CLAAS SCORPION 9040, 7045, 7040, 7030, 6030 SERVICE
  • CLAAS SCORPION 9040, 7045, 7040, 7030, 6030 SERVICE
  • CLAAS SCORPION 9040, 7045, 7040, 7030, 6030 SERVICE
  • CLAAS SCORPION 9040, 7045, 7040, 7030, 6030 SERVICE
  • CLAAS SCORPION 9040, 7045, 7040, 7030, 6030 SERVICE

CLAAS SCORPION 9040, 7045, 7040, 7030, 6030 SERVICE

$50.00
Brand: Claas
Product Code: Claas
Availability: In Stock
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03.2012 / All Regions / 1 CD / Windows OS, MacOS, Linux / 32 & 64 bit

CLAAS Scorpion Telehandler PDF Service & Repair Manual

SCORPION
9040 (404-03)
7045 (403-03)
7040 (402-03)
7030 (401-03)
6030 (400-01)

Service and Repair documentation, Assembly/Installation instructions, Adjustment instructions, Fitting instructions, Lubrication/Maintenance, Technical systems, Electrical diagrams, Troubleshooting and other

Language: English

MANUAL CONTENT:
Machine specifications: overview
Machine outside view
Inside of cab: overview
Instrument panel, multifunctional lever, switch consoles: overview
Abbreviations/symbols
Model and trade names: overview
Type labels and component numbers
Serial number
Cab number
Hydraulic pump number
Variable displacement motor number
Variable displacement motor number (high speed option)
Front and rear axle numbers
Frame
Engine
Oil/water cooling fan
Power train
Variable displacement pump
Variable displacement motor
Axles
Front axle
Rear axle
Service and parking brake
Steering system
Work hydraulics
Hydraulic pump
Hydraulic ram protection
Lift, tilt and push-out rams: velocity
Hydraulic pilot control
Additional control circuit (option)
Electric system
Fuses: overview
Electric components
Main fuse box with relays (88 kW diesel engine)
Main fuse box with relays (103 kW diesel engine)
Relays: overview
Tyres for models 400-01/401-03/402-03/403-03
Tyres for model 404-03
Weights
Noise levels
Vibration
Coolant compound table
Tightening torques
General tightening torques
Specific tightening torques
Trailer couplings: trailer weight/drawbar load
Payload: model 400-01 load diagram
Payload: models 401-03 load diagram
Payload: model 402-03 load diagram
Payloads: model 403 03 load diagram
Payloads: model 404 03 load diagram
Rigid front axle without oscillating axle interlock (rear axle)
Rigid front axle with mechanical or hydraulic oscillating axle
interlock (rear axle)
Front axle with frame levelling and without oscillating axle
interlock (rear axle)
Front axle with frame levelling and hydraulic oscillating axle
interlock (rear axle)
Dimensions with bucket
Dimensions with pallet forks

Maintenance and servicing work
Explanation of symbols on the maintenance label
Maintenance label
Fluids and lubricants: overview
Maintenance plan (overview)
Introduction
Safety prop for telescopic boom
Fuel system
Specific safety instructions
Refuelling
Stationary fuel pumps
Diesel fuel specification
Checking/replacing the fuel prefilter (water separator)
Replacing the fuel filter
Bleeding the fuel system
Engine lubrication system: maintenance
Checking the engine oil level
Filling up engine oil
Replacing the engine oil every 500 s/h (service hours)
Replacing the engine oil filter cartridge every 500 s/h (service hours)
Maintenance of the engine and hydraulics cooling system
Specific safety instructions
Checking the coolant level and quality
Filling up coolant
Draining coolant
Cleaning the radiator fins
Cleaning the radiator with the reversing fan (option)
Air filter maintenance
Checking air filter contamination
Replacing the filter cartridge at 500 s/h (service hours)
Maintenance: V-belts
Checking V-belt tension
Retightening the V-belts
Gearbox and axle maintenance
Checking the oil level in the gearbox
Filling up the gearbox oil
Changing the gearbox oil
Rear axle differential oil level
Draining the oil in the rear axle differential
Front axle differential oil level
Draining the oil in the front axle differential
Planetary drives: checking and filling up the oil level
Changing the oil
Safety instructions regarding the hydraulic system
Specific safety instructions
Monitoring the hydraulic oil and the reflux filter
Checking the hydraulic oil level
Filling up hydraulic oil
Replacing the reflux filter of the hydraulic system
Replacing the microfilter of the hydraulic system
Replacing hydraulic oil
Important information for the use of biodegradable oil
Checking hydraulic pressure lines
Specific safety instructions
Lubrication work
Central lubrication system (option)
Lubricating the rear axle oscillation-type bearing
Lubricating the planetary drive bearing
Lubrication points on the telescopic boom: overview
Lubricating the telescopic boom
Checking the slide plates
Setting the lubrication and break times
Filling the central lubrication system
Maintenance of the brake system
Specific safety instructions
Checking/filling up the brake fluid level
Bleeding the hydraulic powerbrake
Replacing/bleeding the service brake fluid with bleed equipment
Bleeding the trailer brake valve (option)
Bleeding the parking brake
Maintenance: compressed-air brake system (option)
Checking the compressed-air tank and lines
Checking the compressor attachment and drive
Tyre maintenance
Daily tyre checks
Changing wheels
Heating and ventilation maintenance
Cleaning/replacing the fine-dust or active charcoal filter (option)
Cleaning/replacing the recirculated-air filter
Air conditioning (option): maintenance
General safety instructions for maintenance of the air conditioning system
Functional and visual check
Emptying/filling up the air conditioning system
Replacing the air conditioning compressor
Maintenance of the electric system
Specific safety instructions regarding maintenance and servicing
Service and maintenance work at regular intervals
Cables, bulbs and fuses
Alternator
Adjusting the headlights when using lightweight material buckets
Adjusting the headlights
Adjusting the headlights when using a lightweight material bucket
Checking/replacing the battery
Maintenance: trailer coupling
Rockinger trailer coupling
General maintenance work on the machine
Specific safety instructions regarding maintenance and servicing
Cleaning inside the cab
Cleaning the seat belt
Cleaning the exterior of the machine
Checking screw connections
Checking pivots and hinges
Cleaning the engine compartment
Maintenance and servicing work “Aggressive Media”
Anticorrosion protection applied in the factory
Safety instructions for maintenance of anticorrosion protection
Measures for maintaining anticorrosive protection
Applying the protective anticorrosion coating
Treatment of oxidised surfaces
Maintenance and servicing of attachments on the quickhitch

Engine
Electric system/hydraulics – fan: electric diagram
88 kW diesel engine electric system: electric diagram
103 kW diesel engine electric system: electric diagram
Fuel preheater (option): electric diagram
Diagnosis wiring diagram
Fan hydraulics diagram designations
Engine electric diagram designations
Fan: functional description
Fan control
Reversing function
Oil supply of the whole system (boost pressure)
Fan connector assignment for models 402, 403, 404
Diesel engine connector assignment (88 kW)
Diesel engine connector assignment (103 kW)
Fuel preheater connector assignment
Diagnosis connector assignment
Engine oil cooler side (88 kW): overview
Engine drive side (88 kW): overview
Engine turbocharger side (88 kW): overview
Engine oil cooler side (103 kW): overview
Engine drive side (103 kW): overview
Engine turbocharger side (103 kW): overview
Electronics overview (103 kW)
Electronic engine revs setting (103 kW): overview
Function: warning telltale in tip switch (103 kW diesel engine)
Reading out the flash code
Warning limit – coolant temperature
Warning limit – charge-air temperature
Warning limit –engine oil pressure
Overview of flashing codes
Engine drive – clutch (88/103 kW): overview
Fuel system (88/103 kW): overview
Bleeding the fuel system (88/103 kW)
Fan circuit (not in reversing operation)
Fan circuit with reversing fan
Reversing valve block
Revs control
Setting maximum fan revs (reversing fan)
Setting maximum fan revs (without reversing fan)
Cleaning the radiator with the reversing fan (option)
Function: reversing fan operation

Power train
40 kph drive hydraulics diagram for models 400 – 404
40 kph drive electrics diagram for models 402, 403, 404
20 kph hydraulic drive diagram for models 400 – 404
Drive electrics diagram for models 400 – 404
Drive hydraulics diagram descriptions
Electric diagram descriptions
Functional despcription of drive hydraulics and electric system
Oil supply via fan pump
Boost pressure circuit
Boost pressure relief valve
Pump adjustment
Motor adjustment
Drive output regulation
Flush feature
Locking driving direction selection
Holding the signal for the forwards driving direction selection
Holding the signal for the reverse driving direction selection
Drive speed control
Inching pedal function
Calibrating the inching pedal
Crawler gear potentiometer (R3)
Drive settings
Drive electrics connector assignment for models 400 – 404
Towing and transporting the machine
Getting ready for towing
Towing the machine
Hydraulic pump TMP 89 (models 402, 403, 404)
Hydraulic pump H1 P078 (models 400, 401)
High speed gearbox (0 – 40 kph)
High speed gearbox with auxiliary motor (0 – 40 kph)
Function without auxiliary motor (0 – 40 kph)
Function with auxiliary motor (0 – 40 kph)
Gearbox overview (0 – 40 kph)
Overview of control cover and gearbox circuit diagram (0 – 40 kph)
Control cover component parts for gearbox (0 – 40 kph)
Hydraulic drive circuit (0 – 40 kph)
Test report for models 400/401 (0 – 40 kph)
Error description for test report models 400/401 (0 – 40 kph)
Test report for models 402/403/404 (40 kph)
Error description for test report models 402/403/404 (40 kph)
Test report for models 403/404 (30 kph)
Error description for test report models 403/404 (30 kph)
Checking and setting boost pressure (0 – 40 kph gearbox)
Checking high pressure (0 – 40 kph)
Checking engine droop (pump) (0 – 40 kph)
Checking driving direction identification (0 – 40 kph)
Setting engine droop on the gearbox without auxiliary motor (0 – 40 kph)
Setting engine droop on the gearbox with auxiliary motor (0 – 40 kph)
Control initiation set screw (0 – 40 kph gearbox)
Checking the cardan shaft speed (0 – 40 kph gearbox)
Troubleshooting diagram (0 – 40 kph)
Check high pressure (HP valves)
Check pump engine droop, driving direction identification, differential pressure
measurement
Checking the differential pressure between M4 and M3 (0 – 40 kph)
Evaluation: differential pressure measurement M4 (0 – 40 kph)
Descriptions
Example: differential pressure measurement M4 (0 – 40 kph)
Clean the shuttle throttle
Evaluation: differential pressure measurement M3 (0 – 40 kph)
Descriptions
Function
Example: differential pressure measurement M3 (0 – 40 kph)
Cleaning the pressure relief valve
Drive electronics Operator's Manual (SUSMIC)
Error table
Checking proportional valve (1) energisation (0 – 40 kph)
Table of electric current values of proportional valves
Checking the proportional valves by means of current measurement
Exchanging proportional valves (0 – 40 kph)
Interrupting the hydraulic pump/motor circuit (0 – 40 kph)
Separating the consumer circuit from the hydraulic drive
Checking control pressure M4/M5 (0 – 40 kph)
Variable displacement pump control pressure H1 P078
Variable displacement pump TMP 89 control pressure
Checking the control pressure (control piston pressure)
Sealing work on the drive shaft (0 – 40 kph gearbox)
Mounting the rotary shaft seal (0 – 40 kph gearbox)
Mounting the drive flange (0 – 40 kph gearbox)
Checking driving direction identification (0 – 40 kph gearbox)
Removing driving direction identification (0 – 40 kph gearbox)
Variable displacement motor 110 cm3/rev (20 kph, seen from the side)
Variable displacement motor 160 cm3/rev (20 kph)
Test report for models 400 – 404 (20 kph)
Error description for test report models 400/401 (20 kph)
Hydraulic circuit: drive with hydraulic pump H1 P078 (20 kph)
Hydraulic circuit: drive with hydraulic pump TMP 89 (20 kph)
Setting boost pressure (20 kph)
Checking high pressure (20 kph)
Checking engine droop – variable displacement pump (20 kph)
Setting engine droop – hydraulic motor (20 kph)
Setting cardan shaft revs (20 kph)

Axles – differential lock
Differential lock diagrams (hydraulic/electric)
Designations: differential lock electric diagram
Designations: differential lock hydraulics diagram
Functional description of differential lock
Oil supply via fan pump (010)
Differential lock controls
Differential lock connector assignment
Installing the 20 kph gearbox
Front and rear axle flanges
Type label and oil filler neck: overview
Conversion table and tightening torques
Removing the joint housing
Installing the joint housing
Removing the double cardan shaft
Installing the double cardan shaft
Replacing the seals of the planetary drive
Installing the planetary drive
Installing the planetary drive
Sealing the front axle differential
Removing the front axle differential lock
Differential lock: overview
Installing the front axle differential lock
Differential lock: hydraulic circuit
Special tools: overview

Brakes
Brake (20 kph) diagrams (electric/hydraulic)
Brake (40 kph) diagrams (electric/hydraulic)
Hydraulics diagram – trailer brake valve
Designations: hydraulic brake diagram
Designations: electric brake diagram
Functional description of brakes
Oil supply via fan pump (010)8
Compressed-air brake lead
Releasing the parking brake
Starting interlock
Monitoring the parking brake
Service brake
Parking brake
Brakes connector assignment
40 kph brake circuit: overview
20 kph brake circuit: overview
Disabling (releasing) the parking brake in the front axle
Enabling (adjusting) the parking brake in the front axle
Wear check: service brake discs
Setting the brake linkage – master brake cylinder
Service and parking brake: overview
Removing the brake discs
Removing the brake pistons and the belleville spring washers of the
service brake
Brake discs: overview
Installing the the brake pistons of the service and parking brake
Installing the belleville spring washers and the brake cylinder housing
Installing the service brake
Setting value for the service brake discs
Installing the service brake discs
Towing and transporting the machine
Getting ready for towing
Towing the machine
Hydraulic trailer brake circuit (option)

Steering
Steering diagrams (electric/hydraulic)
Designations: hydraulic steering diagram
Designations: electric steering diagram
Functional description of steering system
Steering system oil supply
Priority of steering system oil supply
Emergency steering function
Steering modes 4
Steering electronics
Brakes connector assignment

Work hydraulics
Diagram: work hydraulics fixed displacement pump – raising/lowering
the telescopic boom
Diagram: work hydraulics variable displacement pump – raising/lowering
the telescopic boom
Electric diagram – raising/lowering the telescopic boom, load stabiliser
Work hydraulics
Diagram: work hydraulics fixed displacement pump – raising/lowering
the telescopic boom
Diagram: work hydraulics variable displacement pump – raising/lowering
the telescopic boom
Electric diagram – raising/lowering the telescopic boom, load stabiliser
Work hydraulics diagram – extending/retracting the telescopic boom,
fixed displacement pump
Diagram: work hydraulics variable displacement pump – extending/retracting
the telescopic boom
Electric diagram – extending/retracting the telescopic boom
Diagram: work hydraulics fixed displacement pump – dumping in/out
Diagram: work hydraulics variable displacement pump – dumping in/out
Electric diagram – dumping in/out
Diagram: work hydraulics fixed displacement pump – locking/unlocking
Diagram: work hydraulics variable displacement pump – locking/unlocking
Electric diagram – locking/unlocking
Diagram: work hydraulics fixed displacement pump – rear additional
control circuit
Diagram: work hydraulics variable displacement pump – rear additional
control circuit
Diagram: work hydraulics fixed displacement pump – rear additional
control circuit – Autohitch
Diagram: work hydraulics variable displacement pump – rear additional
control circuit, Autohitch
Diagram: work hydraulics fixed displacement pump – rear additional
control circuit, Autohitch, tipping trailer
Diagram: work hydraulics variable displacement pump – rear additional
control circuit, Autohitch, tipping trailer
Diagram: work hydraulics fixed displacement pump – rear additional
control circuit, tipping trailer
Diagram: work hydraulics variable displacement pump – rear additional
control circuit, tipping trailer
Diagram: work hydraulics fixed displacement pump – Autohitch
Diagram: work hydraulics variable displacement pump – Autohitch
Diagram: work hydraulics fixed displacement pump – Autohitch, tipping trailer
Diagram: work hydraulics variable displacement pump – Autohitch,
tipping trailer
Diagram: work hydraulics fixed displacement pump – tipping trailer
Diagram: work hydraulics variable displacement pump – tipping trailer
Diagram: work hydraulics variable displacement pump – additional
control circuit for quick couplers on telescopic boom
Diagram: work hydraulics – safe load indicator
Electric diagram – front/rear additional control circuit for quick couplers,
Autohitch, tipping trailer, front socket, safe load indicator
Diagram: work hydraulics variable displacement pump – additional
control circuit for quick couplers on quickhitch
Diagram: work hydraulics variable displacement pump – work platform
with radio control
Work platform with radio control: electric diagram
Tilt ram lock: electric diagram
Diagram: work hydraulics variable displacement pump – frame levelling,oscillating axle interlock
Frame levelling, oscillating axle interlock: electric diagram
Work hydraulics diagram: designations
Electric diagram: designations
Functional description of work hydraulics
Oil supply via fan pump (010)
Raising/lowering the telescopic boom
Parallel lifting and lowering of attachments
Switching on the load stabiliser
Load stabiliser function
Retracting and extending the telescopic boom
Safe load indicator function
Overload cutoff (option)
Dumping the attachment in and out
Locking the 3rd control circuit
Operating the 3rd control circuit (unlocking/locking the quickhitch)
Quickhitch lock
Functional description of front socket
Tilt ram lock
Remote radio controls
Oscillating axle interlock
Work hydraulics connector assignment
Test report: models 400-01/401-01
Test report: models 402-01/403-01
Work hydraulics test ports
Variable displacement pump (hydraulic pump)
How the pressure regulator works
How the flow regulator works
How the output regulator works
Checking and setting the work hydraulics
Variable displacement pump pressure regulator: settings
Control valve (primary pressure): settings
Flow regulator: settings
Work hydraulics circuit (gear pump)
Work hydraulics circuit (variable displacement pump LS)
Control valve connections (4-fold)
Control valve (4-fold): overview
Control valve connections (5-fold)
Control valve (5-fold): overview
Lift ram circuit
Tilt ram circuit
Compensating ram circuit
Push-out ram circuit
3rd control circuit
Control valve (4-fold) pilot control circuit
Valve block connections: overview
Pilot control unit, pilot valve
Load stabiliser
Load stabiliser: description
Checking and setting the load stabiliser
Load stabiliser circuit
Changeover valve: Autohitch/tipping trailer connection/additional
control circuit
Autohitch, rear additional control circuit
Tipping trailer connection circuit
Front additional control circuit
Frame levelling with oscillating axle interlock (option) telehandler 404:overview
Specific safety instructions
Mechanical oscillating axle interlock (rear axle)
Working with the front axle frame levelling (option)
Hydraulic rear oscillating axle interlock (option)
Bleeding the hydraulic ram of the oscillating axle interlock
Frame levelling circuit
Frame levelling valve overview
Lift ram with hose burst valve: overview
Tilt ram: overview
Push-out ram with final position damping: overview
Compensating ram: overview
Quickhitch
Installing the telescopic boom
Replacing the control valve
Replacing the priority valve
Replacing the fan pump
Replacing the A 10 work hydraulics pump
Replacing the pilot valve

Electric systems
Machine lights: electric diagram
Turn indicators/horn/rotating beacon: electric diagram
Mirror adjustment/heating: electric diagram
Window wiper/washer, hydraulics monitoring: electric diagram
Heating – air conditioning system/air-suspension seat: electric diagram
Multimedia/cigarette lighter: electric diagram
Electric diagram designations and positions
Connector positions on machine
Functional description of hydraulics monitoring
Hydraulic filter monitoring (open bypass)
Hydraulic oil level monitoring:
Hydraulic oil temperature monitoring:
Hydraulics monitoring connector assigment
Lights connector assignment
Turn indicator/horn connector assignment
Rotating beacon connector assignment
Mirror adjustment connector assignment
Mirror heating connector assignment
Window wiper/wash connector assignment
Heating/air conditioning connector assignment
Air-suspension seat connector assignment
Multimedia connector assignment
Cigarette lighter connector assignment
Ohm's Law (current, voltage, resistance); power
Multifunction measuring device
Terminal description
Cable colour coding
Extract from DIN 72551, sheet 4
Colour coding
Fuses: overview
Fuses: overview
Electric components
Main fuse box with relays (88 kW diesel engine)
Main fuse box with relays (103 kW diesel engine)
Relays: overview
Electronic components: overview
Steering electronics (old)
Steering electronics (new)
Connector assignment
Functional description of the steering electronics
Changing over from 4 wheel steering to front axle steering
Changing over from front axle steering to 4 wheel steering
Carrying out synchronisation manually
Synchronisation requires the following data/prerequisites
Possible errors
New steering electronics (17 LEDs): overview
Proportional controls: overview and connections
Proportional electronics
Hold electronics
Wiring harness 1000103927 (joystick)
Overview and functional check of safe load indicator
Safe load indicator display (version A)
Functional check of safe load indicator (version A)
Safe load indicator display (version B)
Functional check of safe load indicator (version B)
Safety instructions for the safe load indicator
Setting the safe load indicator (0 % point)
Setting the 0 % point
Setting the safe load indicator (100 % point stability)
Determining the maximum authorised load (100 % point)
Possible errors – safe load indicator
Retrofitting the front right and rear right working lights
Retrofitting a rotating beacon
Retrofitting a radio
Retrofitting the low-speed control
Retrofitting the air conditioning system
Retrofitting a front or rear socket
Retrofitting a load stabiliser
Wiring harness disconnect (cab – machine frame)

Appendix A
Hydraulics – 4-fold control valve: overall diagram
Hydraulic fixed displacement pump – 5-fold control valve: overall diagram
Hydraulic variable displacement pump – 5-fold control valve: overall diagram
Machine components: overview

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