CLAAS TeleHandlers SCORPION 6030 Model: 408-01 COMPACT Manual – PDF DOWNLOAD

Description

CLAAS TeleHandlers SCORPION 6030 Model: 408-01 COMPACT Manual – PDF DOWNLOAD

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FILE DETAILS:

CLAAS TeleHandlers SCORPION 6030 Model: 408-01 COMPACT Manual – PDF DOWNLOAD

Language : English
Pages :572
Downloadable : Yes
File Type : PDF
Size:2.95 MB

TABLE OF CONTENTS:

CLAAS TeleHandlers SCORPION 6030 Model: 408-01 COMPACT Manual – PDF DOWNLOAD

Machine specifications (overview) 1
Machine outside view 1-1
Inside of cab (overview) 1-2
Instrument panel, multifunctional lever, switch consoles (overview) 1-3
Notes on the repair manual 1-4
Type labels and component numbers 1-6
Frame 1-9
Engine 1-9
Drive 1-10
Oil/water fan 1-11
Axles 1-11
Service and parking brake 1-12
Steering system 1-12
Work hydraulics 1-13
Electrical system 1-15
Tyres 1-18
Weights 1-18
Trailer couplings: trailer weight/drawbar load 1-18
Noise levels 1-19
Vibration 1-19
Coolant compound table 1-19
Tightening torques 1-20
Payload: bucket 1-20
Payload: pallet forks load diagram 1-21
Payload: pallet forks (Australia) 1-22
Payload: bucket (Australia) 1-22
Dimensions with bucket 1-23
Dimensions with pallet forks 1-24
Maintenance and servicing work 3
Explanation of symbols on the maintenance label 3-1
Maintenance label 3-2
Fluids and lubricants (overview) 3-3
Maintenance plan (overview) 3-4
Introduction 3-9
Safety strut for telescopic boom 3-9
Fuel system 3-10
Maintenance of engine lubrication system 3-15
Maintenance of the engine and hydraulics cooling system 3-19
Cleaning the radiator with the reversing fan (option) 3-24
Air filter maintenance 3-25
Maintenance: V-belts 3-27
Gearbox and axle maintenance 3-28
Safety instructions regarding the hydraulic system 3-35
Monitoring the hydraulic oil and the return filter 3-36
Checking the hydraulic oil level 3-36
Adding hydraulic oil 3-37
Replacing the return filter of the hydraulic system 3-37
Replacing hydraulic oil 3-38
Important notices on the use of biodegradable oil 3-39
Checking hydraulic pressure lines 3-40
Lubrication work 3-41
Maintenance of the brake system 3-45
Replacing/bleeding the service brake fluid with bleed equipment 3-46
Tyre maintenance 3-48
Contents
Contents
I-2 00 0291 635 3 – RHB SCORPION
Heating and ventilation maintenance 3-50
Air conditioning (option): maintenance 3-51
Maintenance of the electrical system 3-54
Maintenance of trailer coupling 3-57
General maintenance work on the machine 3-58
Cleaning inside the cab 3-59
Cleaning the seat belt 3-59
Cleaning the exterior of the machine 3-59
Checking screw connections 3-59
Checking pivots and hinges 3-59
Cleaning the engine compartment 3-60
Maintenance and servicing work “Aggressive Media” 3-61
Maintenance and servicing of attachments on the quickhitch 3-63
Engine/radiator/diagnosis 4
Electrical system/hydraulics – fan (electrical diagram) 4-1
Diesel engine electrical system diagram 4-7
Diagnosis diagram 4-13
Manual throttle diagram 4-17
Overview of electric engine speed lock (accelerator pedal lock) 4-20
Engine/drive coupler (overview) 4-21
Fuel system (88/103 kW) (overview) 4-22
Fuel system 4-23
Bleeding the fuel system 4-24
Fuel specification 4-25
Coolant specification 4-25
Diesel engine TD 2011 L04 W overview 4-26
Electrical components on engine (overview) 4-27
Water circuit: water pump, thermostat 4-28
Switching off minus compensation 4-29
Heating connection 4-29
Engine trouble 4-30
Fan circuit 4-32
Overview of fan drive components 4-33
Valve block with/without reversing function 4-34
Setting the upper fan speed 4-35
Function: reversing fan operation 4-36
Drive 5
40 kph drive hydraulics diagram for model 408 5-1
20 kph drive hydraulics diagram for model 408 5-5
Model 408 drive electrics diagram 5-9
Towing and transporting the machine 5-11
Hydraulic pump H1 P078 (model 408) (40 kph) 5-13
High-speed gearbox (40 kph) 5-14
Gearbox overview (40 kph) 5-15
Overview of control cover and circuit diagram (40 kph) 5-16
Control cover component parts for gearbox (40 kph) 5-17
Hydraulic drive circuit (0 – 40 kph) 5-18
Test report for model 408 (40 kph)
Machine with work hydraulics version: gear pump 5-19
Test report for model 403/404 and model 408 (40 kph)
Machine with work hydraulics version: variable displacement pump 5-20
Checking and setting boost pressure (40 kph gearbox) 5-21
Checking high pressure (0 – 40 kph) 5-22
Checking engine droop (pump) (40 kph) 5-23
Checking driving direction identification (40 kph) 5-24
Setting engine droop on the gearbox (40 kph) 5-25
Contents
00 0291 635 3 – RHB SCORPION I-3
Control initiation set screw (40 kph gearbox) 5-26
Checking the cardan shaft speed (40 kph gearbox) 5-27
Troubleshooting work on drive 5-28
Variable displacement pump test for model 408 (40 kph) 5-29
Hydraulic pump report 5-31
Measurement 1 (engine speed and boost pressure) 5-32
Forward/reverse measurement 2 5-33
Forward measurement 3 5-35
High-speed gearbox test (40 kph) 5-36
Measurement 1 (driving direction identification) 5-37
Measurement 2 (M4 pressure at shuttle throttle) 5-37
Measurements 3 and 4 (proportional solenoid and proportional regulator) 5-38
Measurement 5 (pressure relief valve M3, PCOR valve) 5-38
High-speed gearbox report 5-39
Report: measurement 1 (driving direction identification) 5-40
Report: measurement 2 (M4 shuttle pressure) 5-41
Report: measurements 3 and 4 (proportional solenoid and proportional
regulator) 5-42
Report: measurement 5 (pressure relief valve M3, PCOR valve) 5-43
Repairs on high-speed gearbox (40 kph) 5-44
Repairs on high-speed gearbox (40 kph) 5-47
Repairs on high-speed gearbox (40 kph) 5-48
Checking or replacing the shuttle throttle 5-50
Removing the shuttle throttle 5-51
Installing the shuttle throttle 5-53
Checking the proportional valves by means of current measurement 5-54
Removing the consumers circuit from the hydraulic drive 5-55
Sealing work on the drive shaft (40 kph gearbox) 5-56
Installing the rotary shaft seal (40 kph gearbox) 5-57
Installing the drive flange (40 kph gearbox) 5-58
Hydraulic pump H1 P078 (model 408) (30 kph) 5-59
Variable displacement motor 160 cm3/rev (30 kph) 5-60
Variable displacement motor 160 cm3/rev (30 kph) 5-61
Drive circuit (30 kph) 5-62
Test report for model 408 (30 kph)
Machine with hydraulic pump version: gear pump 5-63
Test report for model 408 (30 kph)
Machine with hydraulic pump version: variable displacement pump 5-64
Setting boost pressure (30 kph) 5-65
Checking high pressure (30 kph) 5-66
Checking engine droop – variable displacement pump (30 kph) 5-67
Setting engine droop – hydraulic motor (30 kph) 5-68
Replacing the control unit on the variable displacement pump 5-69
Axles 6
Axles (overview) 6-2
Screw connections 6-3
Screw locks and tightening torques 6-4
Drain, fill and check plug – front axle 6-6
Drain, fill and check plug – rear axle 6-7
Sealing work 6-8
Sealing the planetary drive, front/rear axle joint housing 6-10
Axle carrier (sealing work) 6-15
Removing the differential 6-19
Removing the differential cage 6-21
Installing the differential cage 6-22
Removing the input bevel gear 6-23
Installing the input bevel gear 6-24
Contents
I-4 00 0291 635 3 – RHB SCORPION
Installing the differential cage in the differential housing 6-27
Intermediate gearbox (overview) 6-30
Installing the intermediate gearbox 6-33
Special tools 6-36
Special tools 6-37
Brakes 7
Brake diagrams (electric/hydraulic) 7-1
Hydraulic diagram – trailer brake valve 7-5
30/40 kph brake circuit (overview) 7-7
Service brake function 7-8
Parking brake overview 7-9
Hydraulic trailer brake overview 7-10
Brakes 7-11
Sealing the brake calliper 7-12
Bleeding the brake system with bleed equipment 7-14
Steering system 8
Hydraulic/electrical diagrams 8-1
Steering circuit overview 8-4
Steering system components 8-5
Axle sensor on rear axle 8-6
Work hydraulics 9
Work hydraulics fixed displacement pump – raising/lowering the telescopic boom
(diagram) 9-1
Work hydraulics variable displacement pump – raising/lowering the telescopic
boom (diagram) 9-5
Work hydraulics fixed displacement pump – raising/lowering the telescopic boom,
load stabilizer (diagram) 9-9
Work hydraulics variable displacement pump – raising/lowering the telescopic
boom, load stabilizer (diagram) 9-13
Raising/lowering the telescopic boom (electrical diagram) 9-17
Load stabilizer (electrical diagram) 9-23
Work hydraulics – extending/retracting the telescopic boom, fixed displacement
pump (diagram) 9-27
Work hydraulics variable displacement pump – extending/retracting the
telescopic boom (diagram) 9-31
Extending/retracting the telescopic boom up to serial no 408010178
(electrical diagram) 9-35
Extending/retracting the telescopic boom from serial no 408010417
(electrical diagram) 9-39
Extending/retracting the telescopic boom (Australia) (electrical diagram) 9-43
Work hydraulics fixed displacement pump – dumping in/out (diagram) 9-47
Work hydraulics variable displacement pump, dumping in/out (diagram) 9-51
Dumping in/out (electrical diagram) 9-55
Work hydraulics fixed displacement pump – locking/unlocking (diagram) 9-59
Work hydraulics variable displacement pump – locking/unlocking (diagram) 9-63
Locking/unlocking to up to serial no 408010178 (electrical diagram) 9-67
Locking/unlocking from serial no 408010417 (electrical diagram) 9-71
Locking/unlocking (Australia) (electrical diagram) 9-75
Work hydraulics fixed displacement pump – rear additional control circuit (diagram) 9-79
Work hydraulics variable displacement pump – rear additional control circuit (diagram) 9-83
Work hydraulics fixed displacement pump – rear additional control circuit –
Autohitch (diagram) 9-87
Work hydraulics variable displacement pump – rear additional control circuit,
Autohitch (diagram) 9-91
Work hydraulics fixed displacement pump – rear additional control circuit,
Autohitch, tipping trailer (diagram) 9-95
Work hydraulics variable displacement pump – rear additional control circuit,
Autohitch, tipping trailer (diagram) 9-99
Work hydraulics fixed displacement pump – rear additional control circuit,
tipping trailer (diagram) 9-103
Work hydraulics variable displacement pump – rear additional control circuit,
tipping trailer (diagram) 9-107
Work hydraulics fixed displacement pump – Autohitch (diagram) 9-111
Work hydraulics variable displacement pump – Autohitch (diagram) 9-115
Work hydraulics fixed displacement pump – Autohitch, tipping trailer (diagram) 9-119
Work hydraulics variable displacement pump – Autohitch, tipping trailer (diagram) 9-123
Work hydraulics fixed displacement pump – tipping trailer (diagram) 9-127
Contents
00 0291 635 3 – RHB SCORPION I-5
Work hydraulics variable displacement pump – tipping trailer (diagram) 9-131
Work hydraulics fixed displacement pump – additional control circuit for
quick couplers on quickhitch (diagram) 9-135
Work hydraulics variable displacement pump – additional control circuit for
quick couplers on quickhitch (diagram) 9-139
Work hydraulics fixed displacement pump – telescopic boom additional
control circuit (diagram) 9-143
Work hydraulics variable displacement pump – telescopic boom additional
control circuit (diagram) 9-147
Front/rear additional control circuit, Autohitch, tipping trailer (electrical diagram) 9-151
Front socket, safe load indicator (electrical diagram) 9-155
Test report: model 408 gear pump 9-158
Work hydraulics/boost pressure test ports 9-158
Variable displacement pump (hydraulic pump) 9-159
Checking and setting the work hydraulics 9-161
Work hydraulics circuit (control pump) 9-163
Work hydraulics circuit (fixed displacement pump) 9-164
Work hydraulics circuit (Load-Sensing variable displacement pump) 9-165
Lift ram circuit 9-166
Tilt ram circuit 9-167
Push-out ram circuit 9-168
3rd control circuit 9-169
Pilot valve circuit 9-170
Tilt ram lock circuit 9-171
Front control circuit, electrical changeover 9-172
Rear additional control circuit 9-173
Tipping trailer circuit 9-174
Autohitch circuit 9-175
Autohitch + tipping trailer + additional control circuit 9-176
Control pump control valve (5-fold) connections 9-177
Gear pump control valve (5-fold) (overview) 9-178
Control pump control valve (5-fold) connections 9-179
Load stabilizer 9-180
Load stabilizer circuit 9-182
Work hydraulics fixed displacement pump – tilt ram lock (diagram) 9-185
Work hydraulics variable displacement pump – tilt ram lock (diagram) 9-189
Tilt ram lock (electrical diagram) 9-193
Hydraulic fixed displacement pump – 4-fold control valve (overall diagram) 9-197
Hydraulic variable displacement pump – 4-fold control valve (overall diagram) 9-199
Hydraulic fixed displacement pump – 5-fold control valve (overall diagram) 9-201
Hydraulic variable displacement pump – 5-fold control valve (overall diagram) 9-203
Electrical systems 10
Machine lights (electrical diagram) 10-1
Turn indicators/horn/rotating beacon (electrical diagram) 10-7
Window heating, wipe/wash diagram 10-11
Hydraulics monitoring diagram 10-15
Cab wiring harness (overload control) 10-19
Frame wiring harness (overload control) 10-23
“Smart Handling” (overload control) operation 10-26
Necessary tools 10-32
Installing the load sensor 10-37
Functional description of overload control (Smart Handling) 10-38
Electrical components from serial no 408010417 10-39
Circuit diagram: overload control enabled 10-40
Circuit diagram: automatic retraction OFF 10-41
Overview of valves 10-42
Circuit diagram: overload control from serial no 408010417 10-44
Circuit diagram legend 10-45
Contents
I-6 00 0291 635 3 – RHB SCORPION
Extend (solenoid valve Y102) (circuit diagram) 10-46
Pallet forks mode (circuit diagram) 10-47
Tip switch S084 pressed (circuit diagram) 10-48
Electrical components 10-49
Overload control relay 10-50
Throttle control from serial no 408010179 – 408010416 10-52
Throttle control from serial no 408010179 – 408010416 (hydraulics diagram) 10-53
Throttle control valve block (overview) 10-54
Throttle control from serial no 408010179 – 408010416 (wiring diagram) 10-55
Legend for throttle control wiring diagram 10-56
Cab wiring harness 10-58
Frame wiring harness 10-61
Frame wiring harness (legend) 10-62
Electrical system (overview) 10-63
Electrical components 10-64
Heating – air conditioning system/air-suspension seat (electrical diagram) 10-67
Multimedia/cigarette lighter (electrical diagram) 10-71
Ohm’s Law (current, voltage, resistance); power 10-73
Multifunction measuring device 10-73
Terminal description 10-74
Cable colour coding 10-78
Electrical system 10-81
Proportional controls (overview and connections) 10-87
Proportional electronics 10-88
Wiring harness disconnect (cab – machine frame) 10-89

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