Claas SCORPION (K3X) Compressed-air trailer brake system Assembly instructions Manual - PDF DOWNLOAD

SCORPION (K3X)

Assembly instructions Compressed-air trailer brake system

Service & Parts

3040-004

3040-004

Table of contents 1

00 1920 092 1 1.1

Validity............................................................................................................................................

4

1.2

Safety rules....................................................................................................................................

5

1.3

Special tool....................................................................................................................................

6

1.4

Assembling....................................................................................................................................

7

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1 00 1920 092 1 1.1 Validity 3040-004

1 00 1920 092 1 1.1 Validity 226450-003

00 1920 092 1

LT_J02_0001

SCORPION 1033

K34

K3400021

-

SCORPION 741

K33

K3300021

-

SCORPION 736

K32

K3200021

-

SCORPION 732

K31

K3100021

-

SCORPION 635

K30

K3000021

-

14.0 h

CDS

4

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1 00 1920 092 1 1.2 Safety rules 3040-004

1.2 Safety rules 211681-002

Work may only be carried out by a qualified specialist workshop employing trained specialist workers.

The general safety, accident prevention and environmental protection regulation must be observed.

Before starting work on the machine, read and observe the safety precautions in the Operator's Manual and the safety decals on the machine.

All work must be carried out with the drive disengaged and the engine stopped! – Remove the ignition key!

Carry out work beneath a raised machine/front attachment or raised components only if a safe support is provided.

Before carrying out work on the hydraulic system, lower the machine/front attachment and hydraulically actuated components to the ground. Depressurise the system.

Relieve the tension of pre-loaded energy accumulators (springs, accumulators, hydraulic cylinders) and of components which are pre-loaded by energy accumulators properly prior to starting installation work!

When parts with safety decals on them are replaced, ensure that the relevant safety decals are applied again to the new parts.

Refit any dismounted safety guards and other parts before putting back into operation and move them to their protective position.

Check the tight seat of all bolts after assembly. Carry out a function check.

The dimensions given follow the metric system. The corresponding U.S. dimensions are added in brackets.

CLAAS KGaA mbH is constantly working to improve our products in line with technical developments. For this reason we reserve the right to make changes to the illustrations and descriptions in this documentation; this shall not provide grounds for claims in respect of changes to machines already supplied. Reproduction or translation of this publication in whole or in part is not permitted without the written consent of CLAAS KGaA mbH. All rights under the copyright laws reserved.

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1 00 1920 092 1 1.3 Special tool 3040-004

1.3 Special tool 226456-002

Special tool

1

Special tool (I)

Pcs.

Test tool

1

00 0181 402 X

1 276700-001

Utilities: ► Sealing agents and glue: Loctite 243

6

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1 00 1920 092 1 1.4 Assembling 3040-004

1.4 Assembling 242031-001

Installation instructions ► Check if all lines and hoses are free of packaging residues, clean them with compressed air and check if air passage is unrestricted.

Air compressor oil supply: ► ► To check the air compressor oil supply, start the diesel engine before connecting the oil supply. ► Check if the screw fittings on the air compressor and on the diesel engine enable unrestricted passage. ► Ensure that rubber hoses are laid with a safety distance from hot components. ► Lay the oil return line with a gradient towards the engine. ► Hydraulic service brake: ► Check the pedal travel before installing the compressed-air brake system.

(The pedal travel increases slightly after installing the compressed-air brake system) ► Check the engagement length of all bolts. ► Seal the conical oil and water screw fittings with Loctite.

Strength class

8.8

Thread

10.9

12.9

Tightening torque (Nm)

M8

25

34

40

M10

48

67

81

M12

84

117

142

M14

132

186

235

M16

205

289

348

M18

284

397

475

M20

402

568

676

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1 00 1920 092 1 1.4 Assembling 3040-004

Compressed-air trailer brake system circuit diagram

429838-001

8

Position

Quantity

1

Designation

CCN

1

Compressed-air compressor

260-LWT

2

1

Anti-freeze pump

261-LWT

3

1

Pressure controller 8.1 bar with silencer

262-LWT

4

2

Compressed-air reservoir

263-LWT

5

2

Drain valve

264-LWT

6

1

Pressure gauge

265-LWT

7

1

Tear-off safety valve

266-LWT

8

1

Trailer control valve

267-LWT

9

1

Accumulator service line hose coupler

268-LWT

10

1

Brake service line hose coupler

269-LWT

11

1

Proportional valve

Y83-LWT

12

1

Test port

271-LWT

2

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1 00 1920 092 1 1.4 Assembling 3040-004 242033-001

Installing the air compressor – Open the engine bonnet.

– Disconnect the battery.

– Jack up the machine and remove the rear wheels.

– Remove the belt cover from the diesel engine. ► Remove support (see arrow).

3 429823-001

► Unscrew the belt pulley. ► 4 hex. socket head cap screws M8x25 with contact washer.

4 429824-001

► Bolt down the support hand-tight. ► 1 bolt M10x35 with blocking washer.

5 429825-001

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1 00 1920 092 1 1.4 Assembling 3040-004

429826-001

6

► Coat 2 hex. socket head cap screws M10x25 (A) with Loctite and screw them on hand-tight. ► Screw on 1 bolt M10x30 (B) hand-tight together with the blocking washer. ► Align the console and the support to be parallel and tighten all bolts. ► Insert the V-belt. ► Bolt down bracket (see arrow).

7 429827-001

429828-001

8

► Install the air compressor. ► 2 hex. socket head cap screws M8x35 with blocking washers (A). ► 2 hex. socket head cap screws M8x55 with blocking washers and nuts (B).

10

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► Install and tension the V-belt as specified in the Repair Manual.

9 429829-001

429830-001

10

► Screw on pressurised oil hose at (A) and (B). ► Use 1 straight screw fitting M10x1-6L with a copper seal at (A).

429831-001

11

► Lay the pressurised oil hose without chafing and secure with cable bands.

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1 00 1920 092 1 1.4 Assembling 3040-004

429832-001

12

► Screw on oil return hose at (A) and (B). ► Use 1 reducer M30x1.5-M22x1.5 with a copper seal and elbow union M22x1.5-15l at (A).

429833-001

13

► Drill a hole Ø 22 mm into the intake pipe and insert compression fitting (A). ► Connect the suction hose. ► 2 hose clamps Ø 22-32 mm. ► Bolt down bracket (see arrow). ► 1 bolt M8x20 with blocking washer.

14 429834-001

12

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1 00 1920 092 1 1.4 Assembling 3040-004

15

429835-001

► Install the compressed air line. ► Bolt down the bracket and the pipe clamp with 1 bolt M6x20 and a blocking washer.

242036-001

Installing the compressed-air reservoir

429839-001

16

► Bolt down the front compressed-air reservoir. ► 2 bolts M12x40 with blocking washer.

429840-001

17

► Bolt down the rear compressed-air reservoir. ► 2 bolts M12x40 with blocking washer.

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1 00 1920 092 1 1.4 Assembling 3040-004

Installing the valve support

429841-001

18

► Bolt down the valve support. ► 4 bolts M8x20 with blocking washer.

14

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Installing the brake lines

429842-001

19

► Connect the brake hose at connection (B) of brake valve (211-LWT).

429843-001

20

► Lay the brake hose along the hose package to the rear.

429844-001

21

► Connect the brake hose to tear-off safety valve (266-LWT).

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1 00 1920 092 1 1.4 Assembling 3040-004

429845-001

22

► Secure the brake hose with cable bands.

429846-001

23

► Connect the hose to proportional valve (Y83LWT). ► Use an adjustable elbow union. ► Lay and connect the hose to the trailer control valve (267-LWT). ► Secure the hose with cable bands.

16

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Installing the antifreeze pump

429848-001

24

► Installing antifreeze pump (261-LWT): ► Drill 2 holes Ø 9 mm into the machine frame as shown in the figure. ► Bolt down the antifreeze pump.

2 bolts M8x100 2 washers 2 blocking washers 2 nuts M8 ► Connect the plastic lines, following the schematic diagram ( Page 8). ► Ensure that the plastic lines are laid with a downward gradient. ► Fill the accumulator with antifreeze for compressed-air systems. ► Switch on the antifreeze pump if necessary.

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1 00 1920 092 1 1.4 Assembling 3040-004

Installing the service line hose couplers ► Install the service line hose couplers.

Red service line hose coupler: accumulator Yellow service line hose coupler: brake

25 429849-001

429850-001

26

► Connect the service line hose couplers to tear-off safety valve (266-LWT), using plastic lines.

Connection (A): red service line hose coupler Connection (B): yellow service line hose coupler See schematic diagram Page 8 ► Do not kink the plastic lines. ► Keep plastic lines away from heat sources.

429852-001

27

► Secure the line with a pipe clamp. ► 1 pipe clamp Gi16.

18

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1 00 1920 092 1 1.4 Assembling 3040-004

► 1 bolt M10x20 with blocking washer. ► Secure the lines with cable bands.

429853-001

28

429854-001

29

► Secure the hose package with cable bands.

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1 00 1920 092 1 1.4 Assembling 3040-004

429855-001

30

► Secure the hose package with cable bands.

20

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1 00 1920 092 1 1.4 Assembling 3040-004

Applying the identification plate decal ► Apply the identification plate decal at the rear of the machine.

31 429851-001 242104-001

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1 00 1920 092 1 1.4 Assembling 3040-004

Installing the basic machine wiring loom

429901-001

32

► Lay the wiring loom as shown and secure at the points shown with cable band. ► Connect cable plug (Y55.X-LWT) to connection PB. ► Connect cable plug (Y56.X-LWT) to connection IS.

429902-001

33

► Lay the wiring loom as shown and secure at the points shown with cable band. ► Ensure that a safety distance from the edge (see arrow) is respected.

22

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429903-001

34

► Lay the wiring loom as shown and secure at the points shown with cable band. ► Connect crimp connector (X200S-LWT) with free connection (X200P-LWT). ► Connect the crimp connector with the tool intended for that purpose and heat it up with a hot-air gun. ► Screw cable lug to earth terminal (MP4).

429904-001

35

► Lay the wiring loom as shown and secure at the points shown with cable band. ► Connect crimp connector (X240S-LWT) with free connection (X240P-LWT). ► Connect the crimp connector with the tool intended for that purpose and heat it up with a hot-air gun.

242105-001

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23

1 00 1920 092 1 1.4 Assembling 3040-004

Installing the cab wiring loom

390947-001

36

Overview of cab wiring loom

24

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390943-001

37

► Remove cover (X) of central terminal compartment.

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1 00 1920 092 1 1.4 Assembling 3040-004

429924-001

38

390945-001

39

► Plug in relay (K41-LWT). ► Plug in fuse (F78-LWT).

► Remove display (A33-LWT).

26

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390946-001

40

► Remove covering (Y) and covering (Z).

429925-001

41

► Connect cable plug (X490S-LWT) with cable plug (X490P-LWT). ► Connect cable plug (X491S-LWT) with cable plug (X491P-LWT).

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1 00 1920 092 1 1.4 Assembling 3040-004

429926-001

42

► Insert pushbutton (S75-LWT). ► Connect cable plug (S75.X-LWT) with pushbutton (S75-LWT). ► Fasten the wiring loom with cable bands.

28

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390950-001

43

► Screw wiring loom to earth terminal (MP2).

390951-001

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44

29

1 00 1920 092 1 1.4 Assembling 3040-004

► Remove insulation mat (AA).

390952-001

45

► Connect cable plug (X240S-LWT) with cable plug (X240P-LWT). ► Connect cable plug (X241S-LWT) with cable plug (X241P-LWT).

390953-001

46

► Screw wiring loom to earth terminal (X4). ► Fasten the wiring loom with cable bands.

30

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390951-001

47

► Insert insulation mat (AA) again.

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1 00 1920 092 1 1.4 Assembling 3040-004

Installing pressure gauge (58)

429927-001

48

► Guiding the pressure gauge compressed air line out of the cab: ► Drill a hole Ø 9 mm into plastic cap (AB) and guide the compressed air line to the outside.

To do this, unlock connector plug (AC) with an unlocking tool.

429928-001

49

► Insert the pressure gauge into the covering.

32

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390956-001

50

► Connect cable plug (B49.X1-LWT) and cable plug (B49.X2-LWT) to the pressure gauge.

390946-001

51

► Install covering (Y) and covering (Z).

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1 00 1920 092 1 1.4 Assembling 3040-004

390945-001

52

390943-001

53

► Install display (A33-LWT).

► Install cover (X) of central terminal compartment.

228095-002

34

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Completing installation – Remove the belt cover from the diesel engine.

– Connect the battery.

– Configure the compressed-air trailer brake system with the CDS. – Vent the brake as described in the Repair Manual.

390963-001

54

► Install covering (S). ► Remove circular plugs (AE).

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1 00 1920 092 1 1.4 Assembling 3040-004

Checking the function

390961-001

55

► Checking the air pressure at both service line hose couplers: Pre-condition

Air pressure at the yellow service line hose coupler

With the service brake fully actuated

5 to 8 bar

(inching pedal pressed down completely) With the inching function actuated

0.6 to 0.8 bar

(inching pedal pressed down slightly) With the parking brake applied

5 to 8 bar

► Pressure must permanently be available at the red service line hose coupler (accumulator). ► Compare the pressure available at the red service line hose coupler with the pressure gauge in the cab.

36

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CLAAS KGaA mbH 33416 HARSEWINKEL GERMANY Tel. +49 (0)5247 12-0 www.claas.com

00 0302 916 2 ABA Druckluftanhängerbremsanlage SCORPION (K3X) EN - 10/2020 Printed in Germany