CLAAS SCORPION 9040 Model: 404-03 Operator’s manual- PDF DOWNLOAD
DESCRIPTION:
CLAAS SCORPION 9040 Model: 404-03 Operator’s manual- PDF DOWNLOAD
1 Introduction
1.1 General information on the Operator’s Manual
- This Operator’s Manual contains important information on how to work safely, correctly and economically with your telehandler. Therefore, it aims not only at new operators, but it also serves as a reference for experienced ones.
- It helps to avoid dangerous situations and reduce repair costs and downtimes. Furthermore, the reliability and the service life of the machine will be increased by following the instructions in the Operator’s Manual. This is why the Operator’s Manual must always be kept at hand in proper condition in the machine.
- The Operator’s Manual is stored in the storage compartment on the backrest of the seat. Please contact your dealer if you require more information on the machine or the Operator’s Manual.
TABLE OF CONTENTS:
CLAAS SCORPION 9040 Model: 404-03 Operator’s manual- PDF DOWNLOAD
Contents
Contents I-10
EC declaration of conformity (model 404-03) EG-1
Introduction 1
General information on the Operator’s Manual 1-1
Abbreviations/symbols 1-1
General information on machine safety 1-1
Machine overview 1-2
Model designation – trade names 1-3
Brief description of telehandler 1-3
General information on the machine 1-3
Main components of machine 1-3
Hydrostatic drive 1-4
Work hydraulics and 4 wheel steering 1-4
Cooling system 1-4
Telehandler warranty 1-4
Information on warranty 1-4
Fields of application and using a telehandler with an attachment 1-5
Attachments with certified material densities 1-5
Regulations 1-7
Driving licence 1-7
Licence/identification 1-7
Adjusting the headlights 1-7
Machine inspections 1-8
On-board equipment 1-8
Documents 1-8
Warning identification of telehandler on public roads (option) 1-8
Type labels and component numbers 1-9
Serial number 1-9
Cab number 1-9
Engine number 1-9
Hydraulic pump number 1-10
Variable displacement motor number 1-10
Variable displacement motor number (high speed option) 1-10
Front and rear axle numbers 1-10
Description of labels 1-11
Labels on the outside of the machine 1-11
Labels on the inside of the machine 1-12
Safety instructions 2
Identification of warnings and dangers 2-1
Designated use and exemption from liability 2-2
General conduct and safety instructions 2-3
Organisational measures 2-3
Selection and qualification of staff, basic responsibilities 2-5
Safety instructions regarding operation 2-6
Normal operation 2-6
Applications with lifting gear 2-8
Trailers and attachments 2-9
Transport 2-9
Safety instructions for maintenance 2-10
Maintenance work on protective ROPS and FOPS structures 2-12
Cab, roll-over bar, protective screen 2-12
Contents
I-2 00 0290 174 1 – BA SCORPION
Contents
Warning of special hazards 2-12
Electric energy 2-12
Gas, dust, steam, smoke 2-12
Hydraulic equipment 2-13
Noise 2-13
Oil, grease and other chemical substances 2-13
Battery 2-13
Tyres 2-13
Operation 3
Overview of control elements 3-1
Cab overview 3-2
Instrument panel, multifunctional lever, switch consoles: overview 3-4
Telltales and warning lights: description 3-6
Telltale and warning light – indicating instrument 3-6
Telltale and warning light – instrument panel 3-7
Putting the machine into operation for the first time 3-8
Safety instructions regarding commissioning 3-8
Important information for the operating staff 3-8
Running-in period 3-8
Start-up checklist 3-9
Operation checklist 3-10
Parking checklist 3-10
Cab 3-11
Locking and unlocking the door 3-11
Closing and opening the side window (to a gap) 3-12
Completely opening and locking the side window 3-12
Opening/closing the rear window 3-13
Rear window emergency exit 3-13
Engine cover 3-13
Opening/closing the engine cover 3-13
Putting the diesel engine into operation 3-14
Preparing to start the engine 3-14
Starting the engine 3-15
Avoiding running the engine under low-load conditions 3-16
Stopping the engine 3-16
Battery master switch 3-16
Switching the battery master switch ON and OFF 3-16
Error code displays (103 kW diesel engine) 3-17
Reading out the flash code 3-17
Warning limit – coolant temperature 3-17
Warning limit – charge-air temperature 3-18
Warning limit – engine oil pressure 3-18
Overview of flashing codes 3-19
Key-based drive interlock (option) 3-22
Coding (“training”) new ignition keys 3-22
Enabling (locking) the drive interlock 3-23
Disabling (releasing) the drive interlock 3-23
Deleting coded keys 3-23
Safety functions 3-23
00 0290 174 1 – BA SCORPION I-3
Contents
Drive interlock with code input (option) 3-24
Entering/changing the personal code 3-25
Enabling the drive interlock 3-25
Disabling the drive interlock 3-26
Putting the drive interlock out of operation 3-27
Putting the drive interlock back into operation again 3-27
Interruption of drive interlock power 3-27
Drive interlock maintenance 3-27
Oil and fuel preheater (option) 3-28
Oil preheater (option) 3-28
Fuel preheater (option) 3-28
Jump-starting the engine (external battery) 3-29
Safety instructions regarding external starting aids 3-29
Providing external starting aid 3-29
Before moving off 3-30
Special instructions for driving on public roads 3-30
Carry out a functional check of brakes, steering system and lights 3-31
Raising the telescopic boom to transport position 3-31
Locking the control lever (joystick) and the 3rd control circuit (attachments) 3-31
Steering system 3-32
Steering column height and angle adjustment 3-32
Checking the steering system 3-32
Synchronising the steering system 3-33
Changeover to front axle steering 3-34
Changing over to 4 wheel steering 3-34
Changing over to diagonal steering (crab steering option) 3-35
Accelerator pedal 3-36
Manual throttle (option) 3-36
Brake/inching pedal 3-37
Specific information on brake/inching pedal actuation 3-37
Inching with the brake/inching pedal 3-37
Braking with the brake/inching pedal 3-37
Parking brake 3-38
General information on the parking brake 3-38
Applying the parking brake 3-38
Moving off the telehandler 3-39
Selecting the drive range 0 – 20 kph (30/40 kph option) 3-39
Changing direction (forwards/reverse) 3-40
Selecting a speed range (low-speed control option) 3-41
Stopping/parking the machine 3-42
Decommissioning the machine for a longer time 3-42
Load stabiliser 3-43
General instructions regarding the load stabiliser function 3-43
Switching the load stabiliser ON or OFF 3-44
Differential lock 3-45
Important information on the differential lock 3-45
Switching the differential lock ON and OFF 3-45
Backup warning system (option) 3-46
Information on the backup warning system 3-46
Electric mirror adjustment (option) 3-46
Adjusting the rearview mirror 3-46
Machine lights 3-47
General instructions regarding the machine lights 3-47
Machine lights operation 3-47
Working lights operation 3-48
Interior light operation (cab) 3-48
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Contents
Signalling system 3-49
Turn indicator operation 3-49
Hazard warning system operation 3-49
Rotating beacon operation (option) 3-49
Cab heating and ventilation 3-50
Operation of the heating and ventilation system 3-50
Air conditioning (option) 3-51
Air conditioning operation 3-51
Washer system 3-52
Washer system operation 3-52
Tank for washer system 3-52
Seat 3-53
Seat adjustment: overview 3-53
Weight adjustment 3-53
Height adjustment (air-suspension seat, option) 3-54
Backrest adjustment 3-54
Horizontal adjustment 3-54
Seat belt (lap belt) 3-55
Specific instructions regarding the seat belt 3-55
Fastening the seat belt 3-55
Unfastening the seat belt 3-56
Longer/shorter lap belt adjustment: 3-56
Fire extinguisher (option) 3-57
Fire extinguisher operation 3-57
Reversing fan (option) 3-57
Towing the machine 3-58
Safety instructions for towing away 3-58
Getting ready for towing 3-58
Towing the machine 3-59
Once towing is over 3-59
Loading and transporting the telehandler on a transport vehicle 3-60
General safety instructions regarding loading 3-60
Loading and tying down the machine 3-61
Crane handling the machine 3-62
Safety instructions regarding crane handling 3-62
Crane handling 3-62
Telescopic boom control lever: overview 3-63
Operating the control lever for the lift, tilt and push-out rams 3-63
Operating and securing the 3rd control circuit 3-64
Locking and unlocking the quickhitch or an attachment 3-64
Releasing the pressure on the quick couplers 3-64
Safe load indicator for telescopic boom 3-65
General safety instructions regarding the safe load indicator 3-65
Safe load indicator display 3-66
Functional check of the safe load indicator 3-67
Disabling/enabling the overload cutoff (option) 3-67
Operating the telescopic boom 3-68
Raising/extending the telescopic boom 3-68
Retracting/lowering the telescopic boom 3-68
Emergency lowering of telescopic boom in case of diesel engine breakdown 3-69
Lower or raise as follows: 3-69
Equipping the machine with a standard bucket 3-70
General information on buckets 3-70
Pressure relief on the quickhitch couplers 3-70
Fitting a standard bucket onto the quickhitch 3-71
Removing a standard bucket from the quickhitch 3-72
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Contents
Working with the standard bucket 3-73
Safety instructions regarding work with the bucket 3-73
Driving on public roads with a standard bucket 3-74
Transport position of standard bucket 3-74
Standard bucket payload 3-75
Safety instructions for transporting material in a full bucket 3-75
Loading loose material 3-76
Loading if the material is hard to penetrate 3-76
Removing material/digging in soft soil 3-77
Removing material/digging in hard soil 3-78
Grading 3-78
Loading vehicles 3-79
Freeing the machine 3-79
Fitting a multipurpose bucket 3-80
General information on the multipurpose bucket 3-80
Picking up a multipurpose bucket with the quickhitch 3-80
Hydraulic connections on the multipurpose bucket: overview 3-80
Connecting hydraulic lines to the 3rd control circuit 3-81
Removing the multipurpose bucket from the quickhitch 3-82
Working with the multipurpose bucket 3-83
Safety instructions regarding work with the bucket 3-83
Driving on public roads with the multipurpose bucket 3-84
Transport position of multipurpose bucket 3-84
Multipurpose bucket payload 3-85
Safety instructions for transporting material in a full bucket 3-85
Grading and scraping 3-86
Removing and spreading material in thin layers 3-86
Pulling out material from slopes 3-87
Moving material with longer reach 3-87
Picking up remaining material completely 3-87
Grabbing bulky material 3-88
Pulling out and setting posts 3-88
Backfilling round gravel and precise unloading 3-89
Unloading from the bottom of the bucket for increased dump heights 3-89
Fitting pallet forks 3-90
Fitting pallet forks onto the quickhitch 3-90
Removing pallet forks from the quickhitch 3-90
Driving on public roads with the pallet forks 3-90
Working with the pallet forks 3-91
General safety instructions regarding the pallet forks 3-91
Specific safety instructions 3-92
Brief instructions for fork arms 3-93
Load diagram for pallet forks (EN 1459/1998) 3-94
Pallet forks payload 3-94
Pallet forks transport position without load 3-94
Adjusting the fork arms of the pallet forks 3-95
Picking up loads with the pallet forks 3-96
Transporting loads with the pallet forks 3-97
“Hose burst valve” safety feature 3-98
Hose burst valve function 3-98
Mechanical oscillating axle interlock (rear axle) 3-99
Mechanically locking the oscillating axle 3-99
Hydraulic rear oscillating axle interlock (option) 3-99
Hydraulically locking the oscillating axle 3-99
Frame levelling feature on front axle (option) 3-100
Switching the frame levelling ON and OFF 3-100
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Contents
Working with a crane jib (option) 3-101
General safety instructions for working with a crane jib 3-101
Continuous operation of 3rd control circuit (option) 3-102
Switching continuous operation of 3rd control circuit ON/OFF 3-102
Tilt ram lock (option) 3-102
Switching the tilt ram lock ON and OFF 3-102
Electric changeover valve for operation of 3rd control circuit as
additional front control circuit (option) 3-103
Switching the additional control circuit ON or OFF 3-103
Front/rear hydraulic additional control circuit (option) 3-104
General information on the additional control circuit 3-104
Connecting an attachment onto the additional control circuit 3-104
Additional control circuit operation 3-105
Automatic bucket repositioning (option) 3-106
General information on automatic bucket repositioning 3-106
Tipping trailer connection (option) 3-106
Operating the tipping trailer connection 3-106
Operation of the Autohitch trailer coupling (option) 3-107
General information on the Autohitch trailer coupling 3-107
Unlocking and opening the Autohitch trailer coupling 3-107
Locking the Autohitch trailer coupling 3-108
Automatic trailer coupling (option) 3-109
General information on the trailer coupling 3-109
Attaching a trailer 3-109
Compressed-air brake system (option) 3-110
General safety instructions regarding the compressed-air braking system 3-110
Coupling and uncoupling compressed-air hoses
(dual-circuit brake system) 3-110
Compressed-air gauge 3-111
Hydraulic trailer brake (option) 3-111
General information on the hydraulic trailer brake 3-111
Fitting attachments from other manufacturers onto the quickhitch (option) 3-112
General information on quickhitches 3-112
Example: inspection plan for attachments other than Kramer 3-113
Troubleshooting 4
Diesel engine malfunctions 4-1
Malfunctions in the air conditioning system (option) 4-3
Maintenance 5
Introduction 5-1
Safety prop for telescopic boom 5-1
Fuel system 5-2
General safety instructions for refuelling 5-2
Diesel fuel specification 5-2
Stationary fuel pumps 5-2
Refuelling 5-3
Bleeding the fuel system 5-3
Checking/replacing the fuel prefilter (water separator) 5-4
Replacing the fuel filter 5-5
Cleaning the fuel cooler (option) 5-5
Engine lubrication system 5-6
Checking the engine oil level daily 5-6
Filling up engine oil 5-6
Replacing the engine oil (every 500 service hours) 5-7
Replacing the engine oil filter (every 500 service hours) 5-8
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Contents
Engine and hydraulics cooling system 5-9
Specific information on cooling system maintenance 5-9
Temperature gauge: engine coolant 5-10
Checking the coolant level and quality 5-10
Filling up coolant 5-11
Draining coolant 5-12
Cleaning the radiator fins 5-13
Cleaning the radiator with the reversing fan (option) 5-14
Air filter 5-15
Checking air filter contamination 5-15
Checking the dust collector once a day 5-15
Replacing the air filter cartridge at 500 s/h (service hours) 5-16
V-belts 5-17
Checking the V-belts 5-17
Retightening the V-belts 5-17
Hydraulic system 5-18
Specific safety instructions regarding the hydraulic system 5-18
Monitoring the hydraulic oil and the reflux filter 5-19
Checking the hydraulic oil level once a day 5-20
Filling up hydraulic oil 5-20
Important information for the use of biodegradable oil 5-21
Checking hydraulic pressure lines 5-22
Specific safety instructions regarding pressure line checks 5-22
Lubrication work 5-23
General safety instructions 5-23
Lubricating the front and rear axle oscillation-type bearings 5-23
Lubricating the planetary drive bearing 5-23
Lubrication points on the telescopic boom: overview 5-24
Lubricating the telescopic boom 5-24
Checking and adjusting the wear plates 5-24
Lubricating with the central lubrication system (option) 5-25
General functional description of the central lubrication system 5-25
Time control 5-25
Setting the lubrication and break times 5-26
Filling the central lubrication system 5-26
Maintenance of the brake system 5-27
Specific safety instructions regarding the brake system 5-27
Checking/filling up the brake fluid level 5-27
Maintenance: compressed-air brake system (option) 5-28
Checking the compressed-air tank and lines 5-28
Checking compressor attachment and drive 5-28
Tyres 5-29
Daily tyre checks 5-29
Changing wheels 5-30
Heating and ventilation system maintenance 5-31
Cleaning/replacing the fine-dust filter 5-31
Cleaning/replacing the recirculated-air filter 5-31
Air conditioning (option): maintenance 5-32
General safety instructions regarding the air conditioning system 5-32
Filling up the air conditioning system 5-32
Daily functional and visual checks of the air conditioning 5-33
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Contents
Maintenance of the electrical system 5-34
General instructions 5-34
Specific safety instructions regarding the electrical system and the battery 5-34
Checking/replacing the battery 5-35
Checks at regular intervals 5-36
Cables, bulbs and fuses 5-36
Alternator 5-36
Checking/replacing relays and fuses 5-37
Maintenance: automatic trailer coupling 5-38
Cleaning and lubricating the trailer coupling 5-38
Check the trailer coupling for wear 5-38
General maintenance work 5-39
Specific safety instructions regarding cleaning 5-39
Cleaning inside the cab 5-40
Cleaning the seat belt 5-40
Cleaning the exterior of the machine 5-40
Cleaning the engine and the engine compartment 5-41
Screw connections 5-41
Pivots and hinges 5-41
Maintenance: diesel particle filter (option) 5-42
Checking the electronic filter monitoring 5-42
Maintenance and service of the attachments 5-42
Maintenance work “Aggressive Media” (option) 5-43
Anticorrosion protection applied in the factory 5-43
Components coated with anticorrosive wax 5-43
Measures for maintaining anticorrosive protection 5-44
Applying the protective anticorrosion coating 5-45
Treatment of oxidised surfaces 5-45
Maintenance plan (overview) 5-47
Fluids and lubricants 5-51
Maintenance label 5-52
Explanation of symbols on the maintenance label 5-52
Maintenance label 5-53
Specifications 6
Model and trade names: overview 6-1
Frame 6-1
Engine 6-1
Oil/water fan 6-2
Power train 6-2
Variable displacement pump 6-2
Variable displacement motor 6-2
Axles 6-3
Front axle 6-3
Rear axle 6-3
Service and parking brake 6-4
Steering system 6-4
Work hydraulics 6-5
Hydraulic pump 6-5
Hydraulic ram protection 6-5
Lift, tilt and push-out rams: velocity 6-5
Hydraulic pilot control 6-6
Additional control circuit (option) 6-6
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Contents
Electrical system 6-7
Fuses: overview 6-7
Electric components 6-8
Main fuse box with relays (88 kW diesel engine) 6-9
Main fuse box with relays (103 kW diesel engine) 6-9
Relays (overview) 6-10
Tyres 6-11
Weights 6-11
Trailer weight/drawbar load: trailer couplings (option) 6-11
Noise levels 6-12
Vibrations, oscillation and acceleration value 6-12
Tightening torques 6-13
General tightening torques 6-13
Specific tightening torques 6-13
Coolant compound table 6-13
Payloads model 404-03 6-14
Rigid front axle without oscillating axle interlock (rear axle) 6-14
Rigid front axle with mechanical or hydraulic oscillating axle
interlock (rear axle) 6-15
Front axle with frame levelling and without oscillating axle
interlock (rear axle) 6-16
Front axle with frame levelling and hydraulic oscillating axle
interlock (rear axle) 6-17
Dimensions with bucket 6-18
Dimensions with pallet forks 6-19
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