Claas Ares 506 606 Tractor repair manual

60 05 029 693 - 10.2003 - EN
01.2004 - EN
A0 A1 A3
B1 B2
C1 C2 C3
D1-1 D1-2
E1 E3
F
G1 G2 G3 G4
G5
A2 A4
B4B3
C4
E2
H1 H2 H3
J1
G7G6
J2
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TIER I TIER II
Engine DPS 4045 TRT 53 Engine DPS 4045 TRT 73
Engine DPS 4045 TRT 54 Engine DPS 4045 HRT 70
Engine DPS 4045 TRT 55 Engine DPS 4045 HRT 71
Engine DPS 6068 DRT 50 Engine DPS 6068 TRT 70
Engine DPS 6068 TRT 55
A0 INJECTION DATA SHEETS
A1 INJECTION FEED TIER I
A3 INJECTION ADDITIVE TIER II
A2 ENGINE TIER I
A4 ENGINE ADDITIVE TIER II
Chapter A
Edition 01.2004 – Ref. : 60 05 029 904

60 05 029 904 - 01.2004 - EN
CONTENTS
A0 - INJECTION DATA SHEETS
A1 - INJECTION FEED TIER I
IDENTIFICATION
INJECTION PUMPS IDENTIFICATION ..........................................................................................................................A1.2
CHARACTERISTICS
MAIN CHARACTERISTICS.............................................................................................................................................A1.4
ENGINES 4 CYLINDERS................................................................................................................................................A1.4
TIGHTENING TORQUES
TIGHTENING TORQUES................................................................................................................................................A1.8
OPERATING PRINCIPLES
POWER SUPPLY..........................................................................................................................................................A1.10
PRE-FILTER..................................................................................................................................................................A1.11
FUEL FILTER ................................................................................................................................................................A1.11
INJECTION PUMP ........................................................................................................................................................A1.12
INJECTORS ..................................................................................................................................................................A1.13
CHECKS/ADJUSTMENTS
ENGINE SPEED............................................................................................................................................................A1.16
CHECKING THE MAXIMUM NO LOAD SPEED...........................................................................................................A1.16
CHECKING AND ADJUSTING THE TICK-OVER.........................................................................................................A1.16
STATIC ADJUSTMENT OF THE INJECTION PUMP ...................................................................................................A1.17
DYNAMIC ADJUSTMENT OF THE INJECTION PUMP ...............................................................................................A1.17
INJECTOR ADJUSTMENT............................................................................................................................................A1.21
CRACKING PRESSURE ADJUSTMENT......................................................................................................................A1.21
NEEDLE STROKE ADJUSTMENT ...............................................................................................................................A1.22
SHUT-OFF SOLENOID VALVE FUNCTIONAL CHECK...............................................................................................A1.23
COLD-START SWITCH FUNCTIONAL CHECK...........................................................................................................A1.23
SUPPLY PRESSURE CHECK ......................................................................................................................................A1.24

60 05 029 904 - 01.2004 - EN
REMOVAL / INSTALLATION
FUEL FILTER REPLACEMENT ....................................................................................................................................A1.26
INJECTION SYSTEM BLEEDING.................................................................................................................................A1.26
INJECTION PUMP REMOVAL......................................................................................................................................A1.27
INJECTION PUMP INSTALLATION..............................................................................................................................A1.28
INJECTOR REMOVAL ..................................................................................................................................................A1.29
INJECTOR SEATING CLEANING (IF REQUIRED)......................................................................................................A1.29
INJECTOR INSTALLATION ..........................................................................................................................................A1.29
CARRYING OVER OF THE ADJUSTMENT MARK ONTO THE FRONT PLATE ........................................................A1.30
CONTROL ADJUSTMENTS
ADJUSTING THE ACCELERATOR CABLE .................................................................................................................A1.32
DIAGNOSTIC SHEETS
"ENGINE START UP DEFECT" SHEET .......................................................................................................................A1.34
"IRREGULAR ENGINE OPERATION" SHEET .............................................................................................................A1.35
"GREY OR BLACK SMOKE EMISSION" SHEET .........................................................................................................A1.36
"WHITE SMOKE EMISSION" SHEET...........................................................................................................................A1.37
"CHECK THE FUEL FEED CIRCUIT" SHEET..............................................................................................................A1.38
TOOLS
INJECTION TOOLS.......................................................................................................................................................A1.40
A2 - ENGINE TIER I
GENERAL SPECIFICATIONS
IDENTIFICATION OF THE ENGINES.............................................................................................................................A2.2
DIMENSIONAL SPECIFICATIONS
CYLINDER HEAD AND VALVES....................................................................................................................................A2.6
CYLINDER BLOCK .........................................................................................................................................................A2.8
LINERS AND PISTONS ..................................................................................................................................................A2.9
CONNECTING RODS ...................................................................................................................................................A2.10
CRANKSHAFT, BEARINGS AND FLYWHEEL.............................................................................................................A2.11
CAMSHAFT...................................................................................................................................................................A2.12
DISTRIBUTION .............................................................................................................................................................A2.13

60 05 029 904 - 01.2004 - EN
LUBRICATION...............................................................................................................................................................A2.14
OIL PUMP......................................................................................................................................................................A2.14
COOLING ......................................................................................................................................................................A2.15
THERMOSTAT..............................................................................................................................................................A2.15
WATER PUMP AND FAN DRIVE SUPPORT ...............................................................................................................A2.15
TURBOCHARGER ........................................................................................................................................................A2.16
TIGHTENING TORQUES
ENGINE/TRANSMISSION LINK....................................................................................................................................A2.18
FRONT CHASSIS / ENGINE LINK................................................................................................................................A2.18
OTHER ITEMS ..............................................................................................................................................................A2.19
DISTRIBUTOR DIAGRAM.............................................................................................................................................A2.22
LUBRICATION SYSTEM...............................................................................................................................................A2.23
COOLING CIRCUIT.......................................................................................................................................................A2.24
CHECKS/ADJUSTMENTS
CHECK OF ENGINE OIL PRESSURE..........................................................................................................................A2.26
CHECK OF COMPRESSION ........................................................................................................................................A2.26
CHECK OF VALVE LIFT (ENGINE COLD)...................................................................................................................A2.27
VALVE CLEARANCE (ENGINE COLD)........................................................................................................................A2.27
VALVE ADJUSTMENT SEQUENCE.............................................................................................................................A2.28
CHECK OF SUPERCHARGING PRESSURE...............................................................................................................A2.28
CHECK OF THE BELT AND THE TENSIONER SPRING ............................................................................................A2.29
PRELIMINARY OPERATIONS......................................................................................................................................A2.32
SEPARATE ENGINE/FRONT AXLE .............................................................................................................................A2.32
SEPARATE ENGINE/GEARBOX..................................................................................................................................A2.34
ENGINE INSTALLATION SPECIFICATIONS ...............................................................................................................A2.36
CYLINDER HEAD..........................................................................................................................................................A2.37
CAMSHAFT...................................................................................................................................................................A2.41
CYLINDER BLOCK .......................................................................................................................................................A2.42
LINERS..........................................................................................................................................................................A2.43
PISTONS AND CONNECTING RODS..........................................................................................................................A2.46
CRANKSHAFT, BEARINGS, AND FLYWHEEL............................................................................................................A2.52
CAMSHAFT, BALANCER SHAFTS AND DISTRIBUTOR ............................................................................................A2.61
LUBRICATION...............................................................................................................................................................A2.67
COOLING ......................................................................................................................................................................A2.72
TURBOCHARGER ........................................................................................................................................................A2.78

60 05 029 904 - 01.2004 - EN
DIAGNOSTIC SHEETS
"EXCESSIVE OIL CONSUMPTION" SHEET................................................................................................................A2.80
INSPECTION PROCEDURE OF THE CYLINDER HEAD GASKET.............................................................................A2.81
"ENGINE OIL PRESSURE TOO HIGH" SHEET...........................................................................................................A2.82
CHECKING PROCEDURE OF THE HIGH OIL PRESSURE IN THE CRANKCASE ........................................................A2.83
"ENGINE OIL PRESSURE TOO LOW" SHEET............................................................................................................A2.84
"COOLING FLUID TEMPERATURE TOO HIGH" SHEET ............................................................................................A2.85
"COOLING FLUID TEMPERATURE TOO LOW" SHEET.............................................................................................A2.86
FAILURE SEARCHING PROCEDURE OF CYLINDER HEAD SEAL...........................................................................A2.87
TOOLS
ENGINE TOOLS............................................................................................................................................................A2.90
A3 - INJECTION ADDITIVE TIER II
TIGHTENING TORQUE
TIGHTENING TORQUE ..................................................................................................................................................A3.2
INJECTION PUMP ..........................................................................................................................................................A3.3
INJECTORS ....................................................................................................................................................................A3.5
SITUATION OF THE DIFFERENT SENSORS................................................................................................................A3.5
CHECKS/ADJUSTMENTS
ACCELERATOR CONTROL ADJUSTMENT..................................................................................................................A3.6
ADJUSTING THE ENGINE INJECTOR ..........................................................................................................................A3.7
SUPPLY PRESSURE CHECK ........................................................................................................................................A3.8
FUEL FILTER REPLACEMENT ......................................................................................................................................A3.9
INJECTION SYSTEM BLEEDING...................................................................................................................................A3.9
INJECTION PUMP REMOVAL......................................................................................................................................A3.11
INJECTION PUMP INSTALLATION..............................................................................................................................A3.11
DIAGNOSTIC SHEETS
DIAGNOSTIC SHEETS.................................................................................................................................................A1.34
SPN AND FMI CODES...................................................................................................................................................... G7

60 05 029 904 - 01.2004 - EN
TOOLS
INJECTION FEED TOOLS TIER II................................................................................................................................A3.13
A4 - ENGINE ADDITIVE TIER II
GENERAL SPECIFICATIONS
IDENTIFICATION OF THE ENGINES.............................................................................................................................A4.2
DIMENSIONAL SPECIFICATIONS
CONNECTING RODS .....................................................................................................................................................A4.5
TIGHTENING TORQUES
FRONT CHASSIS / ENGINE LINK..................................................................................................................................A4.6
ENGINE/TRANSMISSION LINK......................................................................................................................................A4.6
CRANKSHAFT WITH STRAIGHT FRONT END.............................................................................................................A4.7
CRANKSHAFT WITH TAPERING FRONT END.............................................................................................................A4.7
CHECKS/ADJUSTMENTS
CHECK OF SUPERCHARGING PRESSURE.................................................................................................................A4.8
PROCEDURE FOR CHECKING THE VISCOUS FAN COUPLING................................................................................A4.9
ENGINE INSTALLATION SPECIFICATIONS ...............................................................................................................A4.10
REFITTING THE FRONT BEARING SEAL ON THE ENGINES 6068 TRT 70, 6068 TRT 71 AND 6068 TRT 72 .......A4.11
TOOLS
ENGINE TOOL DPS TIER II..........................................................................................................................................A4.13

01 - 2004 Ref: 60 05 029 693
Issue 01
SUPPLY
INJECTION
S 5312 ARES 546 (Engine DPS 4045 TRT 53)

60 05 029 693 - 10.2003 - EN
CONTENTS
IDENTIFICATION
IDENTIFICATION OF THE INJECTION PUMPS ................................................................................. A1.2
SPECIFICATIONS
MAIN SPECIFICATIONS ................................................................................................................... A1.4
4-CYLINDER ENGINES ............................................................................................................... A1.4
6-CYLINDER ENGINES ............................................................................................................... A1.5
TIGHTENING TORQUES
TIGHTENINGTORQUES ................................................................................................................... A1.8
SUPPLY ......................................................................................................................................... A1.10
PRIMARY FILTER ........................................................................................................................... A1.11
FUEL FILTER .................................................................................................................................. A1.11
INJECTION PUMP .......................................................................................................................... A1.12
INJECTORS .................................................................................................................................... A1.13
CHECKS - ADJUSTMENTS
ENGINE SPEED ............................................................................................................................. A1.16
CHECKING THE MAXIMUM NO LOAD SPEED .............................................................................. A1.16
CHECKING AND ADJUSTING THE TICK-OVER ............................................................................. A1.16
STATIC ADJUSTMENT OF THE INJECTION PUMP......................................................................... A1.17
DYNAMIC ADJUSTMENT OF THE INJECTION PUMP .................................................................... A1.17
INJECTORADJUSTMENT............................................................................................................... A1.21
CRACKING PRESSURE ADJUSTMENT ......................................................................................... A1.21
NEEDLE STROKE ADJUSTMENT .................................................................................................. A1.22
SHUT-OFF SOLENOID VALVE FUNCTIONAL CHECK.................................................................... A1.23
COLD-START SWITCH FUNCTIONAL CHECK ................................................................................ A1.23
SUPPLY PRESSURE CHECK ........................................................................................................ A1.24

60 05 029 693 - 10.2003 - EN
CONTENTS (CONT’D)
FUEL FILTER REPLACEMENT ....................................................................................................... A1.26
INJECTION SYSTEM BLEEDING.................................................................................................... A1.26
INJECTION PUMP REMOVAL ........................................................................................................ A1.27
INJECTION PUMP INSTALLATION .................................................................................................. A1.28
INJECTOR REMOVAL..................................................................................................................... A1.29
INJECTOR SEAT CLEANING (IF NECESSARY) ............................................................................. A1.29
INJECTORINSTALLATION .............................................................................................................. A1.29
CARRYING OVER OF THE ADJUSTMENT MARK ONTO THE FRONT PLATE............................... A1.30
CONTROL ADJUSTMENTS
ADJUSTMENT OF THE ACCELERATOR CABLE............................................................................ A1.32
DIAGNOSTIC SHEETS
“ENGINE START FAILURE” SHEET ................................................................................................ A1.34
“IRREGULAR ENGINE RUNNING” SHEET ...................................................................................... A1.35
“GREY OR BLACK SMOKE EMISSION” SHEET ............................................................................ A1.36
“WHITE SMOKE EMISSION” SHEET ............................................................................................. A1.37
“CHECKING THE FUEL SUPPLY SYSTEM” SHEET ...................................................................... A1.38
TOOLS
INJECTIONSTOOLS....................................................................................................................... A1.40

MR 332 - 06.2002 - EN A1.1
IDENTIFICATION
60 05 029 693 - 10.2003 - EN

A1.2 MR 332 - 06.2002 - EN
Identification
Injection pumps identification
Fig. 1
Fig. 2
ROTCART
epyT
645SERA
2135
655SERA
2235
665SERA
2335
616SERA
2128
626SERA
2228
636SERA
2328
696SERA
2428
ENIGNE 35TRT5404 45TRT5404 55TRT5404 05TRD8606 35TRT8606 45TRT8606 55TRT8606
NOITCEJNI
PMUP
ENYDANATS
LEDOM 4BD
EPYT
9244BD
2475
9244BD
1475
9244BD
2375
9264BD
3375
9264BD
8075
9264BD
4475
9264BD
9275
STANADYNE injection pump
Manufacturer’s plate (Fig. 3)
(A) Date of manufacture code: K1
The alpha-numeric code is as follows:
Letter (month) Number (year)
A = January 1 = 2001
B = February 2 = 2002
C = March 3 = 2003
D = April 4 = 2004
E = May 5 = 2005
F = June 6 = 2006
G = July 7 = 2007
H = August 8 = 2008
J = September 9 = 2009
K = October
L = November
M = December
(B) Type code:
DB4 6 29 5729
DB4 = pump series D, rotor B, 4 plungers
6 =number of cylinders
29 =abbreviation for plungers diameter : 29
= 0.29" i.e. 7.37 mm
5729 = specification number
(C) Nominal engine speed
(D) Serial number
(E) Engine manufacturer’s reference:
DPSG → RE 506250
A1-002
A1-001
Fig. 3
A1-001a
4-cylinder pump
6-cylinder pump
60 05 029 693 - 10.2003 - EN

A1.3MR 332 - 06.2002 - EN
SPECIFICATIONS
60 05 029 693 - 10.2003 - EN

MR 332 - 06.2002 - ENA1.4
Specifications
Main specifications
4-cylinder engines
epytrotcarT 645SERA 655SERA 665SERA
enignE 35TRT5404 45TRT5404 55TRT5404
pmupylppuS wolfsuounitnoctacirtcelE
ehttaderusaemwolfleuF
telniretlif
)deppotsrotom(
h/l5.1
erusserpleuF
telniretlifehtta
)daolonlanimon(
rab53.0
erusserpleuF
onlanimon(teltuoretlifehtta
)daol
rab3.0
pmupnoitcejnI ENYDANATS
ledoM 4BD
epyT 2475-9244BD 1475-9244BD 2375-9244BD
sregnulpnotsipforebmuN 4
taelgnagnittescimanyD
llufrednudeepslanimon
daol
°5 °6 °5.5
recneuqesnoitcejnI 2-4-3-1
)nim/ver(deepsrevo-kciT 52±058
deepsdaolonmumixaM
)nim/ver(
51±0932
)nim/ver(deepslanimoN 0022
rotcejnI ENYDANATS
ledoM mm5.9licneP
ecnerefeR 80544ER92792
)rab(erusserpgnittesrotcejnI 052
gnikcarcrotcejniweN
erusserp
rab062ot552
elbatpeccamuminiM
nrowanoerusserpgnikcarc
rotcejni
rab532
niecnereffidmumixaM
neewteberusserpgnikcarc
srednilyc
rab7
60 05 029 693 - 10.2003 - EN

A1.5
Specifications
6-cylinder engines
epytrotcarT 616SERA 626SERA 636SERA 696SERA
enignE 05TRD8606 35TRT8606 45TRT8606 55TRT8606
pmupylppuS wolfsuounitnoctacirtcelE
taderusaemwolfleuF
telniretlifeht
)deppotsrotom(
h/l5.1
erusserpleuF
telniretlifehtta
)daolonlanimon(
rab52.0
ehttaerusserpleuF
teltuoretlif
)daolonlanimon(
rab81.0
pmupnoitcejnI ENYDANATS
ledoM 4BD
epyT 3375-9264BD 8075-9264BD 4475-9264BD 9275-9264BD
notsipforebmuN
sregnulp
4
elgnagnittescimanyD
rednudeepslanimonta
daollluf
°5,8 °7 °7 °5.6
recneuqesnoitcejnI 4-2-6-3-5-1
deepsrevo-kciT
)nim/ver(
52±058
daolonmumixaM
)nim/ver(deeps
51±0932
deepslanimoN
)nim/ver(
0022
rotcejnI ENYDANATS
ledoM mm5.9licneP
ecnerefeR 96475ER16223 80544ER92792
erusserpgnittesrotcejnI
)rab(
022 052
gnikcarcrotcejniweN
erusserp
rab442ot832 rab062ot552
elbatpeccamuminiM
anoerusserpgnikcarc
rotcejninrow
rab891 rab532
niecnereffidmumixaM
erusserpgnikcarc
srednilycneewteb
rab7 rab7
60 05 029 693 - 10.2003 - EN

A1.6
Specifications
Personalnotes:
60 05 029 693 - 10.2003 - EN

A1.7
TIGHTENING TORQUES
60 05 029 693 - 10.2003 - EN

A1.8
Tightening torques
A1-003
60 05 029 693 - 10.2003 - EN

A1.9
60 05 029 693 - 10.2003 - EN

A1.10
Operating principles
MR 332 - 06.2002 - FR
M
+ -
5
6
3
4
2 1
7
Supply
4 or 6-cylinder system
1 -Supply valve
2 -Primary filter
3 -Supply pump
4 -Fuel filter
5 -Injection pump
6 -Injectors
7 -Fuel tank
Supply pump
Supply system (supply pump pressure)
Injection pump pressure system
Return system
A1-005
60 05 029 693 - 10.2003 - EN

A1.11
Fig. 3
Primary filter
Filters : 149 microns
A1-006
A1-007
Fuel filter
1 - Fuel outlet
2 - Fuel inlet
3 - Drain screw
4 - Filter
60 05 029 693 - 10.2003 - EN

A1.12
MR 332 - 06.2002 - FR
Injection pump
InjectionpumpSTANADYNE(DB4)
Description
1 - Drive shaft
2 - Distributor rotor
3 - Transfer pump vanes
4 - Pistons (4)
5 - Internal cam ring
6 - Hydraulic head
7 - Transfer pump pressure regulator
8 - Balance-weight cage
9 - Automatic advance
10 - Housing
11 - Regulatorvalve
12 - Recirculation valve
13 - Electric shut-offf device solenoid
A1-008
60 05 029 693 - 10.2003 - EN

MR 332 - 06.2002 - EN A1.13
Injectors
A1-010
Description
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 - Spacer
12 - Stroke adjustment screw
13 - Locknut
14 - T-union
15 - Locknut
16 - Pressure adjustment screw
17 - Nut
18 - Seal
19 - Clamp
20 - Olive
21 - Filter basket
22 - Injection pipe
60 05 029 693 - 10.2003 - EN

A1.14
MR 332 - 06.2002 - FR
Personal notes :
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A1.15
CHECKS - ADJUSTMENTS
60 05 029 693 - 10.2003 - EN

A1.16
Checks - Adjustments
Engine speed
Checking the maximum no load speed
Note: Before performing the maximum no load
test, ensure that the accelerator lever contacts the
stop (1). If not, adjust the cable (Refer to adjustment
of controls in this chapter).
- Start the engine.
- Engage the 540 or 1,000 rpm power take-off
(depending on the tractor type).
- Leave the engine running until it reaches its normal
operatingtemperature.
- Checktherotationalspeedofthepowertake-offshaft
using a tachometer.
- Adjust the stop screw (1) in order to achieve a
rotationalspeedatthepowertake-offinaccordance
with the values specified in the table in the INJEC-
TION SHEETS at the beginning of this chapter.
- Re-lock the stop screw.
IMPORTANT : If the screw locking seal is broken,
it must be resealed immediately after adjustment.
Checking and adjusting the tick-over
Note : Before checking the tick-over setting, ensure
that the lever contacts the stop (2) (Refer to
adjustment of controls in this chapter).
- Start the engine.
- Engage the 540 or 1,000 rpm power take-off
(depending on the tractor type).
- Leave the engine running until it reaches its normal
operatingtemperature.
- Positiontheacceleratorleverincontactwiththetick-
overstop.
- Checktherotationalspeedofthepowertake-offshaft
using a tachometer.
- Adjust the stop screw (2) in order to achieve a
rotationalspeedatthepowertake-offinaccordance
with the values specified in the table in the INJEC-
TION SHEETS at the beginning of this chapter.
Fig. 1
A1-011
60 05 029 693 - 10.2003 - EN

A1.17
Fig. 3
Static adjustment of the injection
pump
It is MANDATORY to ensure that markings(A) on the
front plate and (B) on the injection pump attachment
flangearepresentbeforeremovingthepumpfromthe
engine.
If the setting mark (A) is missing from the front plate,
scribe it as accurately as possible opposite mark
(B).
- Static adjustment consists in accurately aligning
mark (B) on the pump flange, with mark (A) on the
frontplate.
- Torque tighten the three nuts securing the pump to
the front plate to 2,7 daN.m.
A1-015
Fig. 2
A1-013
Dynamic adjustment of the
injection pump
The TIME-TRAC kit (1) electronically checks the start
of injection in relation to the top dead centre (TDC) of
the piston, enabling accurate adjustment of the injec-
tion pump to achieve optimum power whilst keeping
exhaust gas emissions to a minimum.
The dynamic adjustment check is performed using 2
probes:
- one probe is located on No. 1 injection pipe, to
indicate the start of injection for the cylinder
concerned,
- the second probe is located on the engine flywheel
casing and accurately transmits the piston top dead
centreposition(TDC).
These 2 probes are connected to a test set: the
combined signals from these probes provide an
instantaneous and accurate display of the DYNAMIC
ENGINEADJUSTMENT.
60 05 029 693 - 10.2003 - EN

A1.18
Fig. 4
Fig. 5
Installation of the TIME-TRAC kit
IMPORTANT :The probe which senses the start of
injection should be installed on the injection pipe
adjacent to the injector. If access to injection pipe
No. 1 is difficult, the probe may be mounted on
injection pipe No. 4 (4-cylinder engines) or No. 6
(6-cylinder engines).
Twotypesofprobemaybeusedontheengineinorder
to detect the start of injection:
• a 6-mm dia. clip-on probe (A),
• an in-line probe (B).
1 -To install the clip-on probe (A), strip all the paint
from the injection pipe at the position where the
probe is to be fitted.
2 - Mount the probe (A) on the pipe (C)after cleaning
it and stripping all the paint off.
3 - Tighten the probe and check it firmly grips the
injection pipe (C).
4 - For engines where the in-line probe (B) is installed
between the injector and the injection pipe, mount
the stirrup (D).
5 - Install the harness (E) :
- connect pin (F) to the probes (A) or (B)
employed,
- connect the spring clip (G) to ground,
- connect plug (H) on harness (E) to the test set
in the socket marked SR.
6 - Insert adjustment pin No. 5500 into the hole (J) in
the engine flywheel casing to ensure the engine
IS NOT stopped in the TDC position. If such were
the case, the probe (K) could enter the adjustment
hole on the engine flywheel and would then be
damaged when the engine starts.
7 - Install the probe guide (M) in the engine flywheel
casing (J) tapping it lightly in order to lock it in
position.
8 - Insert probe (K) into the guide until it contacts the
engine flywheel. Using a dial gauge, draw back
probe (K) by 0.64 mm relative to the engine
flywheel.
9 - Connect plug (N) for probe (K) to the socket on
the test-set marked MP.
Fig. 6
A1-017
A1-018
A1-019
Fig. 7
A1-020
60 05 029 693 - 10.2003 - EN

A1.19
Fig. 8
Fig. 9
Fig. 10
A1-021
A1-022
A1-023
Fig. 11
A1-024
Checking the injection pump dynamic
adjustment
1 - Engine STOPPED.
Press the "ON/CLEAR" push-button.
The display should indicate: "R = 0".
2 - Press the "MAG PROBE" (magnetic
probe).
The display should indicate: "Trig level" (trigger
level) 30 %.
3 - Change this to 70 % and press "ENTER".
The display should indicate: "Offset": 20.0°.
4 - Change the offset to 0° and press "ENTER".
The display should indicate: "Calibrate" ?
5 - Start the engine and press "ENTER".
6 - Run the engine at 1,300 rpm. Press "ENTER".
The display should indicate: "Calilbrating" followed
by engine speed (rpm) and adjustment.
Note: If the display indicates «NO PROBE», this
means that the probe mounted on the engine
flywheel casing is not properly installed (the
mounting distance is greater than 0.64 mm) or that
some debris is lodged behind the engine flywheel.
Check that the mounting distance is correct or
clean behind the engine flywheel. Insert a soft
wooden peg into the engine adjustment pin hole
whilst the engine is ticking over.
7 - Allow the engine to reach its normal operating
temperature.
60 05 029 693 - 10.2003 - EN

A1.20
8 - Run the engine at full throttle then gradually apply
a load until it reaches nominal speed.
Read the dynamic adjustment value and compare
this with the value provided in the specifications
at the beginning of this chapter.
Note: a negative value indicates that the signal
from the clip-on probe is poor. Check the probe
and the pipes are clean and that the installation is
correct.
9 - Record the engine speed (rpm) and the adjustment
angle.
IMPORTANT :stop the engine before attempting to
set the adjustment. There is a risk of the injection
pump seizing if the setting is performed whilst the
engine is running.
10 - Stop the engine.
If the dynamic adjustment is retarded by more than
8 degrees in relation to the adjustment marks
applied at the manufacturer’s, prior to delivery, on
the pump flange and on the front plate, this may
indicate that the advance on the pump is not
functioning correctly. Check the following points:
- replace the fuel filter,
- check the pressure between the supply pump
and the injection pump,
- if none of the above checks provides conclusive
results, remove the pump and have it repaired
in an approved diesel engine repair workshop.
Setting the dynamic adjustment of the rotary
injection pump (Fig. 13)
1 - Loosen the nuts (1) on the injection pump
attachment flange and set the pump adjustment.
To advance the pump adjustment, turn it clockwise
(2) as viewed from the rear (engine flywheel end).
To retard the adjustment, turn it anti-clockwise (3).
A 1.524 mm displacement of the injection pump
flange is equivalent to 2 degrees of engine
adjustment.
2 - Torque tighten the pump attachment collar-nuts
to 2,7 daN.m. Start the engine and check again
the dynamic adjustment of the injection pump. Set
the adjustment as required.
3 - After completing all the final settings and achieving
satisfactory engine performance, grind away the
original adjustment mark and scribe a new mark
(B) on the pump flange, in line with mark (A) on
the front plate.
Fig. 12
Fig. 13
Fig. 14
A1-025
A1-026
A1-027
60 05 029 693 - 10.2003 - EN

A1.21
Fig. 15
Fig. 16
A1-028
A1-029
Injector adjustment
Preliminary operations
1 - Clamp the injector in a vice and loosen locknut
(A).
2 - Then back off the needle rise adjustment screw
(B) by 3 turns.
3 - Finally loosen locknut (C).
4 - Connect the injector to the calibration unit, inclining
it at about 30° from the vertical. Check the sealing
at all the connections.
5 - Close the valve on pressure gauge No. 8168 and
quickly pump several strokes in order to bleed the
injector, and for the needle to position itself.
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 trans-
parent container.
Cracking pressure adjustment
Note : it is recommended to aim for the maximum
rather than the minimum value. Repeat the
adjustment in order to obtain a reliable result.
Open the valve on the calibration unit and, whilst
operating the pump, tighten or loosen the opening
pressure adjustment screw (D) until the correct
pressure is achieved (refer to ‘Specifications’).
Toincreasethepressure,tightenthescrew.Closethe
valve and quickly operate the pump several times to
openandclosetheinjectorneedle.Openthevalveand
check the cracking pressure; correct it if necessary.
Torque tighten locknut (C) to 1 daN.m.
60 05 029 693 - 10.2003 - EN

A1.22
Needle stroke adjustment
Carefully turn the stroke adjustment screw (B) inside
the pressure adjustment screw (D) until screw (B)
contacts the needle (E). Check as follows:
- Increase the pressure beyond cracking pressure, a
fewdropsoffuelmaybleed,butthisflowmustremain
limited.
- Unscrew (B) by 3/4 turn to achieve a correct stroke
of the needle.
- Torque-tighten locknut (A) to 0.5 daN.m, whilst
firmly holding the screw.
- Perform another accurate cracking pressure
adjustment.
Note : If after cleaning and servicing operations,
the characteristic hissing noise is not heard, it is
possible that the injector parts are incorrectly
aligned. In such case, tighten and loosen the pres-
sure adjustment screw (D)several times and again
adjust the needle stroke, as described above.
Disconnecttheinjectorfromthecalibrationunitandfit
the protection cap.
Fig. 17
A1-030
60 05 029 693 - 10.2003 - EN

A1.23
Shut-off solenoid valve
functional check
1 - Disconnect the lead from the solenoid valve (A).
2 - Remove the valve, checking whether the plunger
spool jams in the bore.
3 - Use an ohmmeter to measure the coil resistance.
It should be 4 Ω.
4 - Use a 12-volt supply to check the plunger spool
retracts correctly.
Connect the positive lead to the socket terminal
and the negative lead to the solenoid valve body.
From the relaxed position, the plunger spool should
retract inside the solenoid valve body when the
voltage is applied.
If the resistance is not to specification, and/or if
the plunger spool does not retract, replace the
solenoid valve.
5 - Re-install the solenoid valve and torque tighten to
between 1.5 and 2 daN.m.
Cold-start switch functional
check
1 - Disconnect the injection pump harness from the
cold-start switch socket (B).
2 - Remove the cold-start switch (C) from the ther-
mostat/water manifold unit.
3 - Immerse the switch in water at 60 °C for a few
minutes.
4 - Check that the switch contact is open.
5 - Replace it if defective.
6 - Install the switch in the thermostat/water mani-
fold unit and tighten to the specified torque.
Tightening torque: 5 daN.m.
7 - Connect the injection pump harness to the cold-
start switch socket.
8 -Check the continuity and the resistance of the
solenoid (D) : R = 23 Ω.
Fig. 18
A1-037
A1-047
Fig. 19
60 05 029 693 - 10.2003 - EN

A1.24
Fig. 20
A1-046
Fig. 25
Supply pressure check
1. Use the tool (1) réf. 60 05 005 521 as shown in
Fig. 20.
2. Start the engine. Check the pressure of the supply
pump according to the «specifications» provided
at the beginning of this chapter.
3. If the pressure is too low, disconnect the fuel pipe
at the filter inlet and direct it into a graduated con-
tainer. The flow must be 1,5 l/m, engine stopped.
60 05 029 693 - 10.2003 - EN

A1.25
60 05 029 693 - 10.2003 - EN

A1.26
Removal/installation
Fuel filter replacement
To replace the fuel filter:
1 - Loosen retaining ring (A)and remove the filter body
(B).
2 - Recover the retaining ring and the settling bowl
(C) and install them on the new filter.
3 - Install the new filter, taking care to align the
markings on the filter with the slots in the filter
head unit base.
4 - Tighten the retaining ring (A) until it locks.
5 - Bleed the fuel filter.
Note: Correct positioning of the retaining ring is
achievedwhenarelaxationisfeltduringtightening.
Injection system bleeding
1st
case
After replacing the fuel filter
1 - Loosen the bleed screw (D) located on the filter
head.
2 - Switch on the ignition in order to completely bleed
the air.
3 - Tighten the bleed screw (D). The engine should
start.
2nd
case
After running the system completely dry
1 - Perform operations from 1 to 3 described under
the 1st case.
2 - Loosen pipe (F) in order to completely bleed the
air. Tighten pipe (F).
3 - Whilst turning the engine using the starter motor,
loosen the couplings (H) until the fuel escaping
from the coupling is free of air bubbles. Tighten
the coupling whilst still turning the engine.
4 - Repeat the procedure for the other injectors until
the engine starts.
Fig. 1
Fig. 2
A1-032
Fig. 3
A1-033
A1-035
60 05 029 693 - 10.2003 - EN

A1.27
Injection pump removal
It is MANDATORY to ensure that markings(A) on the
front plate and (B) on the injection pump attachment
flangearepresentbeforeremovingthepumpfromthe
engine. If required, scribe them (Fig. 4).
IMPORTANT:Neverusesteamorcoldwatertoclean
a hot or operating injection pump.
1 - Disconnect the electrical cables and the
accelerator cable.
2 - Disconnect the fuel return pipe (A).
3 - Disconnect the fuel supply pipe (B).
4 - Disconnect the injection pipes (C).
IMPORTANT: Take care not to turn the injection
pump couplings when loosening the injection pi-
pes, as this may cause internal damage to the
pump.
5 - Blank off all the couplings (pump and pipes); do
not use fraying materials.
6 - Remove the plug from the distributor housing.
7 - Using the engine flywheel turning tool No. 60 05
005 501, position the engine flywheel and lock it
with adjustment pin No.60 05 005 500.
8 - Remove the nut and washer securing the injec-
tion pump drive pinion to the pump shaft.
9 - Mount special tool No. 60 05 005 514 (1) (Fig. 6)
on the pinion.
10 -Remove the three nuts (D) securing the pump to
the engine front plate.
11 -Turn the screw on the tool clockwise until the pump
shaft lifts off the tapered seat for the drive pinion.
12 -Disengage the pump from the three studs by pulling
it backwards.
Note: Take care not to lose the half-moon key for
the pump shaft when removing the injection pump.
A1-027
A1-038
Fig. 4
Fig. 5
A1-036
Fig. 6
60 05 029 693 - 10.2003 - EN

A1.28
Fig. 7
Injection pump installation
1 - Fit a new seal on the front face of the injection
pump attachment flange.
2 - Slide the injection pump onto the mounting studs,
whilst at the same time inserting the pump shaft
into the drive pinion.
3 - Hand-tighten the nuts (D).
4 - After firmly engaging the drive pinion against the
tapered part of the shaft, fit the washer and nut
(E).
5 - Torque-tighten the nut (E) (Fig. 8) to 20 daN.m.
6 - Remove the setting pin.
7 - Align adjustment mark (B) with the mark (A) on
the front plate (Fig. 9).
8 - Torque-tighten the nuts (D) to 2.7 daN.m.
9 - Tighten the injection pipes (C), then the return (A)
and supply (B) pipes (Fig. 7).
10 -Connect up the various electric cables which were
disconnected prior to removal of the pump.
11 -Connect the accelerator cable to the pump.
12 -Bleed the air from the fuel system.
A1-036
A1-039
A1-027
Fig. 8
Fig. 9
60 05 029 693 - 10.2003 - EN

A1.29
A1-040
Fig. 10
A1-043
A1-041
A1-042
Fig. 11
Fig. 12
Fig. 13
Injector removal
1 - Loosen nuts (B) to disconect the leak off pipes
(A) and the T-fittings.
2 - Disconnect the injectors from the injection pipes
(D).
3 - Remove screw (C).
4 - Extract the injectors from the cylinder head using
extractor tool No.60 05 005 514 (1).
IMPORTANT: Do not use a screwdriver or similar
tool, as this could cause irreparable damage to
the injectors.
Injector seating cleaning (if
required)
Remove the carbon deposit in the injector housings
using tool No. 60 05 005 519 (2).
IMPORTANT: Always turn the tool clockwise, even
when removing it, in order to prevent from
blunting it.
Injector installation
IMPORTANT: The lower carbon deposit arrestor
seal (D) must be replaced every time an injector is
removed.
Slide the top seal (E) onto the injector body. Position
installation tool No. 60 05 005 513 (3) on the injector
nozzleandslidethenewseal(D)ontotheinjectorbody
until it seats properly in the groove.
60 05 029 693 - 10.2003 - EN

A1.30
Fig. 14
Fig. 15
Carrying over of the adjustment
mark onto the front plate
Note: Front plates provided as spare parts are
supplied unmarked.
In order to carry over the front plate marking from the
original plate to the spare plate, make up a template
from aluminium sheet as shown below (Fig. 15).
- Mount the template on the original front plate using
three screws (Part No. 60 012 874) and carry over
the mark from the original front plate (A) onto the
template (B) with a pencil.
- Then mount the template on the replacement front
plateandcarryoverthetemplatemarkontothenew
plate (C) using a scriber.
A1-044
A1-045
Template for the front plate marking
60 05 029 693 - 10.2003 - EN

A1.31
CONTROL ADJUSTMENTS
60 05 029 693 - 10.2003 - EN

A1.32
Control adjustments
265mm
61mm
4
4 4
15
A
3
2
B
Fig. 1
Accelerator control adjustment
The cable length should be adjusted in the following
cases:
- after replacing the cable,
- after adjusting the tick-over and maximum no-load
speed,
- afterremovingtheinjectionpump.
1 - Attach the control cable to the injection pump
accelerator lever (1).
2 - Connect the control cable to the accelerator pedal
(2).
3 - In the cab, check the hand control lever (3) is on
the minimum position (A).
4 - Adjust the hand control cable in order to achieve
the dimension 265 mm.
5 - Adjust the foot control cable in order to achieve
the dimension 61 mm.
6 - Correct adjustment should enable the engine
throttle control lever (5) to return to the mechanical
stop (1) when the lever or pedal are on the mini-
mum position, and allow extension of the
accelerator control spring on the pump when the
hand lever or pedal are on the maximum position.
A1-046
Checkthatthepedalstrokeiscompletelycovered
by the hand control stroke.
Position A: tick-over speed.
Position B: maximum speed.
Markings 4: cable adjustments.
A1-048
Fig. 2
Barefloor
Floor mat
60 05 029 693 - 10.2003 - EN

A1.33
DIAGNOSTIC SHEETS
60 05 029 693 - 10.2003 - EN

A1.34
Diagnostic sheets
Note: before any diagnosis is made, check that the fuel is in sufficient quantity and quality.
"Cold engine start failure" sheet
A1-050
60 05 029 693 - 10.2003 - EN

A1.35
Diagnostic sheets
A1-051
"Irregular engine running" sheet
60 05 029 693 - 10.2003 - EN

A1.36
Diagnostic sheets
A1-052
"Grey or black smoke emission" sheet
60 05 029 693 - 10.2003 - EN

A1.37
Diagnostic sheets
"White smoke emission" SHEET
A1-053
60 05 029 693 - 10.2003 - EN

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Claas Ares 506 606 Tractor repair manual

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