CLAAS Arion 430-410 Repair Manual - PDF DOWNLOAD

04 BRAKES

Technical support Arion 430-410

Repair – Edition 01.2010 Reference n° 00 1139 729 0

04 Brakes Contents

CONTENTS

04 BRAKES 04 05 FOOT BRAKE LOCALLY MANUFACTURED TOOL.................................................................................................................................... 6 DRAINING THE PRIMARY BRAKE CIRCUIT...................................................................................................................... 7 REMOVING THE BRAKE DISCS AND PISTON.................................................................................................................. 8 REFITTING THE BRAKE DISCS AND PISTON .................................................................................................................. 9 SEALING TEST .................................................................................................................................................................. 10 CROSS SECTIONAL VIEW OF THE MASTER CYLINDERS/BOOSTERS....................................................................... 11 REPLACING THE MASTER CYLINDERS ......................................................................................................................... 12 ADJUSTMENT OF THE BRAKE PEDALS ......................................................................................................................... 12 BLEEDING THE CIRCUIT MANUALLY ............................................................................................................................. 13 BLEEDING THE BRAKE CIRCUIT WITH A PRESSURISING DEVICE ............................................................................ 14 BLEEDING THE RIGHT AND LEFT-HAND BRAKES........................................................................................................ 15 DRAINING THE TRAILER BRAKE VALVE ........................................................................................................................ 15

04 15 HANDBRAKE TRANSMISSION HANDBRAKE TOOLS FOR REMOVING THE CRAWLER RANGE PIN AND SLEEVE........................................................................... 18 EXPLODED VIEW .............................................................................................................................................................. 19 TORQUE SETTINGS AND SEALANTS ............................................................................................................................. 20 REMOVING THE HANDBRAKE HOUSING....................................................................................................................... 21 REFITTING THE HANDBRAKE HOUSING ....................................................................................................................... 23 ADJUSTING THE HANDBRAKE MECHANISM................................................................................................................. 25 ADJUSTING THE CONTROL LEVER................................................................................................................................ 26

Arion 430-410 – 01.2010 – GB

04 Brakes Contents

Notes

Arion 430-410 – 01.2010 – GB

04 05 FOOT BRAKE

Arion 430-410 – 01.2010 – GB

04 Brakes 04 05 Foot brake

Locally manufactured tool Oil filling tool (LHM)

Ø6

Ø 25

4

M24 x 1,5

Ø 36,5

JIC 9/16

50 75

Fig. 1

025fl

Tool for holding the brake piston

450 10

410

=

=

40

=

=

Ø 16

Fig. 2

011fl

6

Arion 430-410 – 01.2010 – GB

04 Brakes 04 05 Foot brake

Draining the primary brake circuit Note: It is important to dry the drain plugs properly in order to eliminate all traces of humidity.

Draining the circuit – Open the drain holes (1) on the rear axle central casing, 2 M12 drain screws, as well as the drain screw on the trailer brake valve (2).

– Place a recipient under the drain screws and connect a flexible translucent hose attached to a recipient onto the brake valve drain.

– Coupled pedals, slowly depress and release three times over the complete stroke of the pedal assembly and repeat the operation a dozen of times to enable the liquid to flow.

– Open the right (3) and left (4) drain screws on the receivers, let the LHM brake circuit liquid flow, while leaving the drain holes open for at least 10 minutes.

1 Fig. 3

362msm01

Rinsing the circuit – Close the right (3) and left (4) receiver drain screws, fill the container with new LHM liquid. To enable the brake fluid to flow when flushing, with the pedals linked depress and release slowly about ten times, covering the entire stroke of the pedal unit, and repeat the operation if required.

4

3

– Open the right (3) and left (4) receiver drain screws, let the liquid remaining in the brake circuit flow for at least 10 minutes.

– Screw and lock the right and left drain screws (1) on the receivers, under the central casing.

– Fill up and bleed the circuit.

2 362msm0p

Arion 430-410 – 01.2010 – GB

Fig. 4

7

04 Brakes 04 05 Foot brake

Removing the brake discs and piston – Remove the axle tube (Refer to section: "02 40").

3

1

2

– Remove the disc (1), the sun gear (2).

Important: Loosen the 3 screws (6) of the selfadjusting system.

– Remove the piston (4) from the housing by blasting compressed air through the coupling (5) (Fig. 5).

Note: To make access to the union (5) easier, if necessary disconnect the economy power take-off controls and adjust the union.

– Remove the O-rings (7) and (8) on the housing (Fig. 6).

Fig. 5

362msm02

5

4

6

Fig. 6

362msm03

7 362msm04

8

Arion 430-410 – 01.2010 – GB

8 Fig. 7

04 Brakes 04 05 Foot brake

Refitting the brake discs and piston 9

– Clean and inspect all parts, replace all faulty parts.

– Fit the piston (4) without seals in the casing (9), (Fig. 7).

3

Note: Check that the piston slides freely in the casing bore and it enters without tight points on the centring studs (3) (Fig. 7).

6

Note: Smear the seals with a moderate amount of grease to keep them correctly at the bottom of the groove.

10

4 9 4

– Fit new O-rings (7) and (8).

– Position the piston along the axis of the centring studs, then fit it with the aid of the locally made tool (Fig. 9).

7

– Change the studs (10) when intervening on the brakes (Fig. 7).

8

– Coat the screws (6) with Loctite (243) and tighten to 1 daN.m.

362msm63

Fig. 8

362msm0d

Fig. 9

Arion 430-410 – 01.2010 – GB

9

04 Brakes 04 05 Foot brake

– Smear the brake discs with transmission oil.

– Refit the discs.

N.B.: Check that the disc slides freely on the planetary.

5

– Carry out the tightness test.

A

B

– Refit the axle tubes (Refer to section: "02 40").

– Fill the circuit with "LHM" liquid.

– Drain the main brake circuit.

– If mounted: Drain the trailer brake circuit.

– Check the seals on the dismantled elements.

C

– Perform road braking tests.

D

Sealing test Important: When intervening on the brake piston and O-rings, it is highly recommended to check the sealing.

Fig. 10

362msm08

– Maintain the piston in its housing (Fig.11) using the locally manufactured tool (Fig. 9).

5

– Adapt a pneumatic inflating piece (C) onto a DIN (A) fitting.

– Screw the assembly onto the elbow (5).

– Connect up a conventional inflation valve with its pressure gauge.

– Fit the pressure regulator nr.60 0500 531 0 upstream.

– Connect to a conventional inflation handle fitted with its pressure gauge and place a presssure release valve n° 60 05 005 310 upstream.

– Supply the circuit with 5-bar compressed air to ensure the proper operation of the piston.

– Reduce the pressure to 0,3 bar.

– Close the pressure regulator valve. After 1 minute, no pressure drop should be observed at the pressure gauge.

362msm07

– Remove the pressure gauge. Remove the restraining tool.

– Connect the brake hose.

10

Arion 430-410 – 01.2010 – GB

Fig. 11

04 Brakes 04 05 Foot brake

Cross sectional view of the master cylinders/boosters

1

2

3

4

7

5

6 Fig. 12

362msm0q

Description 1 2 3 4

Brake valve control.

Brake fluid reservoir supply.

Brake supply.

Brake balancer pipe.

5 6 7 8

Return.

20 bar supply.

Master cylinder.

Braking valve control pipe.

Arion 430-410 – 01.2010 – GB

11

04 Brakes 04 05 Foot brake

Replacing the master cylinders Important: The assembly of this type of master cylinder/booster does not require any adjustment.

3

4

– Drain and remove the brake fluid reservoir (10).

9

10

– Remove the braking valve control pipe (8), the two brake supply pipes (3) and the balancer pipe (4).

– Remove the master-cylinder(s) (7) by unscrewing the nuts (11).

– Fit the new master-cylinder(s).

7

11

– Tighten nuts (11) to 2 daN.m.

– Refit the parts removed previously.

8

Adjustment of the brake pedals – Connect the pedals with the lock.

Fig. 13

362msm0r

– Adjust pedal height at the dimension indicated using the stops (1).

– Fit the yokes (2) on the pedals.

– Decouple the pedals.

32

– Bring each rod (3) into contact with the master cylinder piston.

2

4

– Tighten the rod locknuts (4).

– Connect the pedals together again.

1

– Insert a shim between the upper stops (1) and the pedals to obtain a clearance of 10 mm at the pad.

3

– Decouple the pedals.

134

– Connect the stop switches.

92

– Adjust the left-hand switch.

– Connect the pedals together again.

– Adjust the right-hand switch.

– Check that the switches switch simultaneously.

362msm0l

12

Arion 430-410 – 01.2010 – GB

Fig. 14

04 Brakes 04 05 Foot brake

Bleeding the circuit manually – Start the engine.

1

2

– Top up the reservoir with brake fluid (LHM) – Fig. 16: Connect 3 flexible transparent hoses (ID 6 mm), one to each of the right and left-hand bleed screws (D) and (G) plus one to the hydraulic or pneumatic braking valve (I), and immerse them in a 1litre receptacle (J) containing 0,5 litres of fluid (LHM).

– Open the bleed screws.

– With the pedals coupled, pump about 10 times over the entire stroke of the master cylinders in order to fill the entire circuit (the oil must flow towards the receptacle).

Now close the bleed screws (D), (G), (I), (Fig. 16). And fill up the tank.

– Loosen the drain screw (1) on the master cylinder to evacuate the air by pressing the brake pedals very slowly. Carry out the same operation for the balancer pipe (2).

Fig. 15

362msm0m

Note: During the purge, all the translucent hoses must be sibmerged in oil (LHM) to avoid the suction of air.

G

The rest of the operation requires 2 operators (engine running).

– Decouple the pedals.

D

– Press the right-hand pedal 1/3 of the way down and hold it there.

– Pump with the left-hand pedal.

– Keep pressed down and open the left-hand bleed screw (G) (Fig. 16).

– Allow the fluid to flow out then close the bleed screw.

– Repeat these "pump, press and hold" operations until no more air bubbles escape.

– Proceed in the same way to bleed the right-hand side (D) and for the braking valve (I) (Fig. 16).

J 362msm0n

I Fig. 16

Important: The reservoir cap must be replaced at the same time as the brake fluid.

Arion 430-410 – 01.2010 – GB

13

04 Brakes 04 05 Foot brake

Bleeding the brake circuit with a pressurising device

3 G 1 D

2

I

J Fig. 17

362msm0o

– Take a tank cap (LHM).

– Drill a hole of 25 mm in the centre of the cap.

– Build the locally manufactured tool.

– Screw the cap onto the manufactured part (Fig. 18).

362msm94

14

Arion 430-410 – 01.2010 – GB

Fig. 18

04 Brakes 04 05 Foot brake

– Use a brake circuit pressurising device and connect it to the brake fluid reservoir (1).

– On each drain screw (D), (G) and (I), connect a transparent hose and dip them into a container.

Note: It is possible to manufacture the cap locally (3).

Refer to section: Locally manufactured tool.

– Let the (LHM) liquid flow freely during draining until all air bubbles disappear.

– Start the engine.

– Now close the bleed screws .

– Pressurise the brake fluid (LHM) reservoir (0,5 to 1,5 bar maximum). If bleeding completely and flushing the circuit, it is preferable to have a device with a minimum capacity of 5 litres of fluid.

Important: The reservoir cap must be replaced at the same time as the brake fluid.

– Check the pressure of the trailer dynamic brake (Refer to part "04" of the Diagnostic file).

Bleeding the right and left-hand brakes 1. Press the RH brake pedal a third of the way down. Hold it there.

4. Repeat operations (1), (2) and (3) 10 times in succession to bleed the balancing pipe.

2. Gradually press the left brake pedal as far as it will go.

5. Retighten bleed screw (D).

3. Release both brake pedals.

Repeat the same procedure on the left side.

Draining the trailer brake valve • Loosen the bleed screw (I) on the hydraulic or pneumatic braking valve and allow the fluid (LHM) to flow out for at least 3 minutes through a transparent pipe until the air bubbles have disappeared.

• Leave the bleed screw open, then: – Press the right-hand brake pedal down a third of the way and hold it there for one-and-a-half minutes.

– Release the right-hand pedal.

– Press the left-hand brake pedal down a third of the way and hold it there for one-and-a-half minutes.

– Release the brake pedal.

– Tighten up the bleed screw.

– Check the pressure of the trailer dynamic brake (Refer to part "04" of the Diagnostic file).

Arion 430-410 – 01.2010 – GB

15

04 Brakes 04 05 Foot brake

Notes

16

Arion 430-410 – 01.2010 – GB

04 15 HANDBRAKE

Arion 430-410 – 01.2010 – GB

04 Brakes 04 15 Handbrake

Transmission handbrake Tools for removing the crawler range pin and sleeve 300

200

75

008fl

18

Arion 430-410 – 01.2010 – GB

ø3

ø5

ø 10

ø 20

10

Fig. 1

04 Brakes 04 15 Handbrake

Exploded view

13 12 10 9 14 6 15

8 6 7 6

16

11 28

17

27

24 23

18

22

5 2 29 20

26

19

25

21 7d

7f 7a 7c

4 3 1

7e 7b Fig. 2

362msm38

Description 1 2 3 4 5 6 7 7a 7b

Circlip.

Pinion.

Screw.

Locating pin.

Blanking plate.

Discs.

Mechanism assembly.

Plate.

Link.

7c 7d 7e 7f 8 9 10 11 12

Nut. Screw.

Spring.

Balls.

Backplate.

Screw.

Support plate.

Finger.

Shim(s).

13 14 15 16 17 18 19 20 21

Drive pinion.

Seal.

Operating shaft.

Spring.

Locking ring.

Washer.

Cam. Finger.

Circlip.

Arion 430-410 – 01.2010 – GB

22 23 24 25 26 27 28 29

Nut. Plate.

Link.

Pin. Stud.

Fork end.

Pin. Pin.

19

04 Brakes 04 15 Handbrake

Torque settings and sealants

(271)

(271)

11 ± 1 daN.m

11 ± 1 daN.m

(243) 11 ± 1 daN.m

Fig. 3

362msm0s

20

(271)

Arion 430-410 – 01.2010 – GB

04 Brakes 04 15 Handbrake

Removing the handbrake housing Tractor with crawler speeds – Drain the rear axle and gearbox casings.

– Chock the engine between the cradle and the front axle.

50

– Unscrew the screw (49) to release the crawler speed yoke.

– Pull the pin (50).

– Partially remove the cab (Refer to section: "12").

– Uncouple the rear axle from the gearbox.

Tractor without crawler speeds

49

– Drain the rear axle.

– Remove the left rear wheel.

– Remove the left cover (Refer to section: "09").

Fig. 4

343msm2i

– Remove the pin from each coupling sleeve using the drift punch built locally.

– Slide the coupling sleeves (30) and (31) to take out the shaft (32).

13

30 362msm40

Arion 430-410 – 01.2010 – GB

32

31 Fig. 5

21

04 Brakes 04 15 Handbrake

Tractor with or without crawler speeds – Disconnect the cable and remove the hand brake control rod.

12

10

29

28

27

25

23

22

– Remove the gasket (14), (Fig. 8).

– Release the spring using a clip.

– Loosen the nut (22) in order to release the rod (24) off the cam (19).

– Remove the circlip (21).

– Remove the cam (19) using the finger (20).

– Remove screws (3).

– Remove the closing plate (5) and the control shaft (15).

– Remove the spring (16) and the washer (17).

– Remove the clip (18) (if necessary) on the control shaft (15).

– Remove the discs (6), the counterplate (8) and the mechanism (7).

26

24 Fig. 6

362msm79

14

15

16 15 17 20

18

19 21 5

24

11 3 3 362msm95

22

Arion 430-410 – 01.2010 – GB

Fig. 7

04 Brakes 04 15 Handbrake

Refitting the handbrake housing 12

– For the drive pinion preload, check that all the shims (12) remained on the casing.

10

29

28

27

25

23

22

– Smear the screws (9) of the bearing plate with Loctite (243), then tighten them at a torque of 11 +/- 1 daN.m.

– Fit the supporting plate (10).

– Coat the stud (26) with Loctite (271) and lock it in the yoke (27).

– Coat the finger (20) with Loctite (271) and screw it on the cam (19).

– Coat the finger (11) with Loctite (271) and screw it on the support plate (10).

– Fully fit the centring stud (4) on the closing plate shoulder (5).

Note: The strut (23) is rectangular. It must be positioned horizontally for the pin journal (25) to be correct on the rod (24).

26

24 Fig. 8

362msm79

– Fit the blanking plate (5).

14

– Coat the screws (3) with Loctite (243) and tighten to 11 ± 1 daN.m (Fig. 10).

15

– Insert the rod (24) on the finger (11).

– Check that the discs slide freely on the drive pinion shaft (13).

16 15 17 20

18

19 21 5

24

11 3 3 362msm95

Arion 430-410 – 01.2010 – GB

Fig. 9

23

04 Brakes 04 15 Handbrake

– Replace the pins by new ones when refitting the sleeves using the locally made tool (Fig. 11).

Note: The sleeve (36) must be assembled in a certain direction on tractors fitted with crawler gears. The throuat (A) must be on the handbrake side.

– Adjust the mechanism.

– Refit the cab (Refer to section: "12").

– Adjust the power take-off controls (Refer to section: "08").

– Set the crawler speed control (Refer to section: "02 30 Adjusting the control lever").

A

36 343msme5

24

Arion 430-410 – 01.2010 – GB

Fig. 10

04 Brakes 04 15 Handbrake

Adjusting the handbrake mechanism – Remove the left cover to reach the mechanism adjustment nut.

– Activate the handbrake several times to put the cam (19) correctly in place.

– Hold the cam, in freed brake position, using a screwdriver to block it in (A). It must be aligned with the longitudinal axis of the tractor (Fig. 13).

– Using a set of feeler gauges and tighten the nut (22) to obtain a clearance of 0,6 mm between the disc (6) and the counterplate (8).

– Adjust the control.

Description 1 Hand brake freed.

2 Brake system.

3 Tractor longitudinal axis.

Fig. 11

362msm46

1 19

2

3 362msm47

Fig. 12

362msm48

Fig. 13

Arion 430-410 – 01.2010 – GB

25

04 Brakes 04 15 Handbrake

Adjusting the control lever – Maintain the pin (15) and the cam in braking position.

– Release the rod (G) by disconnecting the control cable (F).

– Apply a force of 10 daN with a weight indicator connected to the rod end and position it so as to obtain a dimension of 270 mm between the cable attachment (E) and the rod axis. Remove and install successively the rod to obtain a dimension of 270 mm.

– Connect the control cable (F).

– Tighten the locknut (A) on the washer (B).

Note: For a good aligning of the sheath stop (D) and the cable (F), the nut (C) and the locknut (A) must be mounted at the front of the attachment bracket (E).

– Check operation of the control.

– Tighten the lever, the braking initial stroke should be around 8 notches. The instrument panel indicator must light first in handbrake locked position.

362msm49

Fig. 14

362msm51

Fig. 15

– Release the lever, the control must return freely to the idle position. In this position, the indicator must switch off.

26

Arion 430-410 – 01.2010 – GB