CLAAS SCORPION 6030 (400-01) Telehandler Service Repair Manual

SCORPION 9040 (404-03) 7045 (403-03) 7040 (402-03) 7030 (401-03) 6030 (400-01)

Repair Manual

Table of Contents

Table of Contents

Table of Contents 1 Machine, applications, operation (overview) 1.1 1.2 1.3 1.4 1.5 1.6

Machine outside view ....................................................................................................................................................... 1-2 Inside of cab (overview) ................................................................................................................................................... 1-3 Instrument panel, multifunctional lever, switch consoles (overview) ................................................................................ 1-4 Fields of application and using a telehandler with an attachment .................................................................................... 1-5 Legal regulations regarding telehandler operation ........................................................................................................... 1-8 Type labels and component numbers ............................................................................................................................ 1-11

2 Specifications 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23 2.24 2.25 2.26 2.27 2.28 2.29

Model and trade names (overview) .................................................................................................................................. 2-2 Frame ............................................................................................................................................................................... 2-2 Engine .............................................................................................................................................................................. 2-2 Oil/water fan ..................................................................................................................................................................... 2-3 Drive ................................................................................................................................................................................. 2-3 Axles ................................................................................................................................................................................. 2-4 Service and parking brake ................................................................................................................................................ 2-4 Steering system ................................................................................................................................................................ 2-5 Work hydraulics ................................................................................................................................................................ 2-6 Electrical system ............................................................................................................................................................... 2-8 Tyres for models 401-03/402-03/403-03 ........................................................................................................................ 2-12 Tyres for model 404-03 .................................................................................................................................................. 2-12 Machine weights, axle loads ........................................................................................................................................... 2-13 Noise levels .................................................................................................................................................................... 2-13 Vibrations, oscillation and acceleration value ................................................................................................................. 2-14 Coolant compound table ................................................................................................................................................. 2-14 Tightening torques .......................................................................................................................................................... 2-15 Trailer couplings: trailer weight/drawbar load ................................................................................................................. 2-15 Pallet forks model 400-01 ............................................................................................................................................... 2-16 Load on pallet forks model 401-03 (without counterweight) ........................................................................................... 2-17 Load on pallet forks model 401-03 (with counterweight 2 x 150 kg) .............................................................................. 2-18 Pallet forks model 402-03 (with counterweight 2 x 150 kg) ............................................................................................ 2-19 Pallet forks model 402-03 (with counterweight 2 x 300 kg) ............................................................................................ 2-20 Load on pallet forks model 403-03 ................................................................................................................................. 2-21 Payloads model 404-03 .................................................................................................................................................. 2-22 Dimensions with bucket ................................................................................................................................................. 2-26 Dimensions with bucket .................................................................................................................................................. 2-27 Dimensions with pallet forks ........................................................................................................................................... 2-28 Dimensions with pallet forks .......................................................................................................................................... 2-29

3 Maintenance and servicing work 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13

Explanation of symbols on the maintenance label ........................................................................................................... 3-2 Maintenance label ............................................................................................................................................................ 3-3 Fluids and lubricants (overview) ....................................................................................................................................... 3-4 Maintenance plan ............................................................................................................................................................. 3-5 Introduction ....................................................................................................................................................................... 3-9 Safety prop for telescopic boom ....................................................................................................................................... 3-9 Fuel system .................................................................................................................................................................... 3-10 Maintenance of engine lubrication system ..................................................................................................................... 3-14 Maintenance of the engine and hydraulics cooling system ............................................................................................ 3-18 Cleaning the radiator with the reversing fan (option) ...................................................................................................... 3-23 Air filter maintenance ...................................................................................................................................................... 3-24 Maintenance: V-belts ...................................................................................................................................................... 3-26 Gearbox and axle maintenance ...................................................................................................................................... 3-27

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Table of Contents 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23 3.24 3.25 3.26 3.27 3.28 3.29 3.30 3.31 3.32 3.33 3.34 3.35 3.36 3.37 3.38 3.39 3.40 3.41

Safety instructions regarding the hydraulic system .......................................................................................................

Monitoring the hydraulic oil and the return filter .............................................................................................................

Checking the hydraulic oil level .....................................................................................................................................

Filling up hydraulic oil ....................................................................................................................................................

Replacing the return filter of the hydraulic system .........................................................................................................

Replacing the microfilter of the hydraulic system ..........................................................................................................

Replacing the microfilter in the LS line ..........................................................................................................................

Replacing hydraulic oil ...................................................................................................................................................

Important notices on the use of biodegradable oil .........................................................................................................

Checking hydraulic pressure lines .................................................................................................................................

Lubrication work .............................................................................................................................................................

Maintenance of the brake system ..................................................................................................................................

Replacing/bleeding the service brake fluid with bleed equipment .................................................................................

Maintenance of compressed-air brake system (option) .................................................................................................

Tyre maintenance ..........................................................................................................................................................

Heating and ventilation maintenance .............................................................................................................................

Maintenance of air conditioning (option) ........................................................................................................................

Maintenance of the electrical system .............................................................................................................................

Maintenance of trailer coupling ......................................................................................................................................

General maintenance work on the machine ..................................................................................................................

Cleaning inside the cab .................................................................................................................................................

Cleaning the seat belt ....................................................................................................................................................

Cleaning the exterior of the machine .............................................................................................................................

Checking screw connections .........................................................................................................................................

Checking pivots and hinges ...........................................................................................................................................

Cleaning the engine compartment .................................................................................................................................

Maintenance and servicing work “Aggressive Media” ...................................................................................................

Maintenance and servicing of attachments on the quickhitch .......................................................................................

3-32 3-33 3-33 3-34 3-34 3-34 3-35 3-36 3-37 3-38 3-39 3-42 3-43 3-46 3-47 3-49 3-50 3-55 3-59 3-60 3-61 3-61 3-61 3-61 3-61 3-62 3-63 3-65

4 Engine 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 4.21 4.22 4.23 4.24 4.25 4.26 4.27 I-2

Electrical system/hydraulics – fan (electrical diagram) .................................................................................................... 4-2 Fan (functional description) ............................................................................................................................................. 4-6 Fan connector assignment for models 402, 403, 404 ...................................................................................................... 4-7 Diesel engine connector assignment (88 kW) ................................................................................................................. 4-8 Diesel engine connector assignment (103 kW) ............................................................................................................... 4-9 Fuel preheater connector assignment ........................................................................................................................... 4-10 Diagnosis connector assignment ................................................................................................................................... 4-11 88 kW diesel engine electrical system (electrical diagram) ........................................................................................... 4-14 103 kW diesel engine electrical system (electrical diagram) ......................................................................................... 4-18 Fuel preheater (electrical diagram) ................................................................................................................................ 4-22 Engine diagnosis (electrical diagram) ............................................................................................................................ 4-24 Engine oil cooler side (88 kW) (overview) ..................................................................................................................... 4-25 Engine drive side (88 kW) (overview) ............................................................................................................................ 4-26 Engine turbocharger side (88 kW) (overview) ............................................................................................................... 4-27 Engine oil cooler side (103 kW) (overview) ................................................................................................................... 4-28 Fuel: high-pressure unit ................................................................................................................................................. 4-29 Engine drive side (103 kW) (overview) .......................................................................................................................... 4-30 Engine turbocharger side (103 kW) (overview) ............................................................................................................. 4-31 Electronics overview (103 kW) ...................................................................................................................................... 4-32 Electronic engine speed setting (103 kW) (overview) .................................................................................................... 4-35 Function: warning indicator light in tip switch (103 kW diesel engine) ........................................................................... 4-36 Engine drive – clutch (88/103 kW) (overview) ............................................................................................................... 4-41 Installing the fan pump ................................................................................................................................................... 4-42 Fuel system (88/103 kW) (overview) ............................................................................................................................. 4-43 Bleeding the fuel system (88/103 kW) ........................................................................................................................... 4-44 Fan circuit (not in reversing operation) .......................................................................................................................... 4-45 Fan circuit with reversing fan ......................................................................................................................................... 4-46 00 0295 725 2 - RHB SCORPION

Table of Contents 4.28 4.29 4.30 4.31 4.32

Reversing valve block ..................................................................................................................................................... 4-47 Setting maximum fan speed (reversing fan) ................................................................................................................... 4-48 Setting maximum fan speed (without reversing fan) ...................................................................................................... 4-48 Cleaning the radiator with the reversing fan (option) ...................................................................................................... 4-49 Function: reversing fan operation ................................................................................................................................... 4-50

5 Power train 5.1 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 5.17 5.18 5.19 5.20 5.21 5.22 5.23 5.24 5.25 5.26 5.27 5.28 5.29 5.30 5.31 5.32 5.33 5.34 5.35 5.36 5.37 5.38 5.39 5.40 5.41 5.42 5.43 5.44 5.45 5.46

40 kph drive hydraulic diagram for models 400, 401, 402 ................................................................................................ 5-2 30 – 40 kph drive hydraulic diagram for models 402, 403, 404 ........................................................................................ 5-4 40 kph drive hydraulic diagram for models 402 – 404 ...................................................................................................... 5-6 Drive hydraulic diagram (designations) ............................................................................................................................ 5-7 40 kph drive electrics diagram for models 402, 403, 404 ............................................................................................... 5-10 30 – 40 kph drive electrics diagram for models 400 – 404 ............................................................................................. 5-12 Electrical diagram (designations) ................................................................................................................................... 5-13 Functional despcription of drive hydraulics and electrical system .................................................................................. 5-15 Drive electrics connector assignment for models 400 – 404 .......................................................................................... 5-18 Towing and transporting the machine ............................................................................................................................ 5-19 Hydraulic pump TMP 89 (models 402, 403, 404) ........................................................................................................... 5-21 Hydraulic pump H1 P078 (models 400, 401, 402) .......................................................................................................... 5-22 High speed gearbox (0 – 40 kph) ................................................................................................................................... 5-23 High-speed gearbox with auxiliary motor (0 – 40 kph) ................................................................................................... 5-23 Function without auxiliary motor (0 – 40 kph) ................................................................................................................. 5-24 Function with auxiliary motor (0 – 40 kph) ...................................................................................................................... 5-24 Gearbox overview (0 – 40 kph) ...................................................................................................................................... 5-25 Overview of control cover and diagram up to serial no. (0 – 40 kph) ............................................................................. 5-26 Overview of control cover and diagram from serial no. (0 – 40 kph) .............................................................................. 5-27 Control cover component parts for gearbox (0 – 40 kph) ............................................................................................... 5-28 Hydraulic drive circuit (0 – 40 kph) ................................................................................................................................. 5-29 Legend for gearbox circuit diagram (0 – 40 kph) ............................................................................................................ 5-30 Gearbox circuit diagram (0 – 40 kph) ............................................................................................................................. 5-31 Legend for gearbox circuit diagram with auxiliary motor (0 – 40 kph) ............................................................................ 5-32 Gearbox circuit diagram with auxiliary motor (0 – 40 kph) ............................................................................................. 5-33 Measurement reports ..................................................................................................................................................... 5-34 Test report for model 400/401/402 with H1 pump without auxiliary motor (0 –40 kph) 5-36 Test report for model 403/404/402 with TMP89 pump and auxiliary motor (fixed displacement motor) (0 – 40 kph) 5-37 Test report for model 403/404 diesel engine 103 kW and TMP89 pump and auxiliary motor (variable displacement motor) (0 – 40 kph) 5-38 Test report for model 402/403/404 (30 kph) ................................................................................................................... 5-39 Error description for test report ....................................................................................................................................... 5-40 Checking and setting boost pressure (0 – 40 kph gearbox) ........................................................................................... 5-41 Checking high pressure (0 – 40 kph) .............................................................................................................................. 5-42 Checking engine droop (pump) (0 – 40 kph) .................................................................................................................. 5-43 Checking driving direction identification (0 – 40 kph) ..................................................................................................... 5-44 Setting engine droop on the gearbox with/without auxiliary motor (fixed displacement motor 0 – 40 kph) .................... 5-45 Control initiation set screw (0 – 40 kph gearbox) ........................................................................................................... 5-46 Checking the cardan shaft speed (0 – 40 kph gearbox) ................................................................................................. 5-47 Troubleshooting work on drive ....................................................................................................................................... 5-48 Hydraulic pump report .................................................................................................................................................... 5-49 Report for measurement 1 of hydraulic pump (engine speed and boost pressure) ....................................................... 5-50 Report for forward/reverse measurement 2 of hydraulic pump ...................................................................................... 5-51 Report for measurement of forward driving direction of hydraulic pump: ....................................................................... 5-52 Report for forward measurement 3 of hydraulic pump: .................................................................................................. 5-53 Variable displacement pump test for models 400/401 and 402 ...................................................................................... 5-54 Variable displacement pump test for models 402/403/404 ............................................................................................. 5-56 Checking the high-speed gearbox .................................................................................................................................. 5-58

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Table of Contents 5.47 5.48 5.49 5.50 5.51 5.52 5.53 5.54 5.55 5.56 5.57 5.58 5.59 5.60 5.61 5.62 5.63 5.64 5.65 5.66 5.67 5.68 5.69 5.70 5.71 5.72 5.73 5.74 5.75 5.76 5.77 5.78 5.79 5.80 5.81 5.82 5.83 5.84 5.85 5.86 5.87 5.88 5.89 5.90 5.91 5.92 5.93 5.94

Measurement 1 (driving direction identification) ............................................................................................................ 5-59 Measurement 2 (M4 pressure at shuttle throttle) ........................................................................................................... 5-59 Measurements 3 and 4 (proportional solenoid and proportional regulator) ................................................................... 5-60 Measurement 5 (pressure relief valve M3, PCOR valve) .............................................................................................. 5-60 High-speed gearbox report: measurement 1 (driving direction identification) ............................................................... 5-61 High-speed gearbox report: measurement 2 (M4 shuttle pressure) .............................................................................. 5-62 High-speed gearbox report: measurements 3 and 4 (proportional solenoid and proportional regulator) ...................... 5-63 Report: measurement 5 (pressure relief valve M3, PCOR valve) .................................................................................. 5-64 Repair work on the high-speed gearbox ........................................................................................................................ 5-65 Repair work on the high-speed gearbox ........................................................................................................................ 5-68 Repair work on the high-speed gearbox ........................................................................................................................ 5-69 Checking or replacing the shuttle throttle ...................................................................................................................... 5-72 Removing the shuttle throttle ......................................................................................................................................... 5-73 Installing the shuttle throttle ........................................................................................................................................... 5-76 Checking the auxiliary motor ......................................................................................................................................... 5-77 Switching off rear axle/4 wheel drive ............................................................................................................................. 5-78 Disabling 4 wheel drive (overview) ................................................................................................................................ 5-79 Installation position ........................................................................................................................................................ 5-80 Drive electronics Operator’s Manual (SUSMIC) ............................................................................................................ 5-81 Error table ...................................................................................................................................................................... 5-82 Checking the proportional valves by means of current measurement ........................................................................... 5-83 Removing the consumers circuit from the hydraulic drive ............................................................................................. 5-84 Sealing work on the drive shaft (0 – 40 kph gearbox) ................................................................................................... 5-85 Mounting the rotary shaft seal (0 – 40 kph gearbox) ..................................................................................................... 5-86 Mounting the drive flange (0 – 40 kph gearbox) ............................................................................................................ 5-87 Sealing the Ecospeed gearbox ...................................................................................................................................... 5-88 Removing the control cover (old) from the Ecospeed gearbox ...................................................................................... 5-89 Travelling drive with reduced engine speed .................................................................................................................. 5-98 Overview: auxiliary motor (variable displacement motor) .............................................................................................. 5-99 Overview: auxiliary motor (variable displacement motor) ............................................................................................ 5-100 Checking control initiation/engine droop of auxiliary motor (variable displacement motor) 5-101 Drive (electrical diagram) ............................................................................................................................................. 5-104 20 kph hydraulic drive diagram for models 400 – 404 ................................................................................................. 5-106 Drive hydraulic diagram (descriptions) ........................................................................................................................ 5-107 Functional despcription of drive hydraulics and electrical system ............................................................................... 5-109 Drive electrics connector assignment for models 400 – 404 ....................................................................................... 5-112 Variable displacement motor 110 cm3/rev (20 kph) ..................................................................................................... 5-113 Variable displacement motor 110 cm3/rev (20 kph, seen from the side) ..................................................................... 5-114 Variable displacement motor 160 cm3/rev (20 kph) ..................................................................................................... 5-115 Test report for model 400 – 404 (20 kph) .................................................................................................................... 5-116 Error description for test report models 400/401 (20 kph) ........................................................................................... 5-117 Hydraulic circuit: drive with hydraulic pump H1 P078 (20 kph) .................................................................................... 5-118 Hydraulic circuit: drive with hydraulic pump TMP 89 (20 kph) ..................................................................................... 5-119 Setting boost pressure (20 kph) ................................................................................................................................... 5-120 Checking high pressure (20 kph) ................................................................................................................................. 5-121 Checking engine droop – variable displacement pump (20 kph) ................................................................................. 5-122 Setting engine droop – hydraulic motor (20 kph) ......................................................................................................... 5-123 Setting final speed (20 kph) ......................................................................................................................................... 5-124

6 Axles/differential lock 6.1 6.2 6.3 6.4 6.5 6.6 I-4

Differential lock diagrams (serial no.) ..............................................................................................................................

Designations: differential lock electrical diagram .............................................................................................................

Differential lock diagrams ................................................................................................................................................

Functional description of differential lock .........................................................................................................................

Differential lock connector assignment ............................................................................................................................

20 kph gearbox (overview) ..............................................................................................................................................

6-2 6-3 6-6 6-7 6-8 6-9

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Table of Contents 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.18 6.19 6.20 6.21 6.22 6.23 6.24

Removing the 20 kph gearbox ........................................................................................................................................ 6-10 Installing the 20 kph gearbox .......................................................................................................................................... 6-17 Front and rear axle flanges ............................................................................................................................................. 6-25 Type label and oil filler neck (overview) .......................................................................................................................... 6-26 Conversion table and tightening torques ....................................................................................................................... 6-27 Removing the joint housing ............................................................................................................................................ 6-28 Installing the joint housing .............................................................................................................................................. 6-30 Removing the double cardan shaft ................................................................................................................................. 6-31 Mounting the double cardan shaft .................................................................................................................................. 6-33 Remove the planetary drive ............................................................................................................................................ 6-35 Replacing the seals of the planetary drive ...................................................................................................................... 6-37 Installing the planetary drive ........................................................................................................................................... 6-38 Installing the planetary drive ........................................................................................................................................... 6-40 Sealing the front axle differential .................................................................................................................................... 6-42 Removing the front axle differential lock ......................................................................................................................... 6-44 Installing the front axle differential lock ........................................................................................................................... 6-47 Differential lock: hydraulic circuit .................................................................................................................................... 6-50 Special tools (overview) .................................................................................................................................................. 6-51

7 Brakes 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14 7.15 7.16 7.17 7.18 7.19 7.20 7.21 7.22 7.23 7.24 7.25 7.26

Brake (20 kph) diagrams (electric/hydraulic) .................................................................................................................... 7-2 Brake (40 kph) diagrams (electric/hydraulic) .................................................................................................................... 7-4 Hydraulic diagram – trailer brake valve ............................................................................................................................ 7-6 Designations: hydraulic brake diagram ............................................................................................................................ 7-7 Designations: electric brake diagram ............................................................................................................................... 7-8 Functional description of brakes ....................................................................................................................................... 7-9 Brakes connector assignment ........................................................................................................................................ 7-10 40 kph brake circuit (overview) ....................................................................................................................................... 7-11 20 kph brake circuit (overview) ....................................................................................................................................... 7-12 Disabling (releasing) the parking brake in the front axle ................................................................................................ 7-13 Enabling (adjusting) the parking brake in the front axle ................................................................................................. 7-13 Wear check: service brake discs .................................................................................................................................... 7-14 Setting the brake linkage – master brake cylinder .......................................................................................................... 7-14 Service and parking brake (overview) ............................................................................................................................ 7-15 Removing the brake discs .............................................................................................................................................. 7-16 Brake discs (overview) ................................................................................................................................................... 7-19 Installing the brake pistons of the service and parking brake ......................................................................................... 7-20 Installing the belleville spring washers and the brake cylinder housing ......................................................................... 7-21 Installing the service brake ............................................................................................................................................. 7-23 Towing and transporting the machine ............................................................................................................................ 7-26 Hydraulic trailer brake circuit (option) ............................................................................................................................. 7-28 Air compressor ............................................................................................................................................................... 7-29 Air compressor overview ................................................................................................................................................ 7-30 Air compressor components ........................................................................................................................................... 7-31 Valves (air compressor) .................................................................................................................................................. 7-32 Circuit (air compressor) .................................................................................................................................................. 7-33

8 Steering system 8.1 8.2 8.3 8.4 8.5 8.6

Electrical/hydraulic diagrams for steering system up to serial no. 400 01 0167, 401 03 0195, 402 03 0176, 403 03 0145, 404 03 0146 8-2 Electrical/hydraulic diagrams for steering system from serial no. 400 01 0168, 401 03 0196, 402 03 0177, 403 03 0146, 404 03 0147, 8-4 Designations: electric steering diagram ............................................................................................................................ 8-5 Designations: hydraulic steering diagram ......................................................................................................................... 8-6 Functional description of steering system ........................................................................................................................ 8-7 Steering system connector assignment ............................................................................................................................ 8-8

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Table of Contents 8.7 8.8 8.9 8.10 8.11 8.12 8.13 8.14 8.15 8.16 8.17 8.18 8.19 8.20 8.21 8.22

Steering circuit with variable displacement pump (LS = load sensing) ............................................................................ 8-9 Hydraulic steering diagram: priority valve – variable displacement pump (LS = load sensing) 8-10 Steering circuit with gear pump ..................................................................................................................................... 8-11 Hydraulic steering diagram: priority valve – gear pump ................................................................................................. 8-12 Hydraulic steering diagram: 4 wheel steering/front axle steering .................................................................................. 8-13 Diagonal steering circuit (crab steering) ........................................................................................................................ 8-14 Hydraulic steering diagram: front axle steering with diagonal steering valve (crab steering) ........................................ 8-15 Hydraulic steering diagram: diagonal steering with diagonal steering valve (crab steering) ......................................... 8-16 Hydraulic steering diagram: 4 wheel steering with diagonal steering valve (crab steering) 8-17 Steering system goes out of line (20/40 kph) ................................................................................................................ 8-18 Steering valve (overview) .............................................................................................................................................. 8-19 Pressure relief valve – servostat: settings ..................................................................................................................... 8-20 Front and rear axle steering sensor (magnetic sensor) ................................................................................................. 8-21 Removing the steering rams .......................................................................................................................................... 8-22 Installing the steering rams ............................................................................................................................................ 8-26 Adjusting the steering angle .......................................................................................................................................... 8-30

9 Work hydraulics 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13 9.14 9.15 9.16 9.17 9.18 9.19 9.20 9.21 9.22 9.23 9.24 9.25 9.26 9.27 9.28 9.29 9.30 9.31 9.32 9.33 9.34 9.35 9.36 9.37 I-6

Work hydraulics fixed displacement pump (diagram) – raising/lowering the telescopic boom (HUSCO) ........................ 9-2 Work hydraulics fixed displacement pump (diagram) – raising/lowering the telescopic boom (Bucher) ......................... 9-4 Work hydraulics variable displacement pump (diagram) – raising/lowering the telescopic boom (HUSCO) ................... 9-6 Work hydraulics variable displacement pump (diagram) – raising/lowering the telescopic boom (Bucher) .................... 9-8 Raising/lowering the telescopic boom (electrical diagram) ............................................................................................ 9-10 Load stabiliser (electrical diagram) ................................................................................................................................ 9-12 Work hydraulics (diagram) – extending/retracting the telescopic boom, fixed displacement pump (HUSCO) .............. 9-14 Work hydraulics fixed displacement pump (diagram) – extending/retracting the telescopic boom ............................... 9-16 Work hydraulics variable displacement pump (diagram) – extending/retracting the telescopic boom (HUSCO) .......... 9-18 Work hydraulics variable displacement pump (diagram) – extending/retracting the telescopic boom (Bucher) ............ 9-20 Work hydraulics variable displacement pump (diagram) – extending/retracting the telescopic boom .......................... 9-22 Extending/retracting the telescopic boom (electrical diagram) ...................................................................................... 9-24 Retracting/extending the telescopic boom (designations) ............................................................................................. 9-25 Work hydraulics fixed displacement pump (diagram) – dumping in/out (HUSCO) ........................................................ 9-28 Work hydraulics fixed displacement pump – dumping in/out (diagram) ........................................................................ 9-30 Work hydraulics variable displacement pump (diagram), dumping in/out (HUSCO) ..................................................... 9-32 Work hydraulics variable displacement pump (diagram) – dumping in/out (Bucher) ..................................................... 9-34 Dumping in/out (electrical diagram) ............................................................................................................................... 9-36 4 wheel drive OFF (electrical diagram) .......................................................................................................................... 9-38 Dumping in/out (electrical diagram) ............................................................................................................................... 9-40 Bucket repositioning (electrical diagram) ....................................................................................................................... 9-42 Work hydraulics fixed displacement pump (diagram) – locking/unlocking (HUSCO) .................................................... 9-44 Work hydraulics fixed displacement pump (diagram) – locking/unlocking (Bucher) ...................................................... 9-46 Work hydraulics variable displacement pump (diagram) – locking/unlocking (HUSCO) ............................................... 9-48 Work hydraulics variable displacement pump (diagram) – locking/unlocking (Bucher) ................................................. 9-50 Locking/unlocking (electrical diagram) ........................................................................................................................... 9-52 Work hydraulics fixed displacement pump (diagram) – rear additional control circuit (HUSCO) ................................... 9-54 Work hydraulics fixed displacement pump (diagram) – additional control circuit (Bucher) ............................................ 9-56 Work hydraulics variable displacement pump (diagram) – rear additional control circuit (HUSCO) .............................. 9-58 Work hydraulics variable displacement pump (diagram) – additional control circuit (Bucher) ....................................... 9-60 Work hydraulics fixed displacement pump (diagram) – rear additional control circuit, Autohitch (HUSCO) .................. 9-62 Work hydraulics fixed displacement pump (diagram) – additional control circuit, Autohitch (Bucher) ........................... 9-64 Work hydraulics variable displacement pump (diagram) – rear additional control circuit, Autohitch (HUSCO) ............. 9-66 Work hydraulics variable displacement pump (diagram) – additional control circuit, Autohitch (Bucher) ...................... 9-68 Work hydraulics fixed displacement pump (diagram) – rear additional control circuit, Autohitch, tipping trailer (HUSCO) 9-70 Work hydraulics fixed displacement pump (diagram) – additional control circuit, Autohitch, tipping trailer (Bucher) .... 9-72 Work hydraulics variable displacement pump (diagram) – rear additional control circuit, Autohitch, tipping trailer (HUSCO) 00 0295 725 2 - RHB SCORPION

Table of Contents 9.38 9.39 9.40 9.41 9.42 9.43 9.44 9.45 9.46 9.47 9.48 9.49 9.50 9.51 9.52 9.53 9.54 9.55 9.56 9.57 9.58 9.59 9.60 9.61 9.62 9.63 9.64 9.65 9.66 9.67 9.68 9.69 9.70 9.71 9.72 9.73 9.74 9.75 9.76 9.77 9.78 9.79 9.80 9.81 9.82 9.83 9.84 9.85 9.86 9.87 9.88 9.89 9.90 9.91

9-74 Work hydraulics variable displacement pump (diagram) – additional control circuit, Autohitch, tipping trailer (Bucher) 9-76 Work hydraulics fixed displacement pump (diagram) – rear additional control circuit, tipping trailer (HUSCO) ............. 9-78 Work hydraulics fixed displacement pump (diagram) – additional control circuit, tipping trailer (Bucher) ...................... 9-80 Work hydraulics variable displacement pump (diagram) – rear additional control circuit, tipping trailer (HUSCO) ........ 9-82 Work hydraulics variable displacement pump (diagram) – additional control circuit, tipping trailer (Bucher) ................. 9-84 Work hydraulics fixed displacement pump (diagram) – Autohitch (HUSCO) ................................................................. 9-86 Work hydraulics fixed displacement pump (diagram) – Autohitch (Bucher) ................................................................... 9-88 Work hydraulics variable displacement pump (diagram) – Autohitch (HUSCO) ............................................................ 9-90 Work hydraulics variable displacement pump (diagram) – Autohitch (Bucher) .............................................................. 9-92 Work hydraulics fixed displacement pump (diagram) – Autohitch, tipping trailer (HUSCO) ........................................... 9-94 Work hydraulics fixed displacement pump (diagram) – Autohitch, tipping trailer (Bucher) ............................................ 9-96 Work hydraulics variable displacement pump (diagram) – Autohitch, tipping trailer (HUSCO) ...................................... 9-98 Work hydraulics variable displacement pump (diagram) – Autohitch, tipping trailer (Bucher) ..................................... 9-100 Work hydraulics fixed displacement pump (diagram) – tipping trailer (HUSCO) .......................................................... 9-102 Work hydraulics fixed displacement pump (diagram) – tipping trailer (Bucher) ........................................................... 9-104 Work hydraulics variable displacement pump (diagram) – tipping trailer (HUSCO) ..................................................... 9-106 Work hydraulics variable displacement pump (diagram) – tipping trailer (Bucher) ...................................................... 9-108 Work hydraulics variable displacement pump (diagram) – additional control circuit for quick couplers on telescopic boom (HUSCO) 9-110 Work hydraulics fixed displacement pump (diagram) – additional control circuit for quick couplers on telescopic boom 9-112 Work hydraulics (diagram) – safe load indicator .......................................................................................................... 9-114 Work hydraulics (diagram) – safe load indicator (HUSCO) .......................................................................................... 9-116 Front/rear additional control circuit for quick couplers, Autohitch, tipping trailer (electrical diagram) ........................... 9-118 Front socket, safe load indicator (electrical diagram) ................................................................................................... 9-120 Front socket, safe load indicator (electrical diagram) ................................................................................................... 9-122 Work hydraulics variable displacement pump (diagram) – additional control circuit for quick couplers on quickhitch (HUSCO) 9-124 Work hydraulics variable displacement pump (diagram) – work platform with radio control ........................................ 9-126 Work hydraulics variable displacement pump (diagram) – work platform with radio control ........................................ 9-128 Work platform with radio control: electrical diagram ..................................................................................................... 9-130 Remote radio controls (diagram designations) ............................................................................................................. 9-131 Work platform with radio control (electrical diagram) with common rail ....................................................................... 9-134 Work platform with radio control (electrical diagram) without common rail .................................................................. 9-136 Tilt ram lock (electrical diagram) ................................................................................................................................... 9-138 Tilt ram lock (electrical diagram) ................................................................................................................................... 9-140 Work hydraulics variable displacement pump (diagram) – frame levelling, oscillating axle interlock ........................... 9-142 Frame levelling, oscillating axle interlock (electrical diagram) ...................................................................................... 9-144 Frame levelling, oscillating axle interlock (electrical diagram) ...................................................................................... 9-146 Oscillating axle interlock (electrical diagram) ............................................................................................................... 9-148 Work hydraulic diagram (designations) ........................................................................................................................ 9-149 Functional description of work hydraulics ..................................................................................................................... 9-153 Work hydraulics connector assignment ........................................................................................................................ 9-157 Test report: models 400/401 Husco control valve ........................................................................................................ 9-158 Test report: models 400/401 Bucher control valve ....................................................................................................... 9-159 Test report: models 402/403/404 Husco control valve ................................................................................................. 9-160 Test report: models 402/403/404 Bucher control valve ................................................................................................ 9-161 Work hydraulics test ports ........................................................................................................................................... 9-162 Variable displacement pump (hydraulic pump) ............................................................................................................ 9-163 Checking and setting the work hydraulics .................................................................................................................... 9-165 Work hydraulics circuit (gear pump) ............................................................................................................................ 9-167 Work hydraulics circuit (variable displacement pump LS) ........................................................................................... 9-168 Control valve connections (4-fold) HUSCO .................................................................................................................. 9-169 Control valve (4-fold) (overview) HUSCO ..................................................................................................................... 9-170 Control valve connections (5-fold) HUSCO .................................................................................................................. 9-171 Control valve (5-fold) (overview) HUSCO ..................................................................................................................... 9-172 Control valve connections (5-fold) Bucher .................................................................................................................... 9-173

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Table of Contents 9.92 9.93 9.94 9.95 9.96 9.97 9.98 9.99 9.100 9.101 9.102 9.103 9.104 9.105 9.106 9.107 9.108 9.109 9.110 9.111 9.112 9.113 9.114 9.115 9.116 9.117 9.118 9.119 9.120 9.121 9.122

Control valve (5-fold) (overview) Bucher .....................................................................................................................

Lift ram circuit .............................................................................................................................................................

Tilt ram circuit .............................................................................................................................................................

Compensating ram circuit ...........................................................................................................................................

Push-out ram circuit ....................................................................................................................................................

3rd control circuit ........................................................................................................................................................

Control valve (4-fold) pilot control circuit .....................................................................................................................

Valve block connections (overview) .............................................................................................................................

Pilot control unit, pilot valve .........................................................................................................................................

Load stabiliser ..............................................................................................................................................................

Load stabiliser circuit ..................................................................................................................................................

Changeover valve: Autohitch/tipping trailer connection/additional control circuit 9-186 Autohitch, rear additional control circuit ......................................................................................................................

Tipping trailer connection circuit .................................................................................................................................

Front additional control circuit .....................................................................................................................................

Frame levelling with oscillating axle interlock (option) telehandler 404 (overview) ......................................................

Bleeding the hydraulic ram of the oscillating axle interlock .........................................................................................

Frame levelling circuit ..................................................................................................................................................

Frame levelling valve overview ....................................................................................................................................

Lift ram with hose burst valve (overview) .....................................................................................................................

Tilt ram (overview) .......................................................................................................................................................

Push-out ram with final position damping (overview) ..................................................................................................

Compensating ram (overview) .....................................................................................................................................

Quickhitch ....................................................................................................................................................................

Installing the telescopic boom ......................................................................................................................................

Replacing the flexible line in the telescopic boom .......................................................................................................

Replacing the control valve ..........................................................................................................................................

Replacing the priority valve ..........................................................................................................................................

Replacing the fan pump ...............................................................................................................................................

Replacing the A 10 work hydraulics pump ...................................................................................................................

Replacing the pilot valve ..............................................................................................................................................

9-174 9-175 9-176 9-177 9-178 9-179 9-180 9-181 9-182 9-183 9-185 9-187 9-188 9-189 9-190 9-193 9-194 9-195 9-196 9-197 9-198 9-198 9-199 9-200 9-209 9-212 9-212 9-213 9-214 9-214

10 Electrical systems 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.11 10.12 10.13 10.14 10.15 10.16 10.17 10.18 10.19 10.15 10.16 10.17 10.18 I-8

Machine lights (electrical diagram) ................................................................................................................................ 10-2 Machine lights (electrical diagram) ................................................................................................................................ 10-4 Turn indicators/horn/rotating beacon (electrical diagram) ............................................................................................. 10-6 Turn indicators, horn, rotating beacon (electrical diagram) ........................................................................................... 10-8 Mirror adjustment/heating (electrical diagram) ............................................................................................................ 10-10 Mirror adjustment/heating (electrical diagram) ............................................................................................................ 10-12 Wiper/washer diagram ................................................................................................................................................. 10-14 Hydraulics monitoring diagram .................................................................................................................................... 10-16 Hydraulics monitoring (electrical diagram) ................................................................................................................... 10-18 Wiper/washer diagram ................................................................................................................................................. 10-20 Washer system (electrical diagram) ............................................................................................................................ 10-22 Heating – air conditioning system/air-suspension seat (electrical diagram) ................................................................ 10-24 Multimedia/cigarette lighter (electrical diagram) .......................................................................................................... 10-28 Multimedia/cigarette lighter (electrical diagram) .......................................................................................................... 10-30 Cab legend (SLP II) ..................................................................................................................................................... 10-33 Cab wiring diagram (SLP II) ........................................................................................................................................ 10-34 Cab legend (SLP II) ..................................................................................................................................................... 10-35 Cab wiring diagram (SLP III) ....................................................................................................................................... 10-36 Cab legend (SLP III) .................................................................................................................................................... 10-37 Cab wiring harness ...................................................................................................................................................... 10-41 Cab option wiring harness ........................................................................................................................................... 10-42 Armrest wiring harness ............................................................................................................................................... 10-44 Mirror adjustment wiring harness ................................................................................................................................ 10-45 00 0295 725 2 - RHB SCORPION

Table of Contents 10.19 10.20 10.21 10.22 10.23 10.24 10.25 10.26 10.27 10.28 10.29 10.30 10.31 10.32 10.33 10.34 10.35 10.36 10.37 10.38 10.39 10.40 10.41 10.42 10.43 10.44 10.45 10.46 10.47 10.48 10.49 10.50 10.51 10.52 10.53 10.54 10.55 10.56 10.57 10.58 10.59 10.60 10.61 10.62 10.63 10.64 10.65 10.66 10.67 10.68 10.69 10.70 10.71 10.72 10.73 10.74 10.75

Engine vat signals wiring diagram (SLP IV) ................................................................................................................ 10-46 Engine vat wiring harness ........................................................................................................................................... 10-47 Engine compartment legend ......................................................................................................................................... 10-48 Frame signal wiring diagram (SLP V) ........................................................................................................................... 10-49 Frame wiring harness ................................................................................................................................................... 10-51 Frame legend ............................................................................................................................................................... 10-52 Options signals wiring diagram (SLP VI) ..................................................................................................................... 10-53 Socket wiring harness X3 ............................................................................................................................................ 10-54 Additional valves wiring harness ................................................................................................................................. 10-55 Mirror/preheating option wiring harness ...................................................................................................................... 10-56 Overall diagrams legend ............................................................................................................................................... 10-57 Electric machine components (overview) ..................................................................................................................... 10-59 Electrical diagram designations and positions .............................................................................................................. 10-61 Connector positions on machine .................................................................................................................................. 10-62 Functional description of hydraulics monitoring ............................................................................................................ 10-65 Hydraulics monitoring connector assigment ................................................................................................................. 10-65 Lights connector assignment ........................................................................................................................................ 10-66 Turn indicator/horn connector assignment ................................................................................................................... 10-67 Rotating beacon connector assignment ....................................................................................................................... 10-68 Mirror adjustment connector assignment ..................................................................................................................... 10-68 Mirror heating connector assignment ........................................................................................................................... 10-68 Window wiper/wash connector assignment .................................................................................................................. 10-69 Heating/air conditioning connector assignment ............................................................................................................ 10-69 Air-suspension seat connector assignment .................................................................................................................. 10-70 Multimedia connector assignment ................................................................................................................................ 10-70 Cigarette lighter connector assignment ........................................................................................................................ 10-70 Ohm’s Law (current, voltage, resistance); power ......................................................................................................... 10-71 Multifunction measuring device .................................................................................................................................... 10-71 Terminal description ..................................................................................................................................................... 10-72 Cable colour coding ...................................................................................................................................................... 10-76 Electric components ..................................................................................................................................................... 10-78 Fuses (overview) .......................................................................................................................................................... 10-79 Electronic components (overview) ................................................................................................................................ 10-83 Functional description of the steering electronics ......................................................................................................... 10-85 Proportional controls (overview and connections) ........................................................................................................ 10-88 Proportional electronics ................................................................................................................................................ 10-89 Hold electronics ............................................................................................................................................................ 10-90 Retrofitting the front right and rear right working lights ................................................................................................. 10-91 Retrofitting a rotating beacon ....................................................................................................................................... 10-92 Retrofitting a radio ........................................................................................................................................................ 10-93 Retrofitting the low-speed control ................................................................................................................................. 10-93 Retrofitting the air conditioning system ......................................................................................................................... 10-94 Retrofitting a front or rear socket .................................................................................................................................. 10-95 Retrofitting a load stabiliser .......................................................................................................................................... 10-95 Wiring harness disconnect (cab – machine frame) ...................................................................................................... 10-96 Radio control system (transmitter) operation ................................................................................................................ 10-97 Overview of transmitter and receiver system control elements .................................................................................... 10-98 “STOP switch” safety feature on the transmitter ......................................................................................................... 10-100 Indications regarding the transmitter battery .............................................................................................................. 10-100 Taking the transmitter into service .............................................................................................................................. 10-101 Emergency lowering of the telescopic boom .............................................................................................................. 10-102 Removing the work platform from the quickhitch ........................................................................................................ 10-103 Maintenance work on the work platform ..................................................................................................................... 10-104 Maintenance work on the transmitter and receiver system ........................................................................................ 10-105 Charging the transmitter battery ................................................................................................................................. 10-106 Troubleshooting the transmitter and receiver system ................................................................................................. 10-107 Transmitter and receiver system specifications .......................................................................................................... 10-107

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Table of Contents 10.76 List of frequencies for radio control system ...............................................................................................................

10.77 Specifications – work platform ...................................................................................................................................

10.78 Inspection and maintenance work report ...................................................................................................................

10.79 Remote radio control (hydraulic circuit) .....................................................................................................................

10.80 Relays (overview) ......................................................................................................................................................

10.81 Remote radio control valves (overview) .....................................................................................................................

10.82 Safe load indicator .....................................................................................................................................................

10.83 Safety instructions regarding the safe load indicator .................................................................................................

10.84 Overview of displays ..................................................................................................................................................

10.85 Safe load indicator for telescopic boom (version A) ..................................................................................................

10.86 Safe load indicator for telescopic boom (version B) ..................................................................................................

10.87 Safe load indicator for telescopic boom (version C) ..................................................................................................

10.88 Setting the safe load indicator (version C) .................................................................................................................

10.89 Safe load indicator settings for telescopic boom (version B) .....................................................................................

10.90 Setting the safe load indicator (100 % point stability) ................................................................................................

10.91 Removing the load sensor .........................................................................................................................................

10.92 Overload control in bucket mode ...............................................................................................................................

10.93 Overload control in fork lift mode ...............................................................................................................................

10.94 Disabling the overload control manually ....................................................................................................................

10.95 Adjustment work on the overload control ...................................................................................................................

10.96 Circuit diagram: overload control enabled .................................................................................................................

10.97 Circuit diagram: overload control disabled .................................................................................................................

10.98 Overview of valves .....................................................................................................................................................

10.99 Overview of valve connections and ports ..................................................................................................................

10.100 Circuit diagram: raising/lowering, switch S116 actuated (bucket operation) .............................................................

10.101 Circuit diagram: raising/lowering under 36° and at 80 – 100 % load .........................................................................

10.102 Circuit diagram: raising/lowering over 100 % load and angle detection under 36° ...................................................

10.103 Circuit diagram: raising/lowering, switch S84 actuated (overload control OFF) ........................................................

10.104 Circuit diagram: raising/lowering, switch S125 retract (pallet forks operation) ..........................................................

10.105 Circuit diagram: raising/lowering, switch S125 ON (bucket operation) ......................................................................

10.106 Circuit diagram: extend telescopic boom, load less than 100 % ...............................................................................

10.107 Circuit diagram: extend telescopic boom, load over 100 % .......................................................................................

10.108 Circuit diagram: retract telescopic boom ...................................................................................................................

10.109 Circuit diagram: retraction/extension switch S84 (telescopic boom extension) .........................................................

10.110 Cab wiring harness (overload control) .......................................................................................................................

10.111 Legend: cab wiring harness (overload control) ..........................................................................................................

10.112 Frame wiring harness (overload control) ...................................................................................................................

10.113 Relay wiring harness (overload control) ....................................................................................................................

10.114 Legend: relays (overload control) ..............................................................................................................................

10.115 Electric components (overload control) .....................................................................................................................

10-108 10-109 10-110 10-111 10-112 10-113 10-114 10-115 10-117 10-118 10-119 10-121 10-122 10-125 10-126 10-128 10-129 10-130 10-131 10-132 10-136 10-137 10-138 10-139 10-140 10-141 10-142 10-143 10-144 10-145 10-146 10-147 10-148 10-149 10-150 10-151 10-152 10-153 10-154 10-155

A Appendix A.1 A.1 A.2 A.3 A.4 A.5 A.6 A.7

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4-fold control valve (Bucher), fixed displacement pump (overall hydraulic diagram) ....................................................... A-2 4-fold control valve (Bucher), variable displacement pump (overall hydraulic diagram) .................................................. A-4 4-fold control valve (HUSCO) (overall hydraulic diagram) ............................................................................................... A-6 Hydraulics – 4-fold control valve: overall diagram ........................................................................................................... A-8 Fixed displacement pump – 5-fold control valve (Bucher) (overall hydraulic diagram) ................................................. A-10 Fixed displacement pump – 5-fold control valve (HUSCO) (overall hydraulic diagram) ................................................ A-12 Variable displacement pump – 5-fold control valve (Bucher) (overall hydraulic diagram) ............................................. A-14 Variable displacement pump – 5-fold control valve (HUSCO) (overall hydraulic diagram) ........................................... A-16

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Maintenance and servicing work 3.9 Maintenance of the engine and hydraulics cooling system The combined engine/hydraulic oil cooler is located in the engine compartment.

It cools the diesel engine, and the hydraulic oil of the drive and work hydraulics.

Specific safety instructions Danger!

All work involving antifreeze carries an increased

Danger of poisoning and causticisation! ☞ Seek medical attention immediately if antifreeze has been swallowed ☞ Wear protective clothing and gloves ☞ Keep antifreeze out of reach of children • Dirt on the radiator fins reduces the radiator’s heat dissipation capacity! To avoid this: • Clean the outside of the radiator at regular intervals. Refer to the maintenance plans for the cleaning intervals • In dusty or dirty work conditions, clean more frequently than indicated in the maintenance plans • An insufficient coolant level reduces the heat dissipation capacity as well and can lead to engine damage! Therefore: • Check the coolant level at regular intervals. Refer to the maintenance plans in the appendix for the intervals • If the coolant must be replace frequently, have the cooling system checked for leaks by an authorised workshop!

• Never fill in cold water/coolant if the engine is warm!

• After filling the expansion tank, make a test run with the engine and check the coolant level again after stopping the engine • The use of the wrong coolant can destroy the engine and the radiator. Therefore: • Add enough antifreeze to the coolant.

• Use brand-name antifreeze compounds with anticorrosion additives – see Fluids and lubricants (overview) on page 3-4 • Do not use radiator cleaning compounds if an antifreeze compound has been added to the coolant – otherwise this causes sludge to form that can damage the engine Environment!

Use a suitable container to collect the coolant as it drains and dispose of it in an environmentally friendly manner!

3-18

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Maintenance and servicing work Checking the coolant level and quality Notice!

Check the coolant level every 10 s/h (service hours) or once a day.

We recommend checking it before starting the engine.

Check the antifreeze at regular intervals, especially at temperatures below 4 °C! Replace the coolant every 2 years!

☞ Check the coolant level as follows D

C

MAX

A

B MIN

Fig. 13: Checking the coolant expansion tank

• Park the machine on level ground • Lower the telescopic boom fully • Apply the parking brake with the switch • Stop the engine • Switch off ignition and remove the ignition key • Open the engine cover • Check the coolant level in the expansion tank A If the coolant level is below the MIN mark B of the expansion tank: • Fill up coolant to the MAX mark C ☞ Check the coolant quality (antifreeze) with suitable testing equipment (antifreeze tester)

➥ – see Fluids and lubricants (overview) on page 3-4 and – see chapter 2 “Coolant compound table” on page 2-14

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Maintenance and servicing work Filling up coolant Danger!

Never open the coolant tank and never drain coolant if the warm engine is running since the cooling system is under high pressure

Danger of burns! ☞ Wait at least 10 minutes after stopping the engine! ☞ Wear protective gloves and clothing ☞ Always actuate the safety valve in the filler cap of the expansion tank first.

To do this: Unscrew the filler cap to the first notch and release the pressure

☞ Fill up coolant as follows D

C

MAX

A

MIN

Fig. 14: Filling up coolant in the expansion tank

3-20

• Park the machine on level ground • Lower the telescopic boom fully • Apply the parking brake with the switch • Switch off ignition and remove the ignition key • Allow the engine/cooling system to cool down Release the overpressure in the coolant expansion tank A. To do this: • Open cap D to the first notch and release the pressure • Open filler cap D fully • Fill up coolant to the MAX mark C • Use brand-name antifreeze compounds with anticorrosion additives – see Fluids and lubricants (overview) on page 3-4 and – see chapter 2 “Coolant compound table” on page 2-14 • Close filler cap D • Start and warm up the engine, as you do so: • Open the heating circuit fully (see Operator’s Manual) • Stop the engine • Check the cooling system and the heating water circuit for leaks • If necessary, have leaks immediately repaired by qualified and trained staff • Check the coolant level again • If necessary, fill in coolant and repeat the procedure until reaching the correct coolant level

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Maintenance and servicing work Draining coolant Danger!

Never open the coolant tank and never drain coolant if the warm engine is running since the cooling system is under high pressure

Danger of burns! ☞ Wait at least 10 minutes after stopping the engine! ☞ Wear protective gloves and clothing ☞ Open filler cap D to the first notch of the expansion tank and release the pressure

☞ Drain the coolant as follows: D C

A

MAX MIN

E

Fig. 15: Draining coolant

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• • • • • •

Park the machine on level ground Lower the telescopic boom fully Apply the parking brake with the switch Stop the engine Switch off ignition and remove the ignition key Set the heating temperature controller to max. temperature in order to drain the coolant from the heating circuit as well (see Operator’s Manual) • Open the engine cover • Allow the engine/cooling system to cool down • Place a suitable container underneath the outlet of the radiator to collect the coolant as it drains • Release the overpressure in the coolant expansion tank A. To do this: • Open cap D to the first notch and release the pressure • Open filler cap D fully • Open the lower screw plug on the radiator E and drain the coolant ☞ Fill up coolant as follows: • Close the outlet on radiator E with the screw plug • Fill up coolant up to about 30 mm below filler cap D of the expansion tank ➥ Use brand-name antifreeze compounds with anticorrosion additives – see Fluids and lubricants (overview) on page 3-4 and – see chapter 2 “Coolant compound table” on page 2-14 • Close filler cap D fully • Open the heating circuit fully (see Operator’s Manual) • Start and warm up the engine until the thermostat opens • Stop the engine • Check the cooling system and the heating water circuit for leaks ➥ If necessary, have leaks immediately repaired by qualified and trained staff • Check the coolant level MAX in the expansion tank • If necessary, fill in coolant and repeat the procedure until reaching the correct coolant level

3-21

Maintenance and servicing work Cleaning the radiator fins Danger!

Warm engine

Danger of burns! ☞ Wait at least 10 minutes after stopping the engine! ☞ Wear protective goggles, gloves and clothing!

Caution!

Dirt on the radiator fins reduces the radiator’s heat dissipation capacity and can cause damage to the engine and the hydraulic system!

☞ Check and clean the outside of the radiator once a day. Refer to the maintenance plans for the cleaning intervals

☞ In dusty or dirty work conditions, clean more frequently than indicated in the maintenance plan

☞ Park the telehandler on level ground ☞ Lower the telescopic boom fully ☞ Apply the parking brake with the switch ☞ Stop the engine and let it cool down ☞ Switch off ignition and remove the ignition key ☞ Open the engine cover ☞ Clean the radiator fins by blowing compressed air from the engine side Caution!

Fig. 16: Cleaning the radiator

3-22

In order to ensure the radiator’s optimal cooling capacity, do not damage the radiator fins as you clean them with a compressed-air gun!

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Maintenance and servicing work 3.10 Cleaning the radiator with the reversing fan (option) T

The telehandler is fitted with a reversing fan. Pressing tip switch T reverses the fan’s direction of rotation and cleans the radiator. The radiator can be cleaned at any time with the reversing fan during machine operation and with the diesel engine running.

Caution!

A

Dirt on the radiator fins reduces the radiator’s heat dissipation capacity and can cause damage to the engine and the hydraulic system!

☞ Check and clean the radiator once a day. ☞ Clean the radiator more frequently in dusty or dirty work conditions ☞ Do not clean in closed premises

B Arma_re_02_2.iso

Tip switch T for the reversing fan is located on the instrument panel on the right ☞ Press tip switch T briefly to position B A

➥ The fan reverses its direction of rotation, ➥ the fan is in cleaning mode and the ➥ dirt is removed from the radiator ➥ This can be seen by the dust A blown out from the intake screen on the engine cover

Fig. 17: Tip switch for reversing fan

➥ The fan automatically switches back to cooling mode after about 1 minute Notice!

When working in especially dusty environment, clean the radiator repeatedly and more frequently!

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3-23

Maintenance and servicing work 3.11 Air filter maintenance Checking air filter contamination Clean the dust valve once a day

51

☞ Proceed as follows: • • • • • • •

Stop the engine Apply the parking brake with the switch Switch off ignition and remove the ignition key Open the engine cover Squeeze the discharge slot of dust valve E and remove hardened dust in the discharge slot Clean the discharge slot if necessary

Weekly check: filter cartridge contamination Indicator light 51 on the indicating instrument monitors the filter cartridge ☞ Filter cartridge D must be replaced if:

A

• Indicator light 51 on the indicating instrument comes on • At the latest after 500 service hours (however once every year) • – see Replacing the filter cartridge at 500 s/h (service hours) on page 3-25 Caution!

D

Filter cartridges degrade prematurely when in service in acidic air for longer periods of time. This risk is present for example in acid production facilities, steel and aluminium mills, chemical plants and other nonferrous-metal plants

☞ Replace filter cartridge D and safety cartridge F at the latest after 500 serF

vice hours!

34001b520_02.iso

Fig. 18: Air filter – dust valve

Checking the dust collector (option) once a day ☞ Proceed as follows: 1 2

• • • • • •

Stop the engine Apply the parking brake with the switch Switch off ignition and remove the ignition key Remove cover 1 from the dust collector Remove and empty the dust container 2 Insert the dust container and mount the cover Caution!

Fig. 19: Air filter – dust valve

3-24

Ensure that the dust in the container is no higher than 25 mm under the cover otherwise the engine is damaged!

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Maintenance and servicing work Replacing the filter cartridge at 500 s/h (service hours) Caution!

G

The filter cartridge will be damaged if it is washed or brushed out!

Bear in mind the following to avoid premature engine wear!

☞ Do not clean the filter cartridge ☞ Replace the filter cartridge when the indicator light comes on ☞ Never reuse a damaged filter cartridge ☞ Ensure cleanliness when replacing the filter cartridge!

H

307b0700.ai

D

☞ Proceed as follows:

307b0710.ai

D

H F Fig. 20: Removing the filter element

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• Stop the engine • Apply the parking brake with the switch • Switch off ignition and remove the ignition key • Open the engine cover • Fold both locks G on lower housing section H to the outside • Remove lower housing section H • Carefully remove filter cartridge D with slightly turning movements In addition, every 3rd time the filter is replaced: • Carefully remove safety cartridge F with slightly turning movements • Ensure that all contamination (dust) inside the upper and lower housing sections has been removed • Insert a new safety cartridge F into the upper housing section • Insert new filter cartridge D into the upper housing section • Position lower housing section H (ensure that it is properly seated) • Close both locks G

3-25

Maintenance and servicing work 3.12 Maintenance: V-belts Danger!

Only check or retighten/replace the V-belts when the engine is stopped –

Danger of personal injury! ☞ Stop the engine before performing inspection work in the engine compartment!

Caution!

Cracked and stretched V-belts cause engine damage

☞ Have the V-belts replaced by an authorised workshop

Checking V-belt tension Check the V-belts once a day or every 10 service hours and retighten them if necessary.

Retighten new V-belts after about 15 minutes of running time.

Check as follows: ☞ Stop the engine

☞ Apply the parking brake with the switch ☞ Switch off ignition and remove the ignition key ☞ Open the engine cover ☞ Remove the V-belt guard ☞ Carefully inspect the V-belts for damage

Fig. 21: Checking V-belt tension

If the V-belt is damaged: ☞ Have the V-belt replaced by authorised staff

☞ Press with your thumb to check whether the V-belt can be deflected between the pulleys by no more than about 10 mm

☞ Retighten the V-belts if necessary

Retightening the V-belts A

Retighten as follows: ☞ Stop the engine

☞ Apply the parking brake with the switch ☞ Switch off ignition and remove the ignition key ☞ Open the engine cover ☞ Slacken fastening screws 1, 2 + 4 of alternator 5 ☞ Turn screw 3 to move alternator 5 in the direction of arrow A until you reach the correct V-belt tension Fig. 22: Retightening the V-belts

3-26

☞ Firmly retighten fastening screws 1, 2 + 4 of alternator 5 ☞ Check V-belt tension again

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Maintenance and servicing work 3.13 Gearbox and axle maintenance Maintenance of the axles and the gearbox is limited to checking the oil levels and to changing the oil at the prescribed intervals ➥ – see Maintenance plan on page 3-5

Checking the oil level in the gearbox ☞ Proceed as follows: • Park the machine on level ground when the gearbox is at operating temperature • Oil filler and check plug A on the 20 kph gearbox; or • oil filler and inspection plug B on 30 kph and 40 kph gearbox (Ecospeed): clean and unscrew the plug while holding a cloth under the opening • Only use new sealing rings for oil filler and drain plugs!

If the oil level is below the opening or if the oil level cannot be seen at all: • Fill up oil – see Filling up the gearbox oil on page 3-27

A

Environment!

Use a suitable container to collect the gearbox oil as it drains and dispose of it in an environmentally friendly manner!

B

Fig. 23: Checking the oil level in the gearbox

Filling up the gearbox oil ☞ Proceed as follows: • Park the machine on level ground when the gearbox is at operating temperature • Oil filler and check plug A on the 20 kph gearbox; or • oil filler and inspection plug B on 30 kph and 40 kph gearbox (Ecospeed): clean and unscrew the plug while holding a cloth under the opening If the oil level is below the opening or if the oil level cannot be seen at all: • Fill in oil until it runs out of the filler opening

A

• Only use new sealing rings for oil filler and drain plugs Environment!

Use a suitable container to collect the gearbox oil as it drains and dispose of it in an environmentally friendly manner!

B

Fig. 24: Checking the oil level in the gearbox

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Maintenance and servicing work Changing the gearbox oil Danger!

Careful when draining hot gearbox oil –

Danger of burns! ☞ Wear protective gloves ☞ Use suitable tools, e.g. for unscrewing the oil drain plug ☞ Proceed as follows: 20 kph gearbox

• • • •

Park the machine on level ground when the gearbox is at operating temperature Place a suitable container under the rear axle gearbox to collect the oil Oil filler and check plug A on the 20 kph gearbox; or Unscrew oil filler and inspection plug B on the 30 kph or 40 kph gearbox (Ecospeed) • Unscrew oil drain plug C on the 20 kph gearbox or oil drain plug E on the 30 kph or 40 kph gearbox (Ecospeed)

A C

Caution!

30 kph or 40 kph gearbox

Do not unscrew oil drain plug D!

☞ It is used for draining the hydraulic oil

B

• Completely drain the old gearbox oil • Tighten drain plug C or E with a new sealing ring • Fill in oil until it runs out of filler opening A or B – see Filling up the gearbox oil on page 3-27 Environment!

30 kph or 40 kph gearbox

Use a suitable container to collect the gearbox oil as it drains and dispose of it in an environmentally friendly manner!

D

E Fig. 25: Changing the gearbox oil

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Maintenance and servicing work Rear axle differential oil level Checking the oil ☞ Proceed as follows: A

Fig. 26: Oil filler and inspection plug on the differential

• Park the machine on level ground when the differential is at operating temperature • Clean and unscrew oil filler and inspection plug A on the differential while holding a cloth under the opening If the oil level is below the opening or if the oil level cannot be seen at all: • Fill up the oil If the oil level is correct: • Tighten oil filler and inspection plug A with a new sealing ring to make an oil-tight seal Filling up the oil ☞ Proceed as follows: • Park the machine on level ground when the differential is at operating temperature • Clean and unscrew oil filler and inspection plug A on the differential • Fill in oil until it runs out of the filler opening If the oil level in the differential remains constant: • Tighten oil filler and inspection plug A with a new sealing ring to make an oil-tight seal

Draining the oil in the rear axle differential Notice!

Drain oil only after running the machine for a longer period of time (operating temperature)!

Danger!

Careful when draining hot gearbox oil –

Danger of burns! ☞ Wear protective gloves ☞ Use suitable tools, e.g. for unscrewing the oil drain plug ☞ Proceed as follows: A B C C

C

Fig. 27: Oil drain plug on rear axle differential

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• Park the machine on level ground when the differential is at operating temperature • Place an adequately sized container under the differential housing of the rear axle to collect the oil • Clean and unscrew plugs A and B • Unscrew oil drain plugs C • Completely drain the old gearbox oil • Tighten oil drain plugs C with new sealing rings to make oil-tight seals • Fill in oil through opening A until it runs out of opening B If the oil level in the differential remains constant: • Tighten plugs A and B with new sealing rings to make oil-tight seals After performing a test run: • Check the oil level again after about 5 minutes, and fill up if necessary

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Maintenance and servicing work Front axle differential oil level Checking the oil ☞ Proceed as follows:

A Fig. 28: Oil filler and inspection plug on the differential

• Park the machine on level ground • Clean and unscrew oil filler and inspection plug A on the differential while holding a cloth under the opening If the oil level is below the opening or if the oil level cannot be seen at all: • Fill up with oil If the oil level is correct: • Tighten oil filler and inspection plug A with a new sealing ring to make an oil-tight seal Filling up the oil ☞ Proceed as follows: • Park the machine on level ground • Clean and unscrew oil filler and inspection plug A on the differential while holding a cloth under the opening • Fill in oil until it runs out of the filler opening • Tighten oil filler and inspection plug A with a new sealing ring to make an oil-tight seal

Draining the oil in the front axle differential Notice!

Drain oil only after running the machine for a longer period of time (operating temperature)!

B

A C C

Danger!

C

Careful when draining hot gearbox oil –

Fig. 29: Oil filler and inspection plug on the differential

Danger of burns! ☞ Wear protective gloves ☞ Use suitable tools, e.g. for unscrewing the oil drain plug ☞ Proceed as follows: • • • • • • •

Park the machine on level ground when it is at operating temperature Clean and unscrew plugs A and B Place a container under plugs C to collect the oil Completely drain the old oil Tighten oil drain plug C with new sealing rings to make oil-tight seals Fill in fresh oil through opening A until it runs out of opening B Tighten oil filler and inspection plugs A/B with new sealing rings to make oil-tight seals Caution!

After performing a test run:

☞ Check the oil level again after about 5 minutes, and fill up if necessary

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Maintenance and servicing work Planetary drives: checking and filling up the oil level Notice!

Drain oil only after running the machine for a longer period of time!

A

Fig. 30: Oil filler and inspection plug on planetary drive

☞ Check the oil level • Park the machine on level ground and secure it against rolling away • Place plug A in the position shown in fig. 30 (plug must be at the top) • Clean and unscrew plug A (to release possible overpressure) • Place plug A in the position shown in fig. 31 (plug must be horizontal) • Remove plug A If the oil level is below the opening or if the oil level cannot be seen at all: • Filling up the oil ☞ Fill up the oil

A

Fig. 31: Oil filler and inspection plug on planetary drive

• • • • • • •

Park the machine on level ground Place plug A in the position shown in fig. 30 (plug must be at the top) Clean and unscrew plug A (to release possible overpressure) Place plug A in the position shown in fig. 31 (filler plug must be horizontal) Remove plug A Fill in fresh oil through the opening until it runs out of the filler opening Tighten plug A with a new sealing ring to make an oil-tight seal

Changing the oil ☞ Proceed as follows:

A

Fig. 32: Oil drain plug on planetary drive

A

• Park the machine at operating temperature on level ground and secure it against rolling away • Place a suitable container under drain plug A • Place plug A in the position shown in fig. 32 (plug must be at the top) • Clean and unscrew plug A (to release possible overpressure) Never raise the machine on one side only for the following work!

• Turn the planetary drive downward (plug must be at the bottom) • Remove plug A • • • •

Completely drain the old oil Place opening A in the position shown in fig. 31 (plug must be horizontal) Fill in fresh oil through opening A until it runs out of the filler opening Tighten plug A with a new sealing ring to make an oil-tight seal

Fig. 33: Oil filler and inspection plug on planetary drive

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