Claas Scorpion 756 (K37) Telehandlers Repair Manual EN

File List:

00 0301 792 1.pdf
00 0302 754 3.pdf

00 0301 792 1.pdf:

Deutz TCD 4.1 L4
Table of contents
Introduction
General information
Validity of 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 connections
Dismounting
Installation
Gib head key connections
Dismounting
Installation
Lock collar bearing
Dismounting
Installing
Adapter sleeve bearing
Dismounting
Installation
Chuck bushing
Removing
Dismounting of version A
Dismounting of version B
Installing
Chuck bushing version A
Chuck bushing version B
Circlips
Ferrule fittings
Screwing in
Leaky ferrule fittings
Sealing cone fittings
Hydraulic hoses
Hose routing
Treatment of sealing faces
Spare parts
Operating materials
Tightening torques
Tightening torques for metric ISO screw thread
Tightening torques for metric fine thread
Tightening torques for hydraulic fittings with ferrule
Tightening torques for screwed pipe connections with sealing cone joint and hydraulic threaded joints with soft core seal
Tightening torques for hydraulic male connectors SDS shape B and E
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 worm drive hose clamps
Tightening torques for hose clamps with round pins
CCN explanation
CCN (CLAAS Component Number)
Electric systems standard
Hydraulic system standard
CCN (CLAAS Component Number)
General information
Important
Signal word
General safety and accident prevention regulations
First aid measures
Danger of injury from hydraulic liquid
Leaving the machine
Putting the machine out of operation
Jacking up the machine
Adjusting and maintenance work
Welding work
Instructions for work on the diesel engine
Accident protection
Cleanliness
Installation instructions
Engine overhaul
01 Engine
0102 Complete component
Engine data
TCD 4.1 L4
Engine description
Ignition order
Cranking the engine
Special tool
Installing the cranking tool on the flywheel side
Installing the cranking tool on the torsional vibration damper
0105 Engine suspension
Engine suspension
Technical specifications
0110 Engine housing
Crankcase venting
Technical specifications
Installation
Crankshaft speed sensor
Technical specifications
Work preparation
Camshaft speed sensor
Technical specifications
Flywheel housing
Technical specifications
Special tool
Installation
Gearwheel housing
Technical specifications
Work preparation
Installation
Crankshaft seal
Technical specifications
Special tool
Removing
Installing
Front cover
Technical specifications
Installation
Crankshaft seal
Technical specifications
Special tool
Removing
Installing
Replacing the shaft sleeve
Oil sump
Technical specifications
Work preparation
Special tool
Installation
Crankcase
Technical specifications
Work preparation
Checking the cylinder bore
0115 Engine unit
Technical specifications
Special tool
Installation instructions
Checking the piston
Removing the piston rings
Installing the piston rings
Checking the piston rings
Measuring the piston excess height
Connecting rod
Technical specifications
Special tool
Installation instructions
Removing
Installing
Checking
Torsional vibration damper
Technical specifications
Work preparation
Special tool
Installation
Crankshaft
Technical specifications
Removing
Installing
Checking the axial play
Crankshaft bearing
Technical specifications
Special tool
Installation
Flywheel
Technical specifications
Work preparation
Special tool
Installation
Removing the ring gear
Installing the ring gear
0120 Cylinder head / Valves / Idler gear
Valve cover
Technical specifications
Installation
Cylinder head
Technical specifications
Special tool
Removing
Installing
Rocker lever
Technical specifications
Disassembly
Assembly
Installation
Camshaft
Technical specifications
Installation
Checking
Technical specifications
Special tool
Removing
Installing
Checking
Valve plate and valve shaft diameter
Diameter of valve guides
Valve shaft play
Valve depth
Adjusting the valve lash
Combustion pressure
Special tool
Checking
0125 Injection – / Fuel system
Fuel lift pump
Technical specifications
Fuel filter
Technical specifications
Fuel lines
Technical specifications
Special tool
Installation
Technical specifications
Work preparation
Special tool
Removing the rail / fuel pressure sensor
Removing the pressure relief valve
Installing the pressure relief valve
Installing the rail / fuel pressure sensor
Installation
Injector
Technical specifications
Special tool
Installation instructions
Removing
Installing
Injector sleeve
Technical specifications
Work preparation
Special tool
Removing
Installation
High-pressure pumps
Technical specifications
Work preparation
Special tool
Installation
Control block
Technical specifications
Work preparation
Removing
Disassembly
Assembly
Installing
0130 Lubricating oil system
Oil suction tube
Technical specifications
Lubrication oil cooler
Technical specifications
Work preparation
Lubricating oil cooler housing
Technical specifications
Installation
Lubrication pump
Oil spray nozzle
Technical specifications
Installation instructions
Oil level dipstick
Technical specifications
0135 Cooling system
Coolant lines
Technical specifications
Work preparation
Thermostat housing
Technical specifications
Work preparation
Installation
Thermostat
Technical specifications
Installation
Checking the stroke
Engine temperature sensor
Technical specifications
Coolant pump
Technical specifications
Work preparation
Installation
Fan bearing
Technical specifications
0140 Exhaust system
Turbocharger
Technical specifications
Work preparation
Special tool
Installation
Main exhaust manifold
Technical specifications
Work preparation
Special tool
Installation
Exhaust recirculation cooler
Technical specifications
Work preparation
Special tool
Installation
Reed valve
Technical specifications
Work preparation
Installation
Actuator
Technical specifications
Work preparation
Special tool
Installation instructions
Installation
Exhaust gas mass flow sensor
Technical specifications
Installation instructions
0145 Air intake
Charge air tube
Technical specifications
Work preparation
Installation
Heater flange
Technical specifications
Work preparation
Disassembly
Assembly
Installation
Mixing tube
Technical specifications
Installation
Orifice plate
Technical specifications
Installation
0150 Engine attachment parts
Electric starting motor
Technical specifications
Installation instructions
Alternator
Technical specifications
Disassembly
Assembly
Installation
Removing the support
Installing the support
Technical specifications
Air conditioner compressor
Technical specifications
Installation instructions
Belt tensioner
Technical specifications
Drive belt pulley
Technical specifications
Air compressor
Technical specifications
Work preparation
Installation instructions
0155 Engine control
Starting high-current relay
Technical specifications
0165 Exhaust gas aftertreatment
Diesel particulate filter
Technical specifications
Work preparation
Special tool
Disassembly
Assembly
Diesel particulate filter differential pressure sensor
Technical specifications

00 0302 754 3.pdf:

SCORPION 756 VARIPOWER
Table of contents
Introduction
Notes on the manual
Validity of manual
Information about this Repair Manual
Handling of manual
Document structure based on sub-assemblies
Search and find
Directions
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
Installation
Chuck bushing
Removing
Dismounting of version A
Dismounting of version B
Installing
Chuck bushing version A
Chuck bushing version B
Circlips
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
Tightening torques
Tightening torques for metric standard and fine threads
Tightening torques for hydraulic fittings with ferrule
Tightening torques for screwed pipe connections with sealing cone joint and hydraulic threaded joints with soft core seal
Tightening torques for hydraulic male connectors SDS shape B and E
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 worm drive hose clamps
Tightening torques for 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 pre-filter
Technical specifications
Removing
Installing
0135 Cooling system
Compensating reservoir
Technical specifications
Removing
Installing
Engine radiator
Technical specifications
Removing
Installing
Fan motor
Technical specifications
Removing
Installing
Fan valve block
Technical specifications
Removing
Installing
Fan valve block
Technical specifications
Removing
Installing
0140 Exhaust system
Exhaust gas pipe
Technical specifications
Removing
Installing
Silencer
Technical specifications
Removing
Installing
0145 Air intake
Air filter housing
Technical specifications
Removing
Installing
Charge air cooler
Technical specifications
Removing
Installing
0150 Engine attachment parts
Belt guard
Technical specifications
Work preparation
Removing
Installing
Electric starting motor
Removing
Installing
Alternator
Removing
Installing
Compressed-air compressor
Technical specifications
Removing
Installing
0155 Engine control
Accelerator pedal
Technical specifications
Removing
Installing
0165 Exhaust gas aftertreatment
Exhaust gas treatment – General
Work preparation
Special tool
Checking the purity of the urea solution
Checking the density of the urea solution
Diesel particulate filter
Technical specifications
Removing
Installing
Mixing section
Technical specifications
Removing
Installing
Dosing valve
Technical specifications
Removing
Installing
SCR catalyst
Technical specifications
Removing
Installing
Urea tank
Technical specifications
Special tool
Removing
Installing
Urea withdrawal unit
Technical specifications
Special tool
Removing
Installing
Urea pump
Technical specifications
Removing
Installing
02 Gearbox / Clutch / Universal drive shaft
0210 Oscillation damper
Oscillation damper
Technical specifications
Removing
Installing
0230 Mechanical gearbox
High-speed gearbox
Technical specifications
Work preparation
Removing
Installing
Removing the drive flange
0238 Gearbox control
Timing cover
Technical specifications
Removing
Installing
0260 Universal drive shaft
Universal drive shafts
Technical specifications
Work preparation
Removing
Installing
Removing
Installing
03 Chassis
0305 Axle suspension
Axle bearing
Technical specifications
Removing
Installing
0325 Front steering drive axle
Front steering drive axle
Technical specifications
Removing
Installing
Planetary gear
Technical specifications
Work preparation
Disassembly
Assembly
Stub axle
Technical specifications
Work preparation
Removing
Installing
Floating axle
Technical specifications
Work preparation
Removing
Disassembly
Assembly
Installing
Axle body
Technical specifications
Work preparation
Removing
Installing
Bevel gear drive
Technical specifications
Work preparation
Removing
Installing
Differential
Technical specifications
Work preparation
Removing
Disassembly
Assembly
Installing
0330 Rear steering drive axle
Rear steering drive axle
Technical specifications
Removing
Installing
Planetary gear
Stub axle
Floating axle
Bevel gear drive
Differential
0335 Ground drive
Ground drive hydraulic pump
Technical specifications
Removing
Installing
Ground drive additional variable-displacement motor
Technical specifications
Removing
Installing
04 Brake
0405 Service brake
Service brake
Technical specifications
Work preparation
Removing
Installing
Bleeding the service brake
Service brake hydraulic cylinder
Technical specifications
Removing
Installing
0415 Parking brake
Parking brake
Installation instructions
Releasing the parking brake mechanically
Adjusting the parking brake
0420 Trailer air brake
Compressed-air reservoir
Technical specifications
Removing
Installing
05 Steering
0505 Steering
Steering column
Technical specifications
Removing
Installing
Steering column
Technical specifications
Removing
Installing
Steering unit
Technical specifications
Removing
Installing
Steering hydraulic cylinder
Technical specifications
Work preparation
Removing
Disassembly
Assembly
Installing
Adjusting the track
Adjusting the steering angle
Blocking block
Technical specifications
Removing
Installing
Venting the steering hydraulics
06 Lift device
0620 Telescopic arm
Telescopic arm
Technical specifications
Special tool
Removing
Installing
Telescopic boom
Technical specifications
Removing
Installing
Technical specifications
Removing
Installing
Slide plates
Technical specifications
Work preparation
Installation instructions
Removing
Installing
Tool carrier
Technical specifications
Special tool
Removing
Installing
Tool carrier
Technical specifications
Special tool
Removing
Installing
Lift hydraulic cylinder
Technical specifications
Special tool
Removing
Installing
Lift hydraulic cylinder
Technical specifications
Special tool
Removing
Installing
Compensation hydraulic cylinder
Technical specifications
Special tool
Removing
Installing
Push-out hydraulic cylinder
Technical specifications
Removing
Installing
Tipping hydraulic cylinder
Technical specifications
Special tool
Removing
Installing
Quick-change lock hydraulic cylinder
Technical specifications
Special tool
Installation
Lift angle sensor
Technical specifications
Removing
Installing
Tipping angle sensor
Technical specifications
Removing
Installing
07 Hitch
0705 Coupling frame
Trailer hitch
Technical specifications
Removing
Installing
Height-adjustable trailer hitch
Technical specifications
Removing
Installing
0720 Hitch
Technical specifications
Removing
Installing
Remove sensor B67-LWT
Install sensor B67-LWT
Removing the pin
Installing the pin
08 Drives
0800 Drive diagram
Drive diagram
09 Hydraulic system
0900 Hydraulic system – General
Hydraulic system – General
Special tool
Filling the accumulator
0905 Hydraulic oil tank
Hydraulic oil tank
Technical specifications
Special tool
Removing
Installing
Generating a vacuum in the hydraulic oil tank
Stop generating a vacuum in the hydraulic oil tank.
0907 Hydraulic oil cooler
Hydraulic oil cooler
0910 Pumps
Working hydraulics pump
Technical specifications
Removing
Installing
Hydraulic pump gear pump
Technical specifications
Removing
Installing
0915 Hydraulic lines
HIGHFLOW
Removing
Installing
0920 Valves
Brake hydraulics
Technical specifications
Removing the brake hydraulics valve block
Installing the brake hydraulics valve block
Removing the accumulator charge valve block
Installing the accumulator charge valve block
Removing the differential lock valve block
Installing the differential lock valve block
Hydraulic brake proportional valve
Technical specifications
Removing
Installing
Steering mode valve
Technical specifications
Removing
Installing
Control circuit 3 valve block
Technical specifications
Removing
Installing
Hitch valve block
Technical specifications
Removing
Installing
Working hydraulics valve block
Technical specifications
Removing
Installing
Working hydraulics valve block
Technical specifications
Removing
Installing
Compensating cylinder valve block
Technical specifications
Removing
Installing
Priority valve block
Technical specifications
Removing
Installing
10 Electrical / Electronic equipment
1005 Power supply
Technical specifications
Removing
Installing
Battery isolating switch
Technical specifications
Removing
Installing
1010 Central electrics
Central terminal compartment
Technical specifications
Removing
Installing
Technical specifications
Remove A30-LWT and A40-LWT
Install A30-LWT and A40-LWT
Removing A50-LWT
Installing A50-LWT
Load sensor
Technical specifications
Work preparation
Removing
Installing
1035 Operation / Multifunction control lever
Control lever
Technical specifications
Removing
Installing
Hand inch joystick
Technical specifications
Removing
Installing
Hand gas joystick
Technical specifications
Removing
Installing
Control circuit 4 joystick
Technical specifications
Removing
Installing
Display unit
Technical specifications
Removing
Installing
7 display
Technical specifications
Removing
Installing
Steering type switch panel
Technical specifications
Removing
Installing
DMS evaluation electronics
Technical specifications
Removing
Installing
12 Cab / Operator’s platform
1210 Cab
Technical specifications
Removing
Installing
Front inside lining
Removing
Installing
Front inside lining
Removing
Installing
Front windscreen wiper
Technical specifications
Removing
Installing
Rear wiper
Technical specifications
Removing
Installing
Side wiper
Technical specifications
Removing
Installing
Window cleaning fluid tank
Technical specifications
Removing
Installing
1230 Seat
Driver’s seat
Technical specifications
Removing
Installing
1235 Cab heater
Heating / cooling housing
Technical specifications
Removing
Installing
Heat exchanger
Technical specifications
Removing
Installing
Technical specifications
Removing
Installing
Cab air filter
Technical specifications
Removing
Installing
1240 Air condition
Air conditioning system – General information
Draining the air conditioner
Filling the air condioner
Air conditioner compressor
Technical specifications
Removing
Installing
Evaporator
Technical specifications
Removing
Installing
Condenser
Technical specifications
Removing
Installing
Filter drier
Technical specifications
Removing
Installing
75 Central lubrication system
7500 Central lubrication system – General
Central lubrication system – General
Special tool
7505 Reservoir / Pump
Container and pump
Technical specifications
Removing
Installing
Removing the delivery piston
Installing the delivery piston
7515 Lubrication system / Lines
Lubrication lines
Special tool
80 Various components / Machine body
8005 Frame / Trough
Engine pan
Technical specifications
Installation instructions
Tk console
Technical specifications
Removing
Installing
8020 Rails / Safety devices
Underriding protector
Technical specifications
Work preparation
Removing
Installing
8025 Panellings / Hoods
Engine bonnet
Technical specifications
Removing
Installing
8030 Mud guards
Mudguard
Technical specifications
Removing
Installing
95 Maintenance parts overview
9599 Maintenance jobs
Moving the machine to the maintenance position
Checking the diesel engine tightness
Checking the diesel engine consoles fastening
Adjusting the valve lash
Replacing fuel filter cartridges
Work preparation
Fuel pre-filter
Fuel fine filter
Bleeding the fuel system
Changing the diesel engine oil
Work preparation
Changing the diesel engine oil filter
Work preparation
Check the diesel engine belt (R01).
Changing the diesel engine belt (R01)
Checking the tightness and the condition of cooling system
Changing the coolant
Work preparation
Checking the anti-freeze protection of coolant
Work preparation
Correcting the anti-freeze concentration
Checking the intake system and the exhaust system
Checking the air compressor for tight seat
Checking the cable connections of diesel engine sensors
Replacing the urea pump filter
Changing the drive gearbox oil
Work preparation
Testing and measuring the ground drive
Check the axles’ oil level.
Differential gear
Wheel hub
Changing the axles’ oil
Work preparation
Differential gear
Wheel hub
Checking the tightening torque of axle mounting bolts
Checking the brake lining wear
Cleaning the outer compressed air reservoirs
Checking the tightness of compressed air brake system
Checking the fill level of the pneumatic brake system anti-freeze pump
Testing and measuring the brake system
Testing and measuring the steering system
Checking the wear and tight seat of rear slides.
Changing the hydraulic oil
Work preparation
Replacing the filter element in the hydraulic oil tank return line filter
Changing the hydraulic oil tank fresh air filter element
Checking the tightness of hydraulic system
Changing the charge circuit pressure filter
Checking and measuring the working hydraulics
Checking if battery connections are tightly seated
Checking the liquid level of batteries
Checking the condition and laying of the battery degassing hose
Checking the drier unit
Checking the heater and air conditioner
Cleaning the fresh air filter
Checking the air conditioner water drain valve
Checking the air conditioning compressor belt (R02)
Changing the air conditioner compressor belt (R02)