CLAAS Arion 630-610 C Repair Manual - PDF DOWNLOAD

B GEARBOX

Technical support

Chapter B – Repair

Arion 630-610 C

00 11 379 200 – Edition 1.2009

CONTENTS

B1 – GENERAL MAIN SHIMMING ............................................................................................................................................................B1.3 TORQUE SETTINGS AND SEALANTS ..........................................................................................................................B1.4 Engine coupling - Quadrishift...........................................................................................................................................B1.5 Quadrishift coupling - ranges...........................................................................................................................................B1.5 Coupling ranges / deck ....................................................................................................................................................B1.6 COUPLES SPECIFIC PRODUCTS AND SEALANTS CIRCUIT STEERING .................................................................B1.6 DISMANTLING PROCEDURE ........................................................................................................................................B1.7 Operation of control unit n°60 0500 615 5 on robotized range ........................................................................................B1.8

B2 – "QUADRISHIFT" LOCAL MANUFACTURING TOOL..................................................................................................................................B2.2 Holding rods of the "Quadrishift" and "Revershift" casing................................................................................................B2.2 HOLDER OF THE (B)/(A) CLUTCH/BRAKE MODULE OF THE "QUADRISHIFT".........................................................B2.2 LOCATION CLUTCHES ..................................................................................................................................................B2.3 EXPLODED VIEW ...........................................................................................................................................................B2.4 REMOVAL OF "QUADRISHIFT" .....................................................................................................................................B2.6 REMOVING THE CLUTCH - (D)/(C) BRAKE ..................................................................................................................B2.8 REFITTING THE CLUTCH - (D)/(C) BRAKE.................................................................................................................B2.10 REFITTING THE CLUTCH - (D)/(C) BRAKE.................................................................................................................B2.11 REMOVING THE CLUTCH - (B)/(A) BRAKE ................................................................................................................B2.12 REMOVING THE CLUTCH - (B)/(A) BRAKE ................................................................................................................B2.13 REFITTING THE CLUTCH - (B)/(A) BRAKE .................................................................................................................B2.14 REFITTING THE CLUTCH - (B)/(A) BRAKE .................................................................................................................B2.15 REST OF “QUADRISHIFT” ...........................................................................................................................................B2.16

B3 – "REVERSHIFT" LOCAL MANUFACTURING TOOL..................................................................................................................................B3.2 Elastic washer compressor on forward clutch .................................................................................................................B3.2 EXPLODED VIEW ...........................................................................................................................................................B3.4 REMOVING THE MODULE "REVERSHIFT" ..................................................................................................................B3.6 REMOVING THE “REVERSHIFT” MODULE ..................................................................................................................B3.8 REMOVING THE REVERSE CLUTCH ...........................................................................................................................B3.9 REMOVING THE FORWARD CLUTCH........................................................................................................................B3.10 REFITTING THE "REVERSHIFT" .................................................................................................................................B3.11 Forward gear clutch .......................................................................................................................................................B3.11 Refitting the reverse clutch ............................................................................................................................................B3.12 REFITTING....................................................................................................................................................................B3.12 REMOVING THE MODULE "REVERSHIFT" ................................................................................................................B3.14 Access to clutch forward without removing the cab.......................................................................................................B3.16

Arion 630-610 C – 1.2009 – GB

B4 – ROBOT-DRIVEN RANGES LOCAL MANUFACTURING TOOL..................................................................................................................................B4.2 Support rods of the robot-driven ranges module .............................................................................................................B4.2 Pneumatic fitting (for supply of the robot-driven ranges circuit).......................................................................................B4.2 Rod for dimensioning the reverse gear............................................................................................................................B4.3 EXPLODED VIEW ...........................................................................................................................................................B4.4 REMOVING THE RANGES MODULE ............................................................................................................................B4.6 REMOVING THE RANGES MODULE ............................................................................................................................B4.6 REMOVING THE PRIMARY LINE...................................................................................................................................B4.9 REFITTING THE PRIMARY LINE .................................................................................................................................B4.10 Shimming of tapered roller bearings..............................................................................................................................B4.10 Synchroniser cover adjustment .....................................................................................................................................B4.11 REMOVING THE SECONDARY LINE ..........................................................................................................................B4.12 REFITTING THE SECONDARY LINE...........................................................................................................................B4.12 Shimming of tapered roller bearings..............................................................................................................................B4.14 ADJUSTING THE SHAFTS IN THE HOUSING ............................................................................................................B4.14 MEASURING SHAFT CLEARANCE IN THE CASING..................................................................................................B4.15 REFITTING THE RANGES MODULE ...........................................................................................................................B4.16 Adjusting the lock nuts...................................................................................................................................................B4.18 Adjusting the prevention lock.........................................................................................................................................B4.20

B5 – SLOW RANGE EXPLODED VIEW ...........................................................................................................................................................B5.2 REMOVING/REFITTING THE HOUSING .......................................................................................................................B5.3 REMOVING, ADJUSTING AND REFITTING THE CONTROL SYSTEM........................................................................B5.5 Dismantling ......................................................................................................................................................................B5.5 Adjusting and refitting ......................................................................................................................................................B5.5 ADJUSTING THE CONTROL LEVER.............................................................................................................................B5.6

B6 – EXTRA SLOW RANGE EXPLODED VIEW ...........................................................................................................................................................B6.2 REMOVING/REFITTING THE HOUSING .......................................................................................................................B6.3 REMOVING, ADJUSTING AND REFITTING THE CONTROL SYSTEM........................................................................B6.5 Dismantling ......................................................................................................................................................................B6.5 Adjusting and refitting ......................................................................................................................................................B6.5 ADJUSTING THE CONTROL LEVER.............................................................................................................................B6.6

Arion 630-610 C – 1.2009 – GB

B1 GENERAL

Arion 630-610 C – 12.2008 – GB

Notes

B1.2

Arion 630-610 C – 12.2008 – GB

General description Main shimming A-A

0,10

± 0,05

mm

0 ± 0,05 mm 0,10

± 0,05

mm

A

0

A

± 0,05

mm

A

B

B

A 16,33 mm

326msm3d

0,10 ± 0,05 mm Fig. 1

Arion 630-610 C – 1.2009 – GB

B1.3

General description Torque settings and sealants 1,7 daN·m (243) 6,7 daN·m (243)

3,3 daN·m (243)

3,3 daN·m (243)

1,7 daN·m (243)

A-A

3,3 daN·m (243) 3,3 daN·m (243)

17,5 daN·m (243)

(510)

(271)

(510)

(648)

3,3 daN·m (243) A

A

8 ± 1 daN·m (271)

(271)

6,6 daN·m (243)

3,3 daN·m (243)

326msm3e

B1.4

1,7 daN·m (243)

Fig. 2

Arion 630-610 C – 09.2012 – EN

General description Engine coupling - Quadrishift

Quadrishift coupling - ranges

(510)

326msm03r

Fig. 3

326msm04r

Description

Fig. 4

Description

3,3 daN.m - Loctite (243).

1,7 daN.m - Loctite (243).

6,7 daN.m - Loctite (243).

3,3 daN.m - Loctite (243).

28 daN.m - Loctite (243).

6,7 daN.m - Loctite (243).

73,5 daN.m - Loctite (243).

17,5 daN.m - Loctite (243).

Arion 630-610 C – 1.2009 – GB

B1.5

General description Couples specific products and sealants circuit steering.

(510)

326msm05r

(5910) 0,6 ± 0,1 daN.m 1,4 daN.m

7 ± 1 daN.m

(243) 1,4 daN.m

0,23 ± 0,5 daN.m

3 ± 0,5 daN.m

(243) 3,3 daN.m

(510)

(243) 6,7 daN.m

Range module/rear axle coupling

Fig. 5

Description 17,5 daN.m - Loctite (243).

322msm26

B1.6

Arion 630-610 C – 1.2009 – GB

Fig. 6

General description Dismantling procedure

4

3

4

4

4

4

2 2

2

1

1

1

1

326msm6f

Fig. 7

Description 1 Removing the “Quadrishift” module.

2 Removing the forward/reverse clutches.

3 Access to forward clutch without removal.

Arion 630-610 C – 1.2009 – GB

4 Removing the shafts from the range module.

B1.7

General description Operation of control unit n°60 0500 615 5 on robotized range Y339-3 SVC

Before applying the power, the 4 switches must be set to the solenoid ON position (the 4 yellow LEDs light when the solenoids are powered, corresponding to the "Neutral" state), (fig. 9).

Y339-4 SVD

– Connect a 12 Volt supply to the unit using clips ("Power ON" LED lit).

Note: Check the condition of the unit's LEDs by pressing the "Check leds" switch. If the "Power" LED does not light when the power is applied, check the unit's internal fuse.

Z153-3 S3 Z153-4 S4

When the range module is in neutral, the 4 contact sensors are at rest and the orange LEDs are thus lit (fig.

9).

To select a range, the power must be cut to the opposing solenoid valve situated on the same slide.

If the range is correctly selected, the contact sensor is activated and the corresponding green LED is thus lit.

For example (fig. 10).

Z153-1 S1 Y339-2 SVB

Z153-2 S2

Y339-1 SVA 326msm6g

Important: Its operation differs from the "Auto 5" principle of control, and consists in supplying all the solenoid valves to ensure mechanical neutral and disengaging the solenoid valve opposte the desired gear.

Fig. 8

– Connect the 4 solenoids and the 4 sensors according to the wire markers (fig. 8).

– To shift to the “A” range, power off the solenoid “Y3392” (SVB) [“Z153-1” (S1) switch to 'off'].

– Connect pressure regulator n°(C) n° 60 0500 531 0 to the compressed air network (4 bar).

– Contact sensor “S1” is activated and the green LED on the "Range A" line comes on.

326msm1z

Fig. 9

RANGE A

S1

OFF

SVA

RANGE B

S2

OFF

SVB

RANGE C

S3

OFF

SVC

RANGE D

S4

OFF

SVD

NEUTRAL

CHECK Led's

326msm2a

B1.8

Arion 630-610 C – 1.2009 – GB

ROBOTISED RANGES SIMULATOR

POWER

Fig. 10

B2 “QUADRISHIFT”

Arion 630-610 C – 1.2009 – GB

“Quadrishift” Local manufacturing tool Holding rods of the "Quadrishift" and "Revershift" casing

0

11

2

M1

326msm6h

Fig. 1

Holder of the (B)/(A) clutch/brake module of the "Quadrishift"

≃ 6 mm

250 mm

40 mm

300 mm 322msm27

B2.2

Fig. 2

Arion 630-610 C – 1.2009 – GB

“Quadrishift” Location – Clutches

A C

B

D

322msm28

Fig. 3

Description Reducing gear (A)/(B)

Speed increaser gearing (C)/(D)

A Brakes.

C Brakes.

B Clutch.

D Clutch.

Arion 630-610 C – 1.2009 – GB

B2.3

1

9

2

B2.4

10

3

6

11

4

8

5

12

13

7

14

25

12

22

12

23

15

24

16

26

15

27

30

28

29

16

15 32

18

31

17 34

35

19

326msm6i

Arion 630-610 C – 1.2009 – GB

51

44

38

50

43

39

48

36

37

49

42

47

33

21

41

20

52

45

53

46

54

40

55

56

57

59

58

“Quadrishift”

Exploded view

Fig. 4

“Quadrishift” Description 1 Clutch bearing.

21 Clutch (D) splined hub.

41 Input shaft.

2 Ball bearing with sealed side.

22 Intermediate housing.

42 O-ring.

3 Locking ring.

23 Global multiplier.

43 Clutch, brake (B)/(A) piston.

4 Blanking plate.

44 Piston Springs.

5 Screw.

24 Planet carrier - Speed increaser gearing.

6 Screw.

25 Satellite multiplier.

46 Backplate (B).

7 Additional multiplier cover.

26 Circlip.

47 Brake (A) discs.

8 Screw.

27 Friction washer.

48 Brake (A) backplate.

9 Friction washer.

28 Ring gear holder.

49 Clutch, brake (B)/(A) bearing plate.

10 Clutch (D) housing.

29 Bearing.

50 Belleville washer.

11 Belleville washer.

30 Thrust washer.

51 Spring washer.

12 Brake (C) discs.

31 Serrated washer.

52 Bearing.

13 Clutch, brake (D)/(C) bearing plate.

32 Satellite carriers multiplier.

53 Clutch (B) housing.

14 Brake (C) backplate.

33 Satellite multiplier.

54 Friction washer.

15 Clutch (D) discs.

34 Locking ring.

55 Washer.

16 Clutch (D) backplates.

35 Global multiplier.

56 O-ring.

17 Piston Springs.

36 O-ring.

57 Cover.

18 Clutch, brake (D)/(C) piston.

37 O-ring.

58 Screw.

19 O-rings.

38 Front casing.

59 Shaft gasket.

20 Unit cover (D).

39 Screw.

45 Clutch (B) discs.

40 Unit cover (B).

Arion 630-610 C – 1.2009 – GB

B2.5

“Quadrishift” Removal – “Quadrishift” 99

326msm6j

B2.6

100

98

Fig. 5

Arion 630-610 C – 1.2009 – GB

“Quadrishift” • Remove the front housing (98) of the "Hexashift" and clutches as follows.

94

– Refer to Chapter “H” for complete cab removal.

Operations 1 to 20.

68

– Drain the transmission system.

– Remove the reservoir, the battery support and the exhaust.

– Disconnect any pipes, hoses and wiring harnesses that prevent removal of the housing.

– Make the tractor safe with stands and trolleys.

110 mm

67

– Lock the sway action between the front axle and the cradle.

ø 12 mm

– Uncouple the "Hexashift" housing (98) from the engine and the range module (99).

• Recover the PTO shaft and the reverse countershaft.

• Remove the hydraulic control block (100) with 4 pipes and fitting liaison elbow lubrication on the left side.

326msm6k

Fig. 6

• Stand the front casing upright using locally made threaded rods (fig. 6).

• Attach the shackles in the place of the two screws (94).

• Mark the position of the “Quadrishift” module in respect of the casing.

• Unscrew the screws (68), then pull out the “Quadrishift” assembly and drive clutches through the top while tilting it.

Important: Do not loosen the top 4 small screws used to assemble (67) casings of the multiplier and the multiplier.

Arion 630-610 C – 1.2009 – GB

B2.7

“Quadrishift” Removing the clutch / (D)/(C) brake – Place the “Quadrishift” module assembly on a carrier, with the forward clutch turned downwards.

– Locate the cover (7) relative to intermediate – .Undo the screws (6) to separate the clutches from the “Quadrishift” module

22

22

7 326msm6l

Fig. 7

Remove the 12 return springs (17) of the piston.

– Remove the 6 screws from the clutch unit cover (D)/ (20) and the gear (23).

23

– Remove the 3 brake discs and backplates (C).

– Remove the clutch discs and backplates (D) – See (12), (14), (fig. 4).

20

– Pull out the bearing plate and the last brake disc.

17 326msm6m

Fig. 8

– Remove the Belleville washers (11).

– Pull out the unit (10) - Remove the friction washer.

10 11

326msm6n

B2.8

Arion 630-610 C – 1.2009 – GB

Fig. 9

“Quadrishift” Note: If necessary, remove the 6 screws to separate the casing (7) from the drive clutch feed hub (1).

7

1

322msm29

Fig. 10

In the intermediate housing (22): – Pull out the piston (18) of the brake (C) using compressed air.

24

– Remove the planet carrier (24).

22 322msm30

Arion 630-610 C – 1.2009 – GB

18 Fig. 11

B2.9

“Quadrishift” Refitting the clutch / (D)/(C) brake – Align the oil supply hole between the casing (7) and the clutch supply hub (1).

7

– Tighten the screws , coated with Loctite (243), to 3,3 daN.m.

1

322msm29

Fig. 12

– Fit the first disc (12) of the brake (C) and the back plate.

– Fit the clutch housing (10) fitted with its needle bearing and the friction washer smeared with grease on the 2 sides.

10

12

322msm31

Fig. 13

– Fit the gear (21) while aligning its greasing holes with those of the shaft.

21

322msm32

B2.10

Arion 630-610 C – 1.2009 – GB

Fig. 14

“Quadrishift” Refitting the clutch / (D)/(C) brake – Fit the clutch discs and back plates (D) while aligning the last back plate with the notches on the housing (10).

– Fit the discs and back plates of the brake (C).

– See (12), (14), (fig. 4).

23

– Fit and tighten gradually the screws smeared with Loctite (243) of the cover (20) at 3,3 daN.m

20

– Fit the 12 springs (17) in their housings.

10 17 322msm33

Fig. 15

– Engage the satellite holder (24) on the gear (23).

– Fit the bearing (29).

31

– Insert and turn properly the notched friction washer (31).

29 24

Note: The friction washer must be fitted with the bearing face greased.

– Replace the seals and lubricate the piston rings (18).

– Position and center the piston (18) on the springs (17).

18 322msm34

Arion 630-610 C – 1.2009 – GB

Fig. 16

B2.11

“Quadrishift” Clutch disassembly / (B)/(A) brake – Place the entire module (B)/(A) with the inlet shaft turned upwards, mark the position of the casing (38) in respect of the intermediate casing (22).

38

– Remove the 8 screws to separate the clutches (B)/(A) from the demultiplier.

22

322msm37

Fig. 17

– Remove the stop ring (26) and shim (27).

– Extract the satellite holder (32) and the crown gear holder (28).

26

28 27

32 322msm36

Fig. 18

322msm35

Fig. 19

– Place the clutch module (B)/(A) with the inlet shaft turned downwards on a locally manufactured holder.

B2.12

Arion 630-610 C – 1.2009 – GB

“Quadrishift” Clutch disassembly / (B)/(A) brake – Remove jonc arrest - Remove the cover (40).

– Remove the clutch discs and backplates (B)

40

40

322msm38

Fig. 20

– Loosen the 8 screws of the cover (57).

– Remove the casing (38) with its piston.

– Remove the 12 springs, the discs and back plates of the brake (A), the bearing plate, the Belleville washer and the last brake disc (A).

38

57

322msm39

Fig. 21

Remove the shaft (41) with the spring washer (51) and bearing (52).

– Remove the clutch unit (53) and the friction washer.

51 52 41 53

322msm40

Arion 630-610 C – 1.2009 – GB

Fig. 22

B2.13

“Quadrishift” Clutch disassembly / (B)/(A) brake 59

– Replace all removed gaskets.

55

Refit in reverse order to removal while observing the following instructions: – Fit the bearing (59) in the cover with the press and an appropriate rig.

– Lubricate the inner lip of the seal.

– Ensure the washer (55) is glued with Loctite (648) in the cover (57).

– Position the clutch unit (53) in the cover (57) while inserting the friction washer greased on the 2 sides.

57

– Insert the shaft (41) with the spring washer (51) and the bearing (52).

– Fit and turn the Belleville washer properly (fig. 24).

Important: New discs must be soaked in a bath of transmission fluid for approximately one hour.

326hsm0o

Fig. 23

– Fit the first disc of the brake (A) and the back plate.

– Refit the discs and back plates of the clutch (B).

Important: Align perfectly the last back plate with the notches in the housing.

– Position the cover on the housing (53).

51 53

– Tighten the screws , coated with Loctite (243), to 3,3 daN.m.

52

– Check the rotation of the shaft and clutch housing assembly (B).

– Change and grease the gasket (56) of the cover (57) and the 2 gaskets of the piston (42) (fig. 25).

57 41

– Insert gradually the piston in the casing (38) and alternately around it using a hammer.

– Refit the 12 springs onto the cover.

– Fit and center the casing (38) onto the cover (57) while aligning the marks.

322msm41

Fig. 24

– Fit and tighten the screws coated with Loctite (243) to 3,3 daN.m.

38

42

57 56

322msm42

B2.14

Arion 630-610 C – 1.2009 – GB

Fig. 25

“Quadrishift” Dismantling - Clutch / (B)/(A) brake – Refit the satellite holder (32) fitted with its bearing washer (30) on the crown holder (28).

27

– Fit the shim (27) and stop ring (26).

– Change and smear with grease the 2 O-rings between the casings (fig. 27).

– Screw 2 stems guidance on the intermediate.

30

– Align the marks and lower the module (B)/(A) while engaging the splines of the inlet shaft (41) in the satellite holder.

28

– Tighten the screws , coated with Loctite (243), to 3,3 daN.m.

26

– Position and center the piston (18) on the springs (17), (fig. 28).

32

– Screw 2 guide rods onto the intermediate casing.

– Grease the piston gaskets (18) and its housing in the intermediate casing.

322msm43

Fig. 26

– Lift the clutch assembly (B)/(A) using 2 shackles.

41

– Carefully lower onto the clutch/brake (D)/(C) while aligning the marks on the intermediate casing (22) with that on the casing (7).

– Check the gradual engagement of the piston (18) in its housing.

– Slightly turn the inlet shaft (41) to facilitate the engagement of the satellite holder (24).

41

– Remove the guide rods.

– Install the screws coated with Loctite (243).

– Tighten to 3,3 daN.m.

Important: Check that the inlet shaft and the drive clutches turn properly.

322msm44

Fig. 27

24 22

18

322msm45

Arion 630-610 C – 1.2009 – GB

17

41

7

Fig. 28

B2.15

“Quadrishift” Rest of “Quadrishift” – Change and grease the O-ring (60) between the “Quadrishift” and the gearbox casing.

– Lower the assembly slightly slanted to pass the reverse transmission bossing.

– Ask all housing aligning benchmarks made beforehand – Apply Loctite (243) onto the screws.

60

– Tighten to 6,7 daN.m.

– Lift the assembly “Quadrishift” using 2 shackles on the casing.

– Fit the gear (2) and the reverse transmission shaft (4) (fig. 30).

– Fasten the shaft to the drive clutches (fig. 31).

– Apply Loctite (510) onto the assembly faces.

– Lower the “Quadrishift” assembly onto the ranges module, while slightly turning the inlet shaft to engage the reverse transmission with the range module shaft.

322msm46

Fig. 29

– Detach the reverse transmission shaft.

– Fully lower the casing.

– Coat the Loctite (243) screws.

– Tighten to 17,5 daN.m.

– Change and oil the O-rings of the tubes linking the hydraulic unit with the lubrication elbow.

– Smear the bearing face of the hydraulic unit with Loctite (510).

2

– Apply Loctite (243) onto the screws.

4

– Tighten to 6,7 daN.m.

322msm48

Fig. 30

4

322msm47

B2.16

Arion 630-610 C – 1.2009 – GB

Fig. 31

B3 “REVERSHIFT”

Arion 630-610 C – 1.2009 – GB

“REVERSHIFT” Local manufacturing tool Elastic washer compressor on forward clutch

ø 14,5

0

56

5

46

0

40 U60

60

4

M1

326msm6o

B3.2

Fig. 1

Arion 630-610 C – 1.2009 – GB

Notes

Arion 630-610 C – 1.2009 – GB

B3.3

6

B3.4

326msm31

Arion 630-610 C – 1.2009 – GB

27

16

5

3

23

10

24

11

25

12

26

13

42

14

43

15

4

9

22

8

2

43

7

42

41

40

1

39

23

38

22

36

35

20

37

21

33

18

34

19

32

47

30

48

31

17

46

45

29

44

28

“REVERSHIFT”

Exploded view

Fig. 2

“REVERSHIFT” Description 1 Screw.

18 Reverse gear pinion/hub.

34 Sealing ring.

2 Multiplier cover.

19 Retaining ring.

35 O-ring.

3 Ball bearing.

20 Locking ring.

36 Square section seals.

4 Reverse gear pinion.

21 Blanking plate.

37 Forward piston.

5 Retaining ring.

22 Reverse discs.

38 Thrust washer.

6 Reverse countershaft.

23 Reverse backplates.

39 Belleville washers.

7 Screw.

24 Locking ring.

40 Safety washer.

8 Blanking plate.

25 Safety washer.

41 Locking ring.

9 Locking ring.

26 Belleville washers.

42 Forward backplates.

10 Ball bearing with sealed side.

27 Thrust washer.

43 Forward discs.

11 Clutch bearing.

28 Reverse gear piston.

44 Forward hub.

12 Ball bearing.

29 Square section seals.

45 Blanking plate.

13 Locking ring.

30 Clutch bell housing.

46 Locking ring.

14 Lubricating oil deflector.

31 PTO shaft needle bearing.

47 Retaining ring.

15 Ball bearing.

32 Ball bearing.

48 Power take-off shaft.

16 Retaining ring.

33 Seal.

17 Sealing piston ring.

Arion 630-610 C – 1.2009 – GB

B3.5

“REVERSHIFT” Removing the "Revershift" module

A C

B

326msm6p

Fig. 3

– After removing the cab (see chapter "H").

– Drain the transmission, remove the diesel tanks, the battery cradle and the exhaust.

– Disconnect any pipes, hoses and wiring harnesses that prevent removal of the housing.

– Make the tractor safe with stands and trolleys.

B3.6

– Lock the sway action between the front axle and the cradle.

– Uncouple the "Hexashift" housing (A) from the engine and the range module (B).

– Recover the PTO shaft.

– Remove the reverse transmitter (C).

Arion 630-610 C – 1.2009 – GB

“REVERSHIFT” – Remove the hydraulic command unit (D) fitted with 4 supply tubes.

D

326hsm94

Fig. 4

– Remove the elbowed lubrication fitting (E) located on the left side of the casing

E

326hsm95

Fig. 5

– Position the casing standing using the 6 threaded rods (H) "M14", length 170 mm and nuts (See local manufacturing tooling at the beginning of chapter).

H

326hsm97

Arion 630-610 C – 1.2009 – GB

Fig. 6

B3.7

“REVERSHIFT” – Fasten 2 shackles (I) instead of the screws located opposite the reverse transmitter (to properly balance the assembly upon removal).

I

– Unscrew the 8 screws (J).

Important : Do not loosen the top 4 small screws used to assemble (K) casings of the multiplier and the multiplier.

– Mark the position of the "Quadrishift" module in respect of the casing.

– Exit all "Quadrishift" and "Revershift" from above, by tilting (Fig. 6).

K

J

326msm6q

Fig. 7

Removing the module "Revershift" – Position the "Revershift" (R) and "Quadrishift" (Q) module assembly on a carrier, while laying it on the forward clutch.

– Mark the position of the cover (2) in respect of the assembly "Quadrishift" (Q).

Q

– Remove the screws (49) and separate the cover (2) from the module "Quadrishift".

2 49 R

326msm6r

Fig. 8

– Insert the clutch/brake assembly (D)/(C).

– Remove the screws and the lid 2.

2

326msm6s

B3.8

Arion 630-610 C – 1.2009 – GB

Fig. 9

“REVERSHIFT” Removing the reverse clutch – Remove the plate (8) to extract the pin (9) and bearing (10), (fig. 11).

10

– Remove the retaining ring (19).

11

– Remove the bearing (11) together with the reverse gear pinion and the rear clutch blanking plate (21).

19

21

326hsm3h

Fig. 10

– If necessary, remove retaining rings (13) and (16) in order to replace the bearings.

– Identify the direction of assembly of the deflector (14).

9

Note : With the clutch closing plate (21) held on the hub (18) by a pin (20), push the plate to separate it from the hub.

8 10

14 13

21

16

20 18

326msm6t

Fig. 11

– Remove the discs and the backplates.

– Position the clutch housing on a press and compress the elastic washers (26) using tool n°60 0500 615 3.

– Free the circlip (24) and recover the safety washer (25).

– Remove washers (26).

– Remove the piston (28) using a jet of compressed air.

24 28 25 326hsm3k

Arion 630-610 C – 1.2009 – GB

26 Fig. 12

B3.9

“REVERSHIFT” Removing the forward clutch – Flip the clutch housing, remove the elastic ring (47) and pull out the hub (44) with the closing plate

44

47

33

32 31

326msm6u

Fig. 13

– Remove the discs and the backplates.

– Remove the sealing ring (33), the ball bearing (32) and, if necessary, the needle bearing (31).

33

32

31

326hsm3m

Fig. 14

– Remove the 6 washers (39) (Proceed as with the rear clutch).

39

326hsm3n

B3.10

Arion 630-610 C – 1.2009 – GB

Fig. 15

“REVERSHIFT” Refitting the "Revershift" Note : Properly lubricate joints and valves and ensure that the joints with square section are positioned in grooves.

– Fit the piston by tapping gradually and alternately around its edge with a mallet.

– Replace the circlip (41).

– Check that the circlip (41) is correctly positioned in the safety washer.

Important : New discs must be soaked in a bath of transmission oil for one hour.

Forward gear clutch – Grease properly the seal (35) and new ring (34).

– Fit the bearing (32) and the sealing ring (33).

– Position the hub (44) in the clutch housing.

– Thread discs and backplates onto the hub.

– Fit the blanking plate and the retainig ring (47).

47

326msm6v

Arion 630-610 C – 1.2009 – GB

34

32

35

33

41

44

Fig. 16

B3.11

“REVERSHIFT” Refitting the reverse clutch – Refit the deflector (14) properly (Fig. 17) – Assemble the blanking plate with the hub and the bearing.

– Thread discs and backplates onto the hub (18).

– Place the bearing (11) on a support, leaving sufficient clearance for the shaft.

– Turn over the clutch housing (30) on the stack (Fig. 18).

– Allow the clutch housing to drop down onto the backplates (23).

30

– Fit the retaining ring (19).

18

Refitting

23

– Apply Loctite (510) to the rear mounting face after first having cleaned it.

– Check that the spring is in place in the PTO clutch bell housing.

– Correctly align the reverse idler shaft.

– Reassemble in reverse order to removal using locating pins.

19

14 11

326msm6w

Fig. 17

30

23

11 326msm46

B3.12

Arion 630-610 C – 1.2009 – GB

Fig. 18

“REVERSHIFT” On the clutch assembly (forward and reverse) : – Fit the bearing (10) with the sealed side towards the clutches.

– Position the circlip (9) and the plate (8).

– Tighten the screws (7), coated with Loctite (243), to 1,7 daN.m.

– Fit the cover (2).

9

8

10

7

2

326msm6y

Fig. 19

– Tighten the screws (1), coated with Loctite (243), to 3,3 daN.m.

Important : Set a disc brake before getting all clutch / brake (D)/(C). Coat the friction washer with oil and place it in the location provided under the clutch housing.

8

9

10

1

7 2 326hsm0y

Fig. 20

– Fit the hub (Q) with the inner splines turned upwards and while aligning the greasing holes of the shaft and hub.

Q

322msm49

Arion 630-610 C – 1.2009 – GB

Fig. 21

B3.13

“REVERSHIFT” – Mount the clutch / brake (D)/(C).

– Fit the cover (V).

– Tighten the screws (X), coated with Loctite (243), to 3,3 daN.m.

X

– Fit the 12 springs (W) in their housings.

V

W 322msm50

Fig. 22

– Lower the casing (T) onto the cover (Y) – Tighten the screws of the cover coated with Loctite (243) to 6,6 daN.m.

– Check proper rotation of the inlet shaft before refitting the “Quadrishift”, “Revershift” assembly

T

Y

322msm51

Fig. 23

Refitting the "Revershift" module – Grease the seal (J).

– Assemble in the reverse removal sequence.

– Refit the "Quadrishift" module in the casing while aligning it against the mark made during removal.

J

– Apply Loctite (243) onto the screws and tighten at 6,7 daN.m.

326msm6z

B3.14

Arion 630-610 C – 1.2009 – GB

Fig. 24

“REVERSHIFT”

C D

B

326msm7a

Fig. 25

– Clean the assembly faces (B) and apply some Loctite (510).

– Check the presence of the spring on the power take-off shaft.

– Position the power take-off shaft in the housing (C) of the "Revershift" module hub.

Note : The power take-off shaft can also be fitted after coupling the 'ranges' module.

– Align the shaft to refer back.

– Fit the "Quadrishift" module assembly in the reverse removal sequence, using guide studs.

Arion 630-610 C – 1.2009 – GB

B3.15

“REVERSHIFT” Access to forward clutch without removal (See "Removal step" n°3 in chapter B1).

47

44

Note : The forward drive only clutch can be accessed by decoupling the tractor between the "Quadrishift" casing and the ranges module.

• Decouple the tractor between the "Quadrishift" casing and the ranges module as follows : – See chapter "H" for partial rear cab removal. Operations 1 to 8.

– Drain the transmission system.

– Remove the reservoir and the silencer.

– Disconnect any pipes, hoses and wiring harnesses that prevent removal of the housing.

– Make the tractor safe with stands and trolleys.

– Lock the sway action between the front axle and the cradle.

326msm42

Fig. 26

• Remove the retaining ring (47), followed by the hub (44) with the blanking plate.

• Remove the discs and the backplates.

41

39

• Locally form a "U" section and 2 threaded rods in addition to compression tool No. 60 0500 615 3 (Fig. 27).

• Compress the Belleville washers (Fig. 27).

0 40

• Remove the Belleville washers (39) and the piston (37) from the forward clutch.

m

m m

60 m

• Recover the circlip and the safety washer

• Reassemble in reverse order to removal (see "Refitting").

• Apply Loctite (510) to the rear mounting face after first having cleaned it.

465

mm

ø 14 x 200

• Correctly align the reverse idler shaft • Reassemble in reverse order to removal using locating pins.

326msm43

Fig. 27

37

326msm44

B3.16

Arion 630-610 C – 1.2009 – GB

Fig. 28

B4 ROBOT-DRIVEN RANGES

Arion 630-610 C – 1.2009 – GB

Robot-driven ranges Local manufacturing tool Support rods of the robot-driven ranges module

0

12

2

M1

326msm7b

Fig. 1

Pneumatic fitting (for supply of the robotdriven ranges circuit) Description A Female snap fitting.

B Female 1/2 by 3/8 reduction.

A

B

C

D

C Tap 3/8.

D Union 3/8.

326msm7c

B4.2

Arion 630-610 C – 1.2009 – GB

Fig. 2

Robot-driven ranges

105

Rod for dimensioning the reverse gear

20

ø5

290 326hsm1g

Fig. 3

Arion 630-610 C – 1.2009 – GB

B4.3

43

42

B4.4

91

41

90

40

92

39

36

38

33

54

34

37

53

35

52

34

51

33

50

32

55 56 57

326msm7d

Arion 630-610 C – 1.2009 – GB

82

49

31

81

51

30

75

47

28

80

48

29

79

74

46

27

78

73

44

70

69

68

45

89

67

65

48

85

85

76

66

19

87

20

13

21

86

22

47

23

15

46

24

71

77

72

44

25

17

45

26

18

16

14

87

52

64

88

63

12

86

62

1

53

61

84

60

51

56

59

11

2

57

58

10

3

9

6

83

4

5

8

6

7 8

Robot-driven ranges

Exploded view

Fig. 4

Robot-driven ranges Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Cover.

Range "D" stop nut.

Range "C" stop nut.

Range "B" stop nut.

Range "A" stop nut.

Stop covers.

Stop screw.

Screw.

Prevention lock.

Cam followers.

Locating pin.

Locating pin.

Shims.

Bearing cup.

Bearing cone.

Reverse gear pinion.

Bearing cone.

Bearing cup.

Shims.

Bearing cup.

Bearing cone.

Upper shaft.

Retaining ring.

Washer.

Shims.

Bearing cup.

Bearing cone.

Bearing cone.

Bearing cup.

Washer.

Retaining ring.

Range "C" driving pinion and range "A" driven pinion.

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62

Circlips.

Washers.

Roller bearings.

Retaining ring.

Range "C" and "D" single cone synchroniser.

Bush.

Range "D" driving pinion.

Bearing cone.

Bearing cup.

Locking ring.

Sealing ring.

Retaining ring.

O-rings.

Cover.

O-ring.

Piston.

Retaining ring.

Guide rod.

O-ring.

Piston.

O-ring.

O-ring.

Fork for ranges "C" and "D".

Pin. Plug.

Shims.

Lubrication tube.

O-ring.

Spring.

Bearing cup.

Arion 630-610 C – 1.2009 – GB

63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92

Bearing cone.

Retaining ring.

Washer.

Shims.

Shouldered bushing.

Bearing cup.

Bearing cone.

Bearing cone.

Bearing cup.

Range "A and "B" driven pinion.

Range "A" driving pinion.

Needle bearing.

Lower shaft.

Range "A" and "B" double cone synchroniser.

Locking ring.

Range "A" and "C" driven pinion.

Spacer.

Range "D" driven pinion.

Bearing cone.

Bearing cup.

Guide rod.

Fork for ranges "A" and "B".

Locking ring.

Inner piston.

O-rings.

Retaining ring.

Spring.

Protector.

Pin. Screw.

B4.5

Robot-driven ranges Removing the ranges module • Remove the range module housing as follows: – See chapter "H" for partial rear cab removal.

Operations 1 to 8.

– Drain the transmission system.

– Remove the reservoir and the silencer.

– Disconnect any pipes, hoses and wiring harnesses that prevent removal of the housing.

93

– Make the tractor safe with stands and trolleys.

92

– Lock the sway action between the front axle and the cradle.

– Decouple between the ranges module (92) and the casing “Quadrishift” (93).

– Using a hoist, remove the range module from the rear axle.

326msm48

Removing the ranges module

Fig. 5

6

• Remove the covers (6).

• Remove the slider sensors.

• Remove the nuts and fully tighten the prevention lock (9).

9 326msm49

B4.6

Arion 630-610 C – 1.2009 – GB

Fig. 6

Robot-driven ranges • Remove the plug and extract the range "A" and "B" fork pin (56).

• Remove the retaining ring (44) and the cover (46) via the rear of the housing.

• Take out the guide rod (83 together with the piston (48).

56

326msm50

Fig. 7

83

56

48

44

46

326msm51

Arion 630-610 C – 1.2009 – GB

Fig. 8

B4.7

Robot-driven ranges – Stand the housing upright using four locally manufactured threaded rods (Fig. 9).

– Unscrwe the screws of the range module cover (1).

– Tighten 2 screws to loosen the cover.

– Recover the bearing cups and the shims.

– Remove the plug (57) and extract the range "C" and "D" fork pin.

– Remove the retaining ring (44) and the cover (46).

57

– Extract the range "D" piston and the guide rod (50).

– Position tool No. 60 0500 615 4 on the upper and lower lines.

m 110 m

– Remove the lubrication system at the end of the output shaft.

– Direct range "C" and "D" fork (55) towards the top of the housing (fig. 12).

– Using a hoist, pull the shaft train upwards.

ø 12 mm 326msm52

Fig. 9

– Remove the oil deflector.

– Keep the reverse gear.

Note: Beware of the passage of the synchroniser relative to the reverse gear pinion support.

1

– Separate the two shafts on a table and identify the forks.

326msm53

44

Fig. 10

50

46

55 326msm54

B4.8

Fig. 11

326msm7e

Arion 630-610 C – 1.2009 – GB

Fig. 12

Robot-driven ranges Removing the primary line – Remove the sealing rings from the end of the shaft.

– Position a shouldered bushing (94) in the shaft.

40

94

39

37

– Remove the pinion (39) and the bearing (40) using a suitable jig (fig. 13).

– Recover the pinion lubrication ring.

– Remove the synchroniser (37) and the retaining ring.

– Take off the bearing cone (21).

– Remove the pinion (32) by taking off the retaining ring (23).

– Recover the washer (24) and the shims (25).

– Remove the roller bearings (35).

– Remove the retaining ring (31) and the washer (30).

Important: Any bearing cones (27) and (28) removed must systematically be replaced.

326msm56

Fig. 13

– Remove the bearing cup (29) from the pinion (32) and check whether or not there is a 0,40 mm shim under the cup.

21 23 29

32

326msm57

Fig. 14

35

31 30 28

326msm58

Fig. 15

326msm59

Arion 630-610 C – 1.2009 – GB

27

25

24

21

Fig. 16

B4.9

Robot-driven ranges Refitting the primary line – Refit in reverse order to removal while observing the following instructions.

Note: Lubricate the bearings on refitting.

– Fit the bearing cones (27) and (28) back-to-back.

Note: The bearings shall be heated in a bath of boiling oil or on an induction heater.

– Check that the bearings are in the correct position after cooling.

– Pair up the bearing cups with the bearing cones.

– Fit the appropriate cup in the pinion.

28

– Fit the roller bearings (35) with the two washers and the circlips (33).

27

– Thread the pinion on the shaft.

326msm60

– Perform the two adjustments described below.

Fig. 17

– Refit the retaining ring supporting the synchroniser hub.

33

Important: Align the lubrication slots of the synchroniser (37) with the lubrication holes of the shaft (fig. 19).

Important: Grease the sliding ring and the 2 sides of the brake bushes of the forward synchronizer before fitting it.

35

– Refit the synchronizer.

– Correctly grease the end-of-shaft sealing ring.

Shimming of tapered roller bearings Important: Fit the pinion (32) on the shaft (22) without any shims (even the 0,40 mm shim between the cup (29) and the pinion (32) if fitted).

– Place a dial gauge probe on the face of the pinion (32).

326msm61

Fig. 18

37

326msm62

B4.10

Arion 630-610 C – 1.2009 – GB

Fig. 19

Robot-driven ranges – Push and turn the pinion to properly seat the bearings.

– Set the dial gauge to 0.

– Repeat this operation while pulling on the pinion.

22

– Measure "A" at 3 points and calculate the average of the 3.

A

– Remove the ring (23) and the washer (24).

– Fit a shim of a thickness corresponding to the measured play.

Zero play and preload with a tolerance of 0 ± 0,05 mm.

If possible, adjust towards the maximum end of this tolerance.

For example, if the play measured is 0,62 mm 0,62 - 0,05 = 0,57 0,62 + 0,05 = 0,67 In this example, the thickness of the shims to be installed should be between 0,57 and 0,67 mm (and as close to 0,67 mm as possible).

24

32 23 326msm63

Fig. 20

Synchroniser cover adjustment – Place shims to the thickness determined above behind the washer (24).

Important: No shims are to be fitted between the pinion (32) and the cup (29) during the adjustment procedure.

– Using a depth gauge, measure "B" corresponding to the distance between the retaining ring (36) and the pinion bearing face.

B

If "B" is greater than 16,33 mm, remove a 0,40 mm shim from the shims previously placed and place it between the cup (29) and the pinion (32).

If "B" is less than 16,33 mm, leave the shims previously installed unchanged.

Important: There are only 2 possible choices no shim or a 0,40 mm shim.

326msm64

Fig. 21

24 29

B

32

326msm65

Arion 630-610 C – 1.2009 – GB

36

Fig. 22

B4.11

Robot-driven ranges Removing the secondary line Note: Caution do not pull on the pinion (72) or the synchroniser will disassemble.

– Recover the bearing cone (63) and the spacer (67).

– Position the transmission line on the pinion (72) (fig.

23).

72

– Remove the shaft upwards.

77

– Recover the circlip (77).

– Remove the synchroniser and the pinion.

– Turn over the pinion (72).

– Remove the ring (64), the washer (65), the shims (66) and the bearings.

– Pair up the bearing cones and cups.

– Pull out the gear (80) and the bearing cone (81) using an appropriate fitting (fig. 26).

326msm66

Fig. 23

– Recover the spacer (79) and the pinion (78).

Refitting the secondary line – Refit in reverse order to removal while observing the following instructions.

77

Note: Lubricate the bearings on refitting.

72

67 326msm67

63

64 Fig. 24

66

65

81 64

80 78 79

326msm68

B4.12

Fig. 25

326msm69

Arion 630-610 C – 1.2009 – GB

Fig. 26

Robot-driven ranges – Refit the pinions (78) and (80) with the spacer between them.

– Press-fit the bearing cone (81) with a suitable jig (fig.

27).

– Fit the bearings back-to-back, the shims as determined below, the washer and the ring.

Important: It is essential to fit bearings from the CLAAS spare parts manual corresponding to the diameter of the shouldered bushing.

81

– Press-fit the needle bearing (74) with a suitable jig.

78

80

– Align the lubrication slots of the synchroniser with the lubrication holes of the pinion (fig. 28).

Important: Grease the sliding ring and the 2 sides of the brake bushes of the forward synchronizer before fitting it.

– Refit the synchronizer.

326msm70

Fig. 27

326msm71

Fig. 28

– Position the retaining ring (77).

– Thread the shaft into the pinion/synchroniser assembly.

– Turn the complete shaft over, holding the pinion (72) in place.

– Fit the shouldered bushing (67) in the right direction (Fig. 30).

74

77

67

77 72

326msm72

Fig. 29

326msm7f

Arion 630-610 C – 1.2009 – GB

Fig. 30

B4.13

Robot-driven ranges Shimming of tapered roller bearings – Fit the bearings, the washer (65) and the retaining ring (64) without the shims.

64 65

– Measure "C" with a set of shims.

– Fit shims of a thickness corresponding to the measured play.

Zero play and preload with a tolerance of 0 ± 0,05 mm.

If possible, adjust towards the maximum end of this tolerance.

For example, if the play measured is 0,82 mm 0,82 - 0,05 = 0,77 0,82 + 0,05 = 0,87 In this example, the thickness of the shims to be installed should be between 0,77 and 0,87 mm (and as close to 0,87 mm as possible).

C

326msm74

Fig. 31

326hsm2t

Fig. 32

Adjusting the shafts in the housing – Fit the primary line and reverse gear in the casing.

– Position the cover with the corresponding bearing cups.

– Measure the play of the two shafts (see next paragraph).

– Remove the upper line and the reverse gear pinion.

– Fit the secondary line only in the casing.

– Measure the play (see next paragraph).

– Remove the secondary line.

B4.14

Arion 630-610 C – 1.2009 – GB

Robot-driven ranges Measuring shaft clearance in the casing

c c

• Place a dial gauge probe at the end of the shaft.

• To seat the bearings perfectly: – Push the shaft strongly.

– Turn the shaft.

• Repeat this operation by pressing a lever (A) on the shaft.

• Record dimension "c".

For the reverse transmission, use the 5 mm diameter rod (made locally, refer to the beginning of the chapter) while pulling upwards by inside the reverse gear (B).

For the 3 shafts, place shims of a thickness corresponding to the measured play plus a preload of 0,10 ± 0,05 mm between the cup and the cover.

A 326hsm2u

Fig. 33

If possible, adjust towards the maximum end of this tolerance.

Example: if play measured c = 0,76 mm 0,76 + 0,05 = 0,81 0,76 + 0,15 = 0,91 In this example, the thickness of the shims to be installed should be between 0,81 and 0,91 mm (and as close to 0,91 mm as possible).

Important: Properly grease the shims before fitting them.

B 326hsm2v

Fig. 34

ø 5 mm

B

326msm7g

Arion 630-610 C – 1.2009 – GB

Fig. 35

B4.15

Robot-driven ranges Refitting the ranges module – Assemble the primary and secondary lines using tool n°60 0500 615 4.

– Lift the assembly with a hoist.

– Position the forks to enable the lines to be lowered more easily.

– Fit the oil deflector onto the secondary train.

Note: The remote ends of the forks are positioned towards the front of the tractor.

– .Lower the assembly into the casing.

– Engage the 2 holes of the oil deflector into the guides.

– Position the reverse gear with the mark towards the front of the tractor.

Important: Properly grease the seals on refitting.

– Fit the spring and the lubrication tube (A).

326msm7h

Fig. 36

– Position the small (51) and the large (53) O-rings.

– Fit the piston (52) lightly coated with grease.

– Fit the retaining ring (88).

– Engage the rod with the inner piston.

Note: The inner piston of ranges "A", "B" is fitted with a spring.

– Position the large seal (47).

– Fit the piston (48) lightly coated with grease.

– Position the cover (46) together with its two seals.

– Fit the retaining ring (44).

A

326hsm2p

Fig. 37

51

53

52 326msm79

B4.16

Arion 630-610 C – 1.2009 – GB

47

88

46

48

44 Fig. 38

Robot-driven ranges – Mount the cover (1) with the shims and the cups lightly coated with oil.

– Perform the same operation on the range "A", "B" control via the back of the housing.

1

– Align the holes of the rod and the fork.

– Fit the pin.

– Mount and tighten the cap to a torque of 7 daN.m.

– Correctly grease the sealing ring (43).

– Fit the ring (42) with the lubrication hole facing up.

– Lock the ring in place by tapping 4 times with a punch.

– Adjust the controls (see below).

– Apply Loctite (510) to the front and rear mounting faces after first cleaning them.

– Check that the spring is in place in the PTO clutch bell housing.

– Reassemble in reverse order to removal using locating pins.

43 326msm7i

Arion 630-610 C – 1.2009 – GB

42 Fig. 39

B4.17

Robot-driven ranges Adjusting the lock nuts Important: The prevention lock must be fully released (free) when performing this adjustment.

– Fit the lower nuts on the control rods.

– Supply the circuit under 4 bars using a locally made rig.

– Connect pressure regulator n°60 0500 531 0 to the compressed air network (4 bar).

Note: It is normal for air leakage to occur.

– Adjust the forks using the control unit No. 60 0500 615 5 (see "Operation" in the "General" paragraph).

– Engage range "B" and range "D".

– Bring the nuts into contact with the cover.

– Mark the nuts opposite the tapped holes (Fig 41 green mark).

– Place the gearbox back in neutral.

322msm52

Fig. 40

326msm81

Fig. 41

– Fit the upper nuts on the control rods.

– Fit the cover (6).

– Tighten the screws (8), coated with Loctite (243), to 3,3 daN.m.

– Engage range "A" and range "C".

– Bring the nuts into contact with the covers.

– Mark the nuts opposite the tapped holes (Fig 42 blue mark).

6

326msm82

B4.18

Arion 630-610 C – 1.2009 – GB

8

Fig. 42

Robot-driven ranges – Place the gearbox back in neutral.

– Tighten the lower nuts and loosen the upper nuts as follows: Cross two notches, engage the screws in the next.

7

– After rotation line up the two slots with the tapped hole.

– Tighten the screw (7) coated with Loctite (243) to 1,7 daN.m.

– Check the position of the synchronisers. If the following dimensions are not correct, turn the gearbox and proceed with adjustment of the screws again.

1nd step – With the help of a depth gauge check the depth of the following dimensions "E" (distance between the assembly face of the casing and the guide rod): – Range "A": 21,26 ± 1,10.

– Neutral range "A" and "B": 32,22 ± 1,25.

326msm83

– Range "B": 43,16 ± 1,00.

Fig. 43

– Range "C": 22,31 ± 0,90.

– Neutral range "C" and "D": 33,22 ± 1,10.

2nd step Using a depth gauge, check the difference between range "A" and "B" and between range "C" and "D" (Fig. 45).

The dimension "D" read must be of 21,9 ± 1,4 (between "A" and "B") and 21,66 ± 1,28 (between "C" and "D").

E

– Range "D": 43,96 ± 0,90.

326msm2c

Fig. 44

D

326msm1x

Arion 630-610 C – 1.2009 – GB

Fig. 45

B4.19

Robot-driven ranges Adjusting the prevention lock – Place the gearbox in neutral.

9

– Fully tension the lock (9).

– Apply Loctite (243) to the threaded section.

– Slacken the lock to allow the selection of only one gear.

– Leave the other control rod in neutral.

– Tension the lock with a functional minimum play.

– Tighten the lock-nut.

– Fit the sensors and their plungers.

– Tighten to 3 daN.m.

Using the sensor control LEDs of control unit No. 60 0500 615 5, check that 2 ranges cannot be selected at the same time.

326msm84

B4.20

Arion 630-610 C – 1.2009 – GB

Fig. 46

B5 SLOW RANGE

Arion 630-610 C – 1.2009 – GB

Slow range Exploded view

28 27 26 30 24 25 29

21 22 23 22

27

24 20 19 18 14 13

17 16

11

10

6 5 3

15 8 9 12

326msm7j

B5.2

7 4

Fig. 1

Arion 630-610 C – 1.2009 – GB

Slow range Description 1 2 3 4 5 6 7 8 9 10 11

Control cable (Fig. 7).

Remote control cable support (Fig. 7).

Control lever.

Screw.

O-ring.

Operating lever.

Set screw.

Flat seal.

Nut. Fork.

Sliding sleeve.

12 13 14 15 16 17 18 19 20 21 22

23 24 25 26 27 28 29 30 31 32 33 34

Lock.

Screw.

Washer.

Retaining ring.

Screw.

Pin. Support plate.

Friction washers.

Planet carrier.

Planet gear.

Needle bearing.

Spacer.

Friction plate.

Pins.

Friction washers.

Locating pin.

Crown wheel.

Blanking plate Locking ring.

Cab control.

Yoke/clip.

Yoke/clip.

Nuts.

Removing/refitting the housing • Uncouple the tractor between the gearbox and rear axle as follows:.

– Refer to Chapter "H" for partial cab removal.

Operations 1 to 7.

– Drain the transmission system.

– Remove the reservoir(s) and disconnect the pipes, hoses and wiring harnesses interfering with the uncoupling operation.

– Make the tractor safe with stands and trolleys.

– Lock the sway action between the front axle and the cradle.

Arion 630-610 C – 1.2009 – GB

B5.3

Slow range – Loosen the screw (7) and pull the control lever (6) towards the outside of the housing.

– Split the tractor between the gearbox and the rear axle.

• Loosen the two screws (16) and remove the sliding sleeve, fork and shaft asssembly.

– Loosen the screws (13).

13 11

– Remove the step-down gear assembly.

16

– Remove the friction washers (19) and (26).

17

– Remove the circlip (30) on the planet carrier (20).

• Drive out the pins (25), being careful with the needles, in order to remove each planet gear (21).

6

• Refit the assembly in reverse order to removal while observing the following instructions.

10

– Equip each planet gear with 2 rows of needles coated with grease and separated by a spacer.

– Centre the friction plates (24).

7 322msm53

Fig. 2

– Position the shafts (25) correctly in order to be able to fit the circlip (30).

– Smear the faces of the step-down gear lightly with grease and fit the friction washers (19), (26), positioning their tabs correctly.

24 25 21 22

– Fit the ring gear (28) with the clearance on the bearing side.

23 22

– Position the cutout section of the support plate (18) towards the top.

– Tighten the screws (13) coated with Loctite (243) to 4 ± 0,5 daN.m.

24 20 19 18

• Refit the assembly in reverse order to removal, observing the instructions mentioned in the parts concerned.

322msm54

Fig. 3

28 27 26 30

27 29 322msm55

B5.4

Arion 630-610 C – 1.2009 – GB

Fig. 4

Slow range Removing, adjusting and refitting the control system Dismantling – Disconnect the control cable.

20

– Remove the PTO clutch (see chapter "C").

11

16

– Remove the lock (12) and the retaining ring (15).

– Loosen the two screws (16) and take out the shaft (17).

– Remove the fork and dog assembly from the front.

– Remove the control link (3) and remove the control lever (6) towards the inside.

10 6

Adjusting and refitting – Position the dog properly.

15

– Fit the yoke and pin (17).

– Coat the screws (16) with Loctite (243) and tighten to 2 ± 0,5 daN.m.

3

7

17 9

12

4

322msm56

Fig. 5

– Fit the lock (12) then the nut and adjust.

– Tighten the screw (12) until it touches the spindle (17) then loosen by a ¼ turn.

– Tighten the nut (9) to a torque of 6 ± 1 daN.m – Place the dog (11) in the "slow" position, with the rear face bearing against the planet carrier (20).

– Couple the tractor taking care to not damage the control lever (6).

– Correctly position the control lever (6) in the notches of the fork (10).

– Smear the screw (7) with Loctite Loctite (243) and torque at 2 ± 0,5 daN.m.

– Refit the rocker bar (3) with the screw (4) lightly coated with Loctite (243).

– Manually check with the link that the dog locks correctly in each "direct drive" and "slow" position.

12 322msm57

Arion 630-610 C – 1.2009 – GB

9

10

17 Fig. 6

B5.5

Slow range Adjusting the control lever – Put the rocker bar (3) in the "crawler" position.

33

– Place the cab range lever (31) in the "slow" position.

31

1

2

34

– Screw the yoke (33) onto the control cable (1) and tighten the check nut.

– Mount the yoke (33) on the cab range lever.

– Mount the yoke (32) in the same way on the rocker bar (3).

– Adjust the sheath stops with the nuts (34), while checking that the cable (1) is not stressed.

– Check operation and locking in both positions.

– Adjust nuts (34) if necessary.

3 322msm58

B5.6

Arion 630-610 C – 1.2009 – GB

32

Fig. 7

B6 EXTRA SLOW RANGE

Arion 630-610 C – 1.2009 – GB

Extra slow range Exploded view

30 29 26 25 31 24

23

28

22

27

18 21 18 17

20 19

16 15 11

13 6 5 3 14 10

8 7 12

322msm18

B6.2

9

4 Fig. 1

Arion 630-610 C – 1.2009 – GB

Extra slow range Description 1 2 3 4 5 6 7 8 9 10 11 12

Control cable (Fig. 7).

Control cable support (Fig. 7).

Control lever.

Screw.

O-ring.

Operating lever.

Set screw.

Flat seal.

Nut. Fork.

Sliding sleeve.

Screw.

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35

Pin. Screw.

Screw.

Support plate.

Planet carrier.

Friction plate.

Pin. Planet gear.

Needle bearing.

Friction washer.

Sun gear.

Double ring gear.

Locating pin.

Friction plate.

Pins.

Planet gears.

Planet carrier.

Friction washer.

Blanking plate.

Cab control.

Yoke/clip.

Yoke/clip.

Nuts.

Removing/refitting the housing • Uncouple the tractor between the gearbox and rear axle as follows:: – Refer to Chapter "H" for partial cab removal.

Operations 1 to 7.

– Drain the transmission system.

– Remove the reservoir(s) and disconnect the pipes, hoses and wiring harnesses interfering with the uncoupling operation.

– Make the tractor safe with stands and trolleys.

– Lock the sway action between the front axle and the cradle.

Arion 630-610 C – 1.2009 – GB

B6.3

Extra slow range – Loosen the screw (7) and pull the control lever (6) towards the outside of the housing.

– Uncouple the tractor.

15

• Loosen the two screws (14) and remove the sliding sleeve, fork and shaft asssembly.

14

– Loosen the screws (15).

– Remove the step-down gear assembly.

– Remove the friction washers (30).

– Remove the circlips on the planet carriers (17) and (29).

• Drive out the pins (19) and (27), being careful with the needles, in order to remove each of the planet gears (20) and (28).

13 6

11

• Refit the assembly in reverse order to removal while observing the following instructions: – Equip each planet gear with 2 rows of needles coated with grease and separated by a spacer.

10

7

322msm19

Fig. 2

– Centre the friction plates (18) and (26).

24

– Correctly position pins (19) and (27) in order to fit the circlips.

– Smear the faces of the step-down gear lighty with grease and fit the friction washer (19), (26) with its tab correctly positioned.

18 20 19 18 17

– Fit the ring gear (24).

– Position the cutout section of the support plate (16) towards the top.

– Tighten the screws (15) coated with Loctite (243) to 4 ± 0,5 daN.m.

• Refit the assembly in reverse order to removal, observing the instructions mentioned in the parts concerned.

15 16 322msm20

Fig. 3

30 29 26 28 27 26 24 322msm21

B6.4

Arion 630-610 C – 1.2009 – GB

Fig. 4

Extra slow range Removing, adjusting and refitting the control system

17

Dismantling – Disconnect the control cable.

14

– Remove the PTO clutch (see chapter "C").

– Remove the lock (12).

– Loosen the two screws (14) and remove the shaft (13).

– Remove the fork and dog assembly from the front.

13

– Remove the control link (3) and remove the control lever (6) towards the inside.

6 11

3

Adjusting and refitting 7

– Correctly position the dog and fit the fork and the spindle (13).

– Coat the screws (14) with Loctite (243) and tighten to 2 ± 0,5 daN.m.

10

4

12

322msm22

Fig. 5

– Fit the lock (12) and adjust.

– Tighten the screw (12) until it touches the spindle (13) then loosen by ¼ turn and tighten the nut (9) to 2 ± 0,5 daN.m while holding the screw (12) in position.

– Tighten the nut (9) to a torque of 6 ± 1 daN.m – Place the dog (11) in the "extra slow" position, with the rear face bearing against the planet carrier (17).

– Couple the tractor taking care to not damage the control lever (6).

– Correctly position the control lever (6) in the notches of the fork (10).

– Smear the screw (7) with Loctite (243) and torque at 3 ± 0,5 daN.m – Refit the rocker bar (3) with the screw (4) lightly coated with Loctite (243).

– Manually check with the link that the dog locks correctly in each "direct drive" and "slow" position.

13 322msm23

Arion 630-610 C – 1.2009 – GB

12

9

10 Fig. 6

B6.5

Extra slow range Adjusting the control lever – Put the rocker bar (3) in the "crawler" position.

34

– Place the cab range lever (32) in the "slow" position.

32

1

2

35

– Screw the yoke (34) onto the control cable (1) and tighten the check nut.

– Mount the yoke (34) on the cab range lever.

– Mount the yoke (33) in the same way on the rocker bar (3).

– Adjust the sheath stops with the nuts (35), while checking that the cable (1) is not stressed.

– Check operation and locking in both positions.

– Adjust nuts (35) if necessary.

3 322msm25

B6.6

Arion 630-610 C – 1.2009 – GB

33

Fig. 7