3. 0802 Rear PTO......................................................................................................................................... 297
09 Hydraulic system
0915 Hydraulic lines................................................................................................................................ 301
0920 Valves.............................................................................................................................................. 315
10 Electrical / Electronic equipment
1000 General electrical system.............................................................................................................. 322
1005 Power supply.................................................................................................................................. 333
1012 Modules / sensors.......................................................................................................................... 343
1015 Wiring harnesses............................................................................................................................ 353
12 Cab / Operator's platform
1210 Cab................................................................................................................................................... 374
1240 Air condition.................................................................................................................................... 395
Position of components
Electric system........................................................................................................................................ 420
Index.................................................................................................................................... 437
863-001
00 1150 409 0-RHB TALOS 100-09/2013 4
4. Introduction
General Information
139135-003
Using this repair manual
This repair manual will help ensure the tractor is
always in full working order. Regular maintenance and
upkeep, carried out by the after-sales technical
department will preserve the high value of this CLAAS
tractor.
All of the expertise our after-sales technicians and the
manufacturer can offer is summarised in this repair
manual.
The sequence of illustrations show the breakdown of
a repair process. The text gives the instructions
required for setting, for using the special tools and
much more.
The repair manual, as a reference document, is kept
up to date with supplements and changes to meet any
technical developments made to the tractor.
To ensure the highest level of safety, it is essential to
compare the setting values and filling volumes with
those on the current manual for the corresponding
tractor.
Text and illustrations
References can be easily distinguished from each
other by the symbols. The different symbols are as
follows:
Symbol Meaning Description
Consult the index.
This symbol indicates that additional information
on this subject is available in another part of this
manual.
Consult the index of the
corresponding user
manual.
This symbol indicates that additional information
on this subject is available in the tractor's user
manual.
Consult the technical
system index.
This symbol indicates that additional information
on this subject is available in the tractor's technical
system manual.
Section classification
The different parts of this repair manual are classed
by chapter and section, whenever the content allows
this. The document's structure is identical in each
chapter and section.
CLAAS tries to retain this chapter structure in each
document.
Search and find
The chapter structure, the table of contents and the
document title make the subjects easier to find.
Introduction
General Information
863-001
00 1150 409 0-RHB TALOS 100-09/2013 5
5. The index is also a useful tool for finding the required
subjects. The index appears at the end of each
document.
Direction indications
Indications in the text such as front, rear, right apply
as taken in the direction of travel. In the illustrations,
the direction of travel may be indicated by a direction
arrow.
Your CLAAS After-Sales Service
160471-001
Scope of the repair manual
This repair manual applies to the following tractors:
Description Type Tractor serial number
From TO
TALOS 120
A38
217301xxxx
TALOS 130 217401xxxx
Introduction
General Information
863-001
6 00 1150 409 0-RHB TALOS 100-09/2013
6. General repair instructions
139178-001
Technical specifications
We do not accept liability for the technical
specifications, dimensions and weights. Subject to
modification in line with technical evolutions and
subject to errors.
139179-001
Cause of damage
Recognising the cause of the damage, determining
the damage and securing the machine.
139164-001
Spare parts
Use CLAAS original parts and the corresponding
CLAAS special tools.
For all orders for spare parts and any technical
questions, it is essential to indicate the identification
number of the tractor, the type and serial number of
the engine as well as the EEC structure homologation
number. This specification is necessary as otherwise
the spare parts supplied may not fit.
Use only CLAAS original spare parts, accessories and
tools that have been inspected and approved
by CLAAS. Only by ensuring this is it possible to
preserve the structural properties of the
CLAAS tractor, as well as its operating capabilities.
CLAAS original parts also contribute to active and/or
passive safety when driving, and the safety of the
tractor when working.
CLAAS cannot be held responsible for any damage
resulting from the use of parts, accessories and tools
that are not original CLAAS products.
139181-001
Diesel engine
Before working on the diesel engine, always
disconnect the negative “–” cable from the battery.
139183-001
Gearbox
To remove the gearbox, always drain the oil first, and
then remove the gearbox. Separate stuck overlapping
parts using a soft metal or rubber mallet.
Introduction
General repair instructions
863-001
00 1150 409 0-RHB TALOS 100-09/2013 7
7. 139184-001
Generator
13972-001
CAUTION!
Installation work on alternators.
Destruction of electric components.
– Never disconnect lines between regulator,
alternator and battery while the alternator
is running.
– Ensure correct polarity when connecting
the battery.
– Carry out work on live parts only after
disconnecting the battery.
– Absolutely refrain from applied-voltage
testing by slightly touching the earth
potential with alternators.
– Disconnect the cables from the alternator
before carrying out electric welding work
on the machine!
– The alternator is pre-excited by the battery
via the charge indicator lamp. For this
reason replace any failed lamp
immediately.
139166-001
Welding work
139167-001
Note!
All relevant information is included in the
current Tractor user manual.
139175-001
Drive belt/drive chains
139167-001
Note!
All relevant information is included in the
current Tractor user manual.
139177-002
Tapered ring assemblies
Tapered ring assemblies are a reliable connection
when they are correctly preloaded, even when the
drive element transfers significant forces to the shaft
and vice-versa.
Introduction
General repair instructions
863-001
8 00 1150 409 0-RHB TALOS 100-09/2013
8. Fitting
During assembly, it is important that the shaft, the
hub, the adjustment spring and the tapered rings are
properly cleaned and lubricated with fluid grease of
the NLGI class 00 category e.g. CLAAS
AGRIGREASE LC 00/000 and tightened to the torque
instructed according to the appropriate successive
order of assembly.
13975-002
CAUTION!
Sticking together at the taper ring fasteners.
The joint cannot be loosened or comes off
only with difficulty.
– Do not install parts with tough grease.
Removing
After loosening the axial stop, release the tapered ring
assembly with a driver tube, striking with a firm and
clean motion.
13977-001
CAUTION!
Damage to the taper ring fastener.
– The inside diameter of the block-ended
tube must be large enough to extend over
the tapered ring.
139185-001
Self-locking bolts with microencapsulated
glue
Replace the self-locking bolts for each assembly, for
example: hex/Allen bolts. These bolts can be reused
up to three times under exceptional circumstances.
The self-locking bolts with microencapsulated glue
must always be screwed in quickly, observing the
indicated torque.
Always observe the indicated tightening torque.
To unscrew the self-locking bolts, always unscrew
them quickly and fully. Self-locking bolts must not
come into contact with sealing paste.
Self-locking bolts with microencapsulated glue must
only be used in areas where the operating
temperature does not exceed+ 90°C.
These bolts can be subjected to their maximum rated
load after 24 hours at a temperature of + 20°C. The
hardening time can be reduced by heating, for
example to + 70°C for 15 minutes.
Introduction
General repair instructions
863-001
00 1150 409 0-RHB TALOS 100-09/2013 9
9. In place of self-locking bolts, it is possible in certain
cases to use bolts with liquid threadlock. Only use
these bolts, however, if these connections can be
heated to 200°C in order to undo them. Also observe
the stated bolt grade, for example 8.8 or 10.9.
139186-001
Threadlock
Only use threadlock when it is specified by the
manufacturer.
Correct usage
Metal assemblies carried out with threadlock must be
completely free from all traces of grease. Carry out
the cleaning using the "activator" in the workshop kit.
Before applying the threadlock, the metal surfaces
must be free of any traces of activator and cleaning
products and must be dry. Pay particular attention to
removing any activator residue stuck in the gaps.
Where possible, on the screwed unions, apply the
threadlock drop by drop only on the inner thread of the
nut. For blind holes, apply threadlock only on the end
of the thread, approximately 1 d (d = nominal diameter
of the threaded stud). Proceed in the same way with
very long threaded holes. If the threadlock is applied
to the threaded rod or the start of the threading, the
product will spread over the whole length of the
thread. During later unscrewing, this will require too
much force to detach and the bolt may break.
Assemblies with threadlock are easy to loosen if it is
possible to heat them to approximately 200°C.
139187-001
Lock collar bearing
Lock collar bearings are fixed to the shaft by turning
the eccentric collar on the inner ring of the bearing.
Before fitting, lubricate the inner ring and the shaft
with NLGI category 00 fluid grease for gearboxes, in
order to facilitate later removal.
For example: CLAAS AGRIGREASE LC 00/000.
Never tap the eccentric ring too hard, and always tap
it in the direction of rotation of the shaft then fix it with
a threaded pin. To loosen the bearing, tap the
eccentric ring in the opposite direction of rotation of
the shaft.
139188-001
Collet bearing
Collet bearings do not require a specially machined
housing. They can be fitted to any kind of drawn or
rolled shaft. The advantage of this is having a shaft
that can be axially offset and correctly positioned.
Introduction
General repair instructions
863-001
10 00 1150 409 0-RHB TALOS 100-09/2013
10. Always fit collet bearings according to the internal
tapered ring. Before fitting, clean the collet and shaft
and ensure the collet nut is mobile so that the collet
does not rotate around the shaft when being
tightened.
Tighten
First tighten the collet nut so that the collet is free from
play and is slightly tensioned. Then tighten the nut to
approximately 90° then continue turning until the
following groove lines up with the stop tab. Lock the
collet nut using the stop tab.
Loosening
Firstly unscrew the unlocked collet nut by a few turns.
The thread must still be completely engaged. Loosen
the collet by tapping firmly with a driver tube.
139191-001
Screwed unions with cutting rings on the
hydraulic pipes
For all pre-assemblies, as well as with cutting ring
unions supplied pre-assembled by the manufacturer,
final assembly takes place in the corresponding well
lubricated unions with 1/2 a turn of the nut-union
beyond the point where the required force is much
higher.
Pre-assembly
– Saw the tube at a right angle.
Do not use a tube cutter! This would cut the tube
wall at an angle and would cause a significant
amount of burr lines on both the interior and
exterior.
– Lightly deburr the interior and exterior tube ends.
Do not chamfer!
– Clean the tube ends.
For the tube elbows, the distance from the right-hand
end of the tube to the start of the curve radius must be
at least twice the height of the box nut.
– Insert the box nut and the cutting ring onto the
tube.
– Press the tube against the stop on the connection
sleeve and tighten the box nut until the cutting
ring surrounds the tube.
The tube must not turn. This may easily happen
due to an increase in the force required.
– Tighten the box nut a 1/2 turn beyond the
resistance point.
– Check the line of the cutting edge.
A visible raised shoulder must fill the space in
front of the front surface of the cutting ring. The
cutting ring can turn, but must not be able to shift
axially.
Introduction
General repair instructions
863-001
00 1150 409 0-RHB TALOS 100-09/2013 11
11. Final assembly
– Fit the pre-assembled tube in the well-greased
threaded connector.
– Tighten the box nut until the resistance point is
felt.
– Complete a further 1/2 turn beyond this point.
Repetitive assembly
– Each time the cutting ring bolt connector is
loosened, the box nut must be retightened using
only the minimum amount of force necessary.
Assembly with non-sealing cutting ring
– If the connector is not sealed, first loosen the box
nut until a small amount of oil flows out.
– Then tighten as specified.
139192-001
Progressive ring bolt connectors on hydraulic
pipes
For all pre-assemblies, as well as with profile ring
unions supplied pre-assembled by the manufacturer,
final assembly takes place in the corresponding well
lubricated unions with 1/2 a turn of the nut-union
beyond the point where the required force is much
higher.
Pre-assembly
– Saw the tube at a right angle.
Do not use a tube cutter! This would cut the tube
wall at an angle and would cause a significant
amount of burr lines on both the interior and
exterior.
– Lightly deburr the interior and exterior tube ends.
Do not chamfer!
– Clean the tube ends.
For the tube elbows, the distance from the right-hand
end of the tube to the start of the curve radius must be
at least twice the height of the box nut.
– Insert the box nut and the profile ring onto the
tube.
– Press the tube against the stop on the connection
sleeve and tighten the box nut until the profile ring
surrounds the tube.
The tube must not turn.
This may easily happen due to an increase in the
force required.
– Tighten the box nut a 1/2 turn beyond the
resistance point.
– Check the line of the cutting edge:
A visible raised shoulder must fill the space in
front of the front surface of the profile ring. The
profile ring can turn, but must not be able to shift
axially.
Introduction
General repair instructions
863-001
12 00 1150 409 0-RHB TALOS 100-09/2013
12. Final assembly
– Fit the pre-assembled tube in the well-greased
threaded connector.
– Tighten the box nut until the resistance point is
felt, then turn a further 1/2 turn.
Important: hold the threaded connector using a
spanner!
Repetitive assembly
– After each time the profiled ring screwed union is
loosened, retighten the box nut until the
resistance point is felt, then turn a further 1/2 turn.
Important: hold the threaded connector using a
spanner!
Unsealed profile ring connector
If the connector is not sealed, first loosen the box nut
until a small amount of oil flows out then retighten as
recommended.
Failure to observe the tightening torques reduces the
resulting nominal pressure and the service life of the
screwed union. This can cause leaks and slippage of
the tube.
139195-001
Double flare unions screwed onto the
hydraulic pipes
Fitting
– Oil the o-ring on the double flare. Tighten the box
nut a 1/3 turn beyond the resistance point.
Important: hold the threaded connector using a
spanner!
Failure to observe the tightening torques reduces the
resulting nominal pressure and the service life of the
screwed union. This can cause leaks and slippage of
the tube.
144268-002
Flexible hydraulic hoses
124581-001
DANGER!
Moving machine parts due to work on the
hydraulic system.
Risk of death or serious injury.
– Lower hydraulically movable machine parts
or secure against lowering.
– Depressurise the hydraulic system.
– Stop the engine.
Introduction
General repair instructions
863-001
00 1150 409 0-RHB TALOS 100-09/2013 13
13. 124582-002
CAUTION!
Failure of hydraulic hose lines due to ageing.
Uncontrolled lowering of machine parts.
– Replace hydraulic hose lines 6 years after
manufacture at the latest.
– Check the flexible hydraulic hoses before initial
commissioning, and then once a year.
– Replace the flexible hydraulic hoses if they are
damaged or altered.
Hydraulic screwed connections
Observe the specifications for final assembly:
– Connections with cutting rings screwed on the
hydraulic hoses. Page 11
– Double flare connections screwed onto the
hydraulic hoses. Page 13
– Connectors with progressive ring screwed on
hydraulic hoses. Page 12
Hose routing
To do this, follow the relevant specifications
concerning the five following illustrations.
– Avoid turning the flexible hose during fitting.
13989-002
CAUTION!
Hoses laid in a straight line get shorter as the
hydraulic pressure is built up.
Valves may be torn off.
– Always install hoses with a slight slack.
A25 Y250
87654321
1
Yxxx
1
5728-002
A25 Y250
87654321
1
Yxxx
2
5727-002
Introduction
General repair instructions
863-001
14 00 1150 409 0-RHB TALOS 100-09/2013
14. – Fit the flexible hoses so that they are not
subjected to any tensile stress, whatever the
operating status, nor to any forces pushing back
short lengths.
– Rule: when moving the flexible hose back and
forth in the centre of two mounting/connecting
components (for example: collars) the overall
travel of the flexible hose must be at least 1 cm.
Avoid external damage:
– Avoid external mechanical forces on the flexible
hoses.
– Avoid any hoses rubbing against each other or
other components by positioning and fixing them
correctly.
– Ensure they are a sufficient distance away from
the components.
– Place durable covers over components with sharp
edges.
Avoid using a twisting action:
– When connecting to moving parts, it is important
to avoid turning the hose, particularly when there
is movement and the flex is at the same level.
Protection from the effects of external temperatures:
– In case of high external temperatures, position the
flexible hoses at a sufficient distance from heat-
emitting parts.
– Or protect the flexible hoses with a protective
shield.
A25 Y250
87654321
1
Yxxx
X
3
5726-002
A25 Y250
87654321
1
Yxxx
X
4
5729-002
A25 Y250
87654321
1
Yxxx
X
5
5730-002
Introduction
General repair instructions
863-001
00 1150 409 0-RHB TALOS 100-09/2013 15
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16. 139199-001
Advice for economical repairs
– Before any removal or dismantling, mark the parts
to ensure they are refitted on the correct sides
and to ensure balanced location.
– The slots of the tension pins should always point
in the direction of the stressed side. If they are
fitted at a 90° offset, they will loosen and fall or
shear.
– In case of repair, replace the pins, the safety
wires, the stop plates and the elastic washers.
– Fit the ball bearings and smooth bearings using
the recommended lubricating grease.
– Align the pinions and pulleys with each other.
– For operations on hydraulic installations, ensure
maximum cleanliness.
– Do not mix different grades of oil.
– Slowly turn or actuate the tractor components
once the repair is completed.
Introduction
General repair instructions
863-001
16 00 1150 409 0-RHB TALOS 100-09/2013
