Claas Torion 535 (K50) Wheel Loaders Repair Manual EN

File List:

00 0302 503 3.pdf
00 0302 520 2.pdf

00 0302 503 3.pdf:

TORION 639TORION 535
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
Operating materials
Tightening torques
Tightening torques for metric standard and fine threads
Tightening torques for hydraulic fittings with ferrule
Tightening torques for screwed pipe connections with sealing cone joint and hydraulic threaded joints with soft core seal
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 torque for tubes with O-ring and union nuts
Tightening torques for worm drive hose clamps
Tightening torques for hose clamps with round pins
General tightening torques for Bosch-Rexroth
CCN explanation
CCN (CLAAS Component Number)
Electric systems standard
Hydraulic system standard
CCN (CLAAS Component Number)
General information
Safety and hazard information
Important
Signal word
General safety and accident prevention regulations
First-aid measures
Danger of injury from hydraulic liquid
Leaving the machine
Putting the machine out of operation
Jacking up the machine
Adjusting and maintenance work
Welding work
01 Engine
0102 Complete component
Diesel engine
Technical specifications
Work preparation
Removing
Removing the ground drive pump
Installing the ground drive pump
Installing
0125 Injection / Fuel system
Fuel tank
Technical specifications
Removing
Installing
Fuel cooler
Technical specifications
Removing
Installing
0135 Cooling system
Engine radiator
Technical specifications
Removing
Installing
0140 Exhaust system
Diesel particulate filter
Technical specifications
Work preparation
Removing
Installing
0145 Air intake
Air filter housing
Technical specifications
Installation
0155 Engine control
Accelerator pedal
Technical specifications
Removing
Installing
02 Gearbox / Clutch / Universal drive shaft
0260 Universal drive shaft
Universal drive shaft
Technical specifications
Removing
Installing
03 Chassis
0316 Drive axle, front
Front drive axle
Technical specifications
Removing
Installing
Wheel hub
Technical specifications
Work preparation
Special tool
Removing
Installing
Planetary gear
Technical specifications
Special tool
Disassembling
Assembling
Installation
Axle body
Technical specifications
Special tool
Installation
Bevel gear drive
Technical specifications
Work preparation
Special tool
Removing
Installing
Differential
Technical specifications
Work preparation
Disassembly
Assembly
Installation
0317 Drive axle, rear
Rear drive axle
Technical specifications
Installation
Wheel hub
Axle body
Planetary gear
Bevel gear drive
Differential
Axle transfer gearbox
Technical specifications
Work preparation
Removing
Disassembling
Assembling
Installing
0335 Ground drive
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
0400 Brake
Technical specifications
Removing
Installing
Venting the brake
Brake pedal
Technical specifications
Removing
Installing
Brake oil compensating tank
Technical specifications
Removing
Installing
05 Steering
0505 Steering
Steering column
Technical specifications
Removing
Disassembling
Assembling
Installing
Orbitrol
Technical specifications
Removing
Installing
Steering hydraulic cylinder
Technical specifications
Removing
Installing
06 Lift device
0630 Lift arms
Lift arms
Technical specifications
Removing
Installing
Quick-hitch plate hydraulic cylinder
Technical specifications
Special tool
Removing
Installing
Lift cylinder
Technical specifications
Removing
Installing
Tipping cylinder
Technical specifications
Removing
Installing
Guide lever
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
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
Installing
0920 Valves
Working hydraulics valve block
Technical specifications
Removing
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
Central control module
Removing
Installing
Engine control module
Removing
Installing
1020 Driving lights
Drive light
Technical specifications
Removing, left side
Removing, right side
Installing, left side
Installing, right side
1025 Working lights
Work light
Technical specifications
Removing, left side
Removing, right side
Installing, left side
Installing, right side
1035 Operation / Multifunction control lever
Control lever
Technical specifications
Removing
Installing
Technical specifications
Removing
Installing
Control panel 1
Technical specifications
Removing
Installing
Control panel 2
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
Windscreen washer liquid tank
Technical specifications
Removing
Installing
Front windscreen wiper
Technical specifications
Removing
Installing
Rear windscreen wiper
Technical specifications
Removing
Installing
1230 Seat
Driver’s seat
Technical specifications
Removin Installing
1235 Cab heater
Heater andir conditioner housing
Technical specifications
Removing
Installing
Technical specifications
Removing
Installing
Heater valve
Technical specifications
Removing
Installing
1240 Air condition
Air conditioner condenser
Technical specifications
Removing
Installing
Dry filter
Technical specifications
Removing
Installing
Refrigerating compressor
Technical specifications
Removing
Installing
75 Central lubrication system
7505 Reservoir / Pump
Grease container
Technical specifications
Removing
Installing
7510 Distributor
Progressive distributor
Removing the main progressive distributor
Removing the rear section progressive distributor
Removing the front section progressive distributor
Removing the lift arms progressive distributor
Installing the lift arms progressive distributor
Installing the front section progressive distributor
Installing the rear section progressive distributor
Installing the main progressive distributor
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 the left side panel
Removing the right side panel
Removing the front side panel
Installing the left side panel
Installing the right side panel
Installing the front side panel
Left side cover
Removing the left side cover
Installing the left side cover
Right side cover
Removing the right side cover
Installing the right side cover
8030 Mud guards
Rear right wheel case
Technical specifications
Removing
Installing
Rear left wheel case
Technical specifications
Removing
Installing
8035 Ballast / Additional weight
Ballast weight
Technical specifications
Removing
Installing
95 Maintenance parts overview
9599 Maintenance jobs
Maintenance position 1
Maintenance position 2
Adjusting the valve lash
Replacing the fuel pre-filter element
Changing the fuel fine filter
Changing the diesel engine oil
Draining oil
Topping up oil
Changing the diesel engine oil filter
Work preparation
Checking the anti-freeze and anti-rust protection function of the diesel engine coolant
Correcting the anti-freeze concentration
Use of anti-rust compound without anti-freeze
Changing the coolant
Draining coolant
Topping up coolant
Changing the diesel engine belt
Checking the intake system
Checking the intake system
Checking the tightness and tight seat of the exhaust system
Checking the tightness and tight seat of the exhaust system
Checking the tightness and tight seat of the air intake system
Checking the function of the air filter vacuum switch
Changing the filter module of the diesel particulate filter
Changing the axle transfer gearbox oil
Draining oil
Topping up oil
Checking the axle transfer gearbox oil level
Testing and measuring the ground drive
Checking the universal drive shafts
Checking the tightening torque of the mounting bolts on the axles
Changing the axles’ oil
Draining oil
Topping up oil
Checking the axles’ oil level
Differential
Checking the bearing seat of steering knuckle bearings and conical joints of steering rods
Checking the brake operating clearance and wear
Checking the wear
Checking 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
Performing a hydraulic oil analysis
Changing the hydraulic oil
Draining the hydraulic oil
Topping up hydraulic oil
Changing the hydraulic oil tank fresh air filter element
Changing the hydraulic oil tank return line filter cartridge
Draining the condensate and sediment from the hydraulic oil tank
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 heater and air conditioning system
Checking the air conditioner filter receiver dryer
Checking the air conditioner compressor V-belt
Replacing the air conditioner compressor V-belt

00 0302 520 2.pdf:

YANMAR 4TNV88CYANMAR 4TNV86CHTYANMAR 4TNV98CYANMAR 4TNV98CT
Table of contents
Introduction
General repair instructions
Technical specifications
Information on proper repairs
Self-locking bolts
Liquid locking compound
Steel roller chains
Tensioning
Chain-connect link
Chain-connect link type E with spring
Chain-connect link type G with wire
Chain-connect link type S with cotter pins
Taper ring fasteners
Dismounting
Installing
Gib head key connections
Dismounting
Installing
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
Welding work
ESD protection measures
Special tool
ESD protection measures
Notes on inspection and repair
Tightening torques
Tightening torques for standard bolts/nuts (YANMAR)
Threaded assemblies according to CLAAS works standard CN 02 5000
Description of threaded assembly
Tolerance class
Tightening specifications
Tightening torques for metric ISO screw threads
Tightening torques for metric fine thread screws
Tightening torques for hydraulic couplings/unions 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
CCN explanation
CCN (CLAAS Component Number)
Electric systems standard
Hydraulic system standard
CCN (CLAAS Component Number)
01 Engine
0102 Complete component
Identification plates
4TNV98C / 4TNV98CT
4TNV86CHT / 4TNV88C
Engine serial number plate (example)
Emission regulations decal
EPA decal (example)
EPA/ARB decal (example)
Emission regulations
97/68/EC decal (example)
Engines approved according to regulation 97/68/EC
Engine components 4TNV88C / 4TNV86CHT
Technical specifications
Technical specifications
Engine components 4TNV98C(T)
Technical specifications
Technical specifications
Technical specifications
Diesel engine characteristics
Diesel engine characteristics
Diesel engine characteristics
Diesel engine characteristics
Cranking the diesel engine
0110 Engine housing
Oil sump
Technical specifications
Work preparation
Removing
Installing
Front panel and transmission housing
Technical specifications
Work preparation
Removing
Installing
Timing housing cover
Technical specifications
Work preparation
Removing
Installing
0115 Engine unit
Piston and connecting rod
Technical specifications
Work preparation
Special tool
Removing
Checking
Checking, honing and drilling the cylinder block
Installing
Crankshaft
Technical specifications
Work preparation
Removing
Installing
Timing gears
Technical specifications
Removing
Installing
0120 Cylinder head / Valves / Idler gear
Valve cover
Technical specifications
Removing
Installing
Cylinder head
Technical specifications
Removing
Installing
Checking
Glow plugs
Technical specifications
Removing
Installing
Rocker arm
Technical specifications
Removing
Disassembling
Assembling
Installing
Checking
Technical specifications
Work preparation
Special tool
Removing
Installing
Checking the valves
Checking and adjusting the valve lash
Camshaft
Technical specifications
Work preparation
Removing
Installing
Checking
Technical specifications
Removing
Checking
Installing
0125 Injection / Fuel system
Technical specifications
Work preparation
Removing
Installing
Injector
Technical specifications
Work preparation
Removing
Installing
High-pressure pump
Technical specifications
Work preparation
Removing
Installing
0130 Lubricating oil system
Oil pump
Technical specifications
Removing
Cleaning/checking
Installing
0135 Cooling system
Technical specifications
Draining
Topping up
EGR cooler
Technical specifications
Naturally aspirated engine
Technical specifications
Turbocharged engine
Removing
Cleaning
EGR valve
Technical specifications
Naturally aspirated engine
Turbocharged engine
Removing
Cleaning
Removing
Coolant pump
Technical specifications
Work preparation
Removing
Disassembling
Assembling
Installing
0140 Exhaust system
Exhaust throttle
Naturally aspirated engine
Technical specifications
Turbocharged engine
Cleaning
Exhaust manifold
Technical specifications
Installation instructions
Exhaust turbocharger
Technical specifications
Work preparation
Removing
Installing
0145 Air intake
Inlet manifold
Technical specifications
Installation instructions
0150 Engine attachment parts
Electric starting motor
Technical specifications
Removing
Cleaning and checking
Assembling
Checking the distance the pinion protrudes
Installing
Alternator
Technical specifications
Removing
Disassembling
Assembling
Installing
Technical specifications
Removing
Disassembling
Assembling
Installing