Claas-Ares 806 Tractor Workshop Manual – PDF DOWNLOAD

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Claas-Ares 806 Tractor Workshop Manual – PDF DOWNLOAD

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TABLE OF CONTENTS:

Claas-Ares 806 Tractor Workshop Manual – PDF DOWNLOAD

A0_GB………………………………………………………………………………………………………………. 1
A0 – INJECTION SHEET CHECKING PROCEDURE…………………………………………………………………………….. 1
Checking procedure……………………………………………………………………………………………. 2
Measurement sheet…………………………………………………………………………………………….. 7
Pressure connection (appendix)…………………………………………………………………………………. 8
ARES 816 – H 4412…………………………………………………………………………………………….. 11
ARES 826 QUADRISHIFT – H 4422………………………………………………………………………………….. 13
ARES 826 FULL-POWERSHIFT – H 4322………………………………………………………………………………. 15
ARES 836 – H 4432…………………………………………………………………………………………….. 17
A1_GB………………………………………………………………………………………………………………. 19
A1 – INJECTION FEED………………………………………………………………………………………………. 19
Identification……………………………………………………………………………………………….. 20
Tightening torques (DE 10)…………………………………………………………………………………….. 21
Tightening torques (VP 44)…………………………………………………………………………………….. 22
Operating principles………………………………………………………………………………………….. 23
Checks/Adjustments……………………………………………………………………………………………. 30
Removal/refitting…………………………………………………………………………………………….. 33
Diagnostics………………………………………………………………………………………………….. 38
A2_GB………………………………………………………………………………………………………………. 43
A2 – ENGINE TIER II………………………………………………………………………………………………. 43
General specifications………………………………………………………………………………………… 44
DIMENSIONAL SPECIFICATIONS…………………………………………………………………………………….. 46
General specifications………………………………………………………………………………………… 50
Tightening torques……………………………………………………………………………………………. 58
Checks/Adjustments……………………………………………………………………………………………. 62
Removal/refitting…………………………………………………………………………………………….. 67
Diagnostic Sheets…………………………………………………………………………………………….. 117
TOOLS……………………………………………………………………………………………………….. 127
B1_GB………………………………………………………………………………………………………………. 135
B1–GBA10 GEARBOX…………………………………………………………………………………………………. 135
General specifications………………………………………………………………………………………… 136
Tightening torques……………………………………………………………………………………………. 145
Main adjustments……………………………………………………………………………………………… 148
REVERSHIFT…………………………………………………………………………………………………… 149
Front clutch…………………………………………………………………………………………………. 151
Rear clutch………………………………………………………………………………………………….. 157
Quadrishift unit……………………………………………………………………………………………… 163
Gearshift cover………………………………………………………………………………………………. 180
Guide rods…………………………………………………………………………………………………… 184
Output shaft…………………………………………………………………………………………………. 188
Input shaft………………………………………………………………………………………………….. 193
Countershaft…………………………………………………………………………………………………. 199
Crawler speeds……………………………………………………………………………………………….. 203
B2_GB………………………………………………………………………………………………………………. 209
B2 GTA1040 AND GPA30 LOW-PRESSURE HYDRAULIC CIRCUIT………………………………………………………………….. 209
LS 100l/min low-pressure circuit onGTA1040………………………………………………………………………. 210
LS 110l/min low-pressure circuit onGPA30………………………………………………………………………… 220
Low-pressure hydraulic components………………………………………………………………………………. 225
Solenoid valve measurement and checking points…………………………………………………………………… 233
GBA10 distribution unit measurement and checking points…………………………………………………………… 235
“Hydraulic inspection results” sheet……………………………………………………………………………. 237
GBA10 lubrication measurement and checking points………………………………………………………………… 238
“Hydraulic inspection results” sheet……………………………………………………………………………. 239
LS 110l/min measurement and checking points……………………………………………………………………… 240
“Hydraulic inspection results” sheet……………………………………………………………………………. 242
LS 100l/min measurement and checking points……………………………………………………………………… 243
“Hydraulic inspection results” sheet……………………………………………………………………………. 245
B3_GB………………………………………………………………………………………………………………. 247
B3 GBA 31 FULL POWERSHIFT GEARBOX………………………………………………………………………………….. 247
General……………………………………………………………………………………………………… 248
Repair………………………………………………………………………………………………………. 259
B4_GB………………………………………………………………………………………………………………. 263
B4 FULL POWERSHIFT LOW PRESSURE HYDRAULIC CIRCUIT……………………………………………………………………. 263
General……………………………………………………………………………………………………… 264
Repair………………………………………………………………………………………………………. 270
Measurement and checking points………………………………………………………………………………… 274
“Inspection results” sheet…………………………………………………………………………………….. 278
TOOLS……………………………………………………………………………………………………….. 279
C1_GB………………………………………………………………………………………………………………. 285
C1 – GPA 40 REAR AXLE…………………………………………………………………………………………….. 285
Tightening torques and principal adjustments…………………………………………………………………….. 287
GPA 40 drive pinion…………………………………………………………………………………………… 290
5″ differential………………………………………………………………………………………………. 297
ND axle tubes………………………………………………………………………………………………… 309
HD etHD+ axle tubes…………………………………………………………………………………………… 317
HDE axle tubes……………………………………………………………………………………………….. 325
GPA 40 power take-off clutch…………………………………………………………………………………… 333
GPA 40 power take-off upper shaft………………………………………………………………………………. 338
GPA 40 power take-off lower shaft………………………………………………………………………………. 347
Proportional power take-off……………………………………………………………………………………. 353
C2_GB………………………………………………………………………………………………………………. 359
C2 – GPA 30 REAR AXLE…………………………………………………………………………………………….. 359
Tightening torques and main adjustments…………………………………………………………………………. 360
GPA 30 drive pinion…………………………………………………………………………………………… 365
5″ differential………………………………………………………………………………………………. 374
GPA 30 power take-off clutch…………………………………………………………………………………… 386
GPA 30 power take-off upper shaft………………………………………………………………………………. 392
GPA 30 power take-off lower shaft………………………………………………………………………………. 394
GPA 30 crawler gears………………………………………………………………………………………….. 400
C3_GB………………………………………………………………………………………………………………. 405
C3 – SERVICE BRAKES………………………………………………………………………………………………. 405
Technical specifications………………………………………………………………………………………. 406
Brake pistons and seals……………………………………………………………………………………….. 407
Boosters and master cylinders………………………………………………………………………………….. 411
Replacing the master cylinders…………………………………………………………………………………. 412
Bleeding the brake circuit…………………………………………………………………………………….. 413
C4_GB………………………………………………………………………………………………………………. 421
C4–AUTOMATIC BRAKE, PARK LOCK AND HANDBRAKE…………………………………………………………………………. 421
Automatic brake………………………………………………………………………………………………. 422
Park Lock……………………………………………………………………………………………………. 434
Handbrake……………………………………………………………………………………………………. 444
TOOLS……………………………………………………………………………………………………….. 449
D1_GB………………………………………………………………………………………………………………. 453
D1–FRONT AXLE……………………………………………………………………………………………………. 453
Description………………………………………………………………………………………………….. 454
Removal/refitting…………………………………………………………………………………………….. 457
Disassembly prior to front axle operations………………………………………………………………………. 460
Removal/refitting…………………………………………………………………………………………….. 461
Hydraulic measurement and checking points……………………………………………………………………….. 476
“Hydraulic inspection results” sheet……………………………………………………………………………. 477
D2_GB………………………………………………………………………………………………………………. 479
D2–PROACTIV FRONT AXLE……………………………………………………………………………………………. 479
Description………………………………………………………………………………………………….. 480
Removal/refitting…………………………………………………………………………………………….. 483
Disassembly prior to front axle operations………………………………………………………………………. 486
Removal/refitting…………………………………………………………………………………………….. 487
Hydraulic measurement and checking points……………………………………………………………………….. 526
“Hydraulic inspection results” sheet……………………………………………………………………………. 528
Electric checks………………………………………………………………………………………………. 529
Breakdown diagnosis…………………………………………………………………………………………… 531
D3_GB………………………………………………………………………………………………………………. 533
D3–GPA30 ANDGPA40 4-WHEEL DRIVE POWER TAKE-OFF HOUSING……………………………………………………………….. 533
Description………………………………………………………………………………………………….. 534
Removing/refitting the housing…………………………………………………………………………………. 541
Solenoid valve measurement and checking points…………………………………………………………………… 545
Hydraulic measurement and checking point………………………………………………………………………… 546
“Hydraulic inspection results” sheet……………………………………………………………………………. 547
TOOLS……………………………………………………………………………………………………….. 549
E1_GB………………………………………………………………………………………………………………. 557
E1CLOSED CENTRE HYDRAULICS(110l/min)……………………………………………………………………………….. 557
Description………………………………………………………………………………………………….. 558
Removing/refitting the components………………………………………………………………………………. 567
Hydraulic measurement and checking points……………………………………………………………………….. 618
“Hydraulic inspection results” sheet……………………………………………………………………………. 622
Hydraulic measurement and checking points……………………………………………………………………….. 625
“Hydraulic inspection results” sheet……………………………………………………………………………. 628
E2_GB………………………………………………………………………………………………………………. 629
E2 CLOSED CENTRE HYDRAULICS 100l/min……………………………………………………………………………….. 629
Description………………………………………………………………………………………………….. 630
Removing/refitting the components………………………………………………………………………………. 639
Hydraulic measurement and checking points……………………………………………………………………….. 651
“Hydraulic inspection results” sheet……………………………………………………………………………. 656
Hydraulic measurement and checking points……………………………………………………………………….. 657
“Hydraulic inspection results” sheet……………………………………………………………………………. 661
TOOLS……………………………………………………………………………………………………….. 663
F1_GB………………………………………………………………………………………………………………. 665
F1 – ITEM LISTWIRING AND GENERAL LISTS……………………………………………………………………………… 665
FUSE AND RELAY BOX……………………………………………………………………………………………. 672
DE10 STARTING/CHARGING/PREHEATING CIRCUIT……………………………………………………………………….. 676
VP44 STARTING/CHARGING/PREHEATING CIRCUIT……………………………………………………………………….. 677
DIPPED HEADLIGHTS – HEADLIGHTS – HORN – SIDE LIGHTS – INSTRUMENT PANEL LIGHT………………………………………… 678
ROTATING BEACONS……………………………………………………………………………………………… 679
FRONT WORK LIGHTS…………………………………………………………………………………………….. 680
REAR WORK LIGHTS……………………………………………………………………………………………… 681
STOP LIGHTS – FRONT AXLE ENGAGEMENT – AIR BRAKE SYSTEM SOLENOID VALVE CONTROL……………………………………….. 682
FLASHING LIGHTS AND WARNING LIGHTS……………………………………………………………………………… 683
CIGAR LIGHTER – CLOCK – RADIO – CAB LIGHT AND SPOT……………………………………………………………….. 684
PNEUMATIC SEAT – FRONT POWER TAKE OFF CLUTCH…………………………………………………………………….. 685
FRONT AND REAR WINDSCREEN WIPER / WASHER………………………………………………………………………… 686
INSTRUMENT PANEL VENTILATION AND AIR CONDITIONING………………………………………………………………… 688
INFOTRAC ON-BOARD COMPUTER / ISO SOCKET…………………………………………………………………………. 690
FUEL GAUGE – ENGINE TEMPERATURE OIL PRESSURE – AIR FILTER BLOCKED………………………………………………….. 692
HANDBRAKE – BRAKE FLUID LEVEL………………………………………………………………………………….. 693
ENGINE SPEED…………………………………………………………………………………………………. 694
INSTRUMENT PANEL CALIBRATION – DIAGNOSTIC SOCKET INSTRUMENT PANEL AND TCE 15T……………………………………….. 695
ELECTROPILOT/DRIVETRONIC/GTA 103-202/GPA 40 DIAGNOSTIC SOCKET……………………………………………………… 696
ELECTROPILOT/DRIVETRONIC/FPS DIAGNOSTIC SOCKET…………………………………………………………………… 697
25 A POWER SOCKET…………………………………………………………………………………………….. 698
TRANSMISSION HYDRAULIC PRESSURE – OIL FILTER BLOCKED (HP) – OIL FILTER BLOCKED (SUCTION)……………………………… 699
THEORETICAL SPEED…………………………………………………………………………………………….. 700
INSTRUMENT PANEL – REAR POWER TAKE-OFF SPEED…………………………………………………………………….. 701
TCE 15T LIFT…………………………………………………………………………………………………. 702
ELECTROPILOT (WITH TCE 15T)……………………………………………………………………………………. 706
LIFT TCE – 15/25/35/ RADAR…………………………………………………………………………………….. 708
ELECTROPILOT (WITH TCE 15/25/35)……………………………………………………………………………….. 710
GTA 103-202 – GPA 40 CLUTCH AND DRIVE CONTROL……………………………………………………………………. 712
AUTOMATIC HAND BRAKE………………………………………………………………………………………….. 715
FPS CLUTCH AND DRIVE CONTROL…………………………………………………………………………………… 716
FPS PARK LOCK………………………………………………………………………………………………… 719
QUADRISHIFT II……………………………………………………………………………………………….. 720
QUADRACTIV GTA 103-202 – GPA 40………………………………………………………………………………… 724
FPS QUADRACTIV……………………………………………………………………………………………….. 728
DE10 ENGINE CONTROL…………………………………………………………………………………………… 732
VP44 ENGINE CONTROL…………………………………………………………………………………………… 734
SUSPENDED FRONT AXLE………………………………………………………………………………………….. 736
FRONT AXLE ENGAGING – DIFFERENTIAL AND REAR POWER TAKE OFF………………………………………………………… 738
OIL TEMPERATURE SENSORS – ENGINE SPEED – FORWARD SPEED – REAR POWER TAKE-OFF SPEED – REVERSER MODULE SPEED – DRIVETRONIC…. 740
CROSS CONTROL WITH SOLENOID PILOT………………………………………………………………………………. 741
CROSS CONTROL………………………………………………………………………………………………… 742
DE10 CAN…………………………………………………………………………………………………….. 743
VP44 CAN…………………………………………………………………………………………………….. 744
F2_GB………………………………………………………………………………………………………………. 745
F2-HARNESS AND CONNECTOR PATHS…………………………………………………………………………………….. 745
CONTENTS…………………………………………………………………………………………………….. 746
1 – Instrument panel harness…………………………………………………………………………………… 748
2 – Preheating control harness…………………………………………………………………………………. 756
3/1 – Front harness…………………………………………………………………………………………… 756
3/2a – Front harness………………………………………………………………………………………….. 756
3/2b – Injection harness………………………………………………………………………………………. 756
3/2c – Injection control harness……………………………………………………………………………….. 756
4 – Front axle suspension control harness……………………………………………………………………….. 766
5 – Instrument panel / cab top harness …………………………………………………………………………. 768
5a – Cab top / front lights harness…………………………………………………………………………….. 772
5b – Cab top / rear light harness with air conditioning…………………………………………………………… 772
5c – Front and rear light harness………………………………………………………………………………. 776
6 – Rear harness……………………………………………………………………………………………… 780
7a – Closed centre circuit transmission harness – 110 litres………………………………………………………. 784
7b – Closed centre circuit transmission harness – 100 litres ……………………………………………………… 784
7c – GTA 303 transmission link harness………………………………………………………………………….. 784
7d – GTA 303 transmission harness………………………………………………………………………………. 784
8a – GTA 103/202 – GPA 40 transmission control harness……………………………………………………………. 796
8b – Full Powershift transmission control harness………………………………………………………………… 796
8/1 – ISO socket harness………………………………………………………………………………………. 796
8/2 – Quadrishift 2/Quadractiv/Full Powershift display harness…………………………………………………….. 796
9a – TCE 15/25/35 Control harness………………………………………………………………………………. 810
9b – TCE 15T Control harness…………………………………………………………………………………… 814
9/1a – TCE 15/25/35 Harness……………………………………………………………………………………. 818
9/1b – TCE 15T Harness………………………………………………………………………………………… 822
9/2a – Cross control harness with Electropilot…………………………………………………………………… 826
9/2b – Cross control harness…………………………………………………………………………………… 826
9/3 – Electrohydraulic spool valve control harness……………………………………………………………….. 828
10 – On-board computer harness…………………………………………………………………………………. 828
G1_GB………………………………………………………………………………………………………………. 832
G1 – INSTRUMENT PANEL…………………………………………………………………………………………….. 832
Operating principles………………………………………………………………………………………….. 833
Characteristics………………………………………………………………………………………………. 835
Removal/refitting…………………………………………………………………………………………….. 851
Calibration………………………………………………………………………………………………….. 852
G2_GB………………………………………………………………………………………………………………. 854
G2–TCE15/25 ANDTCE15T ELECTRONIC LIFT………………………………………………………………………………. 854
Description………………………………………………………………………………………………….. 855
Checks and adjustments………………………………………………………………………………………… 859
G3_GB………………………………………………………………………………………………………………. 870
G3–TRANSMISSION/AXLE CONTROL………………………………………………………………………………………. 870
Drivetronic III………………………………………………………………………………………………. 871
Drivetronic V………………………………………………………………………………………………… 902
Full Powershift………………………………………………………………………………………………. 906
G4_GB………………………………………………………………………………………………………………. 924
G4–ENGINE MANAGEMENT……………………………………………………………………………………………… 924
DE 10 Pump…………………………………………………………………………………………………… 925
VP 44 Pump…………………………………………………………………………………………………… 937
G5_GB………………………………………………………………………………………………………………. 952
G5–INFOTRAC AND ISO SOCKET………………………………………………………………………………………… 952
Description………………………………………………………………………………………………….. 953
Removal/refitting and electrical checks…………………………………………………………………………. 957
G6_GB………………………………………………………………………………………………………………. 966
G6–ELECTROPILOT………………………………………………………………………………………………….. 966
Description………………………………………………………………………………………………….. 967
Removal/refitting…………………………………………………………………………………………….. 971
Measurement and checking points………………………………………………………………………………… 972
“Inspection results” sheet…………………………………………………………………………………….. 974
TOOLS……………………………………………………………………………………………………….. 976
G7_GB………………………………………………………………………………………………………………. 980
G7 – WIN METADIAG© ARES 806 MANUAL…………………………………………………………………………………. 980
Connecting Win Métadiag©………………………………………………………………………………………. 985
Engine application……………………………………………………………………………………………. 987
Transmission application……………………………………………………………………………………….1087
Rear axle application………………………………………………………………………………………….1117
Rear lift application………………………………………………………………………………………….1120
Dashboard application………………………………………………………………………………………….1127
Electropilot application……………………………………………………………………………………….1130
H1_GB……………………………………………………………………………………………………………….1138
H1 – CAB LIFT…………………………………………………………………………………………………….1138
Description…………………………………………………………………………………………………..1139
Full cab removal………………………………………………………………………………………………1142
Removal/refitting……………………………………………………………………………………………..1143
Refitting the cab……………………………………………………………………………………………..1152
Removing/refitting the roof…………………………………………………………………………………….1154
H2_GB……………………………………………………………………………………………………………….1156
H2 – HEATING/AIR CONDITIONING………………………………………………………………………………………1156
Description…………………………………………………………………………………………………..1157
Removal/refitting……………………………………………………………………………………………..1161
Troubleshooting Guide………………………………………………………………………………………….1172
H3_GB……………………………………………………………………………………………………………….1174
H3 – BONDING THE WINDOWS…………………………………………………………………………………………..1174
Removal/refitting……………………………………………………………………………………………..1175
TOOLS………………………………………………………………………………………………………..1184
J1_GB……………………………………………………………………………………………………………….1188
J1 – LIFT AND FRONT POWER TAKE-OFF………………………………………………………………………………….1188
Front lift……………………………………………………………………………………………………1189
Measurement and checking points…………………………………………………………………………………1192
“Inspection results” sheet……………………………………………………………………………………..1193
Front power take-off…………………………………………………………………………………………..1194
Measurement and checking points…………………………………………………………………………………1199
“Inspection results” sheet……………………………………………………………………………………..1200
J2_GB……………………………………………………………………………………………………………….1202
J2 – PNEUMATIC BRAKING…………………………………………………………………………………………….1202
How it works………………………………………………………………………………………………….1204
Main components……………………………………………………………………………………………….1211
TOOLS………………………………………………………………………………………………………..1216
SOM_A_GB…………………………………………………………………………………………………………….1218
Som_ARES_GB………………………………………………………………………………………………………….1224
SOM_B_GB…………………………………………………………………………………………………………….1225
B1–GBA10 GEARBOX………………………………………………………………………………………………….1225
B2 – GTA 1040 AND GPA 3 0 LOW-PRESSURE HYDRAULIC CIRCUIT………………………………………………………………1225
B3–GBA31 GEARBOX (FULL POWERSHIFT)………………………………………………………………………………….1225
B4–GBA31 LOW-PRESSURE HYDRAULIC CIRCUIT (FULL POWERSHIFT)……………………………………………………………..1225
SOM_C_GB…………………………………………………………………………………………………………….1233
C1–GPA 40 REAR AXLE……………………………………………………………………………………………….1233
C2–GPA 30 REAR AXLE……………………………………………………………………………………………….1233
C3–FOOT BRAKE…………………………………………………………………………………………………….1233
C4–AUTOMATIC BRAKE, PARK LOCK AND HANDBRAKE………………………………………………………………………….1233
SOM_D_GB…………………………………………………………………………………………………………….1240
D1–FRONT AXLE…………………………………………………………………………………………………….1240
D2–PROACTIV FRONT AXLE…………………………………………………………………………………………….1240
D3–GPA30 ANDGPA40 4-WHEEL DRIVE POWER TAKE-OFF HOUSING………………………………………………………………..1240
SOM_E_GB…………………………………………………………………………………………………………….1246
E1 – CLOSED CENTRE HYDRAULICS (110L/MIN)…………………………………………………………………………….1246
E2 – CLOSED CENTRE HYDRAULICS (100L/MIN)…………………………………………………………………………….1246
SOM_F_GB…………………………………………………………………………………………………………….1252
F1 – ITEM LISTWIRING AND GENERAL LISTS………………………………………………………………………………1252
F2 – HARNESS AND CONNECTOR PATHS……………………………………………………………………………………1252
SOM_G_GB…………………………………………………………………………………………………………….1258
SOM_H_GB…………………………………………………………………………………………………………….1264
H1 CAB LIFT………………………………………………………………………………………………………1264
H2 HEATING/AIR CONDITIONING………………………………………………………………………………………..1264
SOM_J_GB…………………………………………………………………………………………………………….1268

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