Claas Scorpion 736 (K32) Telehandlers Repair Manual EN

File List:

00 0301 796 2.pdf
00 0302 455 3.pdf
00 0302 552 2.pdf

00 0301 796 2.pdf:

Deutz TCD 3.6 L4Liebherr D914
Table of contents
Introduction
General information
Validity of manual
Handling of manual
Text and figures
Document structure based on sub-assemblies
Search and find
Directions
Abbreviations
Technical terms
Abbreviations used in the documentation for the Liebherr diesel engine
General repair instructions
Technical specifications
Information on professional repairs
Reason of damage
Welding work
Self-locking bolts
Liquid locking compound
Radial shaft seals
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
Installing
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
Progressive ring fittings on hydraulic lines
Sealing cone fittings
Hydraulic hoses
Hose placement
Treatment of sealing faces
Spare parts
Operating materials
Tightening torques
Threaded assemblies according to CLAAS works standard CN 02 5000
Description of threaded assembly
Tolerance class
Tightening specifications
Tightening torques for metric ISO screw threads
Tightening torques for metric fine thread screws
Tightening torques for hydraulic screw fittings with ferrule
Tightening torques for pipe fittings with sealing cone joints and hydraulic fittings with soft ring seals
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 hose clamps
Installation instructions
Worm drive hose clamps
Worm-type hose clamps with disc springs
Hose clamps with round pins
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
Identification of warning and danger signs
Leaving the machine
Putting the machine out of operation
Jacking up the machine
Adjusting and maintenance work
Hydraulic accumulators
Welding work
Instructions for work on the diesel engine
Accident protection
Cleanliness
Installation instructions
Engine overhaul
01 Engine
0102 Complete component
Diesel engine characteristics
Deutz TCD 3.6 L4
Diesel engine characteristics
Liebherr D914
Engine description
Ignition order
Cranking the engine
Special tool
0110 Engine housing
Crankshaft speed sensor
Technical specifications
Camshaft speed sensor
Technical specifications
Flywheel housing
Technical specifications
Installation
Intermediate gear wheel
Technical specifications
Installation instructions
Gearwheel housing
Technical specifications
Work preparation
Special tool
Installation
Crankshaft seal
Technical specifications
Special tool
Removing
Installing
Sealing housing
Technical specifications
Work preparation
Installation
Crankshaft seal
Technical specifications
Special tool
Removing
Installing
Oil sump
Technical specifications
Work preparation
Special tool
Installation
Crankcase
Technical specifications
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
Crankshaft pulley
Technical specifications
Work preparation
Special tool
Removing
No air conditioning
With air conditioning
Installing
No air conditioning
With air conditioning
Removing the sensor wheel
Fitting the sensor wheel
Crankshaft
Technical specifications
Removing
Installing
Checking the axial play
Crankshaft bearing
Technical specifications
Installation
Flywheel
Technical specifications
Work preparation
Installation
0120 Cylinder head / Valves / Idler gear
Valve cover
Technical specifications
Work preparation
Installation
Cylinder head
Technical specifications
Special tool
Installation
Glow plugs
Technical specifications
Special tool
Installation
Rocker lever
Technical specifications
Special tool
Installation
Camshaft
Technical specifications
Special tool
Installation
Checking
Camshaft Bearings
Technical specifications
Special tool
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
Bleeding the fuel system
Fuel lift pump
Technical specifications
Fuel filter
Technical specifications
Fuel lines
Technical specifications
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
Installation
High-pressure pump
Technical specifications
Work preparation
Installation instructions
Installation
Position
0130 Lubricating oil system
Engine oil pressure sensor
Technical specifications
Special tool
Oil suction tube
Technical specifications
Work preparation
Installation instructions
Oil filter
Technical specifications
Lubrication oil cooler
Technical specifications
Lubrication pump
Technical specifications
Installation
Control valve
Technical specifications
Work preparation
Installation
Oil pressure control valve
Technical specifications
Oil spray nozzle
Technical specifications
Installation instructions
Adapter line
Technical specifications
Work preparation
Installation
0135 Cooling system
Coolant lines
Technical specifications
Thermostat
Technical specifications
Removing
Installing
Checking the stroke
Coolant pump lines
Technical specifications
Coolant pump
Technical specifications
Work preparation
Special tool
Installation
0140 Exhaust system
Turbocharger
Technical specifications
Installation
Exhaust gas pipe
Technical specifications
Main exhaust manifold
Technical specifications
Installation
Exhaust gas recirculation lines
Technical specifications
Exhaust gas recirculation cooler
Technical specifications
Work preparation
Removing the exhaust gas recirculation cooler
Installing the exhaust gas recirculation cooler
Removing exhaust gas recirculation valve
Installing the exhaust gas recirculation valve
Removing the flutter valve
Installing the flutter valve
0145 Air intake
Intake nozzle
Technical specifications
Charge air lines
Technical specifications
Charge air tube
Technical specifications
Work preparation
Installation
Charge air elbow
Technical specifications
0150 Engine attachment parts
Electric starting motor
Technical specifications
Installation
Alternator
Technical specifications
Work preparation
Installation
Removing the support
Installing the support
Air conditioner compressor
Technical specifications
Installation
Belt tensioner
Technical specifications
Drive belt pulley
Technical specifications
Air compressor
Technical specifications
Installation instructions
0155 Engine control
Starting high-current relay
Technical specifications
Wiring loom
Technical specifications
0165 Exhaust gas aftertreatment
Diesel particulate filter
Technical specifications
Work preparation
Disassembly
Assembly
Exhaust counter pressure sensor downstream of the turbocharger
Technical specifications
Diesel particulate filter differential pressure sensor
Technical specifications

00 0302 455 3.pdf:

SCORPION 635 VARIPOWERSCORPION 732 VARIPOWERSCORPION 736 VARIPOWERSCORPION 741 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
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 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
Installation
0125 Injection / Fuel system
Fuel tank
Technical specifications
Removing
Installing
Tank sensor
Technical specifications
Work preparation
Removing
Installing
Fuel pump
Technical specifications
Removing
Installing
Fuel pre-filter
Technical specifications
Removing
Installing
0135 Cooling system
Compensating reservoir
Technical specifications
Installation
Engine radiator
Technical specifications
Installation
Fan motor
Technical specifications
Installation
Fan valve block
Technical specifications
Installation
Fan valve block
Technical specifications
Installation
0140 Exhaust system
Exhaust gas pipe
Technical specifications
Installation
0145 Air intake
Air filter housing
Technical specifications
Installation
Charge air cooler
Technical specifications
Installation
0150 Engine attachment parts
Belt guard
Technical specifications
Work preparation
Installation
Electric starting motor
Installation
Alternator
Installation
Compressed-air compressor
Technical specifications
Installation
0155 Engine control
Accelerator pedal
Technical specifications
Installation
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 oxidation catalyst
Technical specifications
Installation
Diesel particulate filter
Technical specifications
Installation
Mixing section
Technical specifications
Installation
Dosing valve
Technical specifications
Installation
SCR catalyst
Technical specifications
Installation
Urea tank
Technical specifications
Special tool
Installation
Urea withdrawal unit
Technical specifications
Special tool
Removing
Installing
Urea pump
Technical specifications
Installation
02 Gearbox / Clutch / Universal drive shaft
0210 Oscillation damper
Oscillation damper
Technical specifications
Installation
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
0325 Front steering drive axle
Front steering drive axle
Technical specifications
Installation
Planetary gear
Technical specifications
Special tool
Installation
Wheel hub
Technical specifications
Work preparation
Special tool
Disassembly
Assembly
Installation
Axle body
Technical specifications
Special tool
Installation
Bevel gear drive
Technical specifications
Work preparation
Special tool
Disassembly
Assembly
Differential
Technical specifications
Work preparation
Special tool
Disassembly
Disassembly
Installation
0330 Rear steering drive axle
Rear drive axle
Technical specifications
Installation
Planetary gear
Wheel hub
Axle body
Technical specifications
Special tool
Installation
Bevel gear drive
Differential
0335 Ground drive
Ground drive hydraulic pump
Technical specifications
Removing
Installing
04 Brake
0405 Service brake
Service brake
Technical specifications
Work preparation
Installation
Service brake hydraulic cylinder
Technical specifications
Installation
0415 Parking brake
Parking brake
Installation instructions
Releasing the parking brake mechanically
0420 Trailer air brake
Compressed-air reservoir
Technical specifications
Remove the front compressed-air reservoir.
Installing the front compressed-air reservoir
Removing the rear compressed-air reservoir
Installing the rear compressed-air reservoir
05 Steering
0505 Steering
Steering column
Technical specifications
Removing
Installing
Steering column
Technical specifications
Removing
Installing
Steering unit
Technical specifications
Installation
Steering hydraulic cylinder
Technical specifications
Work preparation
Installation
Adjusting the track
Adjusting the steering angle
Blocking block
Technical specifications
Installation
Venting the steering hydraulics
06 Lift device
0620 Telescopic arm
Telescopic arm
Technical specifications
Special tool
Installation
Emergency telescopic arm lifting
Telescopic arm emergency lowering
Telescopic boom
Technical specifications
Installation
Energy chain
Technical specifications
Removing
Installing
Line laying
Technical specifications
Installation
Slide plates
Technical specifications
Work preparation
Installation instructions
Removing
Installing
Tool carrier
Technical specifications
Special tool
Installation
Tool carrier
Technical specifications
Special tool
Installation
Lift hydraulic cylinder
Technical specifications
Special tool
Installation
Lift hydraulic cylinder
Technical specifications
Special tool
Installation
Compensation hydraulic cylinder
Technical specifications
Special tool
Installation
Push-out hydraulic cylinder
Technical specifications
Only with leak oil pipe:
Only with leak oil pipe:
Installation
Only with leak oil pipe:
Tipping hydraulic cylinder
Technical specifications
Special tool
Installation
Quick-change lock hydraulic cylinder
Technical specifications
Special tool
Installation
Lift angle sensor
Technical specifications
Installation
Tipping angle sensor
Technical specifications
Removing
Installing
07 Hitch
0705 Coupling frame
Trailer hitch
Technical specifications
Installation
Height-adjustable trailer hitch
Technical specifications
Installation
0720 Hitch
Technical specifications
Installation
Remove sensor B67-LWT
Install sensor B67-LWT
Removing the pin
Installing the pin
08 Drives
0800 Drive diagram
Drive diagram
09 Hydraulic system
0905 Hydraulic oil tank
Hydraulic oil tank
Technical specifications
Special tool
Installation
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
Installation
0915 Hydraulic lines
Pitching dampening pressure accumulator
Technical specifications
Installation
0920 Valves
Brake hydraulics valve block
Technical specifications
Installation
Steering mode valve
Technical specifications
Removing
Installing
Control circuit 3 valve block
Technical specifications
Installation
Hitch valve block
Technical specifications
Installation
Working hydraulics valve block
Technical specifications
Removing
Installing
Working hydraulics valve block
Technical specifications
Removing
Installing
Load retaining valve
Technical specifications
Installation
10 Electrical / Electronic equipment
1005 Power supply
Technical specifications
Installation
Battery isolating switch
Technical specifications
Installation
1010 Central electrics
Central terminal compartment
Technical specifications
Installation
Plug overview
Technical specifications
Removing A46-LWT
Installing A46-LWT
Removing A30-LWT
Installing A30-LWT
Removing A50-LWT
Installing A50-LWT
Removing A40-LWT
Installing A40-LWT
Load sensor
Technical specifications
Work preparation
Installation
1035 Operation / Multifunction control lever
Control lever
Technical specifications
Installation
Hand inch joystick
Technical specifications
Removing
Installing
Hand gas joystick
Technical specifications
Removing
Installing
Control circuit 4 joystick
Technical specifications
Installation
Display unit
Technical specifications
Removing
Installing
Steering type switch panel
Technical specifications
Installation
DMS evaluation electronics
Technical specifications
Installation
12 Cab / Operator’s platform
1210 Cab
Technical specifications
Installation
Window cleaning fluid tank
Technical specifications
Removing
Installing
Front windscreen wiper
Technical specifications
Installation
Rear wiper
Technical specifications
Installation
1230 Seat
Driver’s seat
Technical specifications
Installation
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 conditioner
Air conditioner compressor
Technical specifications
Installation
Evaporator
Technical specifications
Removing
Installing
Condenser
Technical specifications
Installation
Filter drier
Technical specifications
Installation
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 Variousomponents / Machine body
8005 Frame / Trough
Engine pan
Technical specifications
Installation instructions
8020 Rails / Safety devices
Underriding protector
Technical specifications
Installation
8025 Panellings / Hoods
Engine bonnet
Technical specifications
Installation
8030 Mud guards
Mudguard
Technical specifications
Installation
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
Replacing fuel filter cartridges
Work preparation
Fuel pre-filter
Fuel fine filter
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
Check if air compressor is tightly seated.
Checking the air compressor belt (R03)
Changing the air compressor belt (R03)
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
Checking the axles’ oil level
Differential
Wheel hub
Changing the axles’ oil
Work preparation
Differential
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.
Checking the tightness of hydraulic system
Changing the hydraulic oil
Work preparation
Changing the hydraulic oil tank fresh air filter element
Replacing the filter element in the hydraulic oil tank return line filter
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)

00 0302 552 2.pdf:

SCORPION 635 TRENDSCORPION 732 TRENDSCORPION 736 TRENDSCORPION 741 TREND
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
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 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 prote