Claas Torion 535 (K65) Wheel Loaders Operator Manual EN

File List:

00 0301 051 0.pdf
00 0305 735 0.pdf

00 0301 051 0.pdf:

PROFI CAM 3
Table of contents
1 Introduction
1.1 Notes on the manual
1.1.1 Validity of manual
1.1.2 Information about this Operator’s Manual
1.1.3 Symbols and notes
1.1.4 Optional equipment
1.1.5 Qualified specialist workshop
1.1.6 Maintenance information
1.1.7 Warranty notes
1.1.8 Spare parts and technical questions
1.2 Intended use
1.2.1 Intended use
1.2.2 Reasonably foreseeable misuse
2 Safety
2.1 Identifying warnings
2.1.1 Hazard signs
2.1.2 Signal word
2.2 Safety rules
2.2.1 Meaning of Operator’s Manual
2.2.2 Observing safety decals and warnings
2.2.3 Optional equipment and spare parts
3 Product description
3.1 Overview and method of operation
3.1.1 How the PROFI CAM works
3.2 Identification plates and identification number
3.2.1 Position of identification plates
3.2.2 Explanation of PROFI CAM identification plate
3.3 Information on the product
3.3.1 CE marking
4 Operating and control elements
4.1 Camera system
4.1.1 Camera system monitor
4.2 Menu structure
4.2.1 Main menu
4.2.2 menu
4.2.3 menu
4.2.4 menu
4.2.5 menu
4.2.6 menu
5 Technical specifications
5.1 PROFI CAM
5.1.1 Monitor
5.1.2 Camera
5.1.3 Switch box
5.1.4 Degree of protection against foreign bodies and water
6 Preparing the product
6.1 Shutting down and securing the machine
6.1.1 Switching off and securing the machine
6.2 Prior to operation
6.2.1 Carry out prior to operation
6.2.2 Installing the sun protection
6.2.3 Aligning the camera
6.2.4 Connecting the camera electrics
7 Operation
7.1 Monitor
7.1.1 Switching on the monitor
7.1.2 Calling up the menu
7.1.3 Setting a menu item
7.1.4 Setting the image orientation
7.1.5 Setting automatic screen darkening
7.1.6 Image mirroring
7.1.7 Setting the trigger view
7.1.8 Setting the follow-up time for trigger view
7.1.9 Setting the display mode
7.1.10 Activating/deactivating a display mode
8 Faults and remedies
8.1 Electrical and electronic system
8.1.1 Overview of problems on PROFI CAM camera system
8.1.2 Replacing the switch box fuse
9 Maintenance
9.1 Maintenance intervals
9.1.1 Every 10 operating hours or daily
9.2 Camera system
9.2.1 Checking the camera system for dirt
9.2.2 Cleaning the camera
9.2.3 Cleaning the switch box
9.2.4 Cleaning the monitor
10 Placing out of operation and disposal
10.1 General Information
10.1.1 Putting out of operation and disposal
11 Technical terms and abbreviations
11.1 Abbreviations
11.1.1 Units
11.1.2 Abbreviations
11.1.3 Technical terms

00 0305 735 0.pdf:

TORION 639TORION 535TORION 530
Table of contents
1 Introduction
1.1 General information
1.1.1 Validity of manual
1.1.2 Information about this Operator’s Manual
1.1.3 Symbols and notes
1.1.4 Optional equipment
1.1.5 Qualified specialist workshop
1.1.6 Maintenance notes
1.1.7 Notes on warranty
1.1.8 Spare parts and technical questions
1.2 Intended use
1.2.1 Intended use
1.2.2 Reasonably foreseeable misuse
2 Safety
2.1 Identifying warnings
2.1.1 Hazard signs
2.1.2 Signal word
2.2 Safety rules
2.2.1 Importance of Operator’s Manual
2.2.2 Observing safety decals and warnings
2.2.3 Requirements for all persons working with the machine
2.2.4 Children in danger
2.2.5 Hazard areas
2.2.6 Persons riding on the machine
2.2.7 Hitching the machine to the working attachment
2.2.8 Hitching of machine to a trailer
2.2.9 Structural alterations
2.2.10 Optional equipment and spare parts
2.2.11 Roll-over protective structure and falling object protective structure
2.2.12 Control of the machine while it is running
2.2.13 Operation only following proper putting into operation
2.2.14 Technical condition
2.2.15 Danger from damage to the machine
2.2.16 Respecting technical limit values
2.2.17 Keeping safety devices functional
2.2.18 Personal protective equipment
2.2.19 Wearing suitable clothing
2.2.20 Removing dirt and loose objects
2.2.21 Field of view and viewing aids
2.2.22 Preparing the machine for road travel
2.2.23 Hazards when driving on the road and on the field
2.2.24 Parking the machine safely
2.2.25 Towing or salvaging the machine
2.2.26 Unsuitable operating utilities
2.2.27 Safe handling of operating and auxiliary utilities
2.2.28 Fuel is harmful to your health
2.2.29 Refrigerant is harmful to your health
2.2.30 Environmental protection and disposal
2.2.31 Keeping the cab free of chemicals
2.2.32 Avoiding fires
2.2.33 Potentially fatal electric shock from electric overhead lines
2.2.34 Behaviour in case of voltage flashover from overhead lines and of lightning strikes
2.2.35 Electrocution by electrical system
2.2.36 Oscillations may damage your health
2.2.37 Pressurised fluids
2.2.38 Toxic exhaust gas
2.2.39 Hot surfaces
2.2.40 Accessing and leaving the machine safely
2.2.41 Working on machine only after shutting it down
2.2.42 Maintenance operations and repair work
2.2.43 Lifted loads
2.2.44 Danger from welding work
2.2.45 Checking and charging the battery
2.3 Safety marking
2.3.1 Structure of safety decals
2.3.2 Warning signs on the machine
Safety decal (1)
Safety decal (2)
Safety decal (3)
safety decal (4)
Safety decal (5)
safety decal (6)
3 Machine description
3.1 Overview and method of operation
3.1.1 Overview of the wheel loader
3.1.2 Overview of work lights and drive lights
3.2 Optional equipment
3.2.1 Coolant pre-heating*
3.2.2 Crane arm*
3.2.3 Fire extinguisher*
3.3 Identification plates and identification numbers
3.3.1 Position of the identification plate
3.3.2 Details provided on the identification plate
3.4 Information on the machine
3.4.1 Position of decals
3.4.2 Decals
Working hydraulics (1)
Sound power level (2)
Hydraulic oil (3)
Fire extinguisher (4)
Seat belt (6)
Refrigerant (7)
Cooling system (8)
Sling point, lifting point (9)
Lashing point (10)
Ground speed (11)
Lubrication chart (12)
Load-bearing capacity table for pallet fork operation* (13)
Coolant (14)
Diesel fuel (15)
Emergency exit (16)
4 Operating and display elements
4.1 Cab and operator’s platform
4.1.1 Operator’s platform
4.1.2 Keys and switches
4.1.3 Multifunction handle
4.1.4 Ignition lock
4.1.5 Steering column switch
4.2 On-board information system
4.2.1 Display
4.2.2 Overview of status symbols
4.2.3 Overview of warning symbols
4.2.4 Overview of diesel particulate filter warning symbols
5 Technical specifications
5.1 TORION
5.1.1 Dimensions of TORION 639 with bucket
5.1.2 Dimensions of TORION 639 with 4-in-1 bucket*
5.1.3 Dimensions of TORION 639 with pallet fork*
5.1.4 Dimensions of TORION 535 with bucket
5.1.5 Dimensions of TORION 535 with 4-in-1 bucket*
5.1.6 Dimensions of TORION 535 with pallet fork*
5.1.7 Dimensions of TORION 530 with bucket
5.1.8 Dimensions of TORION 530 with 4-in-1 bucket*
5.1.9 Dimensions of TORION 530 with pallet fork*
5.1.10 Vibrations
Hand/arm vibrations
Whole-body vibrations
5.1.11 Sound pressure level and sound power level
5.1.12 Temperature of use
5.1.13 4TN86CHT diesel engine
5.1.14 Diesel engine 4TNV88C
5.1.15 CO2 emissions of diesel engine
5.1.16 Chassis
Ground drive
Ground speed
5.1.17 Axles
Front axle
Rear axle
5.1.18 Tyres and tyre pressure
5.1.19 Tyres and tyre pressure
5.1.20 Tyres and tyre pressure
5.1.21 Snow chains* or guard chains*
5.1.22 Foam-filled tyres*
5.1.23 Brake
5.1.24 Steering
5.1.25 Lift arms
Work cycle time at permissible load capacity
5.1.26 Load-bearing capacity table for the telescoping crane arm*
5.1.27 Electric system
5.1.28 Hydraulic system
Working hydraulics
5.1.29 Cab
Driver’s seat
Heating and ventilation
Air conditioning system*
5.1.30 Ballast
5.2 Operating utilities
5.2.1 Lubricants
5.2.2 Lubricants
5.2.3 Hydraulic oil
5.2.4 Coolant
5.2.5 Fuels
5.2.6 Brake fluid
5.2.7 Refrigerant
5.2.8 Windscreen washer liquid
6 Machine preparation
6.1 Switching off and securing the machine
6.1.1 Switching off and securing the machine
6.1.2 Lowering the working attachment to the ground
6.1.3 Switching the battery isolating switch on and off
6.1.4 Securing the machine against rolling away
Securing the machine while the diesel engine is off
Securing the machine while the diesel engine is on
6.2 Accessing workplaces and maintenance spaces
6.2.1 Accessing the workplace in the cab
Accessing the cab
Leaving the cab
6.3 Diesel engine
6.3.1 Selecting the permitted fuel
6.3.2 Observing the fuel specification
6.3.3 Refuelling fuel
6.4 Chassis
6.4.1 Changing the tyre dimensions
6.5 Lift arms and working attachment
6.5.1 Removing the working attachment
6.5.2 Relieving the hydraulic pressures of the lift arms
6.5.3 Relieving the hydraulic pressures of the working attachment
6.5.4 Disconnecting the hydraulic lines
6.5.5 Unlocking and disconnecting the working attachment
6.5.6 Installing the working attachment
6.5.7 Coupling and locking the working attachment
6.5.8 Checking the working attachment lock
Visual inspection
Mechanical check
6.5.9 Connecting the hydraulic lines
Connecting the hydraulic lines
6.6 Loading the machine
6.6.1 Preparing the machine for loading with a crane
6.6.2 Loading the machine with a crane
6.6.3 Preparing the machine for lorry or railway transport
6.6.4 Driving the machine on a loading space
6.6.5 Driving the machine from a loading space
6.6.6 Lashing down the machine
Machine-specific lashing instructions
Centre of gravity of machine
Interface parameters
Lashing material capacities
Securing the machine
6.6.7 Applying and removing the articulation lock
Engaging the articulation lock
Releasing the articulation lock
7 Operation
7.1 Driving and transportation
7.1.1 Preparing for driving operation
7.1.2 Preparing road travel
7.1.3 Carry out a function check
7.1.4 Driving
Starting off the machine
7.1.5 Picking up material
7.1.6 Transporting and transferring material
7.1.7 Transporting the load on a slope
7.1.8 Driving on sloping ground
7.1.9 Emptying the working attachment
7.1.10 Handling materials with high dump buckets
7.1.11 Loading with a clamp bucket
7.1.12 Levelling
Forward levelling
Backwards levelling
7.1.13 Removing material
Removing material from the slope
Removing material from the wall
7.1.14 Loading a transport vehicle
Transport routes
Loading process
7.1.15 Working near electric overhead lines
7.1.16 Loading large rocks
7.1.17 Reversing the machine
7.1.18 Excavating material
Excavating foundations
7.1.19 Towing the machine from the hazard area
Towing with the diesel engine running
After towing
Towing with the diesel engine switched off
After towing
7.1.20 Setting the ground drive to free circulation
7.2 Diesel engine
7.2.1 Pre-heating the coolant in the diesel engine*
7.2.2 Starting the diesel engine
Starting process
Speed increase for improving the charging capacity
7.2.3 Switching off the diesel engine
7.2.4 Automatic diesel engine shut-down*
7.3 Chassis
7.3.1 Shifting gears
7.3.2 Selecting and changing the direction of travel
Selecting the direction of travel.
Changing the direction of travel
7.3.3 Switching vibration damping* on and off
7.3.4 Variable speed limit* and fixed throttle*
Fixing the diesel engine speed for stationary operation
Fixing the diesel engine speed and the ground speed for driving operation
7.4 Brake
7.4.1 Braking the machine
7.4.2 Applying and releasing the parking brake
7.4.3 Releasing the parking brake mechanically
7.5 Lift arms and working attachment
7.5.1 Blocking and releasing the working hydraulics
7.5.2 Moving the lift arms and working attachment
Raising the lift arms
Lowering the lift arms
Tilting bucket in
Tilting bucket out
Raise the lift arms while tilting the bucket in
Raising the lift arms while tilting the bucket out
Lowering the lift arms while tilting the bucket in
Lowering the lift arms while tilting the bucket out
7.5.3 Operating a working attachment with its own hydraulic oil supply*
7.5.4 Mini joystick*
Controlling a working attachment
Switching continuous operation* on and off
7.5.5 Activating and deactivating the float position
7.5.6 Operating the pallet fork*
Adjusting the fork arms on the fork carrier
Working with the pallet fork
7.5.7 Operating the telescoping crane arm*
Installing the crane arm
Adjusting the crane arm
Working with the crane arm
7.5.8 Emergency operation of the lift arms
7.6 Hitch
7.6.1 Operating the automatic trailer hitch*
Hitching the trailer
Unhitching the trailer
7.6.2 Towing hitch*
7.7 Electric and electronic system
7.7.1 Engaging the parking position
7.7.2 Switching the lighting on and off
Switching the dipped beam, tail light, side light* and registration plate light* on and off
Switching the main beam on and off
Switching the work lights on and off
Switching the work lights for reverse travel on and off
Activating the direction indicator
Switching the warning beacon* on and off
7.7.3 Switching the reversing warning systems on and off
Reversing horn
Flashlight
Warning beacon on the cab roof
7.8 Cab and operator’s platform
7.8.1 Adjusting the driver’s seat
7.8.2 Applying the seat belt
7.8.3 Adjusting the steering column*
Adjusting the clearance between steering wheel and body
Adjusting the steering wheel height
Adjusting the steering wheel inclination
7.8.4 Adjusting the rear view mirror
7.8.5 Adjusting heater, ventilation and air conditioner*
Setting the temperature
Setting the fan
Switching the air conditioner* on and off
7.8.6 Switching the rear window heater on and off
7.8.7 Actuating the windscreen washer system
Cleaning the front windscreen
Cleaning the rear window
7.8.8 Switching the cab interior lighting on and off
7.8.9 Adjusting the sun visor
7.8.10 Opening and closing the cab window
Opening the right cab window by 180°
Opening the right cab window by a gap
7.8.11 Opening the emergency exit
7.9 Central lubrication system
7.9.1 Central lubrication system*
Starting intermediate lubrication
8 Faults and remedies
8.1 Overview
8.1.1 Warnings and fault messages
8.1.2 Overview of fault codes
8.1.3 Overview of warning symbols
8.2 Diesel engine
8.2.1 Overview of diesel engine faults
8.3 Brake
8.3.1 Overview of faults on the brake system
8.4 Steering
8.4.1 Overview of faults on the steering system
8.5 Electric and electronic system
8.5.1 Jump-start 12 V
Starting the diesel engine with jumper cables and an external battery
Charging the batteries
8.5.2 Replacing fuses
Fuse board in the cab
Fuses in the battery compartment
Additional fuses*
8.5.3 Overview of faults on the electric system
8.6 Hydraulic system
8..1 Overview of faults on ground drive hydraulics
8.6.2 Overview of faults on wrking hydraulics
8.7 Cab and operator’s platform
8.7.1 Overview of faults on the heating system
8.8 Central lubrication system
8.8.1 Overview of faults on the central lubrication system*
9 Maintenance
9.1 Maintenance intervals
9.1.1 Every 10 operating hours or daily
9.1.2 After the first 50 operating hours
9.1.3 Every 50 operating hours
9.1.4 Every 250 operating hours
9.1.5 After the first 500 operating hours
9.1.6 Every 500 operating hours
9.1.7 Every 1000 operating hours
9.1.8 Every 2 years
9.1.9 Every 2000 operating hours
9.1.10 Every 3000 operating hours
9.1.11 Every 4000 operating hours
9.1.12 Every 6000 operating hours
9.1.13 Every 10000 operating hours
9.2 Lubrication chart
9.2.1 Lubricate the lubrication points every 10 operating hours
9.2.2 Lubricate the lubrication points every 50 operating hours
9.3 Preparing maintenance
9.3.1 Moving the machine to the maintenance position
Maintenance position I
Maintenance position II
9.3.2 Opening the service hatches
Opening and closing the engine bonnet
9.4 Diesel engine
9.4.1 Cleaning the diesel engine
9.4.2 Checking the diesel engine oil level
Checking the oil level on the dipstick
Topping up oil
9.4.3 Checking the diesel engine belt
Checking the belt tension
Adjusting the belt tension
9.4.4 Draining condensed water and sediments from the fuel tank
9.4.5 Draining condensed water from the fuel pre-filter
9.4.6 Cleaning the air filter lid and dust discharge valve
Cleaning the lid
Cleaning the dust discharge valve
9.4.7 Cleaning the air filter main element
Removing the filter element
Cleaning the filter element
Cleaning the filter housing and the cover
Installing the filter element
9.4.8 Replacing the air filter safety cartridge
9.4.9 Checking the coolant level
9.4.10 Cleaning the cooling system
9.4.11 Regenerating the diesel particulate filter
(A) Starting regeneration automatically
(B) Suppressing regeneration
(C) Starting regeneration manually
9.5 Chassis
9.5.1 Checking the wheels, tyres and the tyre pressure
9.5.2 Checking the tyre pressure
9.5.3 Checking the tightening torque of wheel nuts
9.6 Brake
9.6.1 Checking the function and effect of the service brake
9.6.2 Checking the function and effect of the parking brake
9.6.3 Checking the brake fluid level
Checking the brake fluid level
Topping up brake fluid
9.7 Steering
9.7.1 Checking the steering system function
9.8 Lift arms and working attachment
9.8.1 Checking the function of the tool carrier
9.9 Hydraulic system
9.9.1 Checking the hydraulic oil level
Checking the hydraulic oil level
Topping up hydraulic oil
9.9.2 Checking the hydraulic hoses
Marking of hydraulic hoses
9.10 Electric and electronic system
9.10.1 Checking the lights and horn
9.11 Cab and operator’s platform
9.11.1 Cleaning the cab
Cleaning inside the cab
Cleaning the rear window
9.11.2 Cleaning or replacing the cab air filter
9.11.3 Checking the condition and function of the seat belt
9.11.4 Topping up windscreen washer
9.11.5 Draining the air conditioner* condensed water
9.12 Central lubrication system
9.12.1 Checking the grease level in the central lubrication system*
Checking the filling level
Topping up grease
9.12.2 Checking the tightness and function of the central lubrication system*
9.13 Assembled parts/Machine housing
9.13.1 Checking the fire extinguishers
9.13.2 Checking the proper condition of the machine
9.13.3 Removing loose parts and pollution from the machine
9.13.4 Cleaning the machine
Prior to cleaning
Cleaning
After cleaning
9.13.5 Cleaning and servicing seals
Cab seals
Engine bonnet seals
9.13.6 Storing the machine
10 Putting out of operation and disposal
10.1 General information
10.1.1 Removal from service and disposal
11 EC declaration of conformity
11.1 TORION
11.1.1 EC declaration of conformity (sample)
11.1.2 EC declaration of conformity (sample)