Claas ELIOS 240-210 Operating instructions

Service & Parts
ELIOS 240-210 (A28)
NEXOS VE 230-210 (A25)
NEXOS VL 240-210 (A26)
NEXOS F 240-210 (A27)
NEXOS 230-220 FB (A29)
Repair manual

Table of Content
Repair manual Nexos, Elios 240 - 210 5
Chapter 00 - TOOLING 7
TOOLING 7
TOOLING PER CHAPTER 8
TOOLING PER REFERENCE 9
Chapter 01 - ENGINE - F5C 24
01 ENGINE - F5C 24
introduction 30
General 38
Fuel supply 50
Engine auxiliary devices 60
Overhaul of the engine 100
Chapter 01 - ENGINE - NEF 138
01 ENGINE - CRADLE 138
introduction 144
General 152
Fuel supply 158
Engine auxiliary devices 164
Overhaul of the engine 204
Chapter 01 - Engine curves 244
Chapter 02 - Clutch clearance adjustment procedure 252
CLAAS NECTIS - Clutch clearance adjustment procedure 252
Chapter 02 - TRANSMISSION AND GEAR 253
02 TRANSMISSION AND GEAR 253
SAFETY INSTRUCTIONS 259
General safety recommendations 260
Safety symbols 260
General precautions 261
GENERAL INFORMATION 269
Manual use 270
Agreements and definitions 270
General description 273
Special recommendations 274
GENERAL SPECIFICATIONS 277
Technical Features 278
Tightening torques, sealants and grease application 280
Assembly typical data 308
DISASSEMBLY AND ASSEMBLY 321
4WD drop box 322
Final drive 347
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Teflon seals replacement (clutch shaft) 361
Upper covers and rockshaft 365
Speed gears outer levers 368
Clutch housing 371
Wet clutches 383
Synchro splitter 394
PTO 398
Slave cylinder 476
Parking brake 485
Housing sensors assy 499
Differential locking control 505
Inner gear control assy 510
Idle gear 520
Range gears (primary shaft) 522
Input shaft 528
Synchro shuttle 537
Speed gears (primary shaft) 542
Differential assy 548
Pinion - Ranges (secondary shaft) 555
Speed gears (secondary shaft) 561
Chapter 03 - CHASSIS - ELIOS 2 WHEEL DRIVE 569
03 CHASSIS - ELIOS 2 WHEEL DRIVE 569
GENERAL INFORMATION 573
SAFETY INSTRUCTIONS 579
GENERAL SPECIFICATIONS 583
disassembly and assembly operations 589
03 CHASSIS - ELIOS 4 WHEEL DRIVE 615
SAFETY INSTRUCTIONS 619
GENERAL INFORMATION 629
GENERAL SPECIFICATIONS 637
Disassembly and Assembly 645
Chapter 03 - CHASSIS - NEXOS 2 WHEEL DRIVE 699
03 CHASSIS - NEXOS 2 WHEEL DRIVE 699
GENERAL INFORMATION 703
SAFETY INSTRUCTIONS 709
GENERAL SPECIFICATIONS 713
disassembly and assembly operations 721
03 CHASSIS - Nexos F 4 WHEEL DRIVE 753
SAFETY INSTRUCTIONS 757
GENERAL INFORMATION 767
GENERAL SPECIFICATIONS 775
Disassembly and Assembly 785
03 CHASSIS - Nexos VL 4 WHEEL DRIVE 851
GENERAL INFORMATION 855
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SAFETY INSTRUCTIONS 860
GENERAL SPECIFICATIONS 864
DISASSEMBLY AND ASSEMBLY OPERATIONS 873
03 CHASSIS - Nexos VE 4 WHEEL DRIVE 939
SAFETY INSTRUCTIONS 943
GENERAL INFORMATION 953
GENERAL SPECIFICATIONS 961
Disassembly and Assembly 969
Chapter 06 - LIFTING DEVICE 1029
06 LIFTING DEVICE 1029
CONTENT 1031
FRONT LIFTING - NEXOS 1033
FRONT LIFTING - ELIOS 1036
REAR LIFTING 1039
SAFETY INSTRUCTIONS 1040
GENERAL INFORMATION 1049
GENERAL SPECIFICATIONS 1054
HYDRAULIC SYSTEM 1063
MECHANICAL SYSTEMS 1074
Chapter 08 - POWER TAKE-OFF 1086
08 POWER TAKE-OFF 1086
CONTENTS 1088
FRONT POWER TAKE-OFF - NEXOS 1090
FRONT POWER TAKE-OFF - ELIOS 1092
Chapter 09 - HYDRAULIC SYSTEM 1094
09 HYDRAULIC SYSTEM 1094
CONTENT 1096
Hydraulic circuit 1097
Chapter 10 - ELECTRIC SYSTEM 1109
10_Systeme electrique.pdf 1109
10 ELECTRIC SYSTEM 1109
W01 - MAIN HARNESS WITHOUT ELECTRO-DISTRIBUTORS 1135
W01 - MAIN HARNESS WITH ELECTRO-DISTRIBUTORS 1137
W02 - ENGINE HARNESS 1139
W03 - TRANSMISSION HARNESS 1140
W04 - VENTILATION AND A/C HARNESS 1142
W05 - LIGHTING HARNESS 1143
W06 - AIR BRAKE HARNESS 1144
W08 - A/C COMPRESSOR HARNESS 1145
W09 - PRIMARY HITCH OFFSET HARNESS 1146
W09_2 - SECONDARY HITCH OFFSET HARNESS 1147
W11 - REAR LIFTING SUPPLY HARNESS 1148
W11_2 - SECONDARY REAR LIFTING HARNESS 1149
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W11_2 - PRIMARY REAR LIFTING HARNESS 1150
W11_4 - REAR COMMAND HARNESS OF REAR LIFTING 1151
W12 - SECONDARY HARNESS OF ELECTRO-DISTRIBUTORS 1152
W13 - MAIN HARNESS OF THE ELECTRO-DISTRIBUTORS 1153
Chapter 12 - CAB - OPERATOR'S PLATFORM 1154
12 CAB / OPERATOR'S PLATFORM 1154
CONTENT 1156
REMOVE AND INSTALL CAB ROOF 1157
REMOVE AND INSTALL PLATFORM 1162
REMOVE AND INSTALL AIR CONDITIONING 1174
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TOOLING
Technical support
Nexos Elios
240-210
Repair – Issue 06.2011
Reference n
o
00 1142 849 0
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2 Nexos Elios 240-210 – EN
TOOLING
TOOLING PER CHAPTER
TOOLING PER CHAPTER
01
00 1130 886 0
00 1130 887 0
00 1130 888 0
00 1130 889 0
00 1130 890 0
00 1130 892 0
00 1131 095 0
00 1141 387 0
00 1141 389 0
00 1142 423 0
00 1142 424 0
00 1142 425 0
60 0500 556 0
60 0500 556 6
77 0138 811 1
77 0138 816 9
02
00 1131 405 0
00 1131 502 0
00 1131 503 0
00 1131 504 0
00 1131 509 0
00 1131 510 0
00 1131 511 0
00 1131 512 0
00 1131 513 0
00 1135 520 0
00 1135 521 0
00 1141 391 0
00 1141 392 0
00 1142 427 0
00 1142 431 0
00 1142 432 0
00 1142 446 0
60 0500 615 3
77 0138 800 8
77 0138 803 1
77 0138 805 8
77 0138 808 0
77 0138 837 9
03
00 1131 397 0
00 1131 401 0
00 1131 402 0
00 1131 403 0
00 1131 404 0
00 1131 406 0
00 1131 407 0
00 1131 409 0
00 1131 410 0
00 1131 412 0
00 1131 413 0
00 1131 415 0
00 1131 416 0
00 1131 423 0
00 1131 425 0
00 1142 433 0
00 1142 434 0
00 1142 435 0
00 1142 438 0
00 1142 439 0
00 1142 440 0
00 1142 441 0
00 1142 442 0
00 1142 443 0
00 1142 444 0
00 1142 445 0
00 1142 447 0
00 1142 449 0
00 1142 450 0
00 1142 451 0
60 0500 653 4
08
00 1141 391 0
00 1141 393 0
00 1141 394 0
00 1142 452 0
00 1142 453 0
00 1142 454 0
60 0500 615 3
09
00 0178 310 0
00 0178 320 0
60 0571 280 0
60 0571 297 1
10
00 1135 095 0
60 0500 573 4
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TOOLING
TOOLING PER REFERENCE
Nexos Elios 240-210 – EN 3
I
TOOLING PER REFERENCE
00 0178 310 0 00 0178 320 0
Data acquisition and pressure readings base kit. Additional flow reading kit.
00 1130 886 0 00 1130 887 0
Front bearing gasket removing tool Rear bearing gasket removing tool
00 1130 888 0 00 1130 889 0
Front bearing gasket fitting tool Rear bearing gasket fitting tool
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4 Nexos Elios 240-210 – EN
TOOLING
TOOLING PER REFERENCE
00 1130 890 0 00 1130 892 0
Camshaft bushes fitting / removing tool Top dead centre checking tool
00 1131 095 0 00 1131 397 0
Top dead centre checking tool Bearing cup engaging tool
00 1131 401 0 00 1131 402 0
Bush engaging tool Differential bearing
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TOOLING
TOOLING PER REFERENCE
Nexos Elios 240-210 – EN 5
00 1131 403 0 00 1131 404 0
Conical distance measuring tool Bush engaging tool
00 1131 405 0 00 1131 406 0
4WD gasket engaging tool Gasket engaging tool
00 1131 407 0 00 1131 409 0
Nut wrench Wrench for conical gear

6 Nexos Elios 240-210 – EN
TOOLING
TOOLING PER REFERENCE
00 1131 410 0 00 1131 412 0
Bearing cone engaging tool Bush engaging tool
00 1131 413 0 00 1131 415 0
Gasket engaging tool Bush engaging tool
00 1131 416 0 00 1131 423 0
Gasket engaging tool Gasket engaging tool

TOOLING
TOOLING PER REFERENCE
Nexos Elios 240-210 – EN 7
00 1131 425 0 00 1131 502 0
Cassette gasket engaging tool Gear cup fitting tool
00 1131 503 0 00 1131 504 0
Attack gear simulation tool Conical distance tool
00 1131 509 0 00 1131 510 0
Engaging tool for the reinforced shaft tube outer cup Engaging tool for the reinforced shaft tube inner cup

8 Nexos Elios 240-210 – EN
TOOLING
TOOLING PER REFERENCE
00 1131 511 0 00 1131 512 0
Engaging tool for the non reinforced shaft tube outer gasket Engaging tool for the non reinforced shaft tube inner gasket
00 1131 513 0 00 1135 095 0
Engaging tool for the narrow shaft tube cup Multimeter case
00 1135 520 0 00 1135 521 0
ISC clutch gaskets compression tool ISC clutch gaskets fitting tool

TOOLING
TOOLING PER REFERENCE
Nexos Elios 240-210 – EN 9
00 1141 387 0 00 1141 389 0
Flywheel timing gauge Injection pump gear puller
00 1141 391 0 00 1141 392 0
ISC clutch compression washer Hydraulic doubler clutch compression washer
00 1141 393 0 00 1141 394 0
Power take-off clutch gaskets fitting tool Power take-off clutch gaskets compression tool

10 Nexos Elios 240-210 – EN
TOOLING
TOOLING PER REFERENCE
00 1142 423 0 00 1142 424 0
Rear bearing gasket fitting tool Front bearing gasket fitting tool
00 1142 425 0 00 1142 426 0
Valve gaskets fitting tool Engaging tool for the reinforced shaft tube outer gasket
00 1142 427 0 00 1142 431 0
Engaging tool for the reinforced shaft tube inner gasket Engaging tool for the gearbox gasket

TOOLING
TOOLING PER REFERENCE
Nexos Elios 240-210 – EN 11
00 1142 432 0 00 1142 433 0
Engaging tool for the gearbox gasket Bush engaging tool
00 1142 434 0 00 1142 435 0
Gasket engaging tool Nut locking wrench
00 1142 438 0 00 1142 439 0
Preload measuring tool Wrench for conical gear

12 Nexos Elios 240-210 – EN
TOOLING
TOOLING PER REFERENCE
00 1142 440 0 00 1142 441 0
Gasket engaging tool Gasket engaging tool
00 1142 442 0 00 1142 443 0
Bush engaging tool Conical false gear
00 1142 444 0 00 1142 445 0
Conical distance adjusting tool Bearing cone engaging tool

TOOLING
TOOLING PER REFERENCE
Nexos Elios 240-210 – EN 13
00 1142 447 0 00 1142 449 0
Gasket engaging tool Bush engaging tool
00 1142 450 0 00 1142 451 0
Preload measuring tool Conical false gear
00 1142 452 0 00 1142 453 0
Engaging tool for the power take-off bearing gasket Power take-off shaft puller

14 Nexos Elios 240-210 – EN
TOOLING
TOOLING PER REFERENCE
00 1142 454 0 60 0500 556 0
Power take-off brake compression tool Injection pump timing tool
60 0500 556 6 60 0500 573 4
Camshaft bushes fitting / removing tool Solenoid valves checking harness
60 0500 615 3 60 0500 653 4
Compression tool Nut locking wrench