Claas Torion 535 (K50) Wheel Loaders Repair Manual ES

File List:

00 0302 505 3.pdf
00 0302 522 0.pdf

00 0302 505 3.pdf:

TORION 639TORION 535
Introduction
General information
Manual validity
Using the manual
Texts and illustrations
Breakdown of the structure of constructive groups
Search and find
Direction signs
Abbreviations
Technicalities
General repair instructions
Technical instructions
Indications for correct repair
Self-locking screws
Liquid screw insurance
Steel roller chains
connecting link
Type E connecting link with spring
Type G connecting link with wire
S type connecting link with pins
Tapered ring joints
Disassembly
Mounting
Head key joints
Disassembly
Mounting
Bearings with tension ring
Disassembly
Mounting
Bearing with tensioner sleeve
Disassembly
Mounting
Tension bushing
Disassemble
Disassembly version A
Disassembly version B
Tension bushing version A
Tension bushing version B
Safety rings
Screw connections with adjustment ring
Screw connections with non-sealed adjusting ring
Screw connections with sealing cone
Hydraulic hoses
Laying of hoses
Joint surface work
Replacement parts
Consumables
Tightening torques
Tightening torques for metric normal thread and metric fine thread
Tightening torques for hydraulic bolted connections with cutting ring
Tightening torques for fittings with tapered seal connection and hydraulic connections with soft seal ring
Tightening torques for SDS form B and E hydraulic threaded fittings
Tightening torques for oscillating hydraulic threadings
Tightening torques for hollow screws (with copper gasket)
Tightening torques for SDE form H hydraulic threaded fittings, adjustable
Tightening torques for brake pipe threading
Tightening torques for pipe supports with O-ring and union nuts
Tightening torques for helical thread clamps
Tightening torques for hose clamps with round bolt
General tightening torques Bosch-Rexroth
CCN Explanation
CCN (CLAAS Component Number)
General indications
Electrical regulations
Hydraulic regulations
CCN (CLAAS Component Number)
Security
General information
Safety and hazard instructions
Especially important
General safety measures and accident prevention rules
First aid measures
Risk of injury from hydraulic fluid
Leave the machine
Put the machine out of service
Raise the machine on supports
Adjustment and maintenance work
Welding work
01 Engine
0102 Complete component
Diesel engine
Technical instructions
Preparation for work
Disassemble
Remove the propulsion pump
Install the propulsion pump
0125 Fuel/injection system
Fuel tank
Technical instructions
Disassemble
fuel radiator
Technical instructions
Disassemble
0135 Cooling system
engine radiator
Technical instructions
Disassemble
0140 Exhaust gas system
diesel particulate filter
Technical instructions
Preparation for work
Disassemble
0145 Air suction
air filter box
Technical instructions
Disassemble
0155 Engine adjustment
Accelerator pedal
Technical instructions
Disassemble
02 Gears / clutch / cardan shaft
0260 Cardan shaft
cardan shaft
Technical instructions
Disassemble
03 Chassis
0316 Front drive axle
Front drive axle
Technical instructions
Disassemble
wheel hub
Technical instructions
Preparation for work
special tool
Disassemble
planetary gear
Technical instructions
special tool
Disassemble
shaft body
Technical instructions
special tool
Disassemble
Drive with bevel pinion
Technical instructions
Preparation for work
special tool
Disassemble
Differential
Technical instructions
Preparation for work
Disassemble
0317 Rear drive axle
rear drive axle
Technical instructions
Disassemble
wheel hub
shaft body
planetary gear
Drive with bevel pinion
Differential
transfer case
Technical instructions
Preparation for work
Disassemble
0335 Propulsion
Hydraulic propulsion motor
Technical instructions
Preparation for work
Disassemble
0340 Front wheels
front wheels
special tool
Disassemble
0345 Rear wheels
Rear wheels
special tool
Disassemble
04 Brake
0400 Brake
Technical instructions
Disassemble
Bleed the brake
Brake pedal
Technical instructions
Disassemble
Brake oil compensation tank
Technical instructions
Disassemble
05 Address
0505 Address
steering bar
Technical instructions
Disassemble
Orbitrol
Technical instructions
Disassemble
Hydraulic steering cylinder
Technical instructions
Disassemble
06 Lifting device
0630 Lifting arms
Lifting arms
Technical instructions
Disassemble
Hydraulic cylinder, quick changer
Technical instructions
special tool
Disassemble
Lifting cylinder
Technical instructions
Disassemble
tipping cylinder
Technical instructions
Disassemble
Gearshift
Technical instructions
Disassemble
09 Hydraulics
0900 General instructions for the hydraulic installation
General indications of the hydraulic installation
special tool
Fill the pressure accumulator
0905 Hydraulic oil tank
Hydraulic oil tank
Technical data
special tool
Disassemble
Create underpressure
No longer generate underpressure
0907 Hydraulic oil cooler
Hydraulic oil cooler
0910 Bombs
Hydraulic propulsion pump
Technical instructions
Preparation for work
Disassemble
Remove the forward direction valve block
Disassemble the forward direction valve block
Assemble forward direction valve block
Install the forward direction valve block
Adjust the hydraulic zero point
Replace the high pressure limiting valve
Replace the supply pressure limiting valve
Replace pressure cutout
Replace the regulating valve
Replace the circuit selector
Hydraulic pump of working hydraulic system
Technical instructions
Preparation for work
Disassemble
0920 Valves
Valve block of the working hydraulic system
Technical instructions
Disassemble
10 Install. electrical/electronic
1005 Power supply
Technical instructions
Disassemble
1010 Central electrical system
central electrical system
Technical instructions
Disassemble
1012 Modules / sensors
central control module
Disassemble
engine control module
Disassemble
1020 Advance lighting
Advancement focuses
Technical instructions
Remove, left side
Remove, right side
Fit, left side
Fit, right side
1025 Work lighting
Work focuses
Technical instructions
Remove, left side
Remove, right side
Fit, left side
Fit, right side
1035 Multifunctional handle/lever
Joystick
Technical instructions
Disassemble
Technical instructions
Disassemble
Control panel 1
Technical instructions
Disassemble
Control panel 2
Technical instructions
Disassemble
12 Driver’s cab/platform
1210 Cabin
Technical instructions
Disassemble
Roof covering
Technical instructions
Disassemble
Door lock / latch
Technical instructions
Disassemble
windshield wiper reservoir
Technical instructions
Disassemble
Front windshield wiper
Technical instructions
Disassemble
rear wiper
Technical instructions
Disassemble
1230 Seat
Driver’s seat
Technical instructions
Disassemble
1235 Cabin heating
Heating – air conditioning box
Technical instructions
Disassemble
Technical instructions
Disassemble
Heating valve
Technical instructions
Disassemble
1240 Air conditioning equipment
air conditioning condenser
Technical instructions
Disassemble
dry filter
Technical instructions
Disassemble
cold compressor
Technical instructions
Disassemble
75 Central lubrication
7505 Container, pump
Lubricant tank
Technical instructions
Disassemble
7510 Distributor
Progressive dealer
Remove the main progressive distributor
Remove the progressive distributor from the rear
Remove the progressive distributor from the front
Remove the progressive distributor from the lifting arms
Install the progressive distribution of the lifting arms
Install the progressive distributor at the front
Install the progressive distributor at the rear
Assemble the main progressive distributor
80 Attached parts, machine casing
8015 Rise
Technical instructions
Disassemble
8025 Coverings / hoods
engine hood
Technical instructions
Disassemble
Side covering
Technical instructions
Remove the left side panel
Remove the right side panel
Remove the front side panel
Install the left side panel
Install the right side panel
Install the front side panel
Left side cover
Remove the left side cover
Install the left side cover
Right side cover
Remove the right side cover
Install the right side cover
8030 Mudguard
Right rear wheel housing
Technical instructions
Disassemble
Left rear wheel housing
Technical instructions
Disassemble
8035 Counterweight / additional weight
Counterweight
Technical instructions
Disassemble
95 Maintenance parts summary
9599 Maintenance work
Maintenance position 1
Maintenance position 2
Adjust valve clearance
Change fuel prefilter element
Change the fuel filter
Change diesel engine oil
Drain oil
Fill oil
Change the diesel engine oil filter
Preparation for work
Check the antifreeze protection and anticorrosive protection of the diesel engine coolant
Correct the concentration of antifreeze protection
Using anticorrosive agent without antifreeze agent
Change the cooling agent
Empty cooling agent
Fill cooling agent
Change the diesel engine belt
Check the suction system
Check the suction system
Check the tightness and tight fit of the exhaust gas system.
Check the tightness and tight fit of the exhaust gas system.
Check the tightness and firm fit of the air intake system
Check the operation of the air filter underpressure switch
Change the diesel particulate filter module
Change transfer case oil
Drain oil
Fill oil
Check the transfer case oil level
Check and measure propulsion
Check the cardan shafts
Check the tightening torque of the axle retaining screws
Change the axle oil
Drain oil
Fill oil
Check the axle oil level
differential gear
Check the seat of the crankpin bearing and the tapered joints of the steering rods
Check running clearance and brake wear
Wear check
Check operating clearance
Check and measure the brake system
Check and measure the guidance system
Check the lifting arm bucket bushings
Check the bucket stops
Perform hydraulic oil analysis
Change hydraulic oil
Drain hydraulic oil
Fill hydraulic oil
Change the hydraulic oil tank ventilation filter
Change the hydraulic oil tank return filter element
Empty condensate and sediment from the bottom of the hydraulic oil tank
Check and measure the working hydraulic system
Check the battery fluid level
Replacing the rocker arm of the forward direction switch and the cap on the multifunctional control
Check heating and air conditioning equipment
Check the air conditioning filter dryer
Check air conditioning compressor belt
Change the air conditioning compressor belt

00 0302 522 0.pdf:

YANMAR 4TNV98CYANMAR 4TNV98CT
Introduction
General information
Manual validity
Using the manual
Texts and figures
Division with construction group structure
Search and find
Direction signs
Abbreviations
Technicalities
General repair instructions
Technical instructions
Indications for correct repair
Self-locking screws
Liquid screw insurance
Steel roller chains
connecting link
Tapered ring joints
Disassembly
Mounting
Head key joints
Disassembly
Mounting
Bearings with tension ring
Disassembly
Mounting
Bearings with tensioner sleeve
Disassembly
Mounting
Tension bushing
Disassemble
Disassembly version A
Disassembly version B
Tension bushing version A
Tension bushing version B
Safety rings
Screw connections with adjustment ring
Screw connections with non-sealed adjusting ring
Screw connections with sealing cone
Hydraulic hoses
Laying of hoses
Joint surface work
Replacement parts
Tightening torques
Tightening torques for standard screws/nuts (YANMAR)
Tightening torques for normal metric threads
Tightening torques for metric fine threads
Tightening torques for hydraulic threads and air conditioning threads with sealing cone and O-ring DIN 3865
Tightening torques for hydraulic threads with adjusting ring DIN 3861
Tightening torques for SDS form B and E hydraulic threaded fittings
Tightening torques for hydraulic rotary screw connections
Tightening torques for hollow screws DIN 7643
Tightening torques for SDE form H hydraulic threaded fittings, with adjustable direction
Tightening torques for brake hose bolting
Tightening torques for helical thread clamps
Tightening torques for hose clamps with round bolt
CCN Explanation
CCN (CLAAS Component Number)
General indications
Electrical regulations
Hydraulic regulations
CCN (CLAAS Component Number)
Security
Foreword
Symbols explanation
General indications
Requirements for personnel
Prescriptions to avoid accidents with personal injury and damage to the environment
Prescriptions to avoid health & environmental damage
Limitation of liability for spare parts and accessories
Tips on how to avoid engine damage and premature wear
Emergency driving program for engines with electronic control device
Information regarding work on the Common Rail system
AdBlue®/DEF Handling
Engine check
Assembly instructions
01 Engine
0102 Complete component
Engine characteristic data
Engine characteristic data
Engine Description
engine components
Technical instructons
Technical instructions
Technical instructions
turn the engine
0110 Engine asing
Technical instructions
Preparation for work
Disassemble
Faceplate and gear box
Technical instructions
Preparation for work
Disassemble
Control box coverage
Technical instructions
Preparation for work
Disassemble
0115 Engine propulsion
Piston and connecting rod
Technical instructions
Preparation for work
special tool
Disassemble
Find out
Check, hone and bore cylinder block
Crankshaft
Technical instructions
Preparation for work
Disassemble
Drive pinions
Technical instructions
Disassemble
0120 Cylinder head / valves / distributor wheel
Valve Coverage
Technical instructions
Disassemble
Technical instructions
Disassemble
Technical instructions
Disassemble
Technical instructions
Preparation for work
special tool
Disassemble
Check the valves
Check and adjust valve clearance
Camshaft
Technical instructions
Preparation for work
Disassemble
Technical instructions
Disassemble
Find out
0125 Fuel/injection system
Technical instructions
Preparation for work
Disassemble
Injector
Technical instructions
Preparation for work
Disassemble
high pressure pump
Technical instructions
Preparation for work
Disassemble
0130 Lubricating oil system
Oil pump
Technical instructions
Disassemble
Clean/check
0135 Cooling system
Cooling agent
Technical instructions
Fill out
Coolant pump
Technical instructions
Preparation for work
Disassemble
0140 Exhaust gas system
exhaust gas elbow
Technical instructions
Assembly instructions
Exhaust gas turbocharger
Technical instructions
Preparation for work
Disassemble
0145 Air suction
Suction elbow
Technical instructions
Assembly instructions
Technical instructions
Disassemble
0150 Engine coupled parts
Starting motor
Technical instructions
Disassemble
Clean and check
Check the protrusion of the bevel pinion
Generator
Technical instructions
Disassemble
Technical instructions
Disassemble