service repair manual

1. Validity of the manual
This manual is valid for the machine/front attachment:
Designation Type Machine number
from to
XERION TRAC 3800 -3300 781 78100011 –
XERION TRAC VC 3800 -3300 781 78100011 –
XERION SADDLE TRAC 3800 -3300 781 78100011 –
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2. XERION 3800-3300
Repair Manual
Type 781
Original repair manual
1/1Cover RHB XERION 781
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3. Diesel engine
Item Value CCN Remark / designation
1 1400 kg Diesel engine C9
2 Electric starting motor (M21)
Electric starting motor (M21)
3 Alternator (G2-1)
Alternator (G2-1 / G2-2)
4 Alternator (G2-2)
Alternator (G2-1 / G2-2)
5 Fan blade assembly
Fan blade assembly
6 Belt (R1)
Fan drive belt (R1)
7 Belt (R2)
Air conditioner compressor drive belt (R2)
8 Main drive universal drive shaft (GW1)
Universal drive shaft main drive
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4. Item Value CCN Remark / designation
9 Torsion damper
Torsion damper
10 Air conditioner compressor
Air conditioner compressor
11 Thermostat
Thermostat
Tightening torques not specified, see section on tightening torques
NOTICE
Lubricants and fuels end up in the environment.
Environmental pollution
► Collect and store lubricants and fuels in suitable containers and dispose of them properly.
Removing
► Remove cab.
Cab
► Only for SADDLE TRAC
► Remove steps.
► Remove the front wheels.
► Drain the diesel engine coolant.
► Withdraw the air conditioner refrigerant.
Air conditioning system – General information
► Remove the alternators.
Alternator (G2-1 / G2-2)
► Remove electric starting motor.
Electric starting motor (M21)
► Remove the fan blade assembly.
Fan blade assembly
► Remove the fan hub.
Fan hub
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5. On TRAC / TRAC VC
► Unscrew mud guard (1).
► Remove covering (2).
► Repeat this process on the other side of the machine.
On TRAC / TRAC VC
► Unscrew sheet metal cover (1).
► Unscrew plate (2).
On SADDLE TRAC
► Remove platform.
Platform
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6. ► Remove cable band (1).
► Unscrew clamps (2).
► Disconnect hose (3) and close both sides with a plug.
► Remove cable band (1).
► Unscrew clamps (2).
► Disconnect hose (3) and close both sides with a plug.
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7. ► Unscrew clamp (1).
► Unscrew clamp (2).
► Disconnect hose (3) and close both sides with a plug.
► Unscrew clamp (1).
► Unscrew clamp (2).
► Disconnect hose (3) and close both sides with a plug.
► Unscrew clamp (1).
► Disconnect hose (2), seal with plugs on both sides and tie it aside.
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8. ► Disconnect connectors (1).
► Unscrew hose (2) and close both sides with a plug.
► Unscrew bracket (3).
► Disconnect connectors (1).
► Remove cable band (1).
► Unscrew clamp (2).
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9. ► Remove cable band (1).
► Unscrew pipes (2) and plug them with a plug.
► Unscrew bolts (1).
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10. ► Pull out hoses (1) through opening (2) in the direction of the arrow and set aside.
► Unscrew air conditioner compressor (1).
► Do not unscrew hoses (2).
► Put the air conditioner compressor (1) aside along with the lines and fix it.
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11. ► Unscrew hoses (1) and close both sides with a plug.
► Unscrew pipe (1) and plug it with a plug.
On TRAC / TRAC VC
► Unscrew hose (1) and close both sides with a plug.
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12. On TRAC / TRAC VC
► Mark and disconnect cable from connector (Z032).
On TRAC / TRAC VC
► Remove hoses (1), (2) and (3) and seal with plugs.
► Remove compensating tank (4).
► Unscrew bracket (1).
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13. ► Unscrew bracket (1).
► Unscrew clamp (2).
► Unscrew bracket (3).
► Disconnect connector (4).
► Remove wiring loom (5) and put it aside.
► Unscrew connector (1) from module (A015).
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14. ► Unscrew hose (1) and close both sides with a plug.
► Unscrew hose (1) and close both sides with a plug.
► Unscrew clamp (1).
► Unscrew clamp (1).
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15. ► Disconnect hose (1) and seal openings with plugs.
► Unscrew piping (1) and (2), seal openings with plugs and remove completely with clamps (3).
► Disconnect connectors (1).
► Loosen cable bands (2).
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16. ► Slacken off clamp (1) and pull out cable (2) in direction of the arrow.
► Unscrew hose (1) and close both sides with a plug.
► Unscrew drive shaft (1).
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18. WARNING
Lifting of heavy parts.
Death or serious injury.
► Use lifting device of sufficient capacity.
► Use reliable lifting device.
► Use lifting device on solid and level ground.
► Attach lifting device to the intended or a suitable position of the component.
Observe the specifications in the overview!
Diesel engine
► Suspend the diesel engine (1) in a suitable lifting device.
► Unscrew bolts (1).
► Repeat this process on the other side of the machine.
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19. ► Unscrew bolt (1).
► Repeat this process on the other side of the machine.
► Lift out diesel engine (1).
Installing
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20. ► Preparing a parts change and release information when installing a new diesel engine:
► Note down the engine number of the new diesel engine.
► Open CLAAS Extra.Net / Service Online.
► Write the parts change and release information for the machine.
► Check torsion damper (1), install new torsion damper if required.
Torsion damper
WARNING
Lifting of heavy parts.
Death or serious injury.
► Use lifting device of sufficient capacity.
► Use reliable lifting device.
► Use lifting device on solid and level ground.
► Attach lifting device to the intended or a suitable position of the component.
Observe the specifications in the overview!
Diesel engine
► Suspend the diesel engine in a suitable lifting device and install it.
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21. ► Install fan hub (1).
Fan hub
► Install fan blade (2).
Fan blade assembly
► Bolt down bracket (1).
► Align the diesel engine with the fan blades towards the rotary chaff screen.
► Ensure that engine does not touch the frame.
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