Claas Torion 644 Sinus (K53) Wheel Loaders Technical System EN

File List:

00 0302 343 1.pdf
00 0302 565 2.pdf
00 0303 112 1.pdf
00 0303 899 0.pdf
CHP-numbers for connectors CLAAS HARNESS PARTS.pdf
Webasto Water heater Thermo Pro 90 Thermo Pro 90 HDD.pdf

00 0302 343 1.pdf:

PROFI CAM 3
Table of contents
General information
Marking of warnings and hazard prevention notes
First-aid measures
CCN explanation
CCN (CLAAS Component Number)
Electric system standard
Overview
Hydraulic system standard
Overview
CCN (CLAAS Component Number)
10 Electrical / Electronic equipment
1030 Board computer / Indicators
Camera system
Description of function
1097 Testing / Measuring / Adjusting
Testing / measuring / adjusting the PROFI CAM
Checking the fuse in the video channel select box (C102)
Testing the video camera connector (C055)
1098 Fault / remedy
Fault / remedy PROFI CAM
The video monitor (C101) shows no image or cannot be switched on (indicator light fails to light up)
Video monitor (C102) displays a blue image either permanently or temporarily
The video monitor image is blurred
Replacing the fuse in the video channel select box (C102)
Connection and connecting cable with video camera (C055)

00 0302 565 2.pdf:

Sensor system
Table of contents
CCN explanation
CCN (CLAAS Component Number)
Electric system standard
Overview
Hydraulic system standard
Overview
CCN (CLAAS Component Number)
Introduction
Safety rules
Safety and hazard information
10 Electrical / Electronic equipment
1097 Testing / Measuring / Adjusting
Test report of the angle sensor (0011780.x)
Application of test report
Required tools
Test report of the angle sensor (0011780.x)
Testing / Measuring / Adjusting of angle sensor (0011780.x)
1. Reason for test
2. Mechanical test of angle sensor
3. Electric test with CDS
4. Electric test with multimeter
5. Mechanical test of connecting cable
Completing the machine
Test report of position and speed sensors
Application of test report
Required tools
Sensor variants
Part numbers of speed sensors
Part number of position sensor
Test report of position and speed sensors
Testing / measuring / adjusting of position and speed sensors
1. Reason for test
2. Mechanical test
3. Electric test with CDS
4a. Installation dimensions
Check of installation dimension
Installation dimensions of gearbox speed sensor (0011 799.x) and cam speed sensor (0011 810.x)
Installation dimension of position sensor (0011 815.x)
4b. Installation position
Centring of sensor
Metal-free zone
5. Electric test with multimeter
Voltage measurement
Direction of rotation and speed sensor (0011 605.x)
Measured values table
6. Mechanical test of connecting cable
Completing the machine
Test report of the urea sensor (00 0773 207 x)
Application of test report
Required tools
Parts number of the urea sensor
Test report of the urea sensor
Testing / measuring / adjusting urea sensor
1. Reason for test
2. Mechanical test
3. Mechanical test of connecting cable
4. Electric test with multimeter
5. Component test with the CDS

00 0303 112 1.pdf:

TORION 537TORION 644
Table of contents
Introduction
Notes on the manual
Validity of manual
Information about this Technical Systems Manual
Using the manual
Document structure based on subassemblies
Search and find
Directions
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
Overview
Hydraulic system standard
Overview
CCN (CLAAS Component Number)
01 Engine
0135 Cooling system
Variable cooling fan
Without fan reversing
With fan reversing
Measured values table
Description of function
0150 Engine attachment parts
Overview of electric components on the diesel engine
Starting the diesel engine, accelerator pedal, fuel level sensor
Measured values table
Description of function
0155 Engine control
Electronic Engine Control
0165 Exhaust gas aftertreatment
Exhaust gas treatment
0197 Test/Measurement/Setting
Engine and cooling test protocol
Important notes and preparation
Test protocol
Testing and adjusting the drive
Checking the diesel engine speeds
Diesel particulate filter service regeneration
Testing and adjusting the cooling system hydraulics
Testing the fan solenoid valve
Maximum operating pressure
Checking the pressure limitation upon failure of fan solenoid valve
03 Chassis
0316 Drive axle, front
Selectable differential lock
Description of function
0335 Ground drive
Ground drive
Description of function
Drive pump
Description of function
Ground drive motor
Description of function
0397 Testing / measuring / adjusting
Ground drive test protocol
Important notes and preparation
Test protocol
Testing and adjusting the ground drive
Adjusting the pedals
Accelerator pedal
Inching pedal
Testing the deviation of the drive pump pressure sensor
Testing and adjusting the drive pump
Checking the charge pressure limiting valve
Testing the high pressure limiting valves
Testing the pressure cut-off
Drive pump block curve adjustment
Manual drive motor adjustment
Maximum swivel angle
Minimum swivel angle
External control pressure reduction valve
Check external control pressure hydraulic accumulator
04 Brake
0400 Brake
Brake system
Measured values table
Description of function
0497 Testing / measuring / adjusting
Brake system test protocol
Important notes and preparation
Test protocol
Testing and adjusting the brake system
05 Steering
0505 Steering
Steering
Description of function
06 Lift device
0630 Lift arms
Working attachment
Measured values table
Description of function
High flow option
Measured values table
Description of function
0697 Testing / measuring / adjusting
Working hydraulics test protocol
Important notes and preparation
Test protocol
Testing and adjusting the working hydraulics
Working hydraulics control block
Secondary pressure relief valves
Primary pressure relief
Setting the tipping-out rate reduction
Stabilisation module
Checking the pressure relief valve
Testing the vibration damping hydraulic accumulator
09 Hydraulic system
0910 Pumps
Working hydraulics pump
Description of function
0920 Valves
Fan reversing valve block
Compact brake valve
Description of function
Orbitrol steering unit
Description of function
Working hydraulics control block
Description of function
Description of function
Working hydraulics pilot control solenoid valve
Description of function
Working hydraulics pilot control unit
Description of function
Stabilisation module
Description of function
External control pressure valve block
Description of function
Differential lock and parking brake valve block
0980 Hydraulic circuit diagram
Cooling system hydraulic circuit diagram
Cooling system without reversing fan
Cooling system with reversing fan
Drive and gearbox hydraulics hydraulic circuit diagram
Differential lock hydraulic circuit diagram
Brake hydraulic circuit diagram
Steering hydraulic circuit diagram
Working hydraulics circuit diagram
Pipe break protection device hydraulic circuit diagram
High flow hydraulics circuit diagram
0997 Testing / measuring / adjusting
Testing the hydraulic accumulator nitrogen filling
10 Electrical / Electronic equipment
1005 Power supply
Earth points
1010 Central electrics
Cab main board – A4-LBH
Key to diagram
Fuse assignment
Relay assignment
1012 Modules / sensors
Module A10-LBH – Display
Key to diagram
Key to diagram
Module A15-LBH – Master control unit master 5
Key to diagram
Key to diagram
Module A27-LBH – Compact module 1
Key to diagram
Key to diagram
1080 Electrical circuit diagram
Introduction into electric circuit diagrams
Electric circuit diagrams of machine (SCM)
SCM 17 – Ignition switch
Key to diagram
SCM 18 – Alternator
Key to diagram
SCM 19 – Battery, master switch
Key to diagram
SCM 20 – Fan
Key to diagram
SCM 21 – Working hydraulics lock
Key to diagram
SCM 22 – Bucket return, float position
Key to diagram
SCM 23 – Driving ranges, vibration damping
Key to diagram
SCM 24 – Quick-hitch plate option
Key to diagram
SCM 25 – Automatic lift limitation option
Key to diagram
SCM 26 – Control lever fixing option
Key to diagram
SCM 27 – Mini joystick option
Key to diagram
SCM 28 – Working hydraulics valves
Key to diagram
SCM 29 – High flow option
Key to diagram
SCM 30 – Controlled capacity option
Key to diagram
SCM 31 – Accelerator pedal, inching pedal
Key to diagram
SCM 32 – Manual inching unit option
Key to diagram
SCM 33 – Tractive force reduction
Key to diagram
SCM 34 – Travel speed limitation
Key to diagram
SCM 35 – Direction of travel, control lever switch
Key to diagram
SCM 36 – Direction of travel, differential lock, hydraulic oil temperature
Key to diagram
SCM 37 – Ground drive / gearbox (1)
Key to diagram
SCM 38 – Ground drive / gearbox (2)
Key to diagram
SCM 39 – Parking brake, pipe break protection device
Key to diagram
SCM 40 – Lighting
Key to diagram
SCM 41 – Front work light
Key to diagram
SCM 42 – Rear work light
Key to diagram
SCM 43 – Additional lights, buzzer
Key to diagram
SCM 44 – Warning beacon
Key to diagram
SCM 45 – Steering column switch, turn signal indicator, hazard warning flasher
Key to diagram
SCM 46 – Horn, front windscreen wiper
Key to diagram
SCM 47 – Rear windscreen wiper
Key to diagram
SCM 48 – Interior lighting, broadcast receiver, driver’s seat, 12 V socket
Key to diagram
SCM 49 – Rear window heater, mirror heater
Key to diagram
SCM 50 – Heater and air conditioner (machine side)
Key to diagram
SCM 51 – Heater and air conditioner (system side)
Key to diagram
SCM 52 – Additional heater option
Key to diagram
SCM 53 – Additional heater option
Key to diagram
SCM 54 – CAN 1, fuel level sensor
Key to diagram
SCM 56 – Display
Key to diagram
SCM 60 – CAN 2
Key to diagram
SCM 63 – Master power supply
Key to diagram
SCM 64 – Compact module 1 power supply
Key to diagram
SCM 65 – Compact module 1 earth
Key to diagram
SCM 69 – Acoustic back-up warning system option
Key to diagram
SCM 70 – Warning flashlight option
Key to diagram
SCM 71 – Rear socket option
Key to diagram
SCM 72 – Front socket option
Key to diagram
SCM 73 – Central lubrication system option
Key to diagram
SCM 74 – Fuel pre-heater option
Key to diagram
SCM 75 – Cab fan option
Key to diagram
SCM 78 – Spare fuses
Key to diagram
SCM 79 – Spare fuses
Key to diagram
SCM 80 – Spare fuses, spare relays
Key to diagram
SCM 81 – Spare fuses, spare relays
Key to diagram
SCM 85 – Diesel particulate filter regeneration switch
Key to diagram
SCM 88 – Engine control earth
Key to diagram
SCM 89 – Engine timing, electric starting motor, pre-heating system, exhaust gas recirculation power supply
Key to diagram
SCM 90 – Diesel particulate filter
Key to diagram
SCM 91 – Engine timing information terminal 15, fuel lift pump, oil pressure switch, air filter vacuum switch, engine diagnosis
Key to diagram
SCM 92 – Diesel engine (engine side) transfer plug X36
Key to diagram
SCM 93 – Diesel engine (engine side) transfer plug X37
Key to diagram
SCM 94 – Diesel engine (engine side) transfer plug X38
Key to diagram
SCM 95 – Diesel engine (engine side) transfer plug X39
Key to diagram
SCM 99 – OBD diagnostic plug and telemetry system
Key to diagram
1085 Networks
CAN-BUS and Ethernet
Description of function
12 Cab / Operator’s platform
1240 Air condition
Heating, ventilation, air conditioning system
Measured values table
Description of function
75 Central lubrication system
7505 Reservoir / Pump
Central lubrication system
Description of function
7515 Lubrication system / Lines
Grease distribution
92 Diagnosis
9210 Error codes machine
Machine fault codes (DTC)
Position of components
Hydraulic system
1001-1999 Oil tank / filter / cooler
2001-2999 Pump / motor
3001-3999 Hydraulic cylinders
5001-5999 Accumulator
6001-6999 Valves – mechanically actuated (hydraulic system)
7001-7999 Valves – hydraulically actuated
8001-8999 Couplings / connections
9001-9999 Measuring points / gauges
Electric system
A Terminal / modules
B Sensors
E Lighting
G Voltage sources
H Signal device / light
R Potentiometers / resistors
S Switch / pushbutton – Cab operation
T Voltage transformer
X Connectors
Y Solenoid coils

CHP-numbers for connectors CLAAS HARNESS PARTS.pdf:

CLAAS HARNESS PARTS
Table of contents
10 Electrical / Electronic equipment
1081 Overview of connectors
CLAAS HARNESS PARTS (CHP)

Webasto Water heater Thermo Pro 90 Thermo Pro 90 HDD.pdf:

1 Introduction
1.1 Contents and purpose
1.2 Meaning of signal words
1.3 Additional documentation to be used
1.4 Legal requirements and safety information
1.4.1 Statutory regulations governing installation
1.4.2 General safety information
1.5 Spare parts
2 General description
2.1 Combustion air fan
2.2 Overheating protection, coolant temperature sensor and heat exchanger
2.3 Glow plug and burner unit
2.4 Combustion chamber
2.5 Exhaust gas temperature sensor
2.6 U4840 coolant pump
2.7 Control unit
2.8 DP42 fuel pump
3 Functional description
3.1 Switching on and residual heat utilization
3.2 Start and control mode
3.3 Switching off
3.4 Heater functions in ADR vehicles
4 Technical data
5 Malfunctions and troubleshooting
5.1 Procedure in the case of fault, malfunction and lock-out
5.1.1 Fault code output at the control element
5.2 Cause of malfunctions
5.3 Deleting fault code
5.3.1 Without Webasto Thermo Test PC Diagnostics
5.3.2 with Webasto Thermo Test computer diagnostics
5.4 Heater lock-out
5.5 Fault code table (fault codes, flash codes)
5.6 Troubleshooting (fault symptoms)
6 Function checks
6.1 General information
6.2 Function checks in the vehicle
6.3 Setting CO2 content
6.4 Testing individual components
6.4.1 Checking resistance of the coolant temperature sensor
6.4.2 Checking resistance of the glow plug
6.4.3 Checking resistance of the exhaust gas temperature sensor
6.4.4 Checking the combustion air fan
6.4.5 Checking the DP42 fuel pump
6.4.6 Checking the overheating protection
6.4.7 Checking the U4840 coolant pump
7 Servicing
7.1 Working on the heater
7.2 Working on the vehicle
7.3 Heater test run
7.4 Checks
7.5 Removing and installing heater
7.5.1 Removal
7.5.2 Installation
7.6 Visual inspection to assess the burner unit
7.6.1 Metal fiber evaporator
7.6.2 Combustion chamber
7.7 Restarting
8 Repairing and replacing components
8.1 General information
8.2 Component layout
8.3 Work on stripped down components
8.4 Electrical connections
8.5 Control unit
8.6 U4840 coolant pump
8.7 Overheating protection
8.8 Coolant temperature sensor
8.9 Combustion air fan
8.10 Burner unit and glow plug
8.11 Burner head
8.12 Heat exchanger
8.13 Exhaust gas temperature sensor
9 Thermo Pro 90 HDD
9.1 General information
9.2 Technical data
9.3 U4840 coolant pump with EMC suppressor module
9.3.1 Replacing the EMC suppressor module
9.4 Combustion air fan
9.5 Fuel
9.6 Control unit
9.7 Electrical components
9.8 Thermo Pro 90 HDD wiring diagrams
9.8.1 Legend to connector VG95328R2016PN (if installed)
10 Packaging/storage and shipping
10.1 General information
10.2 Storage and transportation
11 Wiring diagrams
11.1 Thermo Pro 90
11.2 Thermo Pro 90 HDD
11.3 System wiring diagram for Thermo Pro 90 with MultiControl control element with battery disconnector
11.4 System wiring diagram for Thermo Pro 90 with SmartControl control element (ADR)
11.5 System wiring diagram for Thermo Pro 90 with on/off switch (ADR)
11.6 System wiring diagram for Thermo Pro 90 with ThermoCall TC4
11.7 System wiring diagram for Thermo Pro 90 with UniBox
11.8 System wiring diagram for Thermo Pro 90 with MultiControl control element (analogue connection)
11.9 System wiring diagram for Thermo Pro 90 HDD with MultiControl control element
11.10 System wiring diagram for Thermo Pro 90 HDD with SmartControl control element (ADR)
11.11 System wiring diagram for Thermo Pro 90 HDD with on/off switch (ADR)
11.12 Cable cross-sections
11.13 Cable colours
11.14 Heater connections
11.15 Plug assignments at control unit
11.16 Legend to wiring diagrams
11.17 Legend for comments
11.18 Legend for plug X8, 12-pin