service repair manual

1. XERION 5000-4000
Repair Manual
Type 783
Original repair manual
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Cover RHB XERION 783
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2. Validity of manual
This manual applies to the following machine / front attachment:
Designation Type Serial number
from to
XERION 783 78300011 –
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Gültigkeit der Anleitung
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3. Front steering drive axle
Applies to:
Drive axle Raba type 579.15
Technical specifications
Value CCN Remark / designation
1 2046 kg Front steering drive axle
2 Front differential Front
differential
3 B152 Floating axle steering angle sensor Steering angle
sensor
4 Front wheel hub Front wheel
hub
5 Front stub axle Front stub axle
6 Front track rods Front track
rods
7 3140 Steering hydraulic cylinder Steering
hydraulic cylinder
8 130 Nm Insert bolts for universal drive shaft with
DELO ML 5328.
9 B396 Floating axle pressure sensor Front pressure
sensor
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4. Value CCN Remark / designation
10 85 Nm Mud guard bracket
11 10 Nm
12 20 +5
Nm
Tightening torques not specified, see "Introduction / Tightening torques" chapter
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.
Work preparation
Utilities:
► Liquid locking compound (high-strength), e.g.:
DELO ML 5328 - 00 0178 779 1
► Multi-purpose grease, e.g.:
CLAAS AGRIGREASE EP 2 - 00 0147 437 0
Tool:
► Suitable lifting device
Load-bearing capacity at least 2046 kg (front drive axle)
► Oil collecting tank
► Plugs (different sizes) for closing oil lines.
Special tool
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5. Jacking up the machine.
Special tool (I) Pcs.
1 Assembly rig
00 0181 919 0
2
Removing
► Put the machine out of operation.
► Disconnect the power supply.
► Draining the differential oil.
► Drain the wheel hub drive oil.
► Remove the wheels from the front drive axle.
See the Operator's Manual of the machine in question.
Use special tool (I).
Front steering drive axle
► Jack up machine at (1).
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6. WARNING
Lifting heavy components.
Risk of death or serious injury.
► Use a lifting tool with a sufficient bearing load.
► Use a lifting tool that operates reliably.
► Use the lifting tool on solid and even ground.
► Attach the lifting tool to the component at the intended or a suitable position.
► Only use faultless and sufficiently dimensioned lifting accessories.
► Protect lifting accessories against sharp corners and edges, for example using protectors.
Left and right side:
► Suspend mud guard (1) in a suitable lifting equipment.
► Unscrew bolts (2) and remove mud guard (1).
► Unscrew hoses (1) and (2) from steering cylinder (3).
► Unscrew hose (4) from the drive axle.
► Plug openings tightly with plugs on both sides.
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7. ► Unscrew hoses (1) and (2).
Plug openings tightly with plugs on both sides.
► Unscrew bolts (3).
► Remove cover (4).
► Unlock and disconnect connector from sensor (B398).
► Unlock and disconnect connector from sensor (B396).
► Unlock and disconnect connector from sensor (B152).
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8. ► Unscrew bolts (1).
► Pull universal drive shaft (2) off of flange of drive axle (3).
► Tie up universal drive shaft (2) and secure shifter piece (4) against slipping out.
Left side:
► Remove lubrication lines (1) and (2).
Rear cross beam:
► Unscrew all bolts (1) from rear cross beam (2) if necessary.
Front cross beam:
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9. ► Unscrew all bolts (1) from front cross beam (2) if necessary.
Left and right side:
► Loosen the bolts (1).
Important! Do not unscrew bolts (1)!
WARNING
Lifting heavy components.
Risk of death or serious injury.
► Use a lifting tool with a sufficient bearing load.
► Use a lifting tool that operates reliably.
► Use the lifting tool on solid and even ground.
► Attach the lifting tool to the component at the intended or a suitable position.
► Only use faultless and sufficiently dimensioned lifting accessories.
► Protect lifting accessories against sharp corners and edges, for example using protectors.
Left and right side:
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10. ► Suspend the drive axle in a suitable lifting device and raise it slightly.
Weight of complete drive axle:
Front steering drive axle
► Fully remove bolts (1) that have already been undone.
► Lower rear drive axle (2) down.
Observe the technical details of the cross beams overview!
Cross beams
► Unscrew bolts (1).
► Remove cross beam (2).
► Unscrew bolts (1).
► Remove cross beam (2).
Installing
Observe the technical details of the cross beams overview!
Cross beams
Grease bearing race at (2) with CLAAS AGRIGREASE EP 2.
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11. Front steering drive axle
► Slide on cross beam (1).
► Bolt down bearing plates (1) with bolts (2).
Grease bearing race at (2) with CLAAS AGRIGREASE EP 2.
Front steering drive axle
► Slide on cross beam (1).
► Bolt down bearing plates (1) with bolts (2).
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12. WARNING
Lifting heavy components.
Risk of death or serious injury.
► Use a lifting tool with a sufficient bearing load.
► Use a lifting tool that operates reliably.
► Use the lifting tool on solid and even ground.
► Attach the lifting tool to the component at the intended or a suitable position.
► Only use faultless and sufficiently dimensioned lifting accessories.
► Protect lifting accessories against sharp corners and edges, for example using protectors.
Left and right side:
► Clean the bolting surfaces so that they are free of rust and paint.
► Suspend drive axle (1) in a suitable lifting equipment and lift it to the installation position.
Weight of complete drive axle:
Front steering drive axle
► Clean the contact surfaces of bolts (2) so that they are free of rust and paint.
► Screw in bolts (2) hand-tight.
► Remove lifting equipment.
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13. Left and right side:
► Tighten the bolts (1).
Tightening torque:
Cross beams
Front cross beam:
► Tighten bolts (1) at the front cross beam (2).
Rear cross beam:
► Tighten bolts (1) at the rear cross beam (2).
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14. Left side:
► Install lubrication lines (1) and (2).
Insert bolts (2) with DELO ML -5328.
Front steering drive axle
Tightening torque for bolts (2):
Front steering drive axle
► Tighten universal drive shaft (1) at the flange of rear drive axle (3) with bolts (2).
► Plug and lock connector on sensor (B396).
► Plug and lock connector on sensor (B152).
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16. ► Screw down hoses (1) and (2).
► Plug and lock connector on sensor (B398).
► Bolt down lid (3) with bolts (4).
► Screw down hoses (1) and (2) to steering cylinder (3).
► Bolt hose (4) down to the drive axle.
WARNING
Lifting heavy components.
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17. Risk of death or serious injury.
► Use a lifting tool with a sufficient bearing load.
► Use a lifting tool that operates reliably.
► Use the lifting tool on solid and even ground.
► Attach the lifting tool to the component at the intended or a suitable position.
► Only use faultless and sufficiently dimensioned lifting accessories.
► Protect lifting accessories against sharp corners and edges, for example using protectors.
Left and right side:
► Suspend mud guard (1) in a suitable lifting equipment.
► Tighten mud guard (1) with bolts (2).
► Fit the wheels of the front drive axle.
► Top up wheel hub gearbox oil.
► Top up differential oil.
► Restore the power supply.
See the Operator's Manual of the machine in question.
► Balance the axles and learn the steering angle with the CDS.
► Check the functions.
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18. Floating axle lock hydraulic cylinder
Technical specifications
Value CCN Remark / designation
1 7.5 kg 3109 Floating axle lock hydraulic cylinder
2 Apply some liquid locking compound (high-
strength) to threads prior to installation (see
work preparation).
Important! To loosen the thread, heat it up to
approx. 100 °C .
3 Apply a little hydraulic oil to seals.
4 Insert pins with multipurpose grease (see work
preparation).
General:
Before removing the cylinder:
- Switch off the swinging axle lock.
- Put the machine out of operation.
When assembling the cylinder:
- Coat all moving parts with hydraulic oil.
After installation of cylinder:
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Hydraulikzylinder (3109) Pendelachssperre
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