CLAAS DIRECT DISC 520 Comfort Repair manual – PDF DOWNLOAD

Description

CLAAS DIRECT DISC 520 Comfort Repair manual – PDF DOWNLOAD

DESCRIPTION:

CLAAS DIRECT DISC 520 Comfort Repair manual – PDF DOWNLOAD

1 Introduction
1.1 General Information

• This repair manual should help you to maintain ongoing operational capacity. The high value of the harvesting machine is ensured through careful maintenance and technical monitoring by customer service.
• This repair manual is a compilation of our service technicians’ and shop-floor experience. The image sequence demonstrates the steps in a repair procedure.
• The text provides you with the information required for making adjustments, using special tools and further similar information.
• Essential repairs are listed in such a way that even individual and small repairs can be easily found and followed. Supplements are added to reflect the ongoing technical development of the machines and the manual is thereby continuously being updated as a reference book.
• As a precaution, always compare the setting values and fill quantities with the most recent operator’s manual for the respective machine.

TABLE OF CONTENTS:

CLAAS DIRECT DISC 520 Comfort Repair manual – PDF DOWNLOAD

Contents
1 Introduction
11 General Information 12
111 Using the manual 12
112 Validity of instructions 13
12 General repair instructions 14
121 Specifications 14
122 Reason of damage 14
123 Spare parts 14
124 Gearboxes 15
125 Fixing material 15
126 Tensioning the steel roller chains 15
127 Welding Work 15
128 Taper ring fasteners 15
129 Self-locking bolts with micro-encapsulated adhesive 16
1210 Liquid locking compound 17
1211 Lock collar bearing 17
1212 Adapter sleeve bearing 17
1213 Ferrule fittings on hydraulic lines 18
1214 Progressive ring fittings on hydraulic lines 19
1215 Taper fittings on hydraulic lines 20
1216 Hydraulic hoses 20
1217 Some advice for speedy and correct repair work 22
13 Torque settings 23
131 Tightening torques for metric standard threads 23
132 Tightening torques for metric fine threads 24
133 Tightening torques for hydraulic screw fittings with ferrule according to DIN 3861 25
134 Tightening torques for hydraulic screw fittings and air conditioner fittings
with a sealing cone and O-ring DIN 3865 26
135 Tightening torques for hydraulic male connector DIN 3901 27
136 Tightening torques for direction-adjustable hydraulic male connectors
ISO 6149-2 / ISO 11926-2 (3) 28
137 Tightening torques for screw thread clamps 29
14 Specifications 30
141 Lubricants 30
2 Safety precautions
21 General information 31
211 Important notice 31
212 Identification of warning and danger signs 31
213 General safety and accident prevention regulations 32
214 First aid measures 32
215 Leaving the machine 32
216 Adjustment and maintenance work 33
217 Front attachments and trailers 33
218 Safety support 34
219 Danger of injury due to escaping hydraulic liquid 34
4 00 0295 073 0 – RHB DIRECT DISC 520 – 09/08
2793
2110 Pressure accumulator 35
2111 Energy accumulators 35
2112 Battery isolating switch 35
2113 Jack up the machine 36
2114 Putting the machine out of action 36
3 Gearbox / clutch / universal drive shaft
31 General Information 37
311 General warnings 37
312 Springs 38
313 Heavy components 38
314 Universal drive shafts 38
32 Drives – overview 40
33 Spur gearbox 42
331 Spur gearbox – overview 42
332 Removing the spur gearbox 42
333 Fitting the spur gearbox 45
334 Removing the tension spring 48
335 Fitting the tension spring 49
336 Adjusting tension springs 50
337 Removing bearings 50
338 Fitting bearings 51
34 Angle drive – main drive 52
341 Removing the angle drive 52
342 Fitting the angle drive 53
343 Checking the adjustment of the coupling flange to the quick attachment coupler 55
344 Adjusting the coupling flange to the quick attachment coupler 56
35 Upper angle drive 57
351 Removing the upper angle drive 57
352 Fitting the angle drive at the top 58
36 Special tool for upper angle drive 61
361 Removing / fitting upper angle drive 61
37 Right / left angle drive 62
371 Removing the left-hand angle drive 62
372 Fitting the left-hand angle drive 62
373 Removing the right-hand angle drive 63
374 Fitting the right-hand angle drive 63
38 Disc clutch 64
381 Removing the disc clutch 64
382 Fitting the disc clutch 64
383 Removing the bearing belt pulley 65
384 Fitting the bearing belt pulley 66
385 Removing the friction clutch 67
386 Fitting the friction clutch 68
387 Venting the friction clutch 69
39 Universal drive shaft 70
391 Universal drive shafts – overview 70
392 Universal drive shaft guard – overview 70
00 0295 073 0 – RHB DIRECT DISC 520 – 09/08 5
2793
393 Removing the universal drive shaft guard 70
394 Fitting the universal drive shaft guard 71
395 Universal drive shaft – Removing the feeder drive 72
396 Universal drive shaft – Fitting the feeder drive 73
397 Universal drive shaft – Removing the cutting disc drive 75
398 Universal drive shaft – Fitting the cutting disc drive 77
399 Universal drive shaft – Removing the left-hand cutting disc drive 80
3910 Universal drive shaft – Fitting the left-hand cutting disc drive 82
3911 Universal drive shaft – Removing the right-hand cutting disc drive 84
3912 Universal drive shaft – Fitting the right-hand cutting disc drive 85
3913 Universal drive shaft – Removing the left-hand mower head 85
3914 Universal drive shaft – Fitting the left-hand mower head 86
3915 Universal drive shaft – Removing the right-hand mower head 88
3916 Universal drive shaft – Fitting the right-hand mower head 88
4 Drives
41 General Information 89
411 General warnings 89
412 Springs 90
413 Heavy components
42 Drives – overview 91
43 Chain 93
431 Drive chain feed roller – overview 93
432 Removing the chain 94
433 Fitting the chain 95
434 Releasing the clamping bracket 95
435 Adjusting the clamping bracket 97
436 Removing the clamping bracket 100
437 Fitting the clamping bracket 101
438 Releasing the chain tensioner 102
439 Adjusting the chain tensioner 103
4310 Removing the bearing sleeves 104
4311 Fitting bearing sleeves 105
4312 Removing the tension spring 106
4313 Fitting the tension spring 106
4314 Removing sprocket Z15 107
4315 Fitting sprocket Z15 108
4316 Removing sprocket Z19 109
4317 Fitting sprocket Z19 110
4318 Removing sprocket Z37 110
4319 Fitting sprocket Z37 111
44 Belts 112
441 Cutting discs belt drive – overview 112
442 Loosening the belt 113
443 Adjusting the belt tension 114
444 Removing the jockey pulley 115
445 Fitting the jockey pulley 116
446 Removing the jockey pulley bearing 118
6 00 0295 073 0 – RHB DIRECT DISC 520 – 09/08
2793
447 Fitting the jockey pulley bearing 119
448 Removing the jockey pulley arm 120
449 Fitting the jockey pulley arm 121
4410 Removing the jockey pulley arm bearing sleeve 122
4411 Fitting the jockey pulley arm bearing sleeve 123
4412 Removing the pressure spring 123
4413 Fitting the pressure spring 124
4414 Removing / fitting the spring guide 125
4415 Removing the belt 126
4416 Fitting the belt 127
45 Belt special tool 130
451 Loosening the belt 130
46 Drive shaft 131
461 Drive shaft – overview 131
462 Removing the belt pulley 131
463 Fitting the belt pulley 132
464 Removing the left-hand flange bearing 134
465 Fitting the left-hand flange bearing 135
466 Removing the right-hand flange bearing 136
467 Fitting the right-hand flange bearing 137
468 Removing / fitting the lock collar bearing 139
47 Drive shaft special tool 140
471 Removing the belt pulley 140
5 Hydraulic system
51 General Information 141
511 General warnings 141
52 Feed roller adjustment 143
521 Feed roller adjustment – overview 143
522 Hydraulics schema 144
523 Releasing the hydraulic pressure 144
524 Lock-up valve unit – overview 145
525 Removing the lock-up valve unit 146
526 Fitting the lock-up valve unit 146
527 Removing the one way valve 147
528 Dismantling / assembling the one way valve 148
529 Fitting the one way valve 149
5210 Removing the left-hand hydraulic cylinder 150
5211 Removing the right-hand hydraulic cylinder 150
5212 Hydraulic cylinder – overview 151
5213 Dismantling the hydraulic cylinder 152
5214 Assembling the hydraulic cylinder 153
5215 Fitting the left-hand hydraulic cylinder 155
5216 Fitting the right-hand hydraulic cylinder 155
6 Electrics
61 General Information 156
611 General warnings 156
00 0295 073 0 – RHB DIRECT DISC 520 – 09/08 7
2793
62 Speed sensor 157
621 Speed sensor wiring diagram 157
622 Pin assignment 157
623 Adjusting the speed sensor 158
7 Feeder unit
71 General Information 159
711 General warnings 159
712 Springs 160
713 Heavy components 160
72 Feed roller 161
721 Feed roller – overview 161
722 Removing / fitting the paddle 162
723 Removing the left-hand adjusting panel 163
724 Fitting the left-hand adjusting panel 164
725 Removing the right-hand adjusting panel 165
726 Fitting the right-hand adjusting panel 165
727 Removing the left-hand adjusting plate 166
728 Fitting the left-hand adjusting plate 167
729 Removing the right-hand adjusting plate 169
7210 Fitting the right-hand adjusting plate 170
7211 Removing / fitting the lock collar bearing 171
7212 Removing the drive flange 172
7213 Fitting the drive flange 173
7214 Removing the bearing flange 175
7215 Fitting the bearing flange 177
7216 Removing the chopping rotor 178
7217 Fitting the chopping rotor 180
73 Feed roller special tool 184
731 Fitting the anti-wrapping guard 184
74 Intake auger 185
741 Intake auger – overview 185
742 Removing the drive flange 186
743 Fitting the drive flange 186
744 Removing the bearing flange 187
745 Fitting the bearing flange 187
746 Removing the swivel arm 188
747 Fitting the swivel arm 190
748 Removing / fitting the lock collar bearing 194
749 Removing / fitting the bearing sleeve 195
7410 Removing the intake auger 196
7411 Fitting the intake auger 197
7412 Removing the left-hand bearing journal 199
7413 Fitting the left-hand bearing journal 199
7414 Removing the right-hand bearing journal 200
7415 Fitting the right-hand bearing journal 200
8 00 0295 073 0 – RHB DIRECT DISC 520 – 09/08
2793
8 Mowing unit
81 General Information 201
811 General warnings 201
812 Unbalance 202
813 Heavy components 203
82 Cutting device – overview 204
83 Fixing lever 205
831 Use – fixing lever 205
84 Knives 206
841 Wear limits – mower knives 206
85 Mower knife quick change system 207
851 Replacing the mower knives 207
852 Wear limits – mower knife holder 210
853 Removing the mower knife holder 212
854 Fitting the mower knife holder 212
86 Screwed in mower knives 214
861 Replacing the mower knives 214
862 Wear limits – knife attachment 216
87 Cutting discs 217
871 Wear limits – cutting discs 217
872 Removing the cutting discs 217
873 Fitting cutting discs 218
874 Removing the conveyor cap 220
875 Fitting the conveyor cap 220
876 Retrofitting the conveyor cap 221
88 Feed drum 222
881 Wear limits – feed drum 222
882 Removing the feed drum 222
883 Fitting the feed drum 223
884 Removing / fitting the wear bars 223
89 Mower head 224
891 Removing the wear skids 224
892 Fitting the wear skids 224
893 Removing the cutterbar skids 224
894 Fitting the cutterbar skids 225
895 Removing the left mower head 225
896 Fitting the left mower head 228
897 Removing the right mower head 231
898 Fitting the right mower head 231
899 Changing the mower head tilt 231
810 Mower head gearbox 235
8101 Drive-in module – overview 235
8102 Removing the drive-in module 235
8103 Fitting the drive-in module 237
8104 Safety module – overview 240
8105 Removing the safety module 241
8106 Fitting the safety module 241
00 0295 073 0 – RHB DIRECT DISC 520 – 09/08 9
2793
9 Attachment parts, machine body
91 General Information 244
911 General warnings 244
912 Springs 245
913 Heavy components 245
914 Suspension frame 246
92 Safety devices – overview 247
93 Right / left safety device 248
931 Opening the left safety device 248
932 Closing the left safety device 249
933 Removing the left safety device 249
934 Fitting the left safety device 250
935 Removing the hinge 251
936 Fitting the hinge 252
937 Removing the catch 252
938 Fitting the catch 253
939 Adjusting the catch 253
9310 Opening the right safety device 254
9311 Closing the right safety device 254
9312 Removing the right safety device 254
9313 Fitting the right safety device 254
94 Right / left plastic hood 255
941 Removing the left plastic hood 255
942 Fitting the left plastic hood 256
943 Removing the right plastic hood 257
944 Fitting the right plastic hood 257
95 Cover 258
951 Opening the cover 258
952 Closing the cover 259
953 Removing the cover 259
954 Fitting the cover 260
955 Adjusting the securing bolt 262
956 Removing / fitting the buffer 263
96 Safety guard 264
961 Safety guards – overview 264
962 Removing the safety guard 264
963 Fitting the safety guard 268
97 Right / left safety guard 272
971 Removing the left safety guard 272
972 Fitting the left safety guard 273
973 Removing the right safety guard 275
974 Fitting the right safety guard 276
98 Anti-wrapping guard 278
981 Adjusting the left anti-wrapping guard 278
982 Removing the left anti-wrapping guard 280
983 Fitting the left anti-wrapping guard 282
984 Removing the right anti-wrapping guard 284
985 Fitting the right anti-wrapping guard 284
10 00 0295 073 0 – RHB DIRECT DISC 520 – 09/08
2793
986 Adjusting the right anti-wrapping guard 284
99 Trough 285
991 Trough – overview 285
992 Removing the left guide plate 286
993 Fitting the left-hand guide plate 286
994 Removing the right-hand guide plate 287
995 Fitting the right-hand guide plate 288
996 Removing the guide 289
997 Fitting the guide 290
998 Removing the wear sheet 291
999 Fitting the wear sheet 292
9910 Removing / fitting the top right-hand buffer 293
9911 Removing the lower right-hand buffer 293
9912 Fitting the lower right-hand buffer 294
9913 Removing / fitting the top left-hand buffer 294
9914 Removing the lower left-hand buffer 295
9915 Fitting the lower left-hand buffer 296
910 Suspension frame 297
9101 Suspension frame – overview 297
9102 Removing tension springs 298
9103 Fitting tension springs 299
9104 Adjusting tension springs 300
9105 Removing the upper brace 301
9106 Fitting the upper brace 301
9107 Removing the lower left-hand brace 302
9108 Fitting the lower left-hand brace 302
9109 Removing the lower right-hand brace 303
91010Fitting the lower right-hand brace 303
91011Removing the suspension frame 304
91012Fitting the suspension frame 306
91013Removing bearings 309
91014Fitting bearings 310
91015Seals – Overview 311
91016Removing seals 312
91017Fitting seals 313
91018Removing the catch 314
91019Fitting the catch 315
911 Cutterbar skids 316
9111 Removing the left-hand cutterbar skid 316
9112 Fitting the left-hand cutterbar skid 317
9113 Removing the right-hand cutterbar skid 317
9114 Fitting the right-hand cutterbar skid 317
9115 Adjusting the cutterbar skids 318
9116 Removing the wear sheet 319
9117 Fitting the wear sheet 320
00 0295 073 0 – RHB DIRECT DISC 520 – 09/08 11
2793
912 Stand 321
9121 Removing the magnet / pressure spring 321
9122 Fitting the magnet / pressure spring
IMAGES PREVIEW OF THE MANUAL:

CLAAS DIRECT DISC 520 COMFORT REPAIR MANUAL – PDF DOWNLOAD:

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

SM