CLAAS SCORPION 9040 Model 404-03 Operator’s manual -PDF DOWNLOAD

Description

CLAAS SCORPION 9040 Model 404-03 Operator’s manual -PDF DOWNLOAD

DESCRIPTION:

CLAAS SCORPION 9040 Model 404-03 Operator’s manual -PDF DOWNLOAD

1 Introduction
1.1 Important information on this Operator’s Manual

• This Operator’s Manual contains important information on how to work safely, correctly and economically with your telehandler. Therefore, it aims not only at new operators, but it also serves as a reference for experienced ones.
• It helps to avoid dangerous situations and reduce repair costs and downtimes. Furthermore, the reliability and the service life of the machine will be increased by following the instructions in the Operator’s Manual. This is why the Operator’s Manual must always be kept at hand in proper condition in the machine. Your own safety, as well as the safety of others,
• depends to a great extent on how the machine is moved and operated. Therefore, carefully read and understand this Operator’s Manual prior to the first drive. The Operator’s Manual will help to familiarise yourself more easily with the machine, thereby enabling you to use it more safely and efficiently. (see also Selection and qualification of staff, basic
• responsibilities on page 2-5) Prior to the first drive, carefully read chapter “Safey Instructions” as well, in order to be prepared for possible dangerous situations, as it will be too late for it during operation. As a rule, keep the following in mind: Careful and prudent working is the best way to avoid accidents! Operational safety and readiness of the machine do
• not only depend on your skill, but also on maintenance and servicing of the machine. This is why regular maintenance and service work is absolutely necessary. Extensive maintenance and repair work must always be carried out by an expert with appropriate training. Insist on using original spare parts when carrying out maintenance and repair work.
• This ensures operational safety and readiness of your machine, and maintains its value. If you require more information on your machine or the Operator’s Manual, please contact your CLAAS dealer. The Operator’s Manual is stored in the storage compartment on the backrest of the seat.

TABLE OF CONTENTS:

CLAAS SCORPION 9040 Model 404-03 Operator’s manual -PDF DOWNLOAD

Table of contents
Index I-8
Introduction 1
Important information on this Operator’s Manual 1-1
Abbreviations/symbols 1-1
Machine overview 1-2
Model designation – trade names 1-3
Brief description 1-3
Hydrostatic drive 1-3
Work hydraulics and 4 wheel steering 1-4
Cooling system 1-4
Fields of application 1-4
Use: attachment 1-4
Regulations 1-6
Driving licence 1-6
Licence 1-6
Equipment 1-6
Machine inspections 1-7
Documents 1-7
Warning identification of the machine 1-7
EC declaration of conformity model 404-03 1-8
Type labels and component numbers 1-9
Serial number 1-9
Cab number 1-9
Engine number 1-9
Hydraulic pump number 1-10
Variable displacement motor number 1-10
Variable displacement motor number (high speed option) 1-10
Front and rear axle numbers 1-10
Signs and symbols 1-11
Labels on the outside of the machine 1-11
Labels on the inside of the machine 1-12
Safety instructions 2
Identification of warnings and dangers 2-1
Warranty 2-1
Designated use and exemption from liability 2-2
General conduct and safety instructions 2-3
Organisational measures 2-3
Selection and qualification of staff, basic responsibilities 2-5
Safety instructions regarding operation 2-6
Normal operation 2-6
Applications with lifting gear 2-8
Trailers and attachments 2-9
Transport 2-9
Safety instructions for maintenance 2-10
Service and maintenance work on ROPS/FOPS superstructures
(ROPS bar) 2-11
Warning of special hazards 2-12
Electric energy 2-12
Gas, dust, steam, smoke 2-12
Hydraulic equipment 2-13
Noise 2-13
Oil, grease and other chemical substances 2-13
Battery 2-13
Tyres 2-13
Table of contents
I-2 000 294 630 1 – BA SCORPION
Table of contents
Operation 3
Overview of control elements 3-1
Cab overview 3-2
Instrument panel, multifunctional lever, switch consoles: overview 3-4
Telltales and warning lights: description 3-6
Telltale and warning light – instrument panel 3-6
Telltale and warning light – instrument panel 3-7
Taking the machine into service for the first time 3-8
Safety instructions 3-8
Important information 3-8
Running-in period 3-8
Check lists 3-9
Start-up checklist 3-9
Operation checklist 3-10
Parking checklist 3-10
Cab 3-11
Opening the door from the outside and inside 3-11
Opening/closing the side window 3-12
Completely opening and locking the side window 3-13
Opening/closing the rear window 3-14
Rear window emergency exit 3-14
Interior light 3-14
Before starting the engine 3-15
General 3-15
Starting the engine 3-16
Overview of error code displays
(103 kW diesel engine from serial no 404 03 0021) 3-17
Reading out the flash code 3-17
Warning limit – coolant temperature 3-17
Warning limit – charge-air temperature 3-18
Warning limit –engine oil pressure 3-18
Overview of flashing codes 3-19
Key-based drive interlock (option) 3-22
Coding (“training”) new ignition keys 3-22
Enabling (locking) the drive interlock 3-23
Disabling (releasing) the drive interlock 3-23
Deleting coded keys 3-23
Safety functions 3-23
Drive interlock with code input (option) 3-24
Entering/changing the personal code 3-25
Enabling the drive interlock 3-25
Disabling the drive interlock 3-26
Taking the drive interlock out of service 3-27
Putting the drive interlock back into service again 3-27
Interruption of drive interlock power 3-27
Drive interlock maintenance 3-27
Oil and fuel preheater (option) 3-28
Oil preheater (option) 3-28
Fuel preheater (option) 3-28
Jump-starting the engine (external battery) 3-29
Safety instructions 3-29
Procedure 3-29
Before moving off 3-30
000 294 630 1 – BA SCORPION I-3
Table of contents
Special instructions for driving on public roads 3-30
Locking the control lever (joystick) and the 3rd control circuit (attachments) 3-31
Steering column height and angle adjustment 3-31
Checking the steering system 3-32
Synchronous wheel position 3-32
Adjusting the height of the control lever base 3-32
Accelerator pedal 3-33
Manual throttle (option) 3-33
Brake/inching pedal 3-34
Inching 3-34
Brakes 3-34
Parking brake 3-35
Moving off the telehandler 3-36
Moving off on slopes 3-36
Changing direction (forwards/reverse) 3-36
Selecting the speed range (0 – 20 kph) 3-37
Selecting the drive range (0 – 30/40 kph, option) 3-37
Low-speed control (option) 3-38
Electric mirror adjustment (option) 3-38
Load stabiliser (option) 3-39
General instructions 3-39
Switching the load stabiliser on and off 3-40
Backup warning system (option) 3-40
Differential lock 3-41
Switching on the differential lock 3-41
Switching off the differential lock 3-41
Synchronising the steering system 3-42
Changing steering mode 3-43
Changing over to front axle steering 3-43
Changing over to 4 wheel steering 3-43
Changing over to diagonal steering (crab steering option) 3-44
Stopping/parking the machine 3-45
Light system 3-46
Headlights 3-46
Working lights 3-47
Signalling system 3-48
Turn indicators 3-48
Hazard warning system 3-48
Rotating beacon (option) 3-48
Cab heating and ventilation 3-49
Air conditioning (option) 3-50
Washer system 3-51
Tank for washer system 3-51
Seat 3-52
Seat adjustment 3-52
Weight adjustment 3-52
Height adjustment (air-suspension seat, option) 3-53
Backrest adjustment 3-53
Horizontal adjustment 3-53
Seat belt (lap belt) 3-54
Fastening the seat belt: 3-54
Unfastening the seat belt: 3-55
I-4 000 294 630 1 – BA SCORPION
Table of contents
Longer/shorter lap belt adjustment: 3-55
Engine cover 3-55
Fire extinguisher (option) 3-56
Battery master switch (option) 3-56
Reversing cooling fan (option) 3-56
Towing and transporting the machine 3-57
Getting ready for towing 3-57
Towing the machine 3-58
Once towing is over 3-58
Loading and transporting the telehandler 3-59
General safety instructions 3-59
Loading the machine 3-60
Strapping down the machine 3-60
Crane handling the machine 3-61
Safety instructions 3-61
Crane handling 3-61
Telescopic boom operation: overview 3-62
Operating the control lever for the lift, tilt and push-out rams 3-62
Operation of 3rd control circuit 3-63
Operating the telescopic boom 3-64
General safety instructions 3-64
Safe load indicator 3-64
Safe load indicator display 3-65
Functional check of the safe load indicator 3-66
Disabling/enabling the lock function of the safe load indicator (option) 3-66
Raising/extending the telescopic boom 3-67
Retracting/lowering the telescopic boom 3-68
Emergency lowering of the telescopic boom in case of a
diesel engine breakdown 3-68
Fitting an attachment onto the hydraulic quickhitch 3-69
Fitting an attachment onto the mechanical quickhitch (option) 3-70
Hose burst valve safety feature 3-71
Mounting/removing the pallet forks 3-72
Driving on public roads with the pallet forks 3-72
Adjusting the fork arms 3-73
Working with the pallet forks 3-74
General safety instructions 3-74
Specific safety instructions 3-75
Brief instructions for fork arms 3-76
Load diagram for pallet forks (EN 1459/1998) 3-77
Approaching the material 3-78
Loading the material 3-78
Picking up material and setting it down in a high position 3-79
Transport position without load 3-79
Working with the standard bucket 3-80
General instructions 3-80
Bucket payloads 3-80
Practical hints for digging 3-81
Tilt position of the bucket 3-81
Transport position of the bucket 3-81
Transporting with a full bucket 3-82
Loading loose material 3-82
Loading if the material is hard to penetrate 3-83
Removing material/digging in soft soil 3-83
Removing material/digging in hard soil 3-84
Grading 3-85
Loading vehicles 3-85
000 294 630 1 – BA SCORPION I-5
Table of contents
Freeing the machine 3-85
Working with a crane jib (option) 3-86
Mechanical oscillating axle interlock (rear axle) 3-87
Hydraulic rear oscillating axle interlock (option) 3-87
Frame levelling feature on front axle (option) 3-88
Continuous operation of 3rd control circuit (option) 3-89
Actuation: 3rd control circuit as additional front control circuit (option) 3-90
Operation: front/rear additional control circuit (option) 3-91
Tipping trailer operation (option) 3-92
Connection of electrically operated attachments (option) 3-92
Operation of the Autohitch trailer coupling (option) 3-93
Trailer coupling operation (option) 3-94
Compressed-air brake system (option) 3-95
General safety instructions 3-95
Coupling and uncoupling compressed-air hoses (dual-circuit brake system) 3-95
Compressed-air gauge 3-96
Hydraulic trailer brake connection (option) 3-96
Fitting attachments from other manufacturers onto the quickhitch (option) 3-97
Example: inspection plan for attachments from other manufacturers 3-98
Troubleshooting 4
Engine trouble 4-1
Malfunctions in the air conditioning system (option) 4-2
Maintenance 5
Introduction 5-1
Safety prop for telescopic boom 5-1
Fuel system 5-2
Specific safety instructions 5-2
Refuelling 5-2
Stationary fuel pumps 5-2
Diesel fuel specification 5-3
Checking/replacing the fuel prefilter (water separator) 5-3
Replacing the fuel filter 5-4
Bleeding the fuel system 5-5
Engine lubrication system 5-6
Checking the engine oil level 5-6
Filling up engine oil 5-7
Replacing the engine oil every 500 s/h (service hours) 5-8
Replacing the engine oil filter cartridge every 500 s/h (service hours) 5-9
Engine and hydraulics cooling system 5-10
Specific safety instructions 5-10
Checking the coolant level and quality 5-11
Filling up coolant 5-12
Draining coolant 5-13
Cleaning the radiator fins 5-14
Cleaning the radiator with the reversing fan (option) 5-15
Air filter 5-16
Checking air filter contamination 5-16
Replacing the air filter cartridge at 500 s/h (service hours) 5-17
V-belt 5-18
Retightening the V-belt 5-18
Hydraulic system 5-19
Specific safety instructions 5-19
Monitoring the hydraulic oil and the reflux filter 5-20
Checking the hydraulic oil level once a day 5-20
Filling up hydraulic oil 5-21
I-6 000 294 630 1 – BA SCORPION
Table of contents
Important information for the use of biodegradable oil 5-21
Checking hydraulic pressure lines 5-22
Specific safety instructions 5-22
Lubrication work 5-23
General safety instructions 5-23
Lubricating the front and rear axle oscillation-type bearings 5-23
Lubricating the planetary drive bearing 5-23
Lubrication points on the telescopic boom: overview 5-24
Lubricating the telescopic boom 5-24
Checking and adjusting the wear plates 5-24
Lubricating with the central lubrication system (option) 5-25
General functional description 5-25
Setting the lubrication and break times 5-26
Filling the central lubrication system 5-26
Maintenance of the brake system 5-27
Specific safety instructions 5-27
Checking/filling up the brake fluid level 5-27
Maintenance: compressed-air brake system (option) 5-28
Checking the compressed-air tank and lines 5-28
Checking compressor attachment and drive 5-28
Tyres 5-29
Daily tyre checks 5-29
Changing wheels 5-30
Heating – fresh air 5-31
Cleaning/replacing the fine-dust or active charcoal filter (option) 5-31
Cleaning/replacing the recirculated-air filter 5-31
Air conditioning (option): maintenance 5-32
General safety instructions 5-32
Functional and visual check once a day 5-33
Maintenance of the electric system 5-34
Specific safety instructions 5-34
Service and maintenance work at regular intervals 5-34
Cables, bulbs and fuses 5-35
Alternator 5-35
Adjusting the headlights 5-35
Checking/replacing the battery 5-36
Maintenance: trailer coupling 5-37
Trailer coupling (option) 5-37
General maintenance work 5-38
Specific safety instructions 5-38
When using washing solvents 5-38
When using compressed air 5-38
When using a high-pressure cleaner or steam jet 5-38
When using volatile and easily flammable anticorrosion agents and sprays 5-38
Cleaning inside the cab 5-39
Cleaning the seat belt 5-39
Cleaning the exterior of the machine 5-39
Cleaning the engine and the engine compartment 5-40
Screw connections 5-40
Pivots and hinges 5-40
Maintenance work “Aggressive Media” (option) 5-41
Anticorrosion protection applied in the factory 5-41
Components coated with anticorrosive wax 5-41
Measures for maintaining anticorrosive protection 5-42
Applying the protective anticorrosion coating 5-43
000 294 630 1 – BA SCORPION I-7
Table of contents
Treatment of oxidised surfaces 5-43
Maintenance and service of the attachments 5-43
Maintenance plan (overview) 5-45
Fluids and lubricants 5-49
Maintenance label 5-50
Explanation of symbols on the maintenance label 5-50
Maintenance label 5-51
Specifications 6
Model and trade names: overview 6-1
Frame 6-1
Deutz engine type: BF4M 2012/BF4M 2012C 6-1
Deutz engine type: TCD 2012 L04 2V 6-2
Oil/water cooling fan 6-2
Power train 6-3
Variable displacement pump 6-3
Variable displacement motor 6-3
Axles 6-4
Front axle 6-4
Rear axle 6-4
Service and parking brake 6-5
Steering system 6-5
Work hydraulics 6-6
Hydraulic pump 6-6
Hydraulic ram protection 6-6
Lift, tilt and push-out rams: velocity 6-7
Hydraulic pilot control 6-7
Additional control circuit (option) 6-7
Electric system 6-8
Fuses: overview 6-8
Electric components 6-9
Main fuse box with relays (75, 88, 90, 100 kW diesel engines) 6-10
Main fuse box with relays (103 kW diesel engine) 6-10
Relays: overview 6-11
Tyres for model 404-03 6-12
Weights 6-12
Trailer weight/drawbar load: trailer couplings (option) 6-12
Noise levels 6-13
Vibration 6-13
Coolant compound table 6-13
Tightening torques 6-14
General tightening torques 6-14
Specific tightening torques 6-14
Payloads model 404-03 6-15
Rigid front axle without oscillating axle interlock (rear axle) 6-15
Rigid front axle with mechanical or hydraulic oscillating axle
interlock (rear axle) 6-16
Front axle with frame levelling and without oscillating axle
interlock (rear axle) 6-17
Front axle with frame levelling and hydraulic oscillating axle
interlock (rear axle) 6-18
Dimensions with bucket 6-19
Dimensions with pallet forks 6-20
I-8 000 294 630 1 – BA SCORPION
Index
Index
A
Abbreviations 1-1
Accident prevention regulations
Deutsche Prüfstelle für Land- und Forsttechnik
(German inspection and certification body for
agriculture and forestry)1-7, 3-97
For machines1-7, 3-97
Adjusting fork arms distance3-73
Adjusting the headlights5-35
Air conditioning (option) 3-50
Air filter5-16
Cleaning the dust collector 5-16
Dust valve5-16
Applications with lifting gear 2-8
B
Battery master switch (option) 3-56
Biodegradable oil 5-21
Brake system5-27
Brake fluid5-27
Safety instructions 5-27
C
Cab
Doors3-11
Side window 3-12
Central lubrication system (option) 5-25
Changing over to 4 wheel steering 3-43
Charge-air temperature 3-18
Check lists 3-9
Cleaning and maintenance
Maintenance work if the machine is used in a
saline environment 5-41
Compressed-air brake system (option)3-95
Coolant temperature 3-17
Crane jib (option) 3-86
D
Designated use and exemption from liability 2-2
Documents1-7
Driving licence 1-6
Driving on public roads
With bucket3-30
E
Electric system6-8
Engine oil pressure 3-18
Error code displays (103 kW diesel engine) 3-17
F
Fitting attachments from other manufacturers onto the
quickhitch (option)3-97
Fluids and lubricants5-49
Fuel preheater (option) 3-28
Fuel system
Bleeding5-5
Cleaning the water separator 5-3
H
Hazard warning system3-48
Heating 3-49
Fine-dust filter5-31
Heating, fresh air 3-49
Heating, mixed mode3-49
Heating, recirculated air mode3-49
Recirculated-air filter5-31
Hose burst valve safety feature 3-71
Hydraulic oscillating axle interlock 3-87
I
Important information
On this Operator’s Manual1-1
Interior light 3-14
K
Key-based drive interlock (option) 3-22
L
Legal regulations 1-6
Licence, equipment1-6
Light system3-46
Load diagram3-77
Load stabiliser (option)3-39
Loading tie-bar3-61
Locking and unlocking the engine cover3-55
Lowering the telescopic boom with the engine switched off 3-68
Index
000 294 630 1 – BA SCORPION I-9
Index
M
Machine
Brief description1-3
Fields of application1-4
Loading and transporting3-59
Overview 1-2
Machine inspections 1-7
Maintenance
Biodegradable oil5-21
Brake system5-27
Changing wheels5-30
Checking the coolant level 5-11
Checking the engine oil level5-6
Checking the hydraulic oil level 5-20
Cleaning 5-38
Compressed-air brake system (option) 5-28
Electric system 5-34
Engine and hydraulics cooling system 5-10
Engine lubrication system5-6
Fill up the hydraulic oil5-21
Filling in engine oil5-7
Filling up coolant 5-12
Fluids and lubricants 5-49
Fuel system5-2
Heating5-31
Hydraulic pressure lines 5-22
Hydraulic system5-19
Maintenance of attachments 5-43
Pivots and hinges5-40
Replacing the air filter cartridge5-17
Replacing the engine oil filter cartridge 5-9
Screw connections 5-40
Service and maintenance work 5-38
Service and maintenance work at regular intervals5-34
Trailer couplings5-37
Tyre care 5-29
V-belt 5-18
Maintenance plan 5-45
Mechanical oscillating axle interlock3-87
Model designation – trade names 1-3
N
Noise levels 1-11
O
Oil preheater (option)3-28
Operation
Before moving off 3-30
Fire extinguisher (option)3-56
Hose burst valve on tilt ram3-71
Load stabiliser 3-39
Moving off3-36
Parking the machine3-45
Reversing cooling fan (option)3-56
Seat belt height adjustment3-54
Speed range selection3-37
Starting the engine 3-15
P
Pallet forks3-74
Approaching the material 3-78
Brief instructions for fork arms3-76
Fitting/removing3-72
Loading the material3-78
Locking lever for fork arms3-73
Safety instructions 3-74
Specific safety instructions3-75
Parking brake 3-35
Picking up pallet forks with the quickhitch 3-72
Q
Quickhitch
Hydraulic lock3-69
Mechanical lock3-70
R
Radiator
Draining coolant 5-13
Re-equipping
Hydraulic quickhitch 3-69
Mechanical quickhitch (option) 3-70
Refuelling 5-2
Removing the pallet forks from the quickhitch3-72
Rotating beacon 3-48
Running-in period 3-8
I-10 000 294 630 1 – BA SCORPION
Index
S
Safe load indicator 3-65
Functional check3-66
Measures to be taken if 3-65
Safety instructions 2-1
Applications with lifting gear 2-8
General conduct 2-3
Identification 2-1
Maintenance2-10
Operation2-6
Special hazards2-12
Trailers and attachments 2-9
Transport 2-9
Seat adjustment3-52
Backrest adjustment 3-53
Horizontal adjustment3-53
Seat belt3-54
Adjustment3-55
Fastening the seat belt 3-54
Signalling system3-48
Signs and symbols1-11
Specifications6-1
Additional control circuit (option) 6-7
Axles6-4
Brakes 6-5
Coolant compound table6-13
Dimensions with bucket6-19
Dimensions with pallet forks 6-20
Electric components 6-9
Engine 6-1, 6-2
Frame 6-1
Front axle6-4
Hydraulic pump6-6
Hydraulic ram protection6-6
Main fuse box with relays 6-10
Model and trade names6-1
Noise levels 6-13
Oil/water cooling fan6-2
Pilot control6-7
Power train 6-3
Rear axle 6-4
Relays (overview) 6-11
Steering system6-5
Tightening torques6-14
Trailer couplings 6-12
Variable displacement motor 6-3
Variable displacement pump 6-3
Vibration 6-13
Weights6-12
Work hydraulics6-6
Speed
Lift, tilt and push-out rams 6-7
Stability
Pallet forks3-72
Starting aid3-29
Steering mode 3-43
4 wheel steering 3-43
Diagonal steering (crab steering option)3-44
Front axle steering3-43
Synchronous wheel position 3-32
T
Taking into service
Check lists 3-9
Safety instructions 3-8
Taking the machine into service for the first time 3-8
Telescopic boom
Checking the tilt position of the bucket 3-81
Checking the transport position of the bucket 3-81
Checking the transport position of the pallet forks3-79
Extending/raising 3-67
Lubrication 5-24
Overview of lubrication points5-24
Retracting/lowering3-68
Telltales 3-6
Towing and transporting the machine3-57
Trailer coupling 3-94
Trailer weight/drawbar load6-12
Transport 3-82
Turn indicators 3-48
Tyre care5-29
V
Ventilation 3-49
Ventilation, fresh air3-49
W
Warning identification1-7
Warranty 2-1
Washer pump 3-51
Washer system
Tank3-51
Wheel change5-30
Wipers3-51
Working
Approaching the material3-78
Freeing the machine3-85
Grading3-85
Loading loose material 3-82
Loading the material 3-78
Practical hints 3-85
Removing material/digging in hard soil3-84
Removing material/digging in soft soil 3-83
Setting down the material 3-79
With a crane jib (option)3-86
With the pallet forks 3-74
Working lights 3-47
IMAGES PREVIEW OF THE MANUAL:

CLAAS SCORPION 9040 MODEL 404-03 OPERATOR’S MANUAL -PDF DOWNLOAD:

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.M