Claas Renault Ares 546 556 566 616 626 636 696 Repair Manual [Tractor]

$24.95

Model: Ares 546 | Ares 556 | Ares 566 | Ares 616 | Ares 626 | Ares 636 | Ares 696
Type: Tractor
Years: 2002-2008
1253 Pages·82 MB·Searchable PDF·English·Print-Ready
  • Wiring Diagrams
  • Hydraulic Schematics
  • Torque Specs
  • Multi-Level Bookmarks (3-level navigation)
Claas Renault Ares 546 556 566 616 626 636 696 Repair Manual [Tractor]
Claas Renault Ares 546 556 566 616 626 636 696 Repair Manual [Tractor] $24.95

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Factory workshop manual for the CLAAS Ares 546, 556, 566, 616, 626, 636 and 696 tractors built from 2002 to 2008, covering both the original and Tier II updated machines. This is the full repair manual, not an operator's handbook. It walks through overhaul of the John Deere DPS engine and injection system with the injection data sheets, teardown and rebuild of the GBA 20 gearbox, rear axle, brakes, 4WD dropbox, standard and Proactiv front axles, and both open-centre and closed-centre hydraulic circuits including the 100 l/min version. Electrics get proper coverage too: wiring item lists, function-by-function schematics, harness routing, plus the TCE 15/25 lift, Drivetronic III and Electropilot electronics. Cab, heating, air conditioning and windscreen bonding round it out.

What's Inside This CLAAS 546-696 Manual

SystemPagesKey Topics
Engine & Injection System2-203Injection Data Sheets and Supply, John Deere DPS Engine, Tier Ii Injection and Engine Updates
Gearbox & Transmission204-359Gba 20 Gearbox Overhaul, Low-Pressure Transmission Hydraulics, Tier Ii Gearbox Updates
Rear Axle, Brakes & 4WD360-481Rear Axle and Differential, Service and Hand Brakes, 4WD Dropbox
Front Axle482-570Standard Front Axle, Proactiv Suspended Front Axle
Main Hydraulic Circuits571-698Open-Centre Hydraulics, Closed-Centre Hydraulics, Closed-Centre 100 l/min Circuit
Wiring, Schematics & Harnesses699-860Wiring Item Lists, Schematic Diagrams by Function, Harness and Connector Paths
Electronic Systems861-1091Instrument Panel, Tce 15/25 Electronic Lift, Drivetronic Iii, Electropilot and Engine Management
Cab, Heating & Air Conditioning1092-1253Cab Overhaul, Heating and Air Conditioning, Windscreen Bonding

Quick Reference Specifications

SpecificationValuePage
ARES 546 (4045 TRT 53)
Rated power ECE R 2467.5 kW (92 hp)p. 81
ARES 556 (4045 TRT 54)
Rated power ECE R 2475 kW (102 hp)p. 81
ARES 566 (4045 TRT 55)
Rated power ECE R 2481.5 kW (110 hp)p. 81
ARES 616 (6068 DRT 50)
Rated power ECE R 2481.5 kW (110 hp)p. 81
ARES 626 (6068 TRT 53)
Rated power ECE R 2490.5 kW (123 hp)p. 81
ARES 636 (6068 TRT 54)
Rated power ECE R 2497 kW (132 hp)p. 81
ARES 696 (6068 TRT 55)
Rated power ECE R 24104 kW (141 hp)p. 81
All engine types
Bore106.5 mmp. 82
Stroke127 mmp. 82
Compression24 barp. 82
Nominal speed2200 rpmp. 82
Tick-over speed850 ± 25 rpmp. 82
Max no-load speed2390 ± 15 rpmp. 82
4-cylinder engines (ARES 546, 556, 566)
Lubrication system capacityMin: 10 l / Max: 12.5 lp. 82
Cooling system capacity15 lp. 82
6-cylinder engines (ARES 616, 626, 636, 696)
Lubrication system capacityMin: 14 l / Max: 17 lp. 83

CLAAS 546-696 Common Problems This Manual Covers

Engine stalls or loses power under load, often with low fuel pressure

Start with fuel supply: filters and lift pump are the usual culprits on the DPS engines before the injection pump gets blamed. The Engine and Injection System section gives the supply layout and injection data sheets so you can verify delivery and match settings to your engine plate before condemning the pump.

Manual Section: Engine & Injection System - injection data sheets and supply
Hydraulic lift will not raise, or drops under load

The fault splits three ways: pump output, control electronics, or leakage in the cylinder. Use the Main Hydraulic Circuits section for your circuit type (open or closed centre) to test pressure at the right points, then the TCE 15/25 lift section if the hydraulics test good, since a position sensor or control fault mimics a mechanical one.

Manual Section: Main Hydraulic Circuits / TCE 15/25 electronic lift
Transmission slips, engages harshly or refuses certain ranges

Check the low-pressure transmission hydraulics first - clutch supply pressure and control faults cause most engagement complaints without any internal wear. If pressures are correct, the GBA 20 gearbox overhaul section covers full teardown, clutch pack inspection and reassembly with the checks needed after rebuild.

Manual Section: Gearbox & Transmission - GBA 20 overhaul and low-pressure hydraulics
Engine runs hot during heavy field work

Overheating on these machines is usually a thermostat, blocked cooler stack or a tired water pump rather than a base engine fault. The engine section covers the cooling side of the John Deere DPS unit, and the instrument panel coverage in the electronics section helps you confirm whether the gauge and sender are telling the truth before you tear into the cooling system.

Manual Section: Engine & Injection System - John Deere DPS engine

Frequently Asked Questions

My Ares loses hydraulic pressure after a couple of hours of work - will this manual help me find the cause?

Yes, and this is exactly the kind of fault where you need the circuit drawings, not guesswork. The manual covers the open-centre and closed-centre main hydraulic circuits separately, with pressure test points and component descriptions, so you can work out whether you are losing pressure at the pump, a valve block or internal leakage in the lift cylinder instead of swapping parts blind. Heat-related pressure loss usually points to internal leakage past worn seals, and the overhaul sections show how each component comes apart.

Does it cover the GBA 20 gearbox rebuild, including slipping or jerky gear engagement?

It does. There is a dedicated GBA 20 gearbox overhaul section with disassembly, inspection and reassembly, plus the low-pressure transmission hydraulics that control clutch engagement. Inconsistent or jerky engagement on these tractors is often a clutch calibration or low-pressure supply issue rather than worn plates, so having the hydraulic side documented alongside the mechanical rebuild saves you from splitting the tractor when the fix is on the outside.

Can I diagnose electronic faults like the Drivetronic III or TCE lift with this manual?

Yes. The electronic systems section covers the instrument panel, TCE 15/25 electronic lift, Drivetronic III, Electropilot and engine management, and the wiring section gives you schematics by function plus harness and connector paths. That combination is what you need to chase a sensor fault or a dead lift back to a specific connector instead of replacing control units on suspicion. Bear in mind these are early-2000s electronics - diagnosis is mostly multimeter work at the connectors, guided by the schematics.

Which engine variants are covered - my tractor is a later Tier II machine?

The manual covers the John Deere DPS engines fitted across the 546 to 696 range, with the injection data sheets and fuel supply system, and it includes the Tier II injection and engine update sections for the later machines. The gearbox Tier II updates are in there too, so a 2006-2008 tractor is covered as well as an early build. Check your engine plate against the data sheets to pick the right injection settings.

Is this a paper manual or a download, and is it the same as the dealer version?

It is a digital copy of the factory workshop documentation - the same material a CLAAS dealer technician would work from for these models, organised by system. You get it as a download you can print or keep on a laptop in the shop. At this price it costs less than half an hour of dealer labour, and one avoided misdiagnosis on a hydraulic pump or clutch job pays for it several times over.

BrandCLAAS
ModelAres 546, Ares 556, Ares 566, Ares 616, Ares 626, Ares 636, Ares 696
Machine TypeTractor
Manual TypeWorkshop Manual
LanguageEnglish
FormatSearchable PDF (Digital Download)
Pages1,253
File Size82 MB
Year Range2002-2008
Wiring DiagramsYes
Hydraulic SchematicsYes
Torque SpecificationsYes
Bookmarked / IndexedYes

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