Claas f1200 c1200 soja getreide lexion (type 442) service repair manual

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Contents
1 General Information
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.1 Important notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.2 Identification of warning and danger signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.3 General safety and accident prevention regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.4 Front attachment and trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2.5 Adjustment and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2.6 First aid measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.7 Danger of injury due to escaping hydraulic liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.1 Reason of damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.2 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.3 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.4 Tensioning the steel roller chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.5 Taper ring fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.6 Self-locking bolts with micro-encapsulated adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.7 Liquid locking compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3.8 Lock collar bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3.9 Adapter sleeve bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3.10 Ferrule fittings on hydraulic lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3.11 Progressive ring fittings on hydraulic lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3.12 Taper fittings on hydraulic lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3.13 Hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3.14 Welding Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.3.15 Some advice for speedy and correct repair work: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.4 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.4.1 Tightening torques for metric standard threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.4.2 Tightening torques for metric fine threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.4.3 Tightening torques for hydraulic screw fittings
with ferrule according to DIN 3861 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.4.4 Tightening torques for hydraulic screw fittings
and air conditioner fittings
with a sealing cone and O-ring DIN 3865 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.4.5 Tightening torques for hydraulic male connector DIN 3901 . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.4.6 Tightening torques for direction-adjustable hydraulic male connectors
ISO 6149-2 / ISO 11926-2 (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.4.7 Tightening torque for hydraulic swivelling screw fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.4.8 Tightening torques for hollow screws DIN 7643 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.4.9 Tightening torques for screw thread clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.5.1 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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2 Outputs / drives
2.1 Drive belts / drive chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.1.1 General warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.1.2 Fixing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.1.3 Drive diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.1.4 Removing belt (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.1.5 Removing belt (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.1.6 Adjusting belt (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.1.7 Removing chain (K6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.1.8 Installing chain (K6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.1.9 Adjusting chain (K6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.1.10 Removing chain (K9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.1.11 Installing chain (K9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.1.12 Adjusting chain (K9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.2 Front attachment drive universal drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.2.1 Removing / disassembling the universal drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.2.2 Universal drive shaft overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.2.3 Assembling / installing the universal drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.2.4 Removing / disassembling the cam-type cut-out clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.2.5 Cam-type cut-out clutch overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.2.6 Assembling / installing the cam-type
cut-out clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.3 Front attachment drive intermediate drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.3.1 Removing / disassembling the intermediate drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.3.2 Intermediate drive shaft - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.3.3 Assembling / installing the intermediate drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.4 Knife drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.4.1 Drive pulley of belt (R1) - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.4.2 Removing drive pulley of belt (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.4.3 Installing the drive pulley of belt (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.4.4 Guide roller of belt (R1) - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.4.5 Removing the guide roller of belt (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.4.6 Installing the guide roller of belt (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.4.7 Overview of jockey pulley belt (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.4.8 Removing the jockey pulley of belt (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.4.9 Installing the jockey pulley of belt (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.4.10 Driven pulley of belt (R1) - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.4.11 Removing the driven pulley of belt (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.4.12 Installing the driven pulley of belt (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.4.13 Planetary gear - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.4.14 Removing the planetary gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.4.15 Disassembling the planetary gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.4.16 Assembling the planetary gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.4.17 Installing the planetary gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.5 Knife drive special tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.5.1 Removing drive pulley of belt (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.5.2 Disassembling the planetary gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.5.3 Assembling the planetary gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

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2.6 Intake auger drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.6.1 Removing the drive sprocket of chain (K6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.6.2 Installing the drive sprocket of chain (K6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.6.3 Removing the driven sprocket of chain (K6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.6.4 Installing the driven sprocket of chain (K6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.6.5 Removing the drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.6.6 Installing the drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.6.7 Removing the outer intake auger bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.6.8 Installing the outer intake auger bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.6.9 Removing / disassembling the inner intake auger bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.6.10 Assembling / installing the inner intake auger bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.7 Special tools for intake auger drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.7.1 Removing the drive sprocket of chain (K6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.7.2 Removing the outer intake auger bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.8 Reel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.8.1 Removing the drive sprocket of chain (K9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.8.2 Installing the drive sprocket of chain (K9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.8.3 Removing the driven sprocket of chain (K9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.8.4 Installing the driven sprocket of chain (K9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.8.5 Removing the left flanged shaft of the left reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.8.6 Installing the left flanged shaft of the left reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.8.7 Removing the right flange of the left reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.8.8 Installing the right flange of the left reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.8.9 Removing the right flanged shaft of the right reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.8.10 Installing the right flanged shaft of the right reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.8.11 Removing the flanged shaft between the left and right reel . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.8.12 Installing the flanged shaft between the left and right reel . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3 Hydraulic system
3.1 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.1.1 Solenoid valves - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.1.2 Removing solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.1.3 Installing solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3.1.4 Non-return valves - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.1.5 Removing the non-return valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.1.6 Installing non-return valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.2 Special tools for valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.2.1 Removing solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.2.2 Installing solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.3 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.3.1 Removing the hydraulic reel drive motor (2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.3.2 Installing the hydraulic reel drive motor (2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.4 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3.4.1 Removing the left reel height adjustment hydraulic cylinder (3015) . . . . . . . . . . . . . . . . . . . . 130
3.4.2 Left reel height adjustment hydraulic cylinder (3015) - Overview . . . . . . . . . . . . . . . . . . . . . . 131
3.4.3 Installing the left reel height adjustment hydraulic cylinder (3015) . . . . . . . . . . . . . . . . . . . . . 132
3.4.4 Removing the centre reel height adjustment hydraulic cylinder (3136) . . . . . . . . . . . . . . . . . 132
3.4.5 Centre reel height adjustment hydraulic cylinder (3136) - Overview . . . . . . . . . . . . . . . . . . . 134

6
20621
3.4.6 Installing the centre reel height adjustment hydraulic cylinder (3136) . . . . . . . . . . . . . . . . . . 135
3.4.7 Removing the right reel height adjustment hydraulic cylinder (3014) . . . . . . . . . . . . . . . . . . 135
3.4.8 Right reel height adjustment hydraulic cylinder (3014) - Overview . . . . . . . . . . . . . . . . . . . . 137
3.4.9 Installing the right reel height adjustment hydraulic cylinder (3014) . . . . . . . . . . . . . . . . . . . 138
3.4.10 Removing the hydraulic fore and aft reel adjustment hydraulic cylinder (3016) . . . . . . . . . . 138
3.4.11 Hydraulic fore and aft reel adjustment hydraulic cylinder (3016) - Overview . . . . . . . . . . . . . 140
3.4.12 Installing the hydraulic fore and aft reel adjustment hydraulic cylinder (3016) . . . . . . . . . . . 141
3.4.13 Cutterbar table lock hydraulic cylinder (3137) - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4 Electric / Electronic systems
4.1 Wiring looms / Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.1.1 Left Auto-Contour sensor band (B3) - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.1.2 Right Auto-Contour sensor band (B4) - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.1.3 Reel height position sensor (B39) - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5 Crop pick-up
5.1 Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.1.1 Removing the left reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.1.2 Installing the left reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.1.3 Removing the right reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.1.4 Installing the right reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
5.1.5 Replacing the cam rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
5.1.6 Removing the control element of cam rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
5.1.7 Installing the control element of cam rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
5.1.8 Removing the control spider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
5.1.9 Installing the control spider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5.1.10 Removing the reel spider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.1.11 Installing the reel spider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5.1.12 Removing the bearing of the reel tine tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5.1.13 Installing the bearing of the reel tine tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5.1.14 Removing the reel tine tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5.1.15 Installing the reel tine tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5.1.16 Changing the reel tines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5.1.17 Installing the reel tine riveting nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5.1.18 Removing the left reel shaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
5.1.19 Installing the left reel shaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5.1.20 Removing / disassembling the centre reel shaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
5.1.21 Assembling / installing the centre reel shaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.1.22 Removing the right reel shaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.1.23 Installing the right reel shaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.1.24 Removing the outer reel support arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.1.25 Installing the outer reel support arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.1.26 Removing the centre reel support arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
5.1.27 Installing the centre reel support arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5.1.28 Replacing the hydraulic fore
and aft reel adjustment slide plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

7
20621
6 Feeder unit
6.1 Intake auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
6.1.1 Removing the intake auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
6.1.2 Installing the intake auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
6.1.3 Removing intake auger fingers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
6.1.4 Installing intake auger fingers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
6.1.5 Removing the adjusting shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
6.1.6 Installing the adjusting shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
6.1.7 Removing the control shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
6.1.8 Installing the control shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
7 Mowing unit
7.1 Mower head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
7.1.1 Removing the knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
7.1.2 Installing the knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
7.1.3 Adjusting knife clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

8 000 295 260 0 - RHB C1200 - 07/07
1.1 General
20622
1.1 General
36905
1.1.1 Introduction
The present CLAAS REPAIR MANUAL is to provide
assistance in maintaining permanent availability. This
is to guarantee the high value of CLAAS machine by
thorough care and technical servicing.
Experience gathered by both our service engineers
and factory staff has been compiled in this REPAIR
MANUAL.
The sequence of pictures shows the repair process.
The text provides the necessary explanations regard-
ing settings, the use of CLAAS special tools and the
like.
The illustrations included in support to the explana-
tions show the sequence of major repairs so that
minor repairs can easily be followed.
The CLAAS REPAIR MANUAL is filled in a folder
which allows to insert supplementary pages as issued
following technical developments and to always have
an updated manual at hand for reference.
To be sure, always compare settings and filling capaci-
ties with specifications stated in the current Operator's
Manual of the combine-harvester.
CLAAS KGaA mbH
Service Department

000 295 260 0 - RHB C1200 - 07/07 9
1.2 Safety rules
20622
1.2 Safety rules
14066
1.2.1 Important notice
The instructions contained in the present CLAAS
REPAIR MANUAL must be carefully read and
observed by all persons involved with the operation,
maintenance and inspection of this machine in order
to prevent accidents.
In particular, read the present section "Safety rules".
Use only spare parts, accessories and ancillary equip-
ment made by CLAAS and inspected and approved by
CLAAS. This is the only way how designed properties
of CLAAS machines and their proper service condition
can be maintained. Moreover, genuine CLAAS parts
preserve the active and/or passive operational safety
of the machine and its occupational safety standards.
CLAAS is in no way liable for any damage or personal
injury caused through the use of other than genuine or
approved CLAAS parts, accessories and ancillary
equipment.
Technical data, dimensions and weights are given as
an indication only. CLAAS reserve the right to make
changes subsequently as technical developments con-
tinue. Responsibility for errors or omissions not
accepted.
Front, rear, right and left always refer to the direction of
forward travel.
12776
1.2.2 Identification of warning and danger
signs
All parts of this manual having to do with your safety or
the safe operation of the front attachment or the
machine are marked with the following signs. Please
pass all safety instructions on to other users, too.
Danger!
Nature and source of danger
Consequences: death or serious injury
– Countermeasures
Warning!
Consequences: injuries
– Countermeasures
Caution!
Consequences: material damage
– Countermeasures

10 000 295 260 0 - RHB C1200 - 07/07
1.2 Safety rules
20622
The warning and instruction signs placed on the
machine provide important information for safe opera-
tion. These instructions involve your safety – observe
them at all times!
14065
1.2.3 General safety and accident prevention
regulations
– In addition to this manual, always comply with the
Operator's Manual of the machine as well.
– Comply with all general safety and accident pre-
vention regulations.
– Always comply with local traffic regulations when
driving on public roads!
– Before starting the diesel engine ensure that the
transmission is in neutral and all guards are
installed and in their correct position.
– Always blow the horn before starting the diesel
engine and engaging the main drive.
– Start the diesel engine only from the operator's
seat. Never attempt to start the diesel engine by
short-circuiting across the starting motor terminals
as the machine may immediately start to move!
– Never run the diesel engine in a closed building!
– Clothing worn by the service technician must be
close-fitting. Avoid wearing loose clothing!
– Handle fuel with care. - Fuel is highly flammable.
– Never refuel the machine in the vicinity of naked
flames or sparks.
– Do not smoke during refuelling!
– Always stop the diesel engine and remove the
ignition key before refuelling. Fill the fuel tank
outdoors.
– Clean up any spilled fuel immediately!
– Prevent fires by keeping the machine clean!
– Be careful when handling brake fluid and electro-
lyte. Electrolyte is toxic and caustic!
– Perform work under the raised machine only when
safe supports are provided.
– Refit guards after completing maintenance and
repair work!
Note!
Nature and source of information
Consequences: enhanced machine economy
or easy assembly
– Measures
Environment!
Consequences: damage to the environment
– Countermeasures

000 295 260 0 - RHB C1200 - 07/07 11
1.2 Safety rules
20622
2420
1.2.4 Front attachment and trailers
• Support raised front attachments securely before
doing any work underneath the units.
• Take particular care when mounting front attach-
ments to the basic machine and when attaching a
trailer.
• Owing to their function, front attachments and
feeder mechanisms such as belts, rollers, chains,
worm gears, reels and the like cannot be com-
pletely protected by design measures; for this
reason, an adequate safety distance must be
maintained from these moving elements during
operation. These instructions also apply to all
other accessories operated on the machine.
• No person must ever be allowed between the
machine and the front attachment unless the park-
ing brake is applied and/or the wheels are
chocked so that the vehicle can not start to move
on its own.
• Front attachments and trailers must only be
attached to the coupling devices provided for that
purpose. Observe the maximum permissible load
capacity of the trailer hitch.
• Hitch the trailer correctly to the forage harvester.
Be alert when connecting a trailer to the forage
harvester.
• Before disconnecting a front attachment always
make sure that it is stable and securely parked.
• When attaching front attachments always make
sure that the load on the existing rear axle is suffi-
cient to maintain the forage harvester's steering
and braking capabilities.
2423
1.2.5 Adjustment and maintenance work
The drives on the machine will not be automatically
secured from moving after the engine has been
switched off.
Moreover, when it comes to adjustments, it may be
necessary to turn the drives.
For this reason, comply with the following rules:
• Before setting, cleaning and maintenance opera-
tions and when remedying problems:
- Switch off the chopper unit.
- Shut off the engine.
- Disconnect the battery isolating switch.
• Before setting, cleaning and maintenance opera-
tions and when remedying problems on the
hydraulic system, lower front attachment and/or
feeder unit completely.
• Always turn off the battery isolating switch before
carrying out any electrical repairs on the machine.

12 000 295 260 0 - RHB C1200 - 07/07
1.2 Safety rules
20622
• The drives will continue to rotate after shutting
down the main drive. Absolutely wait until the
drives have come to a complete halt.
• It must be ensured that other persons cannot start
the machine or rotate the drives.
• Liquids escaping under high pressure (fuel,
hydraulic oil etc.) can penetrate the skin and
cause serious injury, therefore consult a doctor
immediately as otherwise serious infections can
result!
• Only have qualified workshops carry out repair
work on the hydraulic system.
• Be careful when opening the radiator cap. As long
as the engine is hot, the radiator is under
pressure!
• Do not attempt to mount a tyre unless you
have the proper equipment and experience
to perform the job safely.
• Dispose of oil, fuel and filters in a way that is
harmless to the environment and in accordance
with existing anti-pollution regulations!
• Retighten the wheel nuts regularly!
2427
1.2.6 First aid measures
Inhaling:
– Make the person inhale fresh air and consult a
doctor, depending on the symptoms.
– Remove the person from the hazard area.
Eye contact:
– Thoroughly flush with water for several minutes. If
necessary, consult a doctor.
Skin contact:
– Thoroughly clean with plenty of water and soap
and remove polluted and soaked clothing immedi-
ately, consult a doctor if skin is irritated (redness
etc.).
Swallowing:
– Do not cause vomiting, consult a doctor
immediately.

000 295 260 0 - RHB C1200 - 07/07 13
1.2 Safety rules
20622
36550
1.2.7 Danger of injury due to escaping
hydraulic liquid
1
740
Danger!
Liquids under high pressure.
Liquids penetrate the skin and cause serious
injury.
– Only have authorised and qualified work-
shops carry out work on the hydraulic
system.
– Check hose lines at regular intervals.
Search for leaks using a piece of wood or
cardboard.
Ensure that the oil jet will not be directed
towards your body.
– Replace any damaged hose lines.
– Replace hose lines 6 years after the date
of manufacture at the latest.
Danger!
Dealing incorrectly with injuries due to hydrau-
lic fluids.
Death or serious injury.
Even a pinhole can result in severe injuries.
– If hydraulic fluid gets in the skin or eyes,
have the injury treated by a medical spe-
cialist immediately.

14 000 295 260 0 - RHB C1200 - 07/07
1.3 General repair instructions
20622
14015
1.3.1 Reason of damage
Identify reason of damage, limit the case of damage
and safeguard the machine.
36919
1.3.2 Spare parts
Please specify the respective identification nos. when
ordering spare parts and making technical inquiries:
• Machine
• Front attachment
• Engine
• Subassembly
and/or
• Software version / versions
This is necessary as otherwise, incorrect spare part
deliveries may result.
The identification no. can be found on the respective
type plate.
The identification no. / nos. of the software can be
found in the respective menu.
14021
1.3.3 Gearboxes
When removing the gearboxes, always drain the gear-
box oil first and then remove the gearbox. Separate
parts which are firmly connected with each other by
means of a soft metal-tip or plastic-tip hammer.
14025
1.3.4 Tensioning the steel roller chains
Find the centre point in the slack span between
sprockets. With the tight span slightly under load,
push in the centre point of the slack span with the
thumb. The chain tension is correct when its slack
span deflects about 2% of the centre distance
between shafts. Check chain tension more frequently
when using new chains.
Example: Distance between shafts 500 mm =
Deflection of slack span is roughly 10 mm.
Danger!
Use of unauthorised spare parts.
Death or serious injury.
– Spare parts must at least comply with the
technical standards required by the man-
ufacturer of the implement!
– We recommend using genuine CLAAS
spare parts.

000 295 260 0 - RHB C1200 - 07/07 15
20622
14027
1.3.5 Taper ring fasteners
Taper ring fasteners provide a safe mechanical con-
nection, even when transmitting high forces from the
driving element on the shaft and vice versa, provided
they are properly prestressed.
Installation:
When installing taper ring fasteners, it is important
that the shaft, hub, parallel key and the taper rings
have been thoroughly cleaned, that semi-fluid lubricant
of NLGI class 00, e.g. CLAAS AGRIGREASE
LC 00/000, is applied and that the components are
tightened to the specified torque in the correct order
of assembly.
Disassembly:
After loosening the axial clamping, loosen the taper
ring fastener with a sharp blow, using a block-ended
tube.
14029
1.3.6 Self-locking bolts with micro-encapsu-
lated adhesive
Replace self-locking bolts, e.g. Verbus-Plus / Imbus-
Plus upon each assembly. In exceptional cases, they
may be reused up to three times.
Always tighten self-locking bolts with microencapsu-
lated adhesive rapidly to the specified tightening
torque.
Always observe the specified tightening torque.
When removing self-locking bolts, quickly unscrew
them completely. Self-locking bolts must never get in
contact with sealing compound.
Self-locking bolts with microencapsulated adhesive
may be used only where operating temperatures will
not exceed + 90 °C max.
These bolts can be subjected to full stress after
24 hours at + 20 °C. The complete curing period can
be shortened by heating, e.g. to 15 minutes at + 70 °C.
Warning!
Gluing on taper ring fasteners.
– No solid grease must be used when
assembling the parts.
Warning!
Damage to the taper ring fastener.
– The inside diameter of the block-ended
tube must be large enough to extend over
the tapered ring.

16 000 295 260 0 - RHB C1200 - 07/07
20622
In individual cases, bolts with liquid locking compound
can be used instead of self-locking bolts only where
these bolts can be heated up to approx. 200 °C for
removing them. Comply with the specified quality
grade of bolts, e.g. 8.8 or 10.9 here as well.
14031
1.3.7 Liquid locking compound
Use liquid locking compound only where specified
by the manufacturer.
Correct application:
Metal surfaces where liquid locking compound is to
be applied must be absolutely free from grease.
Use the "Activator" included in the workshop package
for cleaning.
Before applying the liquid locking compound, the acti-
vator, i.e. the cleaning agent on the metal surfaces
must have dried. Especially in blind holes, no Activator
residues are allowed.
In threaded assemblies, apply the liquid locking com-
pound only to the internal thread of the nut in drops if
possible. In blind holes only wet approx. 1d (d = nomi-
nal Ø of bolt) at the thread bottom. The same applies
to any extra-long female threads. When applying the
liquid locking compound to the bolt or at the top end of
a female thread, the liquid locking compound will
spread over the entire thread length when screwing
the bolt in. As a result, too much break-away torque is
required to remove the bolt – Danger of breaking!
Threaded assemblies secured with liquid locking com-
pound can be easily unscrewed by heating them up to
approx. 200 °C.
14033
1.3.8 Lock collar bearings
Lock collar bearings are tightened on the shaft by
rotating the eccentric ring over the inside bearing ring.
Prior to installation, apply semi-fluid lubricant of NLGI
class 00, e.g. CLAAS semi-fluid lubricant EP 00, to the
inside ring and the shaft to make bearing removal eas-
ier during any future repairs.
Always fasten the eccentric ring moderately in the
direction of rotation of the shaft and lock by means of a
set screw. To remove the bearing, loosen the eccentric
ring in opposite direction of rotation of the shaft.
14035
1.3.9 Adapter sleeve bearing
Adapter sleeve bearings do not require a specially
machined bearing seat. They may be mounted on any
drawn or scalped shaft. This is an advantage because
it allows the shaft to be axially moved as required to
obtain correct alignment.

000 295 260 0 - RHB C1200 - 07/07 17
20622
Always install adapter sleeve bearings according to
the conical inside ring. Clean the taper lock adapter
sleeve and the shaft and check that the sleeve nut
runs easily so the taper lock adapter sleeve will not
turn on the shaft when tightening.
Tightening the bearing:
First tighten the sleeve nut to the point where the taper
lock adapter sleeve has no more play and is under
slight preload. Now tighten the nut by approx. 90° and
continue turning until the next nearest slot fits the tab.
Secure sleeve nut with the tab.
Loosening the bearing:
Loosen the unlocked sleeve nut only by a few turns for
the time being. The thread must still carry the full load.
Loosen the taper lock adapter sleeve with a sharp
blow, using a block-ended tube.
14037
1.3.10 Ferrule fittings on hydraulic lines
When pre-assembling the unit and for pre-assembled
factory-delivered ferrule fittings, the following applies:
installation is in the associated, well-oiled threaded
joint with half a turn of the union nut beyond the point
where resistance is felt.
Pre-assembly:
– Cut off the tube at right angles.
Do not use a pipe cutter! This will slant the tube
wall, causing heavy inside and outside burrs.
– Slightly deburr the inside and outside tube ends.
Do not chamfer!
– Clean the tube end.
In case of tube bends, the straight tube end up to
where the bending radius starts must be at least twice
the height of the union nut.
– Push the union nut and the ferrule on the tube.
– Push the tube against the stop in the union and
tighten the union nut until the ferrule catches the
tube.
The tube must not rotate. This point can be felt
because increased power is needed from here.
– Tighten the union nut half a turn beyond the point
– Check the cut produced by the cutting edge.
A visible collar must fill up the space ahead of the
ferrule face. The ferrule may rotate, but axial dis-
placement must not be possible.

18 000 295 260 0 - RHB C1200 - 07/07
20622
Final assembly
– Insert the pre-assembled tube into the well-oiled
screw fitting
– Tighten the union nut until considerably more
force is needed.
– Then add another half a turn.
Repeated assembly
– Every time the ferrule fitting has been loosened,
retighten the union nut without using increased
force.
Ferrule fitting leaks
– If a fitting leaks, first loosen the union nut until
some oil escapes.
– Then tighten the union nut as specified.
14039
1.3.11 Progressive ring fittings on hydraulic
lines
When pre-assembling the unit and for pre-assembled
factory-delivered profiled ring fittings, the following
applies: installation is in the associated, well-oiled
threaded joint with half a turn of the union nut beyond
the point where resistance is clearly felt.
Pre-assembly
– Cut off the tube at right angles.
Do not use a pipe cutter! This will slant the tube
wall, causing heavy inside and outside burrs.
– Slightly deburr the inside and outside tube ends.
Do not chamfer!
– Clean the tube end.
In case of tube bends, the straight tube end up to
where the bending radius starts must be at least twice
the height of the union nut.
– Push the union nut and the profiled ring on
the tube.
– Push the tube against the stop in the union and
tighten the union nut until the profiled ring catches
the tube.
The tube must not rotate.
This point can be felt because increased power is
needed from here.
– Tighten the union nut half a turn beyond the point
– Check the cut produced by the cutting edge.
A visible collar must fill up the space ahead of the
profiled ring face. The profiled ring may rotate, but
axial displacement must not be possible.

000 295 260 0 - RHB C1200 - 07/07 19
20622
Final assembly
– Insert the pre-assembled tube into the well-oiled
screw fitting.
– Tighten the union nut until considerably more
force is needed and then add another half a turn.
Important: Back up the threaded joint with
a spanner!
Repeated assembly
– Every time the profiled ring fitting has been loos-
ened, retighten the union nut until resistance is
felt and then continue for half a turn beyond that
point.
a spanner!
Profiled ring fitting leaks
If a fitting leaks, first loosen the union nut until some oil
escapes and then tighten it as specified.
Any deviating tightening torques reduce the rated
pressure resistance and the service life of the screw
fitting. This results in leaks and the tube slipping out.
14041
1.3.12 Taper fittings on hydraulic lines
Installation:
– Oil the O-ring on the sealing cone. Tighten the
union nut a third of a turn beyond the point where
resistance is felt.
a spanner!
Any deviating tightening torques reduce the rated
pressure resistance and the service life of the screw
fitting. This results in leaks and the tube slipping out.
14043
1.3.13 Hydraulic hoses
Hydraulic fittings:
Observe the final assembly instructions:
– For ferrule fittings on hydraulic lines see above.
For progressive ring screw fittings on hydraulic
lines see above. For sealing cone screw fittings on
hydraulic lines see above.
Laying the hoses:
Observe the information provided with the five figures
below.

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20 000 295 260 0 - RHB C1200 - 07/07
20622
– Avoid twisting the hoses during installation.
A = incorrect installation
B = correct installation
– Hoses must be installed in such a way that neither
tensile loads will occur in any operating condition
nor compression loads on short hose lines.
C = incorrect installation
D = correct installation
– As a guideline, the total play of the hose should be
1 cm min. when moving the hose back and forth in
the middle between two holders/connectors
(e.g. clamps).
Avoiding external damage:
– Avoid external mechanical effects on hoses
at (G).
– Avoid chafing of hoses against one another or
against components by ensuring useful arrange-
ment and fixing.
– Keep a sufficient clearance from components (H).
– Cover up sharp-edged components permanently.
E = incorrect installation
F = correct installation
2
5728
3
5727
Warning!
Hoses laid in a straight line become shorter
due to the internal hydraulic pressure.
Fittings may be torn out.
– Always install hoses with a slight sag.
Even in static positions.
4
5726

000 295 260 0 - RHB C1200 - 07/07 21
20622
Avoiding torsional loads:
– When connecting a hose to moving parts, avoid
twisting the hose, especially when the movement
and the bending occur in the same plane.
K = incorrect installation
L = correct installation
Protection against external temperature effects:
– When major external temperature effects occur,
install hoses at a sufficient distance from heat-
emitting components.
– Or protect hose by a shielding (N).
14045
1.3.14 Welding Work
5
5729
6
5730
Note!
All information regarding this subject-matter
can be found in the current Operator's manual
of the machine.

22 000 295 260 0 - RHB C1200 - 07/07
20622
14047
1.3.15 Some advice for speedy and correct
repair work:
– Mark machine parts prior to disassembly to
ensure their correct left-to-right positions and bal-
ance when reassembled.
– Fit expansion pins with the slot facing the side
under load. When fitted with a quarter turn from
this position, they will get loose, fall out or shear
off.
– Replace split pins, locking wires, locking plates,
tab washers and lock washers when carrying out
repairs.
– Install greasable ball and sliding bearings with the
grease specified for them.
– Align sprockets and V-belt pulleys toward each
other.
– Care for strict cleanliness when working on
hydraulic systems.
– Never mix different oil types.
– Run the machine or operate machine assemblies
at low speed after any repair.

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