Claas Scorpion 635 (K30) Telehandlers Repair Manual FR

File List:

00 0301 797 2.pdf
00 0302 456 3.pdf
00 0302 553 2.pdf

00 0301 797 2.pdf:

Deutz TCD 3.6 L4Liebherr D914
Contents
Introduction
General instructions
Validity of the notice
Use of the instructions
Texts and illustrations
Articulation by a structure of modules
Seek and find
Steering Specifications
Abbreviations
Specialized terminology
Abbreviations Liebherr diesel engine documentation
General repair instructions
Technical characteristics
Tips for correct repair
Cause of damage
Welding work
Self-locking screws
Liquid screw brake
Lip rings with spring
Steel roller chains
Quick hitch
Type E quick coupler with spring
Type G quick coupler with wire
Type S quick coupler with pins
Assemblies using conical ring
Disassembly
Assembly
Heel pin assemblies
Assembly
Clamp ring bearing
Disassembly
Assembly
Clamp sleeve bearing
Assembly
Clamping sleeve
Removing version A
Removing version B
To set down
Clamping sleeve version A
Clamping sleeve version B
Circlips
Cutting ring fittings
To screw
Leaky cutting ring fittings
Progressive ring screw connections on hydraulic lines
Sealing Cone Fittings
Hydraulic flexible lines
Passage of hoses
Treatment of sealing surfaces
Spare parts
Operating consumables
Tightening torques
Screw types according to CLAAS factory standard CN 02 5000
Description of the screw type
Tolerance class
Tightening instruction
Tightening torques for metric ISO thread
Tightening torques for metric precision threads
Tightening torques for hydraulic screw connections with cutting ring
Tightening torques for pipe fittings with conical sealing fitting and hydraulic fittings with soft sealing gasket
Tightening torques for hydraulic screwed coupling SDS form B and E
Tightening torques for hydraulic screwed coupling SDE form H, adjustable
Tightening torques for hydraulic swivel screw connections
Tightening torques for hollow screws (with copper seal)
Tightening torques for brake line screw connections
Tightening torques for tubular structures with O-ring and union nuts
Hose clamp tightening torques
Assembly tips
Tangent screw clamps
Tangent screw clamps with spring washers
Hose clamps with round bolts
Tightening torques for hose clamps with round bolts
CCN explanation
CCN (CLAAS Component Number – CLAAS part number)
Electrical standard
Hydraulic standard
CCN (CLAAS Component Number – CLAAS part number)
Security
General instructions
To respect
Signal word
General safety and accident prevention instructions
First aid measures
Risk of injury from hydraulic fluid
Marking of warnings and dangers
Exit the machine
Stop the machine
Place the machine on jack stands
Adjustment and maintenance work
Pressure accumulator
Welding work
Notes for working on the diesel engine
Protection against accidents
Cleanliness
Assembly tips
Engine overhaul
01 Motor
0102 Complete set
Diesel engine characteristics
Deutz TCD 3.6 L4
Diesel engine characteristics
Liebherr D914
Engine Description
Lighting order
Start the engine manually
Special tool
0110 Motor housing
Crankshaft speed sensor
Technical characteristics
Camshaft speed sensor
Technical characteristics
Flywheel housing
Technical characteristics
To set down
Intermediate gear
Technical characteristics
Assembly advice
Gear housing
Technical characteristics
Preparing for work
Special tool
To set down
Crankshaft seal ring
Technical characteristics
Special tool
To set down
Seal housing
Technical characteristics
Preparing for work
To set down
Crankshaft seal ring
Technical characteristics
Special tool
To set down
Technical characteristics
Preparing for work
Special tool
To set down
Crankcase
Technical characteristics
Check cylinder bore
0115 Powertrain
Technical characteristics
Special tool
Assembly advice
Check the piston
Remove the piston rings
Install the piston rings
Check piston rings
Measure the piston protrusion
Connecting rod
Technical characteristics
Special tool
Assembly advice
To set down
Crankshaft pulley
Technical characteristics
Preparing for work
Special tool
Without air conditioner
With air conditioner
To set down
Without air conditioner
With air conditioner
Remove the sensor wheel
Install the sensor wheel
Crankshaft
Technical characteristics
To set down
Check axial play
Crankshaft bearing
Technical characteristics
To set down
Flywheel
Technical characteristics
Preparing for work
To set down
0120 Cylinder head – Valves – Distribution
Upper valve cover
Technical characteristics
Preparing for work
To set down
Cylinder head
Technical characteristics
Special tool
To set down
Glow plugs
Technical characteristics
Special tool
To set down
Rocker arm
Technical characteristics
Special tool
To set down
Camshaft
Technical characteristics
Special tool
To set down
Camshaft bearing
Technical characteristics
Special tool
To set down
Technical characteristics
Special tool
To set down
Valve head and valve stem diameter
Valve guide diameter
Valve stem clearance
Valve Removal
Adjust valve clearance
Compression pressure
Special tool
0125 Injection system, fuel supply
Bleed the air from the fuel system
Fuel feed pump
Technical characteristics
Fuel filter
Technical characteristics
Fuel lines
Technical characteristics
To set down
Technical characteristics
Preparing for work
Special tool
Remove rail/fuel pressure sensor
Dismantle the pressure relief valve
Install the pressure relief valve
Install the fuel rail/pressure sensor
To set down
Injector
Technical characteristics
Special tool
Assembly advice
To set down
High pressure pump
Technical characteristics
Preparing for work
Assembly advice
To set down
Position
0130 Lubrication system
Engine oil pressure sensor
Technical characteristics
Special tool
Oil suction tube
Technical characteristics
Preparing for work
Assembly advice
Oil filter
Technical characteristics
Lubricating Oil Cooler
Technical characteristics
Lubricating oil pump
Technical characteristics
To set down
Pilot valve
Technical characteristics
Preparing for work
To set down
Oil pressure regulator
Technical characteristics
Oil injection nozzle
Technical characteristics
Assembly tips
Intermediate driving
Technical characteristics
Preparing for work
To set down
0135 Cooling system
Coolant lines
Technical characteristics
Thermostat
Technical characteristics
To set down
Check lifting stroke
Coolant pump lines
Technical characteristics
Coolant pump
Technical characteristics
Preparing for work
Special tool
To set down
0140 Exhaust device
Exhaust gas turbocharger
Technical characteristics
To set down
Exhaust duct
Technical characteristics
Exhaust collector tube
Technical characteristics
To set down
Exhaust gas recycling lines
Technical characteristics
Exhaust gas recirculation radiator
Technical characteristics
Preparing for work
Remove the exhaust gas recirculation radiator
Install the exhaust gas recirculation radiator
Remove the exhaust gas recirculation valve
Install the exhaust gas recirculation valve
Remove the floating check valve
Install the floating check valve
0145 Air suction
Suction connection
Technical characteristics
Charge air lines
Technical characteristics
Charge air pipe
Technical characteristics
Preparing for work
To set down
Charge air elbow
Technical characteristics
0150 Engine assembly parts
Technical characteristics
To set down
Generator
Technical characteristics
Preparing for work
To set down
Remove the console
Install the console
Air conditioning compressor
Technical characteristics
To set down
Belt tensioner
Technical characteristics
Drive Belt Pulley
Technical characteristics
Compressor
Technical characteristics
Assembly tips
0155 Engine controls
High current start relay
Technical characteristics
Cable set
Technical characteristics
0165 Exhaust gas aftertreatment
Diesel particulate filter
Technical characteristics
Preparing for work
Disassemble
To assemble
Exhaust back pressure sensor after turbocharger
Technical characteristics
Diesel particulate filter differential pressure sensor
Technical characteristics

00 0302 456 3.pdf:

SCORPION 635 VARIPOWERSSCORPION 732 VARIPOWERSSCORPION 736 VARIPOWERSSCORPION 741 VARIPOWER
Contents
Introduction
Notes on the instructions
Validity of the notice
Repair manual information
Use of the instructions
Articulation by a structure of modules
Seek and find
Steering Specifications
General repair instructions
Technical characteristics
Tips for correct repair
Self-locking screws
Liquid screw brake
Steel roller chains
Quick hitch
Type E quick coupler with spring
Type G quick coupler with wire
Type S quick coupler with pins
Assemblies using conical ring
Disassembly
Assembly
Heel pin assemblies
Assembly
Clamp ring bearing
Disassembly
Assembly
Clamp sleeve bearing
Assembly
Clamping sleeve
Removing version A
Removing version B
To set down
Clamping sleeve version A
Clamping sleeve version B
Circlips
Cutting ring fittings
To screw
Leaky cutting ring fittings
Sealing Cone Fittings
Hydraulic flexible lines
Passage of hoses
Diaphragm accumulator (pressure accumulator) according to factory standard CLAAS CN 24 0403
Features
Means of exploitation
Service and assembly
Modification of gas filling
Special tool
Treatment of sealing surfaces
Spare parts
Operating consumables
Tightening torques
Tightening torques for metric coarse and fine pitch threads
Tightening torques for hydraulic connections with cutting ring
Tightening torques for screw connections with bicone connection and hydraulic connections with flexible sealing gasket
Tightening torques for hydraulic screwed coupling SDS form B and E
Tightening torques for hydraulic screwed coupling SDE form H, adjustable
Tightening torques for hydraulic swivel screw connections
Tightening torques for hollow screws (with copper seal)
Tightening torques for brake line screw connections
Tightening torques for tubular structures with O-ring and union nuts
Tightening torques for tangent screw clamps
Tightening torques for hose clamps with round bolts
Security
Recognize the warnings
Warning pictogram
Signal word
Safety tips
Warning stickers and warnings
Requirements for specialized personnel
Children in danger
Dangerous areas of the machine
Passenger instructor during work
Risk of injury from rotating shafts
Construction modifications on the machine
Optional equipment and spare parts
Controlling the machine in operation
Technical condition
Respect the technical threshold values
Danger due to machine elements continuing to operate by inertia
Maintain safety devices in operational capacity
Personal protective equipment
Wear suitable clothing
Remove dirt and loose objects
Park and store the machine safely
Unsuitable operating consumables
Safe handling of operating consumables and secondary consumables
Environmental protection and disposal
Never put chemicals in the cabin
Avoiding fires
Fatal electrical discharges from overhead power lines and lightning strikes
Electrical discharge from the electrical system
Noise can harm your health
Machine parts under stress
Liquids under pressure
Pressurized air
Toxic exhaust gases
Hot surfaces
Safe ascent and descent
Work only when the machine is stopped
Risks during repair work
Machine elements recorded and loads
Risks due to welding work
Check and charge the battery
Preparations for emergency cases
CCN explanation
CCN (CLAAS Component Number – CLAAS part number)
Electrical standard
Hydraulic standard
CCN (CLAAS Component Number – CLAAS part number)
01 Motor
0102 Complete set
Diesel motor
Technical characteristics
Preparing for work
To set down
0125 Injection system, fuel supply
Fuel tank
Technical characteristics
To set down
Tank transmitter
Technical characteristics
Preparing for work
To set down
Fuel feed pump
Technical characteristics
To set down
Fuel pre-filter
Technical characteristics
To set down
0135 Cooling system
Compensation tank
Technical characteristics
To set down
Radiator
Technical characteristics
To set down
Fan motor
Technical characteristics
To set down
Fan distribution block
Technical characteristics
To set down
Fan distribution block
Technical characteristics
To set down
0140 Exhaust device
Exhaust pipe
Technical characteristics
To set down
0145 Air suction
Air filter housing
Technical characteristics
To set down
Charge air cooler
Technical characteristics
To set down
0150 Engine assembly parts
Belt cover
Technical characteristics
Preparing for work
To set down
To set down
Generator
To set down
Compressed air compressor
Technical characteristics
To set down
0155 Engine controls
Accelerator pedal
Technical characteristics
To set down
0165 Exhaust gas aftertreatment
Post-treatment of exhaust gases, general
Preparing for work
Special tool
Check the purity of the urea solution
Check the density of the urea solution
Diesel Oxidation Catalytic Converter
Technical characteristics
To set down
Diesel particulate filter
Technical characteristics
To set down
Mixing section
Technical characteristics
To set down
Dosing valve
Technical characteristics
To set down
SCR catalyst
Technical characteristics
To set down
Urea tank
Technical characteristics
Special tool
To set down
Urea sampling unit
Technical characteristics
Special tool
To set down
Urea pump
Technical characteristics
To set down
02 Transmission – Clutch – Cardan shaft
0210 Vibration damper
Vibration damper
Technical characteristics
To set down
0230 Mechanical gearbox
Overdrive gearbox
Technical characteristics
Preparing for work
To set down
Replace control flange
0238 Gearbox controls
Control cover
Technical characteristics
To set down
0260 Cardan shaft
Cardan shafts
Technical characteristics
Preparing for work
To set down
To set down
03 Chassis
0325 Drive axle, front
Front wheel steering axle
Technical characteristics
To set down
Planetary gear
Technical characteristics
Special tool
To set down
Wheel hub
Technical characteristics
Preparing for work
Special tool
Disassemble
To assemble
To set down
Axle body
Technical characteristics
Special tool
To set down
Bevel gear drive
Technical characteristics
Preparing for work
Special tool
Disassemble
To assemble
Differential
Technical characteristics
Preparing for work
Special tool
Disassemble
Disassemble
To set down
0330 Drive axle, rear
Rear-wheel steering axle
Technical characteristics
To set down
Planetary gear
Wheel hub
Axle body
Technical characteristics
Special tool
To set down
Bevel gear drive
Differential
0335 Transmission
Transmission hydraulic pump
Technical characteristics
To set down
04 Brake
0405 Service brake
Service brake
Technical characteristics
Preparing for work
To set down
Purge the air
Hydraulic service brake cylinder
Technical characteristics
To set down
0415 Parking brake
Parking brake
Assembly tips
Mechanically release the parking brake
0420 Air trailer brake
Compressed air tank
Technical characteristics
Remove the compressed air tank before
Install the compressed air tank before
Remove the rear compressed air tank
Install the rear compressed air tank
05 Management
0505 Steering
Steering column
Technical characteristics
To set down
Steering column
Technical characteristics
To set down
Management unit
Technical characteristics
To set down
Hydraulic steering cylinder
Technical characteristics
Preparing for work
To set down
Set the track
Adjust the steering angle
Blocking block
Technical characteristics
To set down
Bleed the air from the steering hydraulics
06 Lifting device
0620 Telescopic arm
Telescopic arm
Technical characteristics
Special tool
To set down
Emergency lifting of the telescopic arm
Emergency lowering of the telescopic arm
Telescopic boom
Technical characteristics
To set down
Energy chain
Technical characteristics
To set down
Pipe/cable routing
Technical characteristics
To set down
Sliding plates
Technical characteristics
Preparing for work
Assembly tips
To set down
Technical characteristics
Special tool
To set down
Technical characteristics
Special tool
To set down
Hydraulic cylinder mount
Technical characteristics
Special tool
To set down
Hydraulic cylinder mount
Technical characteristics
Special tool
To set down
Hydraulic compensation cylinder
Technical characteristics
Special tool
To set down
Hydraulic thrust cylinder
Technical characteristics
Only with leaking oil return line:
Only with leaking oil return line:
To set down
Only with leaking oil return line:
Hydraulic cylinder tilt
Technical characteristics
Special tool
To set down
Hydraulic cylinder quick change lock
Technical characteristics
Special tool
To set down
Lift angle sensor
Technical characteristics
To set down
Tilt angle sensor
Technical characteristics
To set down
07 Hitch device
0705 Hitch
Hitch clevis
Technical characteristics
To set down
Height-adjustable hitch clevis
Technical characteristics
To set down
0720 Towing hook
Hitch drawbar
Technical characteristics
To set down
Remove sensor B67-LWT
Install the B67-LWT sensor
Remove the axle
Install the axle
08 Orders
0800 Drive scheme
Training scheme
09 Hydraulic system
0905 Hydraulic oil tank
Hydraulic oil tank
Technical characteristics
Special tool
To set down
Generate a vacuum in the hydraulic oil tank
No longer generate vacuum in the hydraulic oil tank
0907 Hydraulic oil cooler
Hydraulic Oil Cooler
0910 Pumps
Hydraulic pump of working hydraulic system
Technical characteristics
To set down
Hydraulic pump, gear pump
Technical characteristics
To set down
0915 Hydraulic circuit
Vibration damping pressure accumulator
Technical characteristics
To set down
0920 Valves
Brake hydraulic distribution block
Technical characteristics
To set down
Steering mode valve
Technical characteristics
To set down
Control circuit distribution block 3
Technical characteristics
To set down
Hitch Hitch Distribution Block
Technical characteristics
To set down
Working hydraulic system distribution block
Technical characteristics
To set down
Working hydraulic system distribution block
Technical characteristics
To set down
Load maintaining valve
Technical characteristics
To set down
10 Electrical/electronic system
1005 Power supply
Technical characteristics
To set down
Battery cut-off switch
Technical characteristics
To set down
1010 Central electrical system
Central electrical system
Technical characteristics
To set down
Overview of connectors
Technical characteristics
A46-LWT file
A46-LWT pose
A30-LWT file
A30-LWT pose
A50-LWT file
A50-LWT pose
A40-LWT file
A40-LWT pose
Load sensor
Technical characteristics
Preparing for work
To set down
1035 Use / Multifunction lever
Control lever
Technical characteristics
To set down
Manual slow approach monolever
Technical characteristics
To set down
Manual throttle monolever
Technical characteristics
To set down
Monolever control circuit 4
Technical characteristics
To set down
Display unit
Technical characteristics
To set down
Steering mode distribution table
Technical characteristics
To set down
DMS evaluation electronics
Technical characteristics
To set down
12 Cabin – Driving position
1210 Cabin
Technical characteristics
To set down
Windshield washer fluid reservoir
Technical characteristics
To set down
Front wiper
Technical characteristics
To set down
Back windshield wiper
Technical characteristics
To set down
1230 Headquarters
Driver’s seat
Technical characteristics
To set down
1235 Cabin heater
Heating and air conditioning box
Technical characteristics
To set down
Heat exchanger
Technical characteristics
To set down
Technical characteristics
To set down
Cabin air filter
Technical characteristics
To set down
1240 Air conditioning
Air conditioning, general
Empty the air conditioning
Fill the air conditioning
Air conditioning compressor
Technical characteristics
To set down
Evaporator
Technical characteristics
To set down
Capacitor
Technical characteristics
To set down
Filter dryer
Technical characteristics
To set down
75 Central lubrication system
7500 Central lubrication, general
Central lubrication, general
Special tool
7505 Tank, pump
Tank and pump
Technical characteristics
To set down
Remove the feed piston
Install the feed piston
7515 Lubrication system / lines
Lubrication lines
Special tool
80 Assembly / body parts
8005 Chassis
Crankcase
Technical characteristics
Assembly tips
8020 Balustrades / Safety devices
Underbody protection
Technical characteristics
To set down
8025 Covering sheets / covers
Technical characteristics
To set down
8030 Wings
Technical characteristics
To set down
95 Overview of maintenance parts
9599 Maintenance work
Place the machine in maintenance position
Checking the leaks of the diesel engine
Check the fixing of the diesel engine consoles
Replace fuel filter filter cartridges
Preparing for work
Fuel pre-filter
Fine fuel filter
Replace diesel engine oil
Preparing for work
Replace diesel engine oil filter
Preparing for work
Check the belt (R01) of the diesel engine
Replace the belt (R01) of the diesel engine
Check the tightness and condition of the cooling system
Replace the coolant
Preparing for work
Check the coolant antifreeze
Preparing for work
Correct antifreeze concentration
Check the suction system and exhaust gas system
Check the correct attachment of the compressed air compressor
Check the belt (R03) of the compressed air compressor
Replace the belt (R03) of the compressed air compressor
Check the cable connection of the diesel engine sensor system
Replace the urea pump filter
Replace travel gear oil
Preparing for work
Control and measure transmission
Check the axle oil level
Differential
Wheel hub
Replace axle oil
Preparing for work
Differential
Wheel hub
Check the tightening torque of the axle fixing screws
Check brake lining wear
Clean the external compressed air tank
Check the tightness of the air brake system
Check the filling level of the antifreeze pump of the air brake system
Check and measure the braking system
Check and measure the steering system
Check the absence of wear and the correct positioning and tightening of the rear sliding plates
Check the tightness of the hydraulic system
Replace hydraulic oil
Preparing for work
Replace the hydraulic tank air filter
Replace the filter element of the filter on the return of the hydraulic tank
Replace the fuel circuit pressure filter
Check and measure working hydraulics
Check the correct fixation of the battery terminals
Check the battery fluid level
Check the condition and routing of the battery degassing hose
Check the drying unit
Check the heating and air conditioning
Clean the fresh air filter
Check the air conditioning water drain valve
Check the belt (R02) of the air conditioning compressor
Replace the belt (R02) of the air conditioning compressor

00 0302 553 2.pdf:

SCORPION 635 TRENDSCORPION 732 TRENDSCORPION 736 TRENDSCORPION 741 TREND
Contents
Introduction
Notes on the instructions
Validity of the notice
Repair manual information
Use of the instructions
Articulation by a structure of modules
Seek and find
Steering Specifications
General repair instructions
Technical characteristics
Tips for correct repair
Self-locking screws
Liquid screw brake
Steel roller chains
Quick hitch
Type E quick coupler with spring
Type G quick coupler with wire
Type S quick coupler with pins
Assemblies using conical ring
Disassembly
Assembly
Heel pin assemblies
Assembly
Clamp ring bearing
Disassembly
Assembly
Clamp sleeve bearing
Assembly
Clamping sleeve
Removing version A
Removing version B
To set down
Clamping sleeve version A
Clamping sleeve version B
Circlips
Cutting ring fittings
To screw
Leaky cutting ring fittings
Sealing Cone Fittings
Hydraulic flexible lines
Passage of hoses
Diaphragm accumulator (pressure accumulator) according to factory standard CLAAS CN 24 0403
Features
Means of exploitation
Service and assembly
Modification of gas filling
Special tool
Treatment of sealing surfaces
Spare parts
Operating consumables
Tightening torques
Tightening torques for metric coarse and fine pitch threads
Tightening torques for hydraulic connections with cutting ring
Tightening torques for screw connections with bicone connection and hydraulic connections with flexible sealing gasket
Tightening torques for hydraulic screwed coupling SDS form B and E
Tightening torques for hydraulic screwed coupling SDE form H, adjustable
Tightening torques for hydraulic swivel screw connections
Tightening torques for hollow screws (with copper seal)
Tightening torques for brake line screw connections
Tightening torques for tubular structures with O-ring and union nuts
Tightening torques for tangent screw clamps
Tightening torques for hose clamps with round bolts
Security
Recognize the warnings
Warning pictogram
Signal word
Safety tips
Warning stickers and warnings
Requirements for specialized personnel
Children in danger
Dangerous areas of the machine
Passenger guide during work
Risk of injury from rotating shafts
Constructive modifications to the machine
Optional equipment and spare parts
Controlling the machine in operation
Technical condition
Respect the technical threshold values
Danger due to machine elements continuing to operate by inertia
Maintain safety devices in operational capacity