Claas Ares 806 Tractor repair manual

Contents
Content 2
Chapter A 4
A0 – INJECTION SHEET CHECKING PROCEDURE 9
Checking procedure 10
Measurement sheet 15
Pressure connection (appendix) 16
ARES 816 - H 4412 19
ARES 826 QUADRISHIFT – H 4422 21
ARES 826 FULL-POWERSHIFT – H 4322 23
ARES 836 – H 4432 25
A1 – INJECTION FEED 27
Identification 28
Tightening torques (DE 10) 29
Tightening torques (VP 44) 30
Operating principles 31
Checks/Adjustments 38
Removal/refitting 41
Diagnostics 46
A2 – ENGINE TIER II 51
General specifications 52
DIMENSIONAL SPECIFICATIONS 54
Tightening torques 66
Checks/Adjustments 70
Diagnostic Sheets 125
TOOLS 135
Chapter B 143
B1–GBA10 GEARBOX 151
Tightening torques 161
Main adjustments 164
REVERSHIFT 165
Front clutch 167
Rear clutch 173
Quadrishift unit 179
Gearshift cover 196
Guide rods 200
Output shaft 204
Input shaft 209
Countershaft 215
Crawler speeds 219
B2 GTA1040 AND GPA30 LOW-PRESSURE HYDRAULIC CIRCUIT 225
LS 100l/min low-pressure circuit onGTA1040 226
LS 110l/min low-pressure circuit onGPA30 236
Low-pressure hydraulic components 241
Solenoid valve measurement and checking points 249
GBA10 distribution unit measurement and checking points 251
"Hydraulic inspection results" sheet 253
GBA10 lubrication measurement and checking points 254
LS 110l/min measurement and checking points 256
LS 100l/min measurement and checking points 259
B3 GBA 31 FULL POWERSHIFT GEARBOX 263
General 264
Repair 275
B4 FULL POWERSHIFT LOW PRESSURE HYDRAULIC CIRCUIT 279
Find manuals at http://best-manuals.com/search?&s=CLA-6005030493

General 280
Repair 286
Measurement and checking points 290
"Inspection results" sheet 294
TOOLS 295
Chapter C 301
C1 – GPA 40 REAR AXLE 308
Tightening torques and principal adjustments 310
GPA 40 drive pinion 313
5" differential 320
ND axle tubes 332
HD etHD+ axle tubes 340
HDE axle tubes 348
GPA 40 power take-off clutch 356
GPA 40 power take-off upper shaft 361
GPA 40 power take-off lower shaft 370
Proportional power take-off 376
C2 – GPA 30 REAR AXLE 382
Tightening torques and main adjustments 383
GPA 30 drive pinion 388
5" differential 397
GPA 30 power take-off clutch 409
GPA 30 power take-off upper shaft 415
GPA 30 power take-off lower shaft 417
GPA 30 crawler gears 423
C3 – SERVICE BRAKES 428
Technical specifications 429
Brake pistons and seals 430
Boosters and master cylinders 434
Replacing the master cylinders 435
Bleeding the brake circuit 436
C4–AUTOMATIC BRAKE, PARK LOCK AND HANDBRAKE 444
Automatic brake 445
Park Lock 457
Handbrake 467
TOOLS 472
Chapter D 476
D1–FRONT AXLE 482
Description 483
Disassembly prior to front axle operations 489
Hydraulic measurement and checking points 505
D2–PROACTIV FRONT AXLE 508
Description 509
Disassembly prior to front axle operations 515
Electric checks 558
Breakdown diagnosis 560
D3–GPA30 ANDGPA40 4-WHEEL DRIVE POWER TAKE-OFF HOUSING 562
Description 563
Removing/refitting the housing 570
Solenoid valve measurement and checking points 574
Hydraulic measurement and checking point 575
TOOLS 578
Chapter E 586
E1CLOSED CENTRE HYDRAULICS(110l/min) 592

Description 593
Removing/refitting the components 602
E2 CLOSED CENTRE HYDRAULICS 100l/min 664
Description 665
Removing/refitting the components 674
TOOLS 698
Chapter F 700
F1 - ITEM LISTWIRING AND GENERAL LISTS 706
FUSE AND RELAY BOX 713
DE10 STARTING/CHARGING/PREHEATING CIRCUIT 717
VP44 STARTING/CHARGING/PREHEATING CIRCUIT 718
DIPPED HEADLIGHTS - HEADLIGHTS - HORN - SIDE LIGHTS - INSTRUMENT PANEL LIGHT 719
ROTATING BEACONS 720
FRONT WORK LIGHTS 721
REAR WORK LIGHTS 722
STOP LIGHTS - FRONT AXLE ENGAGEMENT - AIR BRAKE SYSTEM SOLENOID VALVE CONTROL
723
FLASHING LIGHTS AND WARNING LIGHTS 724
CIGAR LIGHTER - CLOCK - RADIO - CAB LIGHT AND SPOT 725
PNEUMATIC SEAT - FRONT POWER TAKE OFF CLUTCH 726
FRONT AND REAR WINDSCREEN WIPER / WASHER 727
INSTRUMENT PANEL VENTILATION AND AIR CONDITIONING 729
INFOTRAC ON-BOARD COMPUTER / ISO SOCKET 731
FUEL GAUGE - ENGINE TEMPERATURE OIL PRESSURE - AIR FILTER BLOCKED 733
HANDBRAKE - BRAKE FLUID LEVEL 734
ENGINE SPEED 735
INSTRUMENT PANEL CALIBRATION - DIAGNOSTIC SOCKET INSTRUMENT PANEL AND TCE 15T
736
ELECTROPILOT/DRIVETRONIC/GTA 103-202/GPA 40 DIAGNOSTIC SOCKET 737
ELECTROPILOT/DRIVETRONIC/FPS DIAGNOSTIC SOCKET 738
25 A POWER SOCKET 739
TRANSMISSION HYDRAULIC PRESSURE - OIL FILTER BLOCKED (HP) - OIL FILTER BLOCKED (SUCTION)
740
THEORETICAL SPEED 741
INSTRUMENT PANEL - REAR POWER TAKE-OFF SPEED 742
TCE 15T LIFT 743
ELECTROPILOT (WITH TCE 15T) 747
LIFT TCE - 15/25/35/ RADAR 749
ELECTROPILOT (WITH TCE 15/25/35) 751
GTA 103-202 - GPA 40 CLUTCH AND DRIVE CONTROL 753
AUTOMATIC HAND BRAKE 756
FPS CLUTCH AND DRIVE CONTROL 757
FPS PARK LOCK 760
QUADRISHIFT II 761
QUADRACTIV GTA 103-202 - GPA 40 765
FPS QUADRACTIV 769
DE10 ENGINE CONTROL 773
VP44 ENGINE CONTROL 775
SUSPENDED FRONT AXLE 777
FRONT AXLE ENGAGING - DIFFERENTIAL AND REAR POWER TAKE OFF 779
OIL TEMPERATURE SENSORS - ENGINE SPEED - FORWARD SPEED - REAR POWER TAKE-OFF SPEED -
REVERSER MODULE SPEED - DRIVETRONIC 781
CROSS CONTROL WITH SOLENOID PILOT 782
CROSS CONTROL 783
DE10 CAN 784

VP44 CAN 785
F2-HARNESS AND CONNECTOR PATHS 786
CONTENTS 787
1 - Instrument panel harness 789
2 - Preheating control harness 797
3/1 - Front harness 797
3/2a - Front harness 797
3/2b - Injection harness 797
3/2c - Injection control harness 797
4 - Front axle suspension control harness 807
5 - Instrument panel / cab top harness 809
5a - Cab top / front lights harness 813
5b - Cab top / rear light harness with air conditioning 813
5c - Front and rear light harness 817
6 - Rear harness 821
7a - Closed centre circuit transmission harness - 110 litres 825
7b - Closed centre circuit transmission harness - 100 litres 825
7c - GTA 303 transmission link harness 825
7d - GTA 303 transmission harness 825
8a - GTA 103/202 - GPA 40 transmission control harness 837
8b - Full Powershift transmission control harness 837
8/1 - ISO socket harness 837
8/2 - Quadrishift 2/Quadractiv/Full Powershift display harness 837
9a - TCE 15/25/35 Control harness 851
9b - TCE 15T Control harness 855
9/1a - TCE 15/25/35 Harness 859
9/1b - TCE 15T Harness 863
9/2a - Cross control harness with Electropilot 867
9/2b - Cross control harness 867
9/3 - Electrohydraulic spool valve control harness 869
10 - On-board computer harness 869
Chapter G 873
G1 – INSTRUMENT PANEL 879
Operating principles 880
Characteristics 882
Calibration 899
G2–TCE15/25 ANDTCE15T ELECTRONIC LIFT 901
Description 902
Checks and adjustments 906
G3–TRANSMISSION/AXLE CONTROL 917
Drivetronic III 918
Drivetronic V 949
Full Powershift 953
G4–ENGINE MANAGEMENT 971
DE 10 Pump 972
VP 44 Pump 984
G5–INFOTRAC AND ISO SOCKET 999
Description 1000
Removal/refitting and electrical checks 1004
G6–ELECTROPILOT 1013
Description 1014
TOOLS 1023
G7 – WIN METADIAG© ARES 806 MANUAL 1027
Connecting Win Métadiag© 1032
Engine application 1034
Transmission application 1134
Rear axle application 1164
Rear lift application 1167
Dashboard application 1174

Electropilot application 1177
Chapter H 1185
H1 – CAB LIFT 1189
Description 1190
Full cab removal 1193
Refitting the cab 1203
Removing/refitting the roof 1205
H2 – HEATING/AIR CONDITIONING 1207
Description 1208
Troubleshooting Guide 1223
H3 – BONDING THE WINDOWS 1225
TOOLS 1235
Chapter J 1239
J1 – LIFT AND FRONT POWER TAKE-OFF 1243
Front lift 1244
Front power take-off 1249
J2 – PNEUMATIC BRAKING 1257
How it works 1259
Main components 1266
TOOLS 1271
Blank Page 3

A0 – INJECTION SHEET CHECKING
PROCEDURE
A1 – INJECTION FEED
A2 – ENGINE TIER II
Ares 806
Chapter A
60 05 030 493 – 09.2004 publication

Ares 806 – 09.2004 – GB
CONTENTS
A0 – INJECTION SHEET CHECKING PROCEDURE
CHECKING PROCEDURE
CHECKING PROCEDURE..............................................................................................................................................A0.2
MEASUREMENT SHEET
MEASUREMENT SHEET................................................................................................................................................A0.7
PRESSURE CONNECTION (APPENDIX)
100 L/MIN LS CIRCUIT ...................................................................................................................................................A0.8
110 L/MIN LS CIRCUIT ...................................................................................................................................................A0.9
IDENTIFICATION
INJECTION PUMPS IDENTIFICATION ..........................................................................................................................A1.2
TIGHTENING TORQUES
TIGHTENING TORQUES................................................................................................................................................A1.3
OPERATING PRINCIPLES
PRE-FILTER....................................................................................................................................................................A1.5
FUEL FILTER ..................................................................................................................................................................A1.6
INJECTION PUMP ..........................................................................................................................................................A1.7
INJECTORS ....................................................................................................................................................................A1.9
SITUATION OF THE DIFFERENT SENSORS..............................................................................................................A1.10
CHECKS/ADJUSTMENTS
ACCELERATOR CONTROL ADJUSTMENT................................................................................................................A1.12
ADJUSTING THE ENGINE INJECTOR ........................................................................................................................A1.13
SUPPLY PRESSURE CHECK ......................................................................................................................................A1.14

Ares 806 – 09.2004 – GB
REMOVAL/REFITTING
FUEL FILTER REPLACEMENT ....................................................................................................................................A1.15
INJECTION SYSTEM BLEEDING.................................................................................................................................A1.15
INJECTION PUMP REMOVAL......................................................................................................................................A1.16
DIAGNOSTICS
SHEET N° 1 "ENGINE START-UP DEFECT"...............................................................................................................A1.20
SHEET N° 2 "IRREGULAR ENGINE OPERATION" .....................................................................................................A1.21
SHEET N° 3 "GREY OR BLACK SMOKE EMISSION" .................................................................................................A1.22
SHEET N° 4 "WHITE SMOKE EMISSION"...................................................................................................................A1.23
SHEET N° 5 "CHECK THE FUEL FEED CIRCUIT"......................................................................................................A1.24
A2 – ENGINE TIER II
GENERAL SPECIFICATIONS
IDENTIFICATION OF THE ENGINES.............................................................................................................................A2.2
ENGINES 6 CYLINDERS................................................................................................................................................A2.3
DIMENSIONAL SPECIFICATIONS
CYLINDER HEAD AND VALVES....................................................................................................................................A2.4
CYLINDER BLOCK .........................................................................................................................................................A2.7
LINERS AND PISTONS ..................................................................................................................................................A2.8
CONNECTING RODS .....................................................................................................................................................A2.9
CRANKSHAFT, BEARINGS AND FLYWHEEL.............................................................................................................A2.10
CAMSHAFT...................................................................................................................................................................A2.11
DISTRIBUTION .............................................................................................................................................................A2.12
LUBRICATION...............................................................................................................................................................A2.13
COOLING ......................................................................................................................................................................A2.14
TURBOCHARGER ........................................................................................................................................................A2.15
TIGHTENING TORQUES
FRONT CHASSIS / ENGINE LINK................................................................................................................................A2.16
ENGINE/TRANSMISSION LINK....................................................................................................................................A2.16
CRANKSHAFT WITH STRAIGHT FRONT END...........................................................................................................A2.19
CRANKSHAFT WITH TAPERING FRONT END...........................................................................................................A2.19
CHECKS/ADJUSTMENTS
CHECKING COMPRESSION........................................................................................................................................A2.20
CHECK OF ENGINE OIL PRESSURE..........................................................................................................................A2.20
CHECK OF VALVE LIFT (ENGINE COLD)...................................................................................................................A2.21
VALVE CLEARANCE (ENGINE COLD)........................................................................................................................A2.21

Ares 806 – 09.2004 – GB
VALVE ADJUSTMENT SEQUENCE.............................................................................................................................A2.22
CHECKING THE TURBOCHARGER PRESSURE .......................................................................................................A2.22
CHECK OF THE BELT AND THE TENSIONER SPRING ............................................................................................A2.23
PROCEDURE FOR CHECKING THE VISCOUS FAN COUPLING..............................................................................A2.24
REMOVAL/REFITTING
PRELIMINARY OPERATIONS......................................................................................................................................A2.25
SEPARATE ENGINE/FRONT AXLE .............................................................................................................................A2.26
SEPARATE ENGINE/GEARBOX..................................................................................................................................A2.28
ENGINE INSTALLATION SPECIFICATIONS ...............................................................................................................A2.30
CYLINDER HEAD..........................................................................................................................................................A2.31
CAMSHAFT...................................................................................................................................................................A2.35
CYLINDER BLOCK .......................................................................................................................................................A2.36
LINERS..........................................................................................................................................................................A2.37
PISTONS AND CONNECTING RODS..........................................................................................................................A2.40
CRANKSHAFT, BEARINGS, AND FLYWHEEL............................................................................................................A2.47
CHANGING THE FRONT BEARING SEAL ..................................................................................................................A2.53
CAMSHAFT, BALANCER SHAFTS AND DISTRIBUTOR ............................................................................................A2.55
LUBRICATION...............................................................................................................................................................A2.62
COOLING ......................................................................................................................................................................A2.68
TURBOCHARGER ........................................................................................................................................................A2.74
DIAGNOSTIC SHEETS
"EXCESSIVE OIL CONSUMPTION" SHEET................................................................................................................A2.75
INSPECTION PROCEDURE OF THE CYLINDER HEAD GASKET.............................................................................A2.76
"ENGINE OIL PRESSURE TOO HIGH" SHEET...........................................................................................................A2.77
CHECKING PROCEDURE OF THE HIGH OIL PRESSURE IN THE CRANKCASE....................................................A2.78
"ENGINE OIL PRESSURE TOO LOW" SHEET............................................................................................................A2.79
"COOLANT TEMPERATURE TOO HIGH" SHEET.......................................................................................................A2.80
"COOLANT TEMPERATURE TOO LOW" SHEET........................................................................................................A2.81
FAILURE SEARCHING PROCEDURE OF CYLINDER HEAD SEAL...........................................................................A2.82
TOOLS
ENGINE TOOLS............................................................................................................................................................A2.86

Ares 806 – 09.2004 – GB
Notes

A0.1 Ares 806 – 09.2004 – GB
A0 – INJECTION SHEET CHECKING
PROCEDURE

A0.2 Ares 806 – 09.2004 – GB
Checking procedure
The purpose of this procedure is to check a number of points before and after measuring on the power bench. It is suited
to engines with electronic control (TIER 2).
Failing to carry out these tests may lead to an incorrect power reading.
Always check the following points before starting a PTO power test.
Reminder: Wait until the running-in period has elapsed (minimum 100 hours) before testing an engine on the power bench.
This period is necessary to ensure that measuring is carried out under the right conditions.
1. Visual checks
Make sure that the supply and return circuit lines are
correctly fitted (not trapped or kinked on fitting, etc.).
Check that the engine serial n° read with Métadiag is the
same as the one indicated on the engine identification
plate and if there are any error codes.
2. Engine oil
Check the level:
I Normal level.
II Readjust the level as soon as possible.
III Readjust the level before starting up the engine again.
221hsm01 Fig. 1
3. Hydraulic /transmission oil level
Check the level:
Mark (K): Minimum level.
Mark (J): Maximum level.
Fig. 2: Quadrishift.
Fig. 3: Full Powershift.
A level above level (J) affects engine power and
increases temperature. Example: Overfilling will greatly
affect performance in road transport at high speed.
341hpn09 Fig. 2
542hsn03 Fig. 3
l
ll
lll
J
K
10l
J
K
13l13l13l

Ares 806 – 09.2004 – GB A0.3
Checking procedure
4. Battery
Check the voltage with the engine off (between 12 and 13 V). Alternator-generated power consumption can reach 1,5 kW.
5. Coolers
Check that all radiators/coolers are clean.
6. Diesel filters
Change the filters. Fit the pressure gauge.
Unit reference: 60 05 00 55 21.
See measurement sheet for values.
161msm14 Fig. 4
161msm15 Fig. 5
7. Air filter
Check condition and replace if necessary.

A0.4 Ares 806 – 09.2004 – GB
Checking procedure
8. Turbocharger pressure
Fit the pressure gauge.
Unit reference: 60 05 00 55 21.
See measurement sheet for values.
141msm01 Fig. 6
141msm02 Fig. 7
9. Hydraulic pressure
Fit the pressure gauge(s). See appendix for pressure connections.

Ares 806 – 09.2004 – GB A0.5
Checking procedure
10. Fit the dynamometer
Ensure that the bench is correctly calibrated and that the
universal joint is aligned.
002msm01 Fig. 8
11. Twinshift/Quadrishift/shuttle reverser position (according to equipment)
To limit transmission power take-off, make sure that: the reverser is in neutral, the Twinshift is set to speed 2 and the
Quadrishift to speed 1.
Mechanical doubler: Hare position.
Make sure that the handbrake is applied.
12. Air conditioning/Ventilation
Make sure that the air conditioning and ventilation are switched off.
13. Front power take-off
Make sure that the front power take-off is disengaged.

A0.6 Ares 806 – 09.2004 – GB
Checking procedure
14. Hydraulic pressure
Check hydraulic pressure by referring to the appendix. Make sure that no hydraulic application is running. If hydraulic
pressure is not within the specifications, the PTO power test results will be affected.
15. Check the maximum off-load speed
Ares 816/826: 2 354 ± 50.
Ares 836: 2 275 + 25/ 0.
16. Engage the PTO at the 1 000 rpm position
17. Set the engine to maximum speed for 1 min
18. Measure the power (see injection sheet)
19. After measuring, check the tractor temperature
Engine: 90°C.
Transmission: 60-65°C.
20. Leave the engine running between 1 500 and 1 600 rpm for 3 to 5 minutes, then idle before
switching off
If the results do not match the manufacturer's data following these operations, a flowmeter will need to be installed and the
values compared to the injection sheets.

Ares 806 – 09.2004 – GB A0.7
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 n°: ................................................................................................................................................................................
Engine serial n°: .....................................................................................................................................................................
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 —
Transmission temperature 60 °C ß 65 °C
Engine temperature > 87 °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)
Ares 816
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
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)
Ares 836
— 0,47 0,61 0,78 0,93 1,02 1,13 1,21 1,23 1,24 1,23 1,22 1,18
Diesel supply pressure at filter
outlet (bar) Ares 816-826
0,25 ß 0,30
Diesel supply pressure at filter
outlet (bar) Ares 836
0,50

A0.8 Ares 806 – 09.2004 – GB
Pressure connection (appendix)
100 l/min LS circuit
396hsm01 Fig. 9
Parts list
1 19 cm³ pump pressure = 17 bar (nominal speed).
2 14 cm³ pump pressure = 25 bar (nominal speed).
3 Steering pressure = 50 bar (nominal speed).
3
21

Ares 806 – 09.2004 – GB A0.9
Pressure connection (appendix)
110 l/min LS circuit (Quadrishift and Full Powershift)
396hsm02 Fig. 10
Parts list
1 High-pressure pump output pressure = 30 bar at 1 000 rpm. 2 Booster pump output pressure = 5 bar at 1 000 rpm.
HP
BP
1
2

A0.10 Ares 806 – 09.2004 – GB
Notes

FUELINJECTIONDATASHEET
Ares 806 – 09.2004 – EN
FUEL SUPPLY LINE DATA
161hsm02
Supply system
Suction
Supply system
Supply pump pressure
Dischargeline
Returnline
ARES 816 - H 4412
DPS 6068 HRT 70 engine
Nominal speed 2 200 rpm
1 Main fuel tank: 300 litres
Secondary fuel tank: 80 litres
2 Mechanical supply pumps.
3 Initial fuel filter: 10 microns
4 Final fuel filter: 2 microns
5 Stanadyne rotary injection pump
DE 10 -5807.
Electronically controlled.
6 Stanadyne staggered injection injectors
9.5 mm holder body (type 35107).
Set pressure on injector: 250 bar.
7 Radiator.
DYNAMIC TIMING
Electronic management.
TEST CONDITIONS
– Refer to inspection procedure.
NOTE
–Referencevalues:measurementsmadeonatractorequippedwithpneumaticbraking,ambienttemperatureof25°C
with the visco-coupler free.

Ares 806 – 09.2004 – EN
ENGINE TESTS AT PTO
Position 1 000 rpm
ARES 816 – H 4412
kW
rpm
N.m
rpm
l/h
rpm
g/kW.h
rpm
g/bhp.h
bhpPOWER
SPECIFIC CONSUMPTION
CONSUMPTION PER HOUR
TORQUE
220
230
240
250
260
270
280
290
1000 1200 1400 1600 1800 2000 2200
162
169
177
184
191
198
206
213
700
750
800
850
900
950
1000
1050
1100
1150
1200
1250
1300
1000 1200 1400 1600 1800 2000 2200
15
20
25
30
35
1000 1200 1400 1600 1800 2000 2200
50
60
70
80
90
100
110
1000 1200 1400 1600 1800 2000 2200
68
82
95
109
123
136
150
x 100 = 44.2 %
GTA 1042 GPA 42
Engine
Power
take-off
540 840 860 240 246 2200 629 2304 2404 658 687
540 ECO 840 860 298 305 2200 780 2304 2404 817 852
1000 840 860 420 430 2200 1100 2304 2404 1152 1202
1000 ECO _ _ _ _ _ _ _ _ _ _
Engine rpm 1000 1200 1400 1600 1800 2000 2100 2200
PTO rpm 500 600 700 800 900 1000 1050 1100
kW 53.2 71.6 83.5 93.1 98.2 98.5 96.3 91.2
bhp 72.3 97.3 113.5 126.6 133.5 133.9 130.9 124.0
_ l/h 16.0 19.6 23.4 25.6 27.7 29.4 29.9 29.7
_ l/h _ _ _ _ _ _ _ _
g/kW.h 250 227 233 229 234 249 259 271
g/bhp.h 184 167 171 168 172 183 190 199
CURVE INTERPRETATION
2200
1100
91.2
2000
1000
98.5
1300
650
77.7
124.0
29.7
271
940 792
133.9
29.4
249
N.m
105.6
21.5
230
1142
199
ENGINE TESTS AT POWER TAKE-OFF
Gearbox
Rear
axle
183
169
Engine
g/kW.h
rpm
rpm
Power Take-off (total reduction)
Position 1000Position 540 ECO Position 1000 ECOPosition 540
kW
bhp
l/h
Engine speed
Power take-off speed
TORQUE
POWER
(Power take-off output)
1bhp = 0.7355 kW
1rpm = 0.1047 rad/s
1kW = 1.3596 bhp
1rad/s = 9.5510 rpm
Nominal engine speedPow er take-off standardized speed
* Power (W) = torque (N.m) x speed (rad/s)
Engine Power take-offEngine
TORQUE **
CONSUMPTION PER
HOUR
Maximum torque
g/bhp.h
3.50
Torque feedback =
maximum torque – nominal speed torque
nominal speed torque
Max no loadIdle Nominal
Power take-off
SPEED
Pow er take-
off position
SPEEDS
(rpm)
_2.002.82
Hourly consumption (l/h) x diesel fuel density (0.840)
Power (kW or bhp)
N.m
Torque at Power take-off outlet (N.m)
Power take-off reduction
1042 940 876 792
*** Specific consumption
(g/kW.h or g/bhp,h) =
Injection flow (mm3) =
6068 HRT 70
_
REFERENCE VALUES - Power Take-off position 1000 rpm
1138 1112
POWER *
_
_
SPECIFIC
CONSUMPTION ***
Hourly consumption (l/h) x 1000 000
Number of engine cylinders x engine speed(rpm) x 30
1016 1140
(pow er take-off output)
** Equivalent engine torque (N.m) =
3
2
1
1 32

Ares 806 – 09.2004 – EN
161hsm02
Supply system
Suction
Supply system
Dischargeline
Returnline
ARES 826 QUADRISHIFT – H 4422
DYNAMIC TIMING
TEST CONDITIONS
NOTE
–Referencevalues:measurementsmadeonatractorwithoutpneumaticbraking,ambienttemperatureof25°Cwiththe
visco-couplerfree.
DE 10 -5807. Electronically controlled.
7 Radiator.

Ares 806 – 09.2004 – EN
ENGINE TESTS AT PTO
Position 1 000 rpm
ARES 826 QUADRISHIFT – H 4422
kW
rpm
N.m
rpm
l/h
rpm
g/kW.h
95
g/bhp.h
bhpPOWER
TORQUE
210
220
230
240
250
260
270
280
1000 1200 1400 1600 1800 2000 2200
154
161
169
176
184
191
199
206
800
900
1000
1100
1200
1300
1400
1500
1000 1200 1400 1600 1800 2000 2200
15
20
25
30
35
40
1000 1200 1400 1600 1800 2000 2200
50
60
70
80
90
100
110
120
130
1000 1200 1400 1600 1800 2000 2200
68
82
95
109
123
136
150
163
177
x 100 = 48.4 %
GTA 1044 GPA 44
Engine
Power
take-off
540 840 860 240 246 2200 629 2304 2404 658 687
540 ECO 840 860 298 305 2200 780 2304 2404 817 852
1000 840 860 420 430 2200 1100 2304 2404 1152 1202
1000 ECO _ _ _ _ _ _ _ _ _ _
Engine rpm 1000 1200 1400 1600 1800 2000 2100 2200
PTO rpm 500 600 700 800 900 1000 1050 1100
kW 58.0 78.7 97.9 105.9 111.9 113.1 110.3 103.7
bhp 78.9 107.0 133.1 144.0 152.1 153.8 150.0 141.0
_ l/h 15.7 20.6 25.8 28.4 30.7 32.3 32.9 32.9
_ l/h _ _ _ _ _ _ _ _
g/kW.h 226 218 219 223 228 237 248 263
g/bhp.h 166 160 161 164 168 174 182 193
SPECIFIC
CONSUMPTION ***
1106 1252
6068HRT71
_
1336 1264
POWER *
_
_
_2.002.82
Power (kW or bhp)
N.m
1186 1080 1002 900
SPEED
Pow er take-
off position
SPEEDS
(rpm)
Power take-off
g/bhp.h
3.50
Torque feedback =
1bhp = 0.7355 kW
1rpm = 0.1047 rad/s
1kW = 1.3596 bhp
1rad/s = 9.5510 rpm
TORQUE **
CONSUMPTION PER
HOUR
Maximum torque
Engine speed
TORQUE
POWER
rpm
rpm
kW
bhp
l/h
193
Gearbox
Rear
axle
174
161
Engine
g/kW.h
N.m
133.1
25.8
219
1336
141.0
32.9
263
1080 900
153.8
32.3
237
2200
1100
103.7
2000
1000
113.1
1400
700
97.9
3
2
1
1 32

Ares 806 – 09.2004 – EN
161hsm02
Supply system
Suction
Supply system
Dischargeline
Returnline
ARES 826 FULL-POWERSHIFT – H 4322
DYNAMIC TIMING
TEST CONDITIONS
NOTE
visco-couplerfree.
DE 10 -5807.
7 Radiator.

Ares 806 – 09.2004 – EN
ENGINE TESTS AT PTO
Position 1 000 rpm
ARES 826 FULL-POWERSHIFT – H 4322
x 100 = 50.3 %
GBA 31 GPA 34
Engine
Pow er
take-off
540 840 860 228 233 2200 596 2265 2285 614 619
540 ECO 840 860 313 321 2200 821 2265 2285 845 853
1000 840 860 402 411 2200 1053 2265 2285 1084 1093
1000 ECO _ _ _ _ _ _ _ _ _ _
Engine rpm 1000 1400 1500 1600 1800 2000 2100 2200
PTO rpm 478 670 717 765 900 1000 1004 1052
kW 55.0 96.3 102.5 104.5 110.5 111.0 107.1 100.7
bhp 74.8 130.9 139.4 142.1 150.2 150.9 145.6 136.9
_ l/h 15.8 25.9 27.5 28.4 30.7 32.4 32.9 32.9
_ l/h _ _ _ _ _ _ _ _
g/kW.h 237 222 222 225 231 241 255 270
g/bhp.h 174 163 163 165 170 177 188 199
2200
1052
100.7
2000
1000
111.0
1400
670
96.3
136.9
32.9
270
1108 914
150.9
32.4
241
N.m
130.9
25.9
222
1374
199
Gearbox
Rear
axle
177
163
Engine
Torque feedback =
rpm
rpm
kW
bhp
l/h
Engine speed
TORQUE
POWER
1bhp = 0.7355 kW
1rpm = 0.1047 rad/s
1kW = 1.3596 bhp
1rad/s = 9.5510 rpm
TORQUE **
CONSUMPTION PER
HOUR
Maximum torque
g/kW.h
g/bhp.h
3.69
Power take-off
SPEED
Power
take-off
position
SPEEDS
(rpm)
_2.092.68
Power (kW or bhp)
N.m
1221 1108 1018 914
6068 HRT 71
_
1365 1309
POWER *
_
_
SPECIFIC
CONSUMPTION ***
1098 1374
3
2
1
1 32
kW
rpm
N.m
rpm
l/h
rpm
g/kW.h
rpm
g/bhp.h
bhpPOWER
TORQUE
220
230
240
250
260
270
280
290
1000 1200 1400 1600 1800 2000 2200
162
169
177
184
191
198
206
213
800
900
1000
1100
1200
1300
1400
1500
1000 1200 1400 1600 1800 2000 2200
15
20
25
30
35
40
1000 1200 1400 1600 1800 2000 2200
50
60
70
80
90
100
110
120
130
1000 1200 1400 1600 1800 2000 2200
68
82
95
109
123
136
150
163
177

Ares 806 – 09.2004 – EN
1
2
3
6
7
4
5
161hsm01
Supply system
Suction
Supply system
Dischargeline
Returnline
ARES 836 – H 4432
DYNAMIC TIMING
TEST CONDITIONS
NOTE
visco-couplerfree.
2 Electric supply pumps.
VP 44 0 470 506680.
6 Stanadyne conventional injectors
7 Radiator.

Ares 806 – 09.2004 – EN
ENGINE TESTS AT PTO
Position 1 000 rpm
ARES 836 – H 4432
kW
rpm
N.m
rpm
l/h
rpm
g/kW.h
rpm
g/bhp.h
bhpPOWER
TORQUE
210
220
230
240
250
260
1000 1200 1400 1600 1800 2000 2200
154
161
169
176
184
191
1000
1100
1200
1300
1400
1500
1600
1700
1000 1200 1400 1600 1800 2000 2200
15
20
25
30
35
40
1000 1200 1400 1600 1800 2000 2200
60
70
80
90
100
110
120
130
140
150
1000 1200 1400 1600 1800 2000 2200
82
96
109
123
136
150
163
177
190
204
x 100 = 40.6 %
GTA 1044 GPA 44
Engine
Power
take-off
540 840 860 240 246 2200 629 2265 2285 647 653
540 ECO 840 860 298 305 2200 780 2265 2285 803 810
1000 840 860 402 411 2200 1052 2265 2285 1083 1093
1000 ECO _ _ _ _ _ _ _ _ _ _
Engine rpm 1000 1200 1400 1600 1800 2000 2090 2200
PTO rpm 478 574 670 765 861 957 1000 1052
kW 66.8 88.5 108.3 124.7 136.6 132.5 131.0 123.1
bhp 90.8 120.3 147.2 169.5 185.7 180.1 178.1 167.4
_ l/h 18.2 23.0 28.3 31.9 35.4 36.1 36.5 36.0
_ l/h _ _ _ _ _ _ _ _
g/kW.h 229 219 220 216 218 230 235 247
g/bhp.h 168 161 162 159 160 169 173 182
SPECIFIC
CONSUMPTION ***
1334 1472
6068HRT72
_
1543 1556
POWER *
_
_
_2.092.82
Power (kW or bhp)
N.m
1516 1321 1246 1117
SPEED
Pow er take-
off position
SPEEDS
(rpm)
Power take-off
g/bhp.h
3.50
Torque feedback =
1bhp = 0.7355 kW
1rpm = 0.1047 rad/s
1kW = 1.3596 bhp
1rad/s = 9.5510 rpm
TORQUE **
CONSUMPTION PER
HOUR
Maximum torque
Engine speed
TORQUE
POWER
rpm
rpm
kW
bhp
l/h
182
Gearbox
Rear
axle
173
158
Engine
g/kW.h
N.m
181.8
34.0
215
1570
167.4
36.0
247
1246 1117
178.1
36.5
235
2200
1052
123.1
2090
1000
131.0
1700
813
133.7
3
2
1
1 32

Ares 806 – 09.2004 – GB
Engine DPS 6068 HRT 70

A1.2 Ares 806 – 09.2004 – GB
Identification
Injection pumps identification
STANADYNE injection pump
161hsm01c
BOSCH injection pump
161hsm02c
TRACTOR
Type
ARES 816
4412
ARES 826
4422
ARES 836
4232
Engine 6068HRT70 6068HRT71 6068HRT72
Injection pump STANADYNE BOSCH
Model DE 10 VP 44
Type DE 10 5807
Injection order 1-5-3-6-2-4
Injector STANADYNE
Model Pencil-type 9 mm *2
Reference 35107 RE 507766 35101 RE 506688
Injector calibration pressure
(bar)
250
New injector opening pressure 255 to 260 bar
Minimum acceptable opening
pressure of a worn injector
235 bar
Maximum opening pressure
difference between cylinders
7 bar

Ares 806 – 09.2004 – GB A1.3
Tightening torques (DE 10)
161msm01
0,5 daN.m
3 daN.m
4 daN.m
2,7 daN.m
2,7 daN.m
2,5 daN.m
19,5 daN.m
9,5 daN.m
2,7 daN.m
0,6 daN.m

A1.4 Ares 806 – 09.2004 – GB
Tightening torques (VP 44)
161hsm03c
0,5 daN.m
4 daN.m
2,7 daN.m
2,7 daN.m
7 daN.m
4,8 daN.m
0,6 daN.m
2,7 daN.m

Ares 806 – 09.2004 – GB A1.5
Operating principles
Pre-filter
Filters: 149 microns
ARES 816 and 826
Note: The original strainer (6) is to be replaced by a
removable strainer on the first compulsory service
(first 100 hours).
- Clean around the strainer located between the cab and
the main tank.
- Loosen the clips to free the strainer from the tubing.
- Collect any diesel still in the feed pipe.
- Open the strainer by unscrewing parts (B) and (C).
- Clean the 2 parts of the strainer.
- Reassemble.
- Drain the feed circuit.
IMPORTANT: Be careful not to introduce any
impurities into the diesel circuit during this operation.
161hpn05
161hpn01
6
B
C

A1.6 Ares 806 – 09.2004 – GB
Fuel filter
161hsm13c
Parts list
A Final filter
1 Fuel outlet
2 Fuel inlet
B Primary filter
3 Drain screw
4 Filter
4
1 12 2
33
BA

Ares 806 – 09.2004 – GB A1.7
Injection pump
STANADYNE injection pump (DE 10)
161msm02
Parts list
A Fuel inlet.
B Drive shaft.
C Transfer pump.
D Cam ring.
E Pipe coupling for injector.
F Fuel control solenoid.
G Pump distributor.
H Distributor rotor.
I Fuel temperature sensor.
J Fuel return.

A1.8 Ares 806 – 09.2004 – GB
Injection pump
BOSCH injection pump (VP 44)
161hsm04c
Parts list
A Drive shaft.
B Fuel pump.
C High-pressure radial piston pump.
D Distributor shaft.
E High-pressure solenoid valve.
F Pump control unit (UCE).
G Timing device.
H Timing solenoid valve.

Ares 806 – 09.2004 – GB A1.9
Injectors
Parts list
1 Injector nozzle.
2 Carbon deposit arrestor seal.
3 Needle.
4 Injector body.
5 Seal.
6 Injection pipe coupling.
7 Needle guide.
8 Union nut.
9 Spring retainer.
10 Adjustable spring.
11 Stroke adjustment screw.
12 Locknut.
13 Union.
14 Locknut.
15 Pressure adjustment screw.
16 Clamp.
17 Olive.
18 Filter basket.
19 Injection pipe.
20 Cap.
161msm03
20
14
12
16 18 19
17
8
65
1
2
3
4
7
9
10
15
11
13

A1.10 Ares 806 – 09.2004 – GB
Situation of the different sensors (DE 10)
161msm04
Parts list
A Engine oil pressure sensor: 1,5 daN.m.
B Pump control solenoid.
C Engine control unit.
D Crankshaft position sensor: 1,4 daN.m.
E Fuel temperature sensor: 1,3 to 1,8 daN.m.
F Engine coolant temperature sensor: 1,5 daN.m.
G Manifold air temperature sensor: 1 daN.m.
A
C
B
D
E
F
G

Ares 806 – 09.2004 – GB A1.11
Situation of the different sensors (VP 44)
161hsm05c
Parts list
A Engine coolant temperature sensor: 1,5 daN.m.
B Engine oil pressure sensor: 1,5 daN.m.
C Fuel pressure sensor: 1,3 to 1,8 daN.m.
D Electric transfer pump connector.
E Pump position sensor.
F Crankshaft position sensor: 1,4 daN.m.
G Engine control unit.
H Coolant temperature sensor (thermostat housing): 1,5 daN.m.
I Manifold air temperature sensor: 1 daN.m.

A1.12 Ares 806 – 09.2004 – GB
Checks/Adjustments
Accelerator control adjustment
161msm05
Make sure that:
1 - The adjustment measurement (A) satisfies the
following 2 conditions:
- The pedal shoe effort must be between 3 and 5 daN.
- The pedal must return easily to the high position.
2 - The angular detector values:
- Raised pedal (in idling speed stop): Maximum 0,9 V.
- Pedal fully depressed: Minimum 3,1 V.
The voltage will be measured with ignition switched on.
Use the cable n° 60 05 005 577 to measure the output
voltage.
A

Ares 806 – 09.2004 – GB A1.13
Checks/Adjustments
Adjusting the engine injector
For any operation assembling/dismantling the injectors,
use tool n° 60 05 005 579 combined with a sliding
hammer.
- Unscrew the protection cover (F).
- 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 n° 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).
- 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
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.
161msm06
C
B
D
E
A 0,5 daN.m
1 daN.m
F

A1.14 Ares 806 – 09.2004 – GB
Checks/Adjustments
Supply pressure check
- Fit the tool (1) n° 60 05 005 521.
- Start the engine.
The fuel pump must maintain the minimum pressure
indicated below. If the pressure is low, change the filters
and start the check again.
Pressures and flows (see injections sheets, chapter A0).
Parts list
A Output .
B Input.
C Primary filter.
D Final filter.
161msm07
1
A B
A B
C
D

Ares 806 – 09.2004 – GB A1.15
Removal/refitting
Fuel filter replacement
To replace the fuel filter:
- Loosen retaining ring (A) and remove the filter
body (B).
- Retain the holding ring (A) and put it in place on the
new filter.
- Put the new filter in place, aligning the filter locators
with the oblong holes in the mounting flange for the
filter head.
- Tighten the retaining ring (A) until it locks.
- Bleed the fuel filter.
Note: The holding ring is in the correct position when
no further resistance is felt during tightening.
Change both at the same time. Polarising slot on cartridge
and filter (no possibility of inversion).
Injection system bleeding
1st case
After changing the fuel filter
- Undo the drain screw on the front of the filter head.
- Activate the mechanical feed pump.
- Tighten up the drain screw again. The engine should
start.
2nd case
After complete draining of the circuit
- Perform operations from 1 to 3 described under
the 1st case.
- Loosen the return pipe (F) until all the air is eliminated,
then tighten it up again.
- Whilst turning the engine using the starter motor,
loosen the couplings (H) until the fuel escaping from
the coupling is free of air bubbles. Retighten the union
while turning the starter.
- Repeat the procedure for the other injectors until the
engine starts.
161msm08
161msm09
161msm10
A
B
F

A1.16 Ares 806 – 09.2004 – GB
Removal/refitting
Injection pump removal (DE 10)
IMPORTANT: Before any work is done on the injection
pump, it is IMPERATIVE to position the timing axle
n° 60 05 005 575 in aperture (E), as well as the
flywheel timing axle n° 60 05 005 576 using flywheel
turning tool n° 60 05 005 501 turning the gear to the
left when facing the tractor. Make sure that these
timing pins remain in place until reassembly.
IMPORTANT: Never use steam or cold water to clean
a hot or operating injection pump.
IMPORTANT: Take care not to turn the injection pump
couplings when loosening the injection pipes, as this
may cause internal damage to the pump.
- Blank off all the couplings and apertures as soon as
dismantling takes place (pump and pipes), do not use
fraying materials.
- Disconnect electrical connections.
- Disconnect the fuel return pipe (A).
- Disconnect the fuel supply pipe (B).
- Disconnect the injection pipes (C).
- Dismantle the diesel filter.
- Remove the pump gear access plate.
- Remove the nut and washer securing the injection
pump drive pinion to the pump shaft.
- Attach special tool n° 60 05 005 514 to the gear.
- Remove the three nuts (D) securing the pump to the
engine front plate.
- Turn the screw of tool n° 60 05 005 514 clockwise until
the pump shaft separates from the drive gear.
- Disengage the pump from the three studs by pulling it
backwards.
161msm11
B A
D
C
E

Ares 806 – 09.2004 – GB A1.17
Removal/refitting
Injection pump removal (VP 44)
IMPORTANT: Before carrying out any work on the
injection pump, it is ESSENTIAL to fit timing pin
n° 60 05 005 578 near to screws (E), and flywheel
timing pin n° 60 05 005 576 with the aid of flywheel
turner n° 60 05 005 501 while rotating the pinion to the
left when facing the tractor. Make sure that these
timing pins remain in place until reassembly.
IMPORTANT: Never use steam or cold water to clean
a hot or operating injection pump.
IMPORTANT: Take care not to turn the injection pump
couplings when loosening the injection pipes, as this
may cause internal damage to the pump.
- Blank off all the couplings and apertures as soon as
dismantling takes place (pump and pipes), do not use
fraying materials.
- Disconnect electrical connections.
- Disconnect the fuel return pipe (A).
- Disconnect the fuel supply pipe (B).
- Disconnect the injection pipes (C).
- Dismantle the diesel filter.
- Remove the pump gear access plate.
- Remove the 4 screws and washers (E) attaching the
injection pump driving pinion to the pump shaft.
- Disengage the pump from the three studs by pulling it
backwards.
161hsm06c
E
C
B
D
A

A1.18 Ares 806 – 09.2004 – GB
Removal/refitting
Injection pump installation (DE 10)
WARNING: Before replacing the pump, make sure
that the pump timing pin and the flywheel timing pin
have remained in place. If not repeat the operation
indicated prior to the pump removal.
- Fit a new seal on the front face of the injection pump
attachment flange.
- Slide the injection pump onto the mounting studs,
whilst at the same time inserting the pump shaft into
the drive pinion.
- Hand-tighten the nuts (D).
- After firmly engaging the drive pinion against the
tapered part of the shaft, fit the washer and nut (E).
- Tighten nut (E) to 19,5 daN.m.
- Remove the pump timing and flywheel pins.
- Torque-tighten the nuts (D) to 2,5 daN.m.
- Tighten the injection pipes (C), then the return (A) and
supply (B) pipes.
- Connect up the various electric cables which were
disconnected prior to removal of the pump.
- Bleed the air from the fuel circuit.
IMPORTANT: Never remove the pump and flywheel
timing pins before the pump and gear are fastened.
161msm12
19,5 daN.mE
B A
C
D

Ares 806 – 09.2004 – GB A1.19
Removal/refitting
Injection pump installation (VP 44)
WARNING: Before replacing the pump, make sure
that the pump timing pin and the flywheel timing pin
have remained in place. If not repeat the operation
indicated prior to the pump removal.
- Fit a new seal on the front face of the injection pump
attachment flange.
- Slide the injection pump onto the mounting studs while
inserting the pump hub into the driving pinion.
- Hand-tighten the nuts (D).
- After engaging the driving pinion with the pump hub, fit
screws (E) and washers.
- Torque tighten the screws (E) to 4,8 daN.m.
- Remove the pump timing and flywheel pins.
- Torque-tighten the nuts (D) to 7 daN.m.
- Tighten the injection pipes (C), then the return (A) and
supply (B) pipes.
- Connect up the various electric cables which were
disconnected prior to removal of the pump.
- Bleed the air from the fuel circuit.
IMPORTANT: Never remove the pump and flywheel
timing pins before the pump and gear are fastened.
161hsm07c
B
C
4,8 daN.m
E
D
A
7 daN.m
E

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Claas Ares 806 Tractor repair manual

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