Claas Scorpion 960 (K38) Telehandlers Repair Manual FR

File List:

00 0301 793 1.pdf
00 0303 533 3.pdf

00 0301 793 1.pdf:

Deutz TCD 4.1 L4
Contents
Introduction
General informations
Validity of the notice
Use of the instructions
Texts and illustrations
Plan with module structure
Seek and find
Steering Specifications
Abbreviations
Specialized terminology
General repair tips
Technical characteristics
Proper repair advice
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
Assembly
Heel pin assemblies
Assembly
Clamp ring bearing
Disassembly
Assembly
Clamp sleeve bearing
Assembly
Clamping sleeve
Removal of version A
Submission of 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
Treatment of sealing surfaces
Spare parts
Operating consumables
Tightening torques
Tightening torques for metric ISO threads
Tightening torques for metric 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
CCN explanation
CCN (CLAAS Component Number)
Electrical standard
Hydraulic standard
CCN (CLAAS Component Number)
Security
General informations
To respect
Signal word
General safety and accident prevention instructions
First aid measures
Risk of injury from hydraulic fluid
Exit the machine
Stop the machine
Place the machine on jack stands
Adjustment and maintenance work
Welding work
Notes for working on the diesel engine
Protection against accidents
Cleanliness
Assembly tips
Engine overhaul
01 Motor
0102 Complete set
Rated motor characteristic data
TCD 4.1 L4
Engine Description
Lighting order
Start the engine manually
Special tool
Install the rotation tool on the flywheel side
Place the rotation tool on the torsional vibration damper
0105 Engine suspension
Engine suspension
Technical characteristics
0110 Motor housing
Crankcase air bleeding
Technical characteristics
To set down
Crankshaft speed sensor
Technical characteristics
Preparing for work
Camshaft speed sensor
Technical characteristics
Flywheel housing
Technical characteristics
Special tool
To set down
Gear housing
Technical characteristics
Preparing for work
To set down
Crankshaft seal ring
Technical characteristics
Special tool
To set down
Front cover
Technical characteristics
To set down
Crankshaft seal ring
Technical characteristics
Special tool
To set down
Replace shaft liner
Technical characteristics
Preparing for work
Special tool
To set down
Crankcase
Technical characteristics
Preparing for work
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
Torsional vibration damper
Technical characteristics
Preparing for work
Special tool
To set down
Crankshaft
Technical characteristics
To set down
Check axial play
Crankshaft bearing
Technical characteristics
Special tool
To set down
Flywheel
Technical characteristics
Preparing for work
Special tool
To set down
Remove the ring gear
Install the ring gear
0120 Cylinder head – Valves – Distribution
Upper valve cover
Technical characteristics
To set down
Cylinder head
Technical characteristics
Special tool
To set down
Rocker arm
Technical characteristics
Disassemble
To assemble
To set down
Camshaft
Technical characteristics
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
Fuel feed pump
Technical characteristics
Fuel filter
Technical characteristics
Fuel lines
Technical characteristics
Special tool
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
Injector socket
Technical characteristics
Preparing for work
Special tool
To set down
High pressure pumps
Technical characteristics
Preparing for work
Special tool
To set down
Command block
Technical characteristics
Preparing for work
Disassemble
To assemble
To set down
0130 Lubrication system
Oil suction tube
Technical characteristics
Lubricating Oil Cooler
Technical characteristics
Preparing for work
Lubricating oil cooler housing
Technical characteristics
To set down
Lubricating oil pump
Oil injection nozzle
Technical characteristics
Assembly tips
Oil level gauge
Technical characteristics
0135 Cooling system
Coolant lines
Technical characteristics
Preparing for work
Thermostat housing
Technical characteristics
Preparing for work
To set down
Thermostat
Technical characteristics
To set down
Check lifting stroke
Engine temperature sensor
Technical characteristics
Coolant pump
Technical characteristics
Preparing for work
To set down
Fan bearing
Technical characteristics
0140 Exhaust device
Exhaust gas turbocharger
Technical characteristics
Preparing for work
Special tool
To set down
Exhaust collector tube
Technical characteristics
Preparing for work
Special tool
To set down
Exhaust gas recirculation radiator
Technical characteristics
Preparing for work
Special tool
To set down
Special check valve
Technical characteristics
Preparing for work
To set down
Adjustment device
Technical characteristics
Preparing for work
Special tool
Assembly advice
To set down
Exhaust gas mass flow sensor
Technical characteristics
Assembly tips
0145 Air suction
Charge air pipe
Technical characteristics
Preparing for work
To set down
Heating flange
Technical characteristics
Preparing for work
Disassemble
To assemble
To set down
Mixing tube
Technical characteristics
To set down
Butterfly
Technical characteristics
To set down
0150 Engine assembly parts
Technical characteristics
Assembly advice
Generator
Technical characteristics
Disassemble
To assemble
To set down
Remove the console
Install the console
Protection plate
Technical characteristics
Air conditioning compressor
Technical characteristics
Assembly advice
Belt tensioner
Technical characteristics
Drive Belt Pulley
Technical characteristics
Compressor
Technical characteristics
Preparing for work
Assembly tips
0155 Engine controls
High current start relay
Technical characteristics
0165 Exhaust gas aftertreatment
Diesel particulate filter
Technical characteristics
Preparing for work
Special tool
Disassemble
To assemble
Diesel particulate filter differential pressure sensor
Technical characteristics

00 0303 533 3.pdf:

Repair instructions
Contents
Introduction
Notes on the instructions
Validity of the notice
Repair manual information
Use of the instructions
Classification in module/group structure
Seek and find
Directions
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
Lip rings with spring
Hose clamps
Tightening speed
Tightening torques
Collar Alignment
Auxiliary mounting means
Assembly tools
Cutting ring fittings
To screw
Leaky cutting ring fittings
Sealing Cone Fittings
Hydraulic flexible lines
Passage of hoses
Diaphragm accumulator (pressure accumulator)
Consumable materials
Service and Assembly
Modification of gas filling
Special tool
Treatment of sealing surfaces
Spare parts
Glues, sealing pastes and assembly pastes
Consumable materials
ESD protective measures
Special tool
ESD protective measures
Inspection and repair advice
Tightening torques
Tightening torques for metric coarse and fine pitch threads
General tightening torques Bosch-Rexroth
General tightening torques Mannesmann-Rexroth
General tightening torques Dana / Spicer
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 nuts for feed-through fitting, straight and angular
Tightening torques for hydraulic screwed coupling SDS form B and E
Tightening torques for hydraulic screwed socket SDS form F and sealing screw
Tightening torques for hydraulic screwed coupling SDS form H
Tightening torques for form E cover screws
Tightening torques for hydraulic screwed coupling form C, conical thread
Tightening torques for hydraulic screwed coupling SDE form F, adjustable
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 threaded rods / calibrated holes
Tightening torques for threaded bolts and special screws
Tightening torques for hydraulic components
Tightening torques for hexagonal sealing nuts
Hose clamp tightening torques
Assembly tips
Tangent screw clamps
Tangent screw clamps with spring washers
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
Diesel motor
Technical characteristics
Preparing for work
To set down
0125 Injection system, fuel supply
Fuel tank
Technical characteristics
To set down
Fuel pre-filter
Technical characteristics
To set down
0135 Cooling system
Compensation tank
Technical characteristics
To set down
Engine radiator
Technical characteristics
Preparing for work
To set down
Fan motor
Technical characteristics
To set down
Fan distribution block
Technical characteristics
To set down
Fan valve block
Technical characteristics
To set down
0140 Exhaust device
Exhaust pipe
Technical characteristics
To set down
Technical characteristics
To set down
0145 Air suction
Air filter housing
Technical characteristics
To set down
Intercooler
Technical characteristics
To set down
0150 Engine assembly parts
Belt cover
Technical characteristics
Preparing for work
To set down
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
Exhaust gas post-treatment, 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 Gearbox – 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
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
0305 Axle suspension
Level compensation valve block
Technical characteristics
To set down
Hydraulic level compensation cylinder
Technical characteristics
To set down
Hydraulic cylinder pendulum axle lock
Technical characteristics
To set down
Axle bearing
Technical characteristics
To set down
0325 Drive axle, front
Front wheel steering axle
Technical characteristics
To set down
Planetary gear
Technical characteristics
Preparing for work
Disassemble
To assemble
Technical characteristics
Preparing for work
To set down
Half shaft
Technical characteristics
Preparing for work
Disassemble
To assemble
To set down
Axle body
Technical characteristics
Preparing for work
To set down
Bevel gear drive
Technical characteristics
Preparing for work
To set down
Differential
Technical characteristics
Preparing for work
Disassemble
To assemble
To set down
0330 Drive axle, rear
Rear-wheel steering axle
Technical characteristics
To set down
Planetary gear
Half shaft
Bevel gear drive
Differential
0335 Transmission
Transmission hydraulic pump
Technical characteristics
To set down
Transmission hydraulic pump
Technical characteristics
To set down
Transmission auxiliary variable displacement motor
Technical characteristics
To set down
04 Brake
0405 Service brake
Service brake
Technical characteristics
Preparing for work
To set down
Bleed air from service brake
Hydraulic service brake cylinder
Technical characteristics
To set down
0415 Parking brake
Parking brake
Assembly tips
Mechanically release the parking brake
Adjust the parking brake
0420 Air trailer brake
Compressed air tank
Technical characteristics
To set down
05 Management
0505 Steering
Steering column
Technical characteristics
Preparing for work
To set down
Steering column
Technical characteristics
Preparing for work
To set down
Management unit
Technical characteristics
To set down
Hydraulic steering cylinder
Technical characteristics
Preparing for work
Disassemble
To assemble
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
Telescopic boom
Technical characteristics
To set down
Tread sensor
Technical characteristics
Telescopic lines
To set down
To set down
Technical characteristics
To set down
Sliding plates
Technical characteristics
Preparing for work
Assembly tips
To set down
CLAAS tool holder, mechanical
Technical characteristics
Special tool
To set down
CLAAS tool holder, hydraulic
Technical characteristics
Special tool
To set down
JCB tool holder, hydraulic
Technical characteristics
Special tool
To set down
Manitou tool holder, mechanical
Technical characteristics
Special tool
To set down
Manitou tool holder, hydraulic
Technical characteristics
Preparing for work
Special tool
To set down
Volvo tool carrier, hydraulic
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
To set down
Hydraulic cylinder tilt
Technical characteristics
Special tool
To set down
Hydraulic cylinder quick change lock
Technical characteristics
Special tool
To set down
Hydraulic cylinder quick change lock
Technical characteristics
To set down
Hydraulic cylinder quick change lock
Technical characteristics
To set down
Hydraulic cylinder quick change lock
Technical characteristics
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
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
0900 Hydraulic system General
Flush the hydraulic system
Assemble the filter elements
Install the line filter
Install the filter elements
Complete the rinsing process
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 of working hydraulic system
Technical characteristics
To set down
Hydraulic pump, gear pump
Technical characteristics
To set down
0915 Hydraulic circuit
Forward control circuit (HIGHFLOW)
Technical characteristics
Preparing for work
To set down
Multicoupler
Technical characteristics
To set down
Multicoupler
Technical characteristics
To set down
0920 Valves
Hydraulic braking
Technical characteristics
Remove the brake hydraulic valve block
Install the brake hydraulic valve block
Remove the accumulator charging valve valve block
Install the accumulator charging valve valve block
Remove differential lock valve block
Install the differential lock valve block
Trailer brake valve block
Technical characteristics
To set down
Steering mode valve
Technical characteristics
To set down
Control circuit valve block 3
Technical characteristics
To set down
Hitch Hitch Valve Block
Technical characteristics
To set down
Working hydraulic system valve block
Technical characteristics
To set down
Working hydraulic system valve block
Technical characteristics
To set down
Compensation cylinder distribution block
Technical characteristics
To set down
Priority valve distribution block
Technical characteristics
To set down
Emergency lowering valve block
Technical characteristics
Assembly tips
10 Electrical and electronic systems
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
Technical characteristics
Drop A30-LWT and A40-LWT
Install A30-LWT and A40-LWT
Drop A50-LWT
Lay A50-LWT
Load sensor
Technical characteristics
Preparing for work
To set down
1035 Control / multifunction handle
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
7 screen
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
Front interior trim
To set down
Front interior trim
To set down
Front wiper
Technical characteristics
To set down
Back windshield wiper
Technical characteristics
To set down
Side wiper
Technical characteristics
To set down
Windshield washer fluid reservoir
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
Heating and air conditioning box
Technical characteristics
To set down
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 parts, bodywork
8005 Chassis
Crankcase
Technical characteristics
Assembly tips
Tank console
Technical characteristics
To set down
8020 Balustrades / Safety devices
Underbody protection
Technical characteristics
Preparing for work
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
Adjust valve clearance
Replace fuel filter filter cartridges
Preparing for work
Fuel pre-filter
Fine fuel filter
Bleed the air from the fuel system
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 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 gear
Wheel hub
Replace axle oil
Preparing for work
Differential gear
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
Replace hydraulic oil
Preparing for work
Replace the filter element of the filter on the return of the hydraulic tank
Replace the hydraulic tank air filter
Check the tightness of the hydraulic system
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 rout