Claas Torion 1177 (K55) Wheel Loaders Repair Manual EN

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00 0302 508 4.pdf
00 0305 185 0.pdf
Spezialwerkzeuge Special Tools Outils spéciaux DPS 4045 TIER 4f 4i.pdf
Webasto Water heater Thermo Pro 90 Thermo Pro 90 HDD.pdf

00 0302 508 4.pdf:

Repair Manual
Table of contents
Introduction
General information
Validity of manual
Information about this Repair Manual
Using the manual
Text and figures
Document structure based on sub-assemblies
Search and find
Directions
Abbreviations
Technical terms
General repair instructions
Technical specifications
Information on technically correct repairs
Self-locking bolts
Liquid locking compound
Steel roller chains
Tensioning
Chain connector
Chain connector type E with spring
Chain connector type G with wire
Chain connector type S with cotter pins
Taper ring fasteners
Dismounting
Installing
Gib head key connections
Dismounting
Instalig
Lock collar bearing
Dismounting
Installing
Adapter sleeve bearing
Dismounting
Installing
Chuck bushing
Removing
Dismounting of version A
Dismounting of version B
Installing
Chuck bushing version A
Chuck bushing version B
Circlips
Radial shaft seals
Hose clamps
Tightening speed
Tightening torques
Alignment of clamps
Installation aids
Assembly tools
Ferrule fittings
Screwing in
Leaky ferrule fittings
Sealing cone fittings
Hydraulic hoses
Hose placement
Diaphragm accumulator (pressure accumulator) according to CLAAS works standard CN 24 0403
Operating utilities
Service and assembly
Change of gas filling
Special tool
Treatment of sealing faces
Spare parts
Operating materials
ESD protection measures
Special tool
ESD protection measures
Notes on inspection and repair
Tightening torques
Tightening torques for metric standard and fine threads
General tightening torques for Bosch-Rexroth
General tightening torques for Mannesmann-Rexroth
General tightening torques Dana / Spicer
Tightening torques for hydraulic fittings with ferrule
Tightening torques for pipe fittings with sealing cone joints and hydraulic fittings with soft ring seals
Tightening torques for bulkhead union nuts, straight and angled
Tightening torques for hydraulic male connectors SDS shape B and E
Tightening torques for hydraulic male connectors SDS shape F and screw plug
Tightening torques for SDS shape H hydraulic male connectors
Tightening torques for screw plugs shape E
Tightening torque for hydraulic male connectors shape C, conical thread
Tightening torques for hydraulic male connectors SDE shape F, adjustable direction
Tightening torques for hydraulic male connectors SDE shape H, with adjustable direction
Tightening torques for hydraulic swivel screw fittings
Tightening torque for hollow screws (with copper sealing ring)
Tightening torques for brake line screw fittings
Tightening torque for tubes with O-ring and union nuts
Tightening torques for threaded pins / orifice plates
Tightening torque for studs and special screws
Tightening torques for hydraulic components
Tightening torques for hex. sealing nuts
Tightening torques for hose clamps
Installation instructions
Worm drive hose clamps
Worm-type hose clamps with disc springs
Hose clamps with round pins
Identifying warnings
Hazard signs
Signal word
Safety rules
Safety signs and warnings
Requirement made on technical staff
Children in danger
Hazard areas of the machine
Instructors travelling along during fieldwork
Risk of injury from rotating shafts
Structural alterations of the machine
Optional equipment and spare parts
Control of running machine
Technical condition
Respecting technical limit values
Danger from machine parts that continue rotating
Keeping safety devices functional
Personal protective equipment
Wearing suitable clothing
Removing dirt and loose objects
Parking the machine safely
Unsuitable operating utilities
Safe handling of service fluids and auxiliary utilities
Environmental protection and disposal
Keeping the cab free of chemicals
Avoiding fires
Potentially fatal electric shock from overhead lines and lightning strike
Electric shock from electric system
Noise may damage your health
Pre-loaded machine parts
Liquids under pressure
Compressed air
Toxic exhaust gases
Hot surfaces
Safe access and leaving
Working only on the stopped machine
Hazards during repairs
Raised machine parts and loads
Danger from welding work
Checking and charging the battery
Preparations for cases of emergency
CCN explanation
CCN (CLAAS Component Number)
Electric systems standard
Hydraulic system standard
CCN (CLAAS Component Number)
01 Engine
0102 Complete component
Diesel engine
Special tool
Removing
Installing
Diesel engine
Removing
Installing
0125 Injection / Fuel system
Fuel tank
Technical specifications
Removing
Installing
Fuel sediment filter
Technical specifications
Installation
Fuel cooler
Technical specifications
Removing
Installing
0130 Lubricating oil system
Oil filter
Technical specifications
Installation
0135 Cooling system
Engine radiator
Technical specifications
Removing
Installing
Fan motor
Technical specifications
Removing
Installing
Gear pump
Technical specifications
Removing
Installing
0140 Exhaust system
Diesel particulate filter
Removing
Installing
Diesel particulate filter
Removing
Installing
Exhaust pipe
Technical specifications
Removing
Installing
0145 Air intake
Air filter housing
Removing
Installing
Air filter housing
Removing
Installing
Charge air cooler
Technical specifications
Removing
Installing
0150 Engine attachment parts
Electric starting motor
Technical specifications
Alternator
Technical specifications
0165 Exhaust gas aftertreatment
Exhaust gas treatment – General
Work preparation
Special tool
Checking the purity of the urea solution
Checking the density of the urea solution
Urea tank
Technical specifications
Removing
Installing
Dosing unit
Technical specifications
Removing
Installing
Urea injection nozzle
Technical specifications
Removing
Installing
02 Gearbox / Clutch / Universal drive shaft
0260 Universal drive shaft
Universal drive shaft
Technical specifications
Installation
03 Chassis
0316 Drive axle, front
Front drive axle
Technical specifications
Removing
Installing
Wheel hub
Technical specifications
Work preparation
Auxiliary tool
Removing
Installing
Axle body
Technical specifications
Work preparation
Removing
Installing
Bevel gear drive
Technical specifications
Work preparation
Special tool
Auxiliary tool
Removing
Disassembling
Assembling
Installing
Differential
Technical specifications
Auxiliary tool
Removing
Disassembling
Assembling
Installing
0316 Drive axle, front
Front drive axle
Technical specifications
Removing
Installing
Wheel hub
Technical specifications
Work preparation
Auxiliary tool
Removing
Installing
Axle body
Technical specifications
Work preparation
Auxiliary tool
Removing
Installing
Bevel gear drive
Technical specifications
Work preparation
Auxiliary tool
Removing
Disassembling
Assembling
Installing
Differential
Technical specifications
Work preparation
Auxiliary tool
Removing
Disassembling
Assembling
Installing
0317 Drive axle, rear
Rear drive axle
Technical specifications
Special tool
Removing
Installing
Wheel hub
Technical specifications
Work preparation
Auxiliary tool
Removing
Installing
Axle body
Technical specifications
Work preparation
Removing
Installing
Bevel gear drive
Technical specifications
Work preparation
Special tool
Auxiliary tool
Removing
Disassembling
Assembling
Installing
Differential
Technical specifications
Auxiliary tool
Removing
Disassembling
Assembling
Installing
0317 Drive axle, rear
Rear drive axle
Technical specifications
Special tool
Removing
Installing
Wheel hub
Technical specifications
Work preparation
Auxiliary tool
Removing
Installing
Axle body
Technical specifications
Work preparation
Auxiliary tool
Removing
Installing
Bevel gear drive
Technical specifications
Work preparation
Auxiliary tool
Removing
Disassembling
Assembling
Installing
Differential
Technical specifications
Work preparation
Auxiliary tool
Removing
Disassembling
Assembling
Installing
0317 Drive axle, rear
Axle transfer gearbox
Technical specifications
Work preparation
Auxiliary tool
Removing
Disassembling
Assembling
Installing
0335 Ground drive
Ground drive hydraulic motor
Technical specifications
Work preparation
Removing
Installing
Ground drive hydraulic motor
Technical specifications
Work preparation
Removing
Installing
0340 Front wheels
Front wheels
Special tool
Installation
0345 Rear wheels
Rear wheels
Special tool
Installation
04 Brake
0405 Service brake
Service brake
Technical specifications
Removing
Installing
Checking the wear
Service brake
Technical specifications
Removing
Installing
Checking the wear
Brake pedal
Technical specifications
Removing
Installing
0415 Parking brake
Parking brake
05 Steering
0505 Steering
Steering column
Technical specifications
Removing
Disassembling
Assembling
Installing
Orbitrol
Technical specifications
Removing
Installing
Steering hydraulic cylinder
Technical specifications
Removing
Installing
Emergency steering pump
Technical specifications
Removing
Disassembling
Assembling
Installing
06 Lift device
0625 Tools
Technical specifications
Removing
Installing
0630 Lift arms
Lift arms
Technical specifications
Removing
Installing
Link plate
Technical specifications
Removing
Installing
Lift cylinder
Technical specifications
Special tool
Work preparation
Removing
Installing
Tipping cylinder
Technical specifications
Special tool
Work preparation
Removing
Installing
Guide lever
Technical specifications
Removing
Installing
Rotary angle sensor for lift arms
Technical specifications
Removing
Installing
Rotary angle sensor for tipping cylinder
Technical specifications
Removing
Installing
09 Hydraulic system
0900 Hydraulic system – General
Hydraulic system – General
Special tool
Filling the accumulator
0905 Hydraulic oil tank
Hydraulic oil tank
Specifications
Special tool
Removing
Installing
Generating a vacuum
Stopping generating a vacuum
0907 Hydraulic oil cooler
Hydraulic oil cooler
Technical specifications
Removing
Installing
0910 Pumps
Ground drive hydraulic pump
Technical specifications
Work preparation
Removing
Installing
Removing the direction of travel valve block
Disassembling the direction of travel valve block
Assembling the direction of travel valve block
Installing the direction of travel valve block
Adjusting the hydraulic zero position
Replacing the high-pressure relief valve
Replacing the charge pressure relief valve
Replacing the pressure cut-off
Replacing the regulating valve
Replacing the shuttle valve
Working hydraulics pump
Technical specifications
Work preparation
Removing
Sealing the drive shaft
Installing
10 Electrical / Electronic equipment
1005 Power supply
Technical specifications
Removing
Installing
1010 Central electrics
Central terminal compartment
Technical specifications
Removing
Installing
1012 Modules / sensors
Rear compartment monitoring
Technical specifications
Removing
Installing
1020 Driving lights
Front main head lamp
Technical specifications
Removing
Installing
Rear drive lights
Technical specifications
Removing
Installing
Numberplate lighting
Technical specifications
Removing
Installing
1025 Working lights
Work light
Technical specifications
Removing
Installing, left side
1030 Board computer / Indicators
Rear camera
Technical specifications
Removing
Installing
1035 Operation / Multifunction control lever
Control lever
Technical specifications
Removing
Installing
Control panel
Technical specifications
Removing
Installing
12 Cab / Operator’s platform
1210 Cab
Technical specifications
Removing
Installing
Roof covering
Technical specifications
Removing
Installing
Door lock / locking device
Technical specifications
Removing
Installing
Front windscreen wiper
Technical specifications
Removing
Installing
Rear wiper
Technical specifications
Removing
Installing
1230 Seat
Driver’s seat
Technical specifications
Installation
1235 Cab heater
Heater/air conditioning unit
Technical specifications
Removing
Installing
1240 Air condition
Air conditioner compressor
Technical specifications
Installation
Anti-icing protection sensor
Removing
Installing
75 Central lubrication system
7505 Reservoir / Pump
Grease container
Technical specifications
Installing
7510 Distributor
Progressive distributor
Technical specifications
Removing
Installing
80 Various components / Machine body
8015 Access
Cab access
Technical specifications
Removing
Installing
8025 Panellings / Hoods
Engine bonnet
Technical specifications
Removing
Installing
Side panel
Technical specifications
Removing
Installing
8035 Ballast / Additional weight
Ballast weight
Technical specifications
Removing the left ballast weight
Installing the left ballast weight
Removing the right ballast weight
Installing the right ballast weight
8045 Legal equipment
Backup warning unit
Removing
Installing
95 Maintenance parts overview
9599 Maintenance jobs
Maintenance position 1
Maintenance position 2
Adjusting the valve lash
Adjusting the valve lash
Checking the glow plugs of the diesel engine
Changing the fuel pre-filter
Changing the fuel fine filter element
Changing the fuel fine filter element
Changing the diesel engine oil
Draining oil
Topping up oil
Changing the diesel engine oil
Draining oil
Topping up oil
Changing the diesel engine oil filter
Work preparation
Changing the diesel engine oil filter
Work preparation
Replacing the filter element of the diesel engine oil separator
Replacing the filter element of the diesel engine oil separator
Checking the ventilation system of the crankcase
Checking the ventilation system of the crankcase
Checking the anti-freeze and anti-corrosion protection function of the diesel engine coolant
Correcting the anti-freeze concentration
Use of anti-corrosion agent without anti-freeze
Changing the coolant
Draining the coolant
Topping up coolant
Top up coolant in the cooling system
Topping up coolant in the compensating tanks
Checking the intake system and the exhaust system
Checking the intake system
Checking the exhaust system
Checking the diesel engine belt
Changing the diesel engine belt
Changing the filter module of the diesel particulate filter
Changing the urea filter
Changing the urea pre-filter element
Checking the axle transfer gearbox oil level
Changing the axle transfer gearbox oil
Draining oil
Topping up oil
Testing and measuring the ground drive
Checking the universal drive shafts
Checking the axles’ oil level
Differential gear
Wheel hubs
Changing the axles’ oil
Draining the differential gearbox oil
Topping up the differential gearbox oil
Draining the wheel hubs’ oil
Topping up the wheel hubs’ oil
Checking the tightening torque of the mounting bolts on the front axle
Checking the service brake wear
Checking the parking brake wear
Work preparation
Checking the brake lining wear
Checking the operating clearance
Replacing the brake linings
Adjusting the operating clearance
Testing and measuring the brake system
Testing and measuring the steering system
Checking the bucket bearing sleeves on the lift arms
Checking the bucket stops
Checking the magnetic rod of the hydraulic oil tank
Draining the condensate and sediment from the hydraulic oil tank
Changing the hydraulic oil tank return line filter cartridge
Changing the hydraulic oil tank fresh air filter element
Changing the hydraulic oil
Draining the hydraulic oil
Topping up hydraulic oil
Performing a hydraulic oil analysis
Checking and measuring the working hydraulics
Checking the liquid level of batteries
Replacing the forward/reverse control rocker switch and the multifunction handle cap
Checking the air conditioner filter receiver dryer
Checking the heater and air conditioning system

00 0305 185 0.pdf:

DPS 4045DPS 6068
Table of contents
Introduction
General information
Validity of manual
Using the manual
Text and figures
Document structure based on sub-assemblies
Search and find
Directions
Abbreviations
Technical terms
General repair instructions
Technical specifications
Information on technically correct repairs
Self-locking bolts
Liquid locking compound
Steel roller chains
Tensioning
Chain connector
Chain connector type E with spring
Chain connector type G with wire
Chain connector type S with cotter pins
Taper ring fasteners
Dismounting
Installation
Gib head key connections
Dismounting
Installation
Lock collar bearing
Dismounting
Installing
Adapter sleeve bearing
Dismounting
Installation
Chuck bushing
Removing
Dismounting of version A
Dismounting of version B
Installing
Chuck bushing version A
Chuck bushing version B
Circlips
Ferrule fittings
Screwing in
Leaky ferrule fittings
Sealing cone fittings
Hydraulic hoses
Hose placement
Treatment of sealing faces
Spare parts
Tightening torques
Tightening torques for metric ISO screw thread
Tightening torques for metric fine thread
Tightening torques for screwed pipe connections with sealing cone joint and hydraulic threaded joints with soft core seal
Tightening torques for hydraulic fittings with ferrule
Tightening torques for hydraulic male connectors SDS shape B and E
Tightening torques for hydraulic swivel screw fittings
Tightening torque for hollow screws (with copper sealing ring)
Tightening torques for hydraulic male connectors SDE shape H, with adjustable direction
Tightening torques for brake line screw fittings
Tightening torques for worm drive hose clamps
Tightening torques for hose clamps with round pins
CCN explanation
CCN (CLAAS Component Number)
Electric systems standard
Hydraulic system standard
CCN (CLAAS Component Number)
Explanation of symbols
Personnel requirements
Follow the safety instructions
Proposition 65 (California)
Rules for avoiding damage to health and personal injury
Rules and regulations on pollutant emissions
Fuels, lubricants and coolant
01 Engine
0102 Complete component
Cranking the engine
Special tool
0110 Engine housing
Timing gear cover
Technical specifications
Removing
Installing
Timing gear cover
Technical specifications
Removing
Installing
Front panel
Technical specifications
Removing
Installing
Front panel
Technical specifications
Removing
Installing
Cylinder block
Technical specifications
Dimensional properties of the four-cylinder engine
Work preparation
Special tool
Removing
Checking
Installing
Cylinder block
Technical specifications
Special tool
Removing
Checking
Installing
Oil sump
Technical specifications
Removing
Installing
Oil sump
Technical specifications
Removing
Installing
Exhaust gas throttle valve (twin turbochargers)
Technical specifications
Removing
Installing
Crankcase ventilation
Technical specifications
Checking
Crankcase ventilation
Technical specifications
Removing
Checking
Installing
Crankshaft front seal
Technical specifications
Special tool
Removing
Installing
Crankshaft front seal
Technical specifications
Special tool
Removing
Installing
Crankshaft rear seal
Technical specifications
Special tool
Removing
Installing
Crankshaft rear seal
Technical specifications
Special tool
Removing
Installing
Flywheel housing
Technical specifications
Removing
Checking
Installing
Flywheel housing
Technical specifications
Removing
Checking
Installing
0115 Engine unit
Piston with connecting rod
Technical specifications
Special tool
Removing
Disassembling
Checking
Assembling
Installing
Measuring the excess dimension
Piston with connecting rod
Technical specifications
Special tool
Removing
Disassembling
Checking
Assembling
Installing
Measuring the excess dimension
Cylinder liner
Technical specifications
Special tool
Removing
Installing
Checking
Check the excess length
Cylinder liner
Technical specifications
Special tool
Removing
Installing
Checking
Check the excess length
Crankshaft
Technical specifications
Special tool
Removing
Checking
Checking the oil clearance
Checking the axial play
Reconditioning
Installing
Removing the crankshaft gear
Installing the crankshaft gear
Removing the crankshaft timing wheel
Installing the crankshaft timing wheel
Crankshaft
Technical specifications
Special tool
Removing
Checking
Checking the oil clearance
Checking the axial play
Reconditioning
Installing
Removing the crankshaft gear
Installing the crankshaft gear
Removing the crankshaft timing wheel
Installing the crankshaft timing wheel
Oscillation damper
Technical specifications
Special tool
Removing
Checking
Installing
Flywheel
Technical specifications
Removing
Disassembling
Assembling
Checking
Installing
Flywheel
Technical specifications
Removing
Disassembling
Assembling
Checking
Installing
Gear wheels of the valve train
Technical specifications of the four-cylinder engine
Dimensional properties
Special tool
Removing the upper intermediate gear wheel
Installing the upper intermediate gear wheel
Removing the lower intermediate gear wheel
Installing the lower intermediate gear wheel
Axial play of the intermediate gear wheels
Checking the upper intermediate gear wheel
Checking the lower intermediate gear wheel
Checking the backlash of the gear wheels of the valve train
Six-cylinder engine
Gear wheels of the valve train
Technical specifications of the six-cylinder engine
Dimensional properties
Special tool
Removing the upper intermediate gear wheel
Installing the upper intermediate gear wheel
Removing the lower intermediate gear wheel
Installing the lower intermediate gear wheel
Axial play of the intermediate gear wheels
Checking the upper intermediate gear wheel
Checking the lower intermediate gear wheel
Checking the backlash of the gear wheels of the valve train
Six-cylinder engine
Piston spray nozzle
Technical specifications
Removing
Checking
Installing
Piston spray nozzle
Technical specifications
Removing
Checking
Installing
Equaliser shafts
Specifications
Dimensional properties
Work preparation
Special tool
Removal Procedure
Removing the bushes
Checks and measurements
Bushings
Bore holes for the bushes
Main bearing of the equaliser shaft
Stop plate
Installing the bushes
Exchanging the equaliser shaft gear wheel
Installation
Checking the axial play of the equaliser shaft
Adjusting the equaliser shaft and the lower intermediate gear wheel
0120 Cylinder head / Valves / Idler gear
Valve cover
Technical specifications
Removing
Installing
Valve cover
Technical specifications
Removing
Installing
Checking
Cylinder head
Technical specifications
Special tool
Removing
Installing
Checking
Cylinder head
Technical specifications
Special tool
Removing
Installing
Checking
Glow plugs
Technical specifications
Removing
Installing
Checking
Glow plugs
Technical specifications
Removing
Installing
Checking
Glow plug heat shield
Technical specifications
Glow plug heat shield
Option A
Technical specifications
Removing
Installing
Option B
Technical specifications
Removing
Installing
Glow plug wiring harness
Technical specifications
Removing
Installing
Glow plug wiring harness
Technical specifications
Removing
Installing
Rocker arm
Technical specifications
Work preparation
Removing
Disassembling
Assembling
Installing
Checking the rocker arm
Rocker arm
Technical specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Checking the rocker arm
Technical specifications
Special tool
Removing the valves
Removing the valve guide
Removing the valve seat inserts
Installing the valve guide
Installing the valve seat inserts
Installing the valves
Checking the valves
Checking / adjusting the valve clearance
Technical specifications
Special tool
Removing the valves
Removing the valve guide
Removing the valve seat inserts
Installing the valve guide
Installing the valve seat inserts
Installing the valves
Checking the valves
Checking / adjusting the valve clearance
Camshaft
Technical specifications
Special tool
Removing the camshaft
Removing the camshaft gear
Removing the camshaft bush
Installing the camshaft bush
Installing the camshaft gear
Installing the camshaft
Checking
Adjusting the camshaft gear
Camshaft
Technical specifications
Special tool
Removing the camshaft
Removing the camshaft gear
Removing the camshaft bush
Installing the camshaft bush
Installing the camshaft gear
Installing the camshaft
Checking
Adjusting the camshaft gear
Cam tappet
Technical specifications
Removing
Installing
Cam tappet
Technical specifications
Removing
Installing
Checking
0125 Injection / Fuel system
High-pressure pump
Technical specifications
Special tool
Removing
Disassembling
Assembling
Installing
Control valve
Technical specifications
Removing
Installing
High-pressure pump
Specifications
Work preparation
Special tool
Removing
Disassembling
Assembling
Installing
Low-pressure fuel pump (four-cylinder engine)
Technical specifications
Removing
Installing
Pressure relief valve of the fuel common rail
Technical specifications
Removing
Installing
Pressure relief valve
Technical specifications
Removing
Installing
Flow controller
Technical specifications
Special tool
Removing
Installing
Flow controller
Technical specifications
Special tool
Removing
Installing
Technical specifications
Special tool
Removing
Installing
Technical specifications
Special tool
Removing
Installing
Fuel control solenoid coil
Technical specifications
Removing
Installing
Fuel pressure sensor
Technical specifications
Removing
Installing
Injection nozzle wiring harness
Technical specifications
Removing
Installing
Injection nozzle wiring harness
Technical specifications
Removing
Installing
Solenoid coil of the pressure control valve
Technical specifications
Removing
Installing
High-pressure injection lines and supply pipes
Technical specifications
Special tool
Removing
Installing
High-pressure injection lines and supply pipes
Technical specifications
Special tool
Removing
Installing
Injection nozzles
Technical specifications
Special tool
Removing
Installing
Injection nozzles
Technical specifications
Special tool
Removing
Installing
Injection nozzle sleeves
Technical specifications
Work preparation
Special tool
Removing
Installing
Injection nozzle sleeves
Technical specifications
Work preparation
Special tool
Removing
Installing
Push rods of the