)
Measurement (l/h)
Measurement of boost pressure
(bar)
Measurement of diesel supply pressure
at filter outlet (bar)
Boost pressure (bar)
0,36 0,39 0,51 0,65 0,79 0,85 0,87 0,91 0,94 0,97 1,02 1,04 1,00
Ares 816
Boost pressure (bar) Ares 826 0,39 0,50 0,66 0,87 1,05 1,16 1,21 1,27 1,32 1,36 1,40 1,40 1,37
Boost pressure (bar)
ā 0,47 0,61 0,78 0,93 1,02 1,13 1,21 1,23 1,24 1,23 1,22 1,18
Ares 836
Diesel supply pressure at filter
0,25 Ć 0,30
outlet (bar) Ares 816-826
Diesel supply pressure at filter
0,50
outlet (bar) Ares 836
Ares 806 ā 09.2004 ā GB A0.7
--- Page 4 ---
A1 ā INJECTION FEED
Engine DPS 6068 HRT 70
Engine DPS 6068 HRT 71
Engine DPS 6068 HRT 72
Ares 806 ā 09.2004 ā GB
--- Page 5 ---
Checks/Adjustments
Adjusting the engine injector
B F
For any operation assembling/dismantling the injectors,
use tool nĀ° 60 05 005 579 combined with a sliding D A 0,5 daN.m
hammer.
- Unscrew the protection cover (F). C 1 daN.m
- Loosen and remove the locking nut (A) of the needle
rise adjustment screw.
- Loosen locking nut (C) of the injection pressure
adjustment screw, use tool nĀ° 60 05 005 574.
- Connect the injector to the tester then adjust the
pressure to the specified value by turning the pressure
adjustment screw (D). E
- Tighten the locknut (A) and check the pressure.
Carry out the adjustment again if necesssary.
WARNING: It is recommended to aim for the
maximum value in the adjustment because after
operating for some time the pressure drops slightly
before stabilising. Repeat the adjustment in order to
obtain a reliable result.
- Gently turn the needle rise adjustment screw (B) until it
reaches the seat of the spring (E).
- Unscrew the needle rise adjustment screw a 7/8 turn.
- Tighten the locknut (A) at torque.
WARNING: The injector nozzle must never be
pointing towards the person performing the 161msm06
adjustment. The jet escaping from a port can pierce
clothing and skin, and cause serious infections. It is
recommended to contain the jet within a transparent
container.
Ares 806 ā 09.2004 ā GB A1.13
--- Page 6 ---
A2 ā ENGINE TIER II
Engine DPS 6068 HRT 70
Engine DPS 6068 HRT 71
Engine DPS 6068 HRT 72
Ares 806 ā 09.2004 ā GB
--- Page 7 ---
General specifications
Lubrication
Oil pump
Oil pump delivery at maximum speed, at 3 bar pressure .......................................................................................... 70 l/min
Minimum oil pressure at tick-over, with the oil at 90Ā°C ................................................................................... 1 bar minimum
Minimum oil pressure at maximum off-load speed, with the oil at 90Ā°C
ā All engine types ........................................................................................................................................... 3 bar minimum
Bypass valve spring.
ā Spring length (off-load) ............................................................................................................................................. 51 mm
ā Spring force at a length of 29 mm .......................................................................................................................... 8,7 daN
B = Ć 16,05 ā 16,10
A = Ć 16,02 ā 16,03
35,97 ā 36,05
D = 0,04 ā 0,165
C = Ć 12,35 ā 12,36
A = Ć 12,31 ā 12,33
D = 0,04 ā 0,165
0,131 ā 0,211
1
0,21
1ā
0,13
220hsm00 Fig. 12
Parts list
A Shaft. B Bush. C Bore. D Axial clearance.
Ares 806 ā 09.2004 ā GB A2.13
--- Page 8 ---
Removal/refitting
Preliminary operations
Cab
ā Apply the handbrake.
ā Set the gearbox lever to neutral.
Electricity
ā Disconnect the battery.
Sheet metal elements
ā Remove the lateral, frontal and upper covers.
ā Remove the exhaust pipe (according to the engine
type).
ā Remove the exhaust/battery support assembly*.
Transmission shaft
ā Remove the protective casing.
101hsm02 Fig. 33
ā Disconnect and remove the transmission shaft.
Drains
(according to intervention)
ā Drain the cooling system.
ā Drain the engine casing.
Front weights
ā Remove the removable ballast weights.
Tractor adjustment
ā Chock the rear wheels.
ā Neutralize the tilt angle by fixing the front axle.
* According to equipment.
Ares 806 ā 09.2004 ā GB A2.25
--- Page 9 ---
Removal/refitting
Liners
Disassembling the liners 1
Important: Before disassembly, number the liners
and the pistons. Mark the FRONT part of the liner to
ensure its proper reassembly position.
Extract the liners from the cylinder block using tool
nĀ° 60 05 005 504 (1).
Important: After removing the cylinder head, never
turn the crankshaft unless all the liners are held (C)
using bolts (A) and washers (B).
Checking the ovalization and tapering of
the liners
Refer to the chapter "Dimensional specifications".
120hsm00 Fig. 63
A B C
120hsm01 Fig. 64
120hsm02 Fig. 65
Ares 806 ā 09.2004 ā GB A2.37
--- Page 10 ---
Removal/refitting
Removing the flywheel
1 Remove the two securing screws and replace them with
studs (1), then remove the other securing screws.
N.B.: Build locally with two screws reference
nĀ° 60 05 021 489 and 2 studs. 1 A
2 Insert 2 screws (reference nĀ° 60 05 021 489) into the
tapped holes (A) to push the flywheel off the crankshaft
and simplify handling.
Note: As the flywheel is heavy, appropriate lifting
equipment is required to prevent accidents.
Changing the flywheel ring gear
1 Extract the ring gear from the flywheel using a brass drift A
1
and a hammer.
2 Heat the new ring gear to 150 Ā°C in an oil bath, in an
appropriate oven or using a flame.
121hsm22 Fig. 96
Note: The oil and oil vapours are flammable
from 190Ā°C. Use a thermometer to ensure that a
temperature of 180Ā°C is not exceeded. Heat the oil in
a well ventilated room. Beware when handling hot oil:
Danger of burns !
Important: If heated using a flame, check that the heat
is applied evenly over the entire circumference of the
ring gear.
3 Shrink on the ring gear to fit it correctly onto the flywheel
shoulder. The edge (A) of the teeth must be turned
towards the engine.
N.B.: Check that the ring gear is supported all around
the flywheel shoulder.
121hsm23 Fig. 97
A
121hsm24 Fig. 98
Ares 806 ā 09.2004 ā GB A2.49
--- Page 11 ---
Removal/refitting
Assembling the lower distribution
1 Bring piston nĀ° 1 to TDC using flywheel rotator
nĀ° 60 05 005 501 and adjustment pin nĀ° 60 05 005 576.
2 Fit the oil pump and the balancer shafts.
3 Turn the right-hand balancer shaft until mark (A) is
aligned with timing tool nĀ° 60 05 005 511 (1).
4 Fit the lower intermediate pinion without turning the
balancer shaft.
N.B.: Fit the stop washer while turning the "X" mark in
the opposite direction to the pinion.
Tighten the bolt to 7 daN.m (oil the bolt).
Repeat operation 3 with the left-hand balancer shaft.
Fit the oil pump pinion on its shaft. Tighten the nut
to 5 daN.m and lock it with 3 punches.
Check the timing of the two balancer shafts again.
Important: When adjusting the balancer shafts, the 111hsm28 Fig. 134
key groove on the shafts must be in the high position
(12 o'clock), with the 2 pinion marks turned inwards
towards the end of the crankshaft.
Fitting the distributor casing
1 Check that the casing gasket faces and the front plate
are clean.
2 Fit the cover (C) providing access to the injection pump
pinion using a new seal (D) if required. Tighten the screws
D
to 0,6 daN.m.
3 Install the gasket seal (A) and cut it in the lower part to
ensure it contacts the oil casing seal.
4 Install the distributor casing (B). Smear the bolt (E) with
sealing compound. Tighten the bolts and nuts to 3,5
daN.m.
111hsm29 Fig. 135
A B C
E D
111hsm30 Fig. 136
Ares 806 ā 09.2004 ā GB A2.61
--- Page 12 ---
Removal/refitting
B
1
4
5
3 2
251hsm20 Fig. 167 251hsm21 Fig. 168
Changing the drive belt
1 Inspect the moulded end pieces (2) and (3) on the belt
tensioner (1). 1 7
2 If the stop (2) on the tensioner swivel arm contacts the
fixed stop (3), check the condition of the various pulleys
on which the belt passes. If the pulleys seem normal, 2 5
replace the belt.
3 To change, loosen the belt tension using a wrench
placed on the pulley (B).
4 Remove the old belt from the pulleys, then cut it. 3
6
5 Slip the new belt between fan (4) and the cooling
nozzle (5).
A
6 Install the new belt so that it passes correctly over all the 4
pulleys (see drawing opposite).
7 Tighten the belt with the tensioner (B). Remove the
wrench. 251hsn03 Fig. 169
Parts list (Fig. 169 and 170)
A With air conditioning, without air compressor.
B With air conditioning and air compressor.
1 Alternator. 5
7
2 Tensioner roller.
3 Water pump.
4 Crankshaft. 1 8
5 Refrigeration or air compressor.
6 Return roller.
7 Fan pulley.
2
8 Air compressor.
6
3
4
B
251hsn04 Fig. 170
Ares 806 ā 09.2004 ā GB A2.73
--- Page 13 ---
TOOLS
Engine tools
Ares 806 ā 09.2004 ā GB
--- Page 14 ---
REMOVING THE SHAFT ..............................................................................................................................................B1.63
REFITTING THE SHAFT...............................................................................................................................................B1.63
ADJUSTING THE SHAFT .............................................................................................................................................B1.64
COUNTERSHAFT
GENERAL......................................................................................................................................................................B1.65
EXPLODED VIEW (STAGE 6 PAGE B1.10) .................................................................................................................B1.65
REMOVING THE SHAFT ..............................................................................................................................................B1.66
ADJUSTING THE SHAFT .............................................................................................................................................B1.67
REFITTING THE SHAFT...............................................................................................................................................B1.67
ADJUSTING THE BEARINGS.......................................................................................................................................B1.68
CRAWLER SPEEDS
GENERAL......................................................................................................................................................................B1.69
EXPLODED VIEW .........................................................................................................................................................B1.70
REMOVING/REFITTING THE HOUSING .....................................................................................................................B1.72
REMOVING, ADJUSTING AND REFITTING THE CONTROL SYSTEM......................................................................B1.73
SETTING THE CONTROLS ..........................................................................................................................................B1.74
B2 ā GTA 1040 AND GPA 30 LOW-PRESSURE HYDRAULIC CIRCUIT
LS 100 L/MIN LOW-PRESSURE CIRCUIT ON GTA 1040
CIRCUIT LAYOUT ON BEAM .........................................................................................................................................B2.2
HYDRAULIC SYSTEM ....................................................................................................................................................B2.3
GEARBOX AND REAR AXLE LUBRICATION ................................................................................................................B2.5
AXLE TUBE LUBRICATION............................................................................................................................................B2.6
LS 110 L/MIN LOW-PRESSURE CIRCUIT ON GTA 1040
CIRCUIT LAYOUT ON BEAM .........................................................................................................................................B2.7
HYDRAULIC SYSTEM ....................................................................................................................................................B2.8
GEARBOX AND REAR AXLE LUBRICATION ..............................................................................................................B2.10
AXLE TUBE LUBRICATION..........................................................................................................................................B2.11
LS 110 L/MIN LOW-PRESSURE CIRCUIT ON GPA 30
CIRCUIT LAYOUT ON BEAM .......................................................................................................................................B2.12
HYDRAULIC SYSTEM ..................................................................................................................................................B2.13
REAR AXLE LUBRICATION .........................................................................................................................................B2.15
AXLE TUBE LUBRICATION..........................................................................................................................................B2.16
Ares 806 ā 09.2004 ā GB
--- Page 15 ---
General specifications
GBA 10 removal/refitting procedure
Stage 1: Front clutch
322hsm09 Fig. 7
Stage 2: Rear clutch
322hsm10 Fig. 8
Stage 3: Quadrishift unit
322hsm08 Fig. 9
Ares 806 ā 09.2004 ā GB B1.9
--- Page 16 ---
Front clutch
Refitting
13 18
Clutch
ā Refit the assembly in reverse order to removal, making 10
sure that the parts are the right way round.
28 A
ā Refit the bearings using a press and an appropriate jig.
ā Lubricate the new seals before fitting.
ā Refit the piston (13), aligning it with the cover (10) by 17
means of a pin of appropriate diameter in the indexed
holes (A). Tap gradually and alternately around the
edge with a mallet. Check that there are no fragments 3 Ā± 0,4 daN.m
of seal after assembling. Frenbloc (270)
ā Fit the bearing (16) using an appropriate jig, with the 16
sealed side against the shoulder of the shaft.
32
ā Assemble the shaft (28), retainers, spacer (32),
Belleville washers and cover (10) with the locally made
Frenbloc (270)
tool. 322hsm30 Fig. 27
ā Assemble the body (18) and cover (10), inserting the
backplates and discs (first backplate against the
6 Scelbloc (648)
piston).
ā Check the rotation of the hub (17) by hand.
Important: New discs must be soaked in a bath of
transmission fluid for approximately one hour. 10
Pump
ā Refit the rings (9) with miscible grease.
ā Check that the pin (38) is fitted (hydraulic calibration).
ā Refit the bush (7) inside the pump body (6), positioning
the chamfer so as to ensure easier fitting on the rings. 38
ā Check that the hydraulic ports are not blocked by the
product and lubricate the bush.
ā Refit the 1,5 bar valve.
ā Oil and reassemble the pump on the cover (10),
9 7
positioning the flat sections of the rotor appropriately.
322hsm29 Fig. 28
5 Ā± 0,3 daN.m 4,1 Ā± 0,5 daN.m
3 Ā± 0,4 daN.m
Frenbloc (270)
322hsm31 Fig. 29
Ares 806 ā 09.2004 ā GB B1.21
--- Page 17 ---
Quadrishift unit
Parts list
1 Greasing ring. 23 Screw. 46 Spacer.
2 Screw. 24 Spring washer. 47 Secondary planet carrier.
3 Front cover. 25 Ball bearing. 48 Secondary sun gear.
4 Spring. 26 Primary ring gear. 49 Retaining ring.
5 Bearing. 27 Primary shaft. 50 Shims.
6 Screw. 28 Retaining ring. 51 Rear clutch splined hub.
7 Needle bearing. 29 Thrust bearing. 52 Rear brake thrust plate.
8 Washer. 30 Secondary ring gear. 53 Rear clutch housing.
9 Friction washer. 31 Retaining ring. 54 Rear clutch disc.
10 Front clutch housing. 32 Screw. 55 Rear clutch backplate.
11 Front brake disc. 33 Rear brake piston. 56 Rear brake disc.
12 Front clutch Belleville washer. 34 Tab washer. 57 Rear brake backplate.
13 Front clutch and brake thrust plate. 35 Shims. 58 Rear clutch and brake thrust plate.
14 Front clutch disc. 36 Primary ring gear carrier. 59 Belleville washers.
15 Front clutch backplate. 37 Planet gear pin. 60 Cover.
16 Front clutch splined hub. 38 Washer. 61 Screw.
17 Front brake backplate. 39 Needle bearing. 62 Friction washer.
18 Front brake piston. 40 Planet gear. 63 Washer.
19 O-ring. 41 Deflector. 64 Spring.
20 Centre housing. 42 Primary sun gear. 65 Rear cover.
21 Guide pin. 43 Needle. 66 Screw.
22 Secondary ring gear carrier. 44 Retaining ring. 67 Secondary shaft.
45 Bearing.
Ares 806 ā 09.2004 ā GB B1.33
--- Page 18 ---
Quadrishift unit
Refitting the Quadrishift unit
ā¢ Check that the centring pin and the oil restrictor are 66
present on the cover (65).
ā¢ Check that the thrust bearing (29) is present.
ā¢ Refit the cover (65) on the centre housing (20), aligning
the marks made on removal.
ā¢ Rotate the shaft to engage the planet gears in the ring 65
gears.
ā¢ Tighten the screws (66), coated with Frenetanch (242),
to 3,3 Ā± 0,4 daN.m.
ā¢ Check shaft rotation.
ā¢ Refit the greasing ring (1), lightly coated with
Scelbloc (648), taking care not to block the lubrication 20
holes.
ā¢ Refit the parts according to the component refitting
methods covered in this chapter.
ā Refit the Quadrishift unit. 322hsm86 Fig. 87
ā Refit the rear clutch.
ā Refit the front clutch.
ā Refit the pump.
66 29
ā Couple up the tractor.
1
322hsm87 Fig. 88
Ares 806 ā 09.2004 ā GB B1.45
--- Page 19 ---
Output shaft
20 4
B
21
A 9
322hsm1e Fig. 106 322hsm1f Fig. 107
9
Refitting the shaft
ā Replace the faulty parts.
ā Fit the bearings using appropriate jigs.
ā Refit the assembly in reverse order to removal while
observing the following instructions:
ā Fit the bush (4), with its sealing ring lightly smeared
with grease, into the input shaft (20). 22
ā Position the bush (4) such that the flat section is facing
upwards.
ā Smear the synchroniser bushes and cones lightly with
grease.
ā Fit the pinion assembly and secure it
with 2 screws (21) flush with pinion (9).
ā If the gearbox has been removed, position it vertically
Fig. 108
and secure pinion (9) with 2 overturned threaded 322hsm1g
rods (22) (Fig. 108), then fit the rest of the pinions.
Important: Position the pinion locator (A) and the A
synchroniser lubrication duct (B) to the rear of the
gearbox.
ā Engage the shaft, positioning the flat section
uppermost (aligned with the previously fitted bush (4)).
ā Refit the assembly in reverse order to removal,
observing the instructions mentioned in the parts
concerned.
B
7
322hsm1h Fig. 109
Ares 806 ā 09.2004 ā GB B1.57
--- Page 20 ---
Crawler speeds
General
It is made up of a step-down gear and a dog control is mounted on the rear axle and activates the engagement
function. The step-down gear is made up of an epicyclic dog of the step-down gear via the fork. The dog can only
gear set comprising a planet carrier and ring gear be engaged at a standstill. The reduction ratio of the step-
assembly housed at the rear of the gearbox. The control down gear is 0,25.
Ares 806 ā 09.2004 ā GB B1.69
--- Page 21 ---
LS 110 l/min low-pressure circuit on GTA 1040
Circuit layout on beam
1
2
3
9
20
28
21
12
30 32
31 33
22
16
23
11
24
14
25
8
26
10
7 18
19
27