Claas Torion 644 Sinus (K53) Wheel Loaders Repair Manual EN

File List:

00 0302 520 2.pdf
00 0303 370 3.pdf
00 0303 840 0.pdf
Webasto Water heater Thermo Pro 90 Thermo Pro 90 HDD.pdf

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

00 0303 370 3.pdf:

TORION 644 SINUSTORION 537 SINUS
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
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
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
Technical specifications
Work preparation
Removing
Installing
0125 Injection / Fuel system
Fuel tank
Technical specifications
Removing
Installing
Fuel sediment filter
Technical specifications
Removing
Installing
Fuel cooler
Technical specifications
Removing
Installing
0135 Cooling system
Engine radiator
Technical specifications
Work preparation
Removing
Installing
Fan motor
Technical specifications
Removing
Installing
Gear pump
Technical specifications
Removing
Installing
0140 Exhaust system
Diesel particulate filter
Technical specifications
Removing
Installing
0145 Air intake
Air filter housing
Technical specifications
Removing
Installing
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
Auxiliary tools
Removing
Installing
Axle body
Technical specifications
Removing
Installing
Bevel gear drive
Technical specifications
Work preparation
Auxiliary tools
Removing
Installing
Differential
Technical specifications
Work preparation
Auxiliary tools
Removing
Disassembling
Assembling
Installing
0316 Drive axle, front
Front drive axle
Technical specifications
Removing
Installing
Wheel hub
Technical specifications
Auxiliary tools
Removing
Installing
Axle body
Technical specifications
Work preparation
Installation instructions
Bevel gear drive
Technical specifications
Work preparation
Auxiliary tools
Removing
Installing
Differential
Technical specifications
Work preparation
Auxiliary tools
Removing
Disassembling
Assembling
Installing
0330 Rear steering drive axle
Rear driven steering axle
Technical specifications
Removing
Installing
Stub axle
Technical specifications
Auxiliary tools
Removing
Installing
Wheel hub
Technical specifications
Work preparation
Auxiliary tools
Removing
Installing
Axle body
Technical specifications
Removing
Installing
Floating axle
Technical specifications
Work preparation
Auxiliary tools
Removing
Installing
Differential
Technical specifications
Work preparation
Auxiliary tools
Removing
Disassembling
Assembling
Installing
0330 Rear steering drive axle
Rear driven steering axle
Technical specifications
Removing
Installing
Stub axle
Technical specifications
Auxiliary tools
Removing
Installing
Wheel hub
Technical specifications
Work preparation
Auxiliary tools
Removing
Installing
Axle body
Technical specifications
Work preparation
Auxiliary tools
Removing
Installing
Differential
Technical specifications
Work preparation
Removing
Disassembling
Assembling
Installing
0330 Rear steering drive axle
Axle transfer gearbox
Technical specifications
Work preparation
Auxiliary tools
Dismounting and disassembling
Assembling and installing
Shift cylinder
Technical specifications
Work preparation
Removing
Installing
0335 Ground drive
Ground drive hydraulic motor
Technical specifications
Work preparation
Removing
Installing
0340 Front wheels
Front wheels
Technical specifications
Removing
Installing
Special tool
0345 Rear wheels
Rear wheels
Technical specifications
Removing
Installing
Special tool
04 Brake
0400 Brake
Service brake
Technical specifications
Work preparation
Removing
Installing
Technical specifications
Work preparation
Removing
Installing
Service brake 2nd circuit
Technical specifications
Work preparation
Auxiliary tools
Removing
Installing
Service brake 2nd circuit
Technical specifications
Work preparation
Removing
Installing
Brake pedal
Technical specifications
Removing
Installing
Brake oil compensating tank
Technical specifications
Removing
Installing
05 Steering
0505 Steering
Steering column
Technical specifications
Removing
Installing
Orbitrol
Technical specifications
Removing
Installing
Steering hydraulic cylinder
Technical specifications
Removing
Installing
0530 Articulated steering
Steering linkage
Technical specifications
Work preparation
Removing the left steering rod
Removing the right steering rod
Installing the left steering rod
Installing the right steering rod
Adjusting the track
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 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
Removing
Installing
Working hydraulics pump
Technical specifications
Removing
Installing
0915 Hydraulic lines
Pilot control hydraulic accumulator
Technical specifications
Removing
Installing
0920 Valves
Pilot control unit
Technical specifications
Removing
Installing
Working hydraulics valve block
Technical specifications
Removing
Installing
10 Electrical / Electronic equipment
1005 Power supply
Technical specifications
Work preparation
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
Work preparation
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 wiper
Technical specifications
Removing
Installing
1230 Seat
Driver’s seat
Technical specifications
Removing
Installing
1235 Cab heater
Heating/cooling 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
Air conditioner 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 distribur
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
Inspection cover
Removing the inspection cover
Installing the inspection 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
Checking the valve lash
Adjusting the valve lash
Changing the fuel fine filter element
Changing the fuel pre-filter
Changing the diesel engine oil
Draining oil
Topping up oil
Changing the diesel engine oil filter
Checking the anti-freeze and anti-corrosion protection function of the diesel engine coolant
Correcting the anti-freeze concentration
Draining coolant
Topping up anti-corrosion/anti-freeze agent or pure water
Use of anti-corrosion agent without anti-freeze
Checking the concentration of the anti-corrosion agent
Changing the coolant
Draining the 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 the differential gearbox oil
Topping up the differential gearbox oil
Draining the wheel hubs’ oil
Topping up the wheel hubs’ oil
Checking the axles’ oil level
Differential gear
Wheel hubs
Checking the bearing seat of steering knuckle bearings and conical joints of steering rods
Checking the wear of brake discs
Checking the wear of brake discs
Checking the operating clearance and the wear of service brake 2nd circuit
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
Cleaning and lubricating the pilot control unit
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
If the value is not within the marked area:
Checking the heating system
Checking the air conditioner filter receiver dryer
Checking the air conditioner compressor V-belt
Replacing the air conditioner compressor V-belt

00 0303 840 0.pdf:

TORION 537TORION 644TORION 956
Table of contents
Validity of manual
Validity of manual
General safety precautions
Important
Marking of warnings and hazard prevention notes
10 Electrical / Electronic equipment
1000 Electrical / Electronic equipment general
Shipping package of repair kit 00 1954 769 X
Installation of repair kit 00 1954 769 X – machine types K51 and K53
Installation of repair kit 00 1954 769 X – machine type K54

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